CN110887018B - Production process method of sharp-edge integrated lampshade and lampshade manufactured by adopting process - Google Patents
Production process method of sharp-edge integrated lampshade and lampshade manufactured by adopting process Download PDFInfo
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- CN110887018B CN110887018B CN201911172255.5A CN201911172255A CN110887018B CN 110887018 B CN110887018 B CN 110887018B CN 201911172255 A CN201911172255 A CN 201911172255A CN 110887018 B CN110887018 B CN 110887018B
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- 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
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Abstract
The invention discloses a sharp-edge integrated lamp shade production process method and a lamp shade, comprising the following steps of: milling or punching the plastic plate into a blank, wherein a diffusing agent is added in the blank and can be used as a diffusing plate for light diffusion; square notches are formed in four corners of the blank, and four side edges are formed in the blank part between every two adjacent notches; bending: sequentially bending the side edges to form a box-shaped semi-finished lampshade; after the side edges are bent, a side butt joint structure is formed between the adjacent side edges of the box-shaped semi-finished lampshade, and a gap exists at the butt joint part of the adjacent side edges; sealing: bonding the edge strips to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade or welding the adjacent sides by using a plastic welding rod, sealing the gaps, and bonding the two sides of the edge strips with the adjacent sides; and repairing and polishing the fillets. The lampshade adopting the structure and the process can ensure that the lampshade realizes the sharp edge effect, is clean and tidy as a whole, has stable size, uniform and consistent light transmission, is not loosened and cracked after long-term use, and meets the requirements of mass production on quality stability and consistency.
Description
Technical Field
The invention relates to the technical field of lighting lamps, in particular to a production process method of an integrated lampshade.
Background
Along with the improvement of the economic development level, various demands of people on life are gradually increased, the panel lamp is complex and various, is economical and practical, and has a concise appearance, so that the panel lamp is widely popularized and used. In the product category of the panel lamp, most of the panel lamp is framed, and the non-frame is one of the development trends of the panel lamp, which is mainly because the non-frame panel lamp can be used as a single lamp like the framed panel lamp, and can be freely spliced into a light wall or a light curtain with uniform light emission and no dark area; in the field of borderless panel light products, especially sharp-edged square or special-shaped borderless panel lights, the application field is the most extensive and the most promising.
As a panel light replacement product, how to realize efficient production of economic cost by using a sharp-edged borderless panel light with uniform light emission is still an important subject in the lighting industry. The sharp-edged lampshade which is flat, uniform in light emitting and suitable for splicing the light wall or the light curtain is used as a key component of the borderless panel lamp, and how to design and produce is quite different for various enterprises.
There are four main technologies for lamp covers used for borderless panel lamps in the market at present.
As shown in fig. 1 and fig. 2, the first method is to use a thick PMMA plate, and produce the PMMA plate by a mechanical grooving method, which has high cost although realizing the design feature of sharp edges, and cannot eliminate optical shadows caused by the grooving positions themselves, that is, cannot ensure uniform light emitting surfaces, cannot meet the application requirements of non-dark area light wall or light curtain splicing, and the problem cannot be solved.
As shown in fig. 3, the second method is to bond the PMMA flat plate and the PMMA side strips on four sides by UV glue to form a square lampshade, which also realizes a sharp edge effect and avoids optical shadows caused by the milling grooves, but because the lampshade is to be split into a plurality of parts (a flat plate and 4 side strips are split), the parts are mutually fixed by UV glue bonding, and the total bonding length is very long; at present, the bonding procedure basically depends on manual treatment, the total curing time of the glue is generally 24 hours, various problems such as foaming, whitening, degumming and the like are easy to occur, and the product quality is difficult to keep stable. The bonding process has high requirements on the processing surface and precision of the parts because of the large number of the parts, and the processing cost of the parts is high; the PMMA plate also has the condition of dimensional change caused by moisture absorption and heat absorption, the UV glue is solidified and belongs to brittle materials, and the risk that each part is easy to loosen due to ageing of the glue or mechanical fatigue after long-term application of the lamp shade with a pure bonding structure exists.
Thirdly, producing PMMA or PS lamp covers by a precise injection molding method; the lampshade adopting the process can realize a small-sized sharp-edged integrated lampshade; the length and width dimensions of the product are not more than 300mm basically, the appearance of the lampshade is concise, and the light transmission is uniform; however, if a sharp-edged integrated lamp shade with a larger size is required to be produced, the technical risk is great and the cost is high. This is quite different from the requirements of opaque large-size injection molded panels for indoor units of central air conditioners for our daily use. The indoor vertical machine of the household central air conditioner or other similar large-size injection molding parts are generally opaque, the outer surface of the indoor vertical machine of the household central air conditioner is generally designed into an arc surface, and a large number of rib positions are allowed to be arranged in the indoor vertical machine of the household central air conditioner to meet the requirements of an injection molding process. Therefore, the injection molding process cannot be applied to the production of large-size sharp-edged square or special-shaped integrated lamp covers.
As shown in fig. 4, the fourth process is to produce an integral PMMA or PS lamp cover by a mature plastic sucking or blow molding process, which can indeed meet the requirement of producing a circular, oval or corner-sized arc-side square or polygonal lamp cover (the corners of the lamp cover have radians and other modeling places have arc transitions). By adopting the process, the quality is stable, the efficiency is high, and the cost is low. However, this process can not produce a sharp-edged square or polygonal or other special-shaped integral lamp shade, and mainly adopts the blow molding or plastic suction process, in which plastic plate materials are heated and softened, then the plastic plate materials are shaped and produced by a mold, all the shaping parts of the lamp shade are round and excessively moist, otherwise, the problem of stretch cracking or wrinkling can occur. This also directly determines that the blister or blow molding process cannot produce a lamp shade that can meet the splice light wall or curtain.
Disclosure of Invention
The invention aims at solving the technical problems in the prior art and provides an integrated lampshade which accords with sharp edges of spliced light walls or light curtains and a process method for manufacturing the lampshade.
In order to achieve the above purpose, the invention adopts the following technical scheme: a process for producing a sharp-edged integrated lampshade, which aims at a side butt joint structure and a sealing treatment process thereof, comprises the following steps,
Step one, cutting: punching the plastic plate into a rectangular blank, wherein a diffusing agent is added in the blank and can serve as a diffusing plate for light diffusion; square notches are formed in four corners of the blank, two wall surfaces of each notch keep straight edges and form right angles, four sides are formed in the blank part between every two adjacent notches, the four sides are divided into two groups of long sides and short sides, and each pair of sides is one group; the bottom of the square notch is provided with a V-shaped crack-stopping groove, and two wall surfaces of the V-shaped crack-stopping groove keep straight edges;
Bending: sequentially bending four side edges formed by the blank in the first step to form a box-shaped semi-finished lampshade, wherein the bending angle range of the four side edges is 80-90 degrees, and the bending inner radius R=0-3 MM; after the side edges are bent, a side butt joint structure is formed between adjacent side edges of the box-shaped semi-finished lampshade, and right angles are formed between the adjacent side edges; gaps exist at the butt joint positions of the adjacent side edges, and the specific is that: the gap is formed between the outer end surfaces of the two end parts of the short side edge and the inner side surfaces of the end parts of the long side edge;
And step three, sealing joints: bonding the edge strips to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade or welding the adjacent sides by using a plastic welding rod, sealing the gaps, and bonding the two sides of the edge strips with the adjacent sides;
The glue coating process comprises the following steps: fixing the semi-finished lampshade on a concave positioning clamp to ensure that the relative positions of four side edges are kept stable, coating the adhesive on the inner side of a gap and the area on the side edges, which is equal to the width of the edge strip, adhering the edge strip to a gluing area, and curing at normal temperature; or directly coating the sticky adhesive on the gap for filling treatment;
And (3) a hot melt welding process: placing the semi-finished lampshade on a positioning clamp, and performing hot-melting welding on the plastic welding rods to the four-corner gaps of the lampshade blank by using a hot-melting plastic welding gun to form a triangular plastic filling welding seam effect;
and fourthly, repairing and polishing fillets: and (3) carrying out fillet or bevel angle repair polishing treatment on the outer sides of the four corners of the semi-finished product of the lampshade after the sealing treatment by using a chamfering machine or a gong machine, removing residual glue, burrs, flash, stains and the like at the corners, and ensuring that the glue thickness at the corners is basically consistent with that of the sides and is smooth.
The specific bending mode in the second step is cold bending or hot bending, wherein the cold bending is performed by adopting a hydraulic bending machine, a blank is horizontally arranged on a V-shaped machine, a hydraulic head is arranged above the blank, and a bending part is bent by pressing down; the hot bending is carried out by adopting an automatic hot bending machine, the blank is flatly arranged on a machine table, the part to be bent is heated and softened, then the blank is folded, and air cooling is carried out after the folding is finished, so that the blank is solidified and formed.
Before the bending step, a 90-degree V-shaped groove is formed in the part to be bent of the side edge of the surface of the blank, and the side edge is bent along the 90-degree V-shaped groove in sequence. Through the design of the V-shaped groove, the convenience of bending can be effectively ensured, and the better sharp edge effect of the side edge part is ensured.
Aiming at 45-degree inclined plane butt joint and joint sealing treatment process, the method comprises the following steps,
Step one, cutting: punching the plastic plate into square blank, wherein a diffusing agent is added in the blank and can be used as a diffusing plate for light diffusion; square notches are formed in four corners of the blank, 45-degree chamfers are milled on the wall surfaces of the square notches, four equal-length side edges are formed in the blank part between adjacent square notches, and arc-shaped bending process inclined planes are formed in the bottoms of the square notches; the surface of the blank with the side edge connected with the blank main body is provided with a 90-degree V-shaped groove, and the bending procedure can be more effectively ensured by the design of the V-shaped groove, so that the better sharp edge effect of the side edge part is ensured;
Bending: sequentially bending four equal-length side edges of the blank to form a box-shaped semi-finished lampshade; the bending angles of the four equal-length side edges are 80-90 degrees, and the inner radius of bending is R=0-3 MM; after the four side edges are bent, a 45-degree inclined plane butt joint structure is formed between the four adjacent side edges of the box-shaped semi-finished lampshade; gaps exist between 45-degree inclined planes of adjacent sides;
And step three, sealing joints: bonding the edge strips to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade or welding the adjacent sides by using a plastic welding rod, sealing the gaps, and bonding the two sides of the edge strips with the adjacent sides;
The glue coating process comprises the following steps: fixing the semi-finished lampshade on a concave positioning fixture, ensuring that the relative positions of four equal-length side edges are kept stable, coating the adhesive on the inner side of a gap and the area on the side edges, which is equal to the width of the side edges, and then adhering the side edges to a gluing area for curing at normal temperature; or directly coating the sticky adhesive on the gap for filling treatment;
And (3) a hot melt welding process: placing the semi-finished lampshade on a positioning clamp, and performing hot-melting welding on the plastic welding rods to the four-corner gaps of the lampshade blank by using a hot-melting plastic welding gun to form a triangular plastic filling welding seam effect;
And fourthly, repairing and polishing fillets: and (3) carrying out fillet or bevel angle repair polishing treatment on the outer sides of the four corners of the lampshade after the sealing treatment by using a chamfering machine or a gong machine, removing residual glue, burrs, flash, stains and the like at the corners, and ensuring that the glue thickness at the corners is basically consistent with that of the sides and is smooth.
Aiming at 60-degree inclined plane butt joint and joint sealing treatment process, the method comprises the following steps,
Step one, cutting: punching the plastic plate into hexagonal blank, wherein a diffusing agent is added in the blank and can be used as a diffusing plate for light diffusion; a triangular notch is formed in a corner of the blank, a 60-degree chamfer is milled on the wall surface of the triangular notch, six sides are formed in the blank part between adjacent triangular notches, and an arc-shaped bending process inclined plane is arranged at the inner bottom of the triangular notch;
Bending: sequentially bending six sides of the blank to form a box-shaped semi-finished lampshade; the bending angle range of the six side edges is 80-90 degrees, and the inner radius of bending is R=0-3 MM; after the six side edges are bent, a 60-degree inclined plane butt joint structure is formed between the six adjacent side edges of the box-shaped semi-finished lampshade; gaps exist between 60-degree inclined planes of adjacent sides; forming a 90-degree V-shaped groove on the surface of the blank with the side edge connected with the blank main body;
And step three, sealing joints: bonding the edge strips to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade or welding the adjacent sides by using a plastic welding rod, sealing the gaps, and bonding the two sides of the edge strips with the adjacent sides;
The glue coating process comprises the following steps: fixing the semi-finished lampshade on a concave positioning clamp to ensure that the relative positions of the side edges are kept stable, coating the adhesive on the inner side of a gap and the area on the side edges, which is equal to the width of the side edges, and then adhering the side edges to a gluing area for curing at normal temperature; or directly coating the sticky adhesive on the gap for filling treatment;
And (3) a hot melt welding process: placing the semi-finished lampshade on a positioning clamp, and performing hot-melting welding on the plastic welding rods to the four-corner gaps of the lampshade blank by using a hot-melting plastic welding gun to form a triangular plastic filling welding seam effect;
And fourthly, repairing and polishing fillets: and (3) carrying out fillet or bevel angle repairing and polishing treatment on the outer side edges of the corners of the lampshade after the sealing treatment by using a chamfering machine or a gong machine, removing residual glue, burrs, flash, stains and the like at the corners, and ensuring that the glue thickness at the corners is basically consistent with that of the side edges and is smooth.
The invention also provides a lampshade according to the production process method, which comprises a planar lampshade main body, wherein the edges of the lampshade main body are bent in the same direction to form a lampshade edge, 80-90 degrees are formed between the lampshade and the lampshade main body, the bending inner radius R=0-3 MM, and a right angle or a 120-degree included angle is formed between the adjacent lampshade edges; the connecting strip is arranged at the joint of the adjacent cover edges, two sides of the connecting strip are respectively connected with the adjacent cover edges through glue or thermal welding, or the adjacent cover edges are directly coated on the gaps through sticky adhesive for filling treatment.
Compared with the prior art, the invention has the following technical effects that the lampshade is formed by firstly carrying out hot bending or cold bending on a PC or PMMA or PS flat plate to form a box-shaped structure, and then carrying out sealing treatment on the corner parts of the adjacent side edges to form the lampshade with a seamless integrated structure. The lampshade adopting the structure and the process can ensure that the lampshade realizes the sharp edge effect, is clean and tidy as a whole, has stable size, uniform and consistent light transmission, is not loosened and cracked after long-term use, and meets the requirements of mass production on quality stability and consistency.
Drawings
FIG. 1 is a schematic diagram (I) of a prior art rimless panel lamp shade;
FIG. 2 is a schematic diagram (II) of a prior art rimless panel lamp shade;
FIG. 3 is a schematic diagram of a second prior art rimless panel lamp shade;
FIG. 4 is a schematic diagram of a fourth prior art rimless panel lamp shade;
FIG. 5 is a front view of a blank with a notch in step one (a blanking step) according to an embodiment of the present invention;
FIG. 6 is a perspective view of FIG. 5;
FIG. 7 is an enlarged schematic view of portion A of FIG. 6;
FIG. 8 is a schematic side view of the side-folded structure of FIG. 6 (folding step);
FIG. 9 is a schematic perspective view of FIG. 8;
FIG. 10 is an enlarged schematic view of portion B of FIG. 9;
FIG. 11 is a schematic view of the L-shaped edge strip bonding and fixing process in the seaming step;
FIG. 12 is an enlarged schematic view of portion C of FIG. 11;
FIG. 13 is a schematic view of a hot-melt welding structure in a sealing step;
FIG. 14 is a front view of a blank in a second opening step according to the embodiment of the present invention;
Fig. 15 is a perspective view of fig. 14;
FIG. 16 is a schematic side view of the side-folded rear view of FIG. 14 (folding step);
FIG. 17 is a perspective view of FIG. 16;
FIG. 18 is an enlarged schematic view of portion D of FIG. 17;
FIG. 19 is a schematic view of the process for bonding and fixing the L-shaped edge strip in the second seaming step according to the second embodiment of the invention;
FIG. 20 is an enlarged schematic view of portion E of FIG. 19;
FIG. 21 is a front view of a blank in a third step of opening in accordance with an embodiment of the present invention;
FIG. 22 is a schematic perspective view of the side edge of FIG. 21 after being bent (bending step)
Fig. 23 is a schematic diagram of a lampshade structure according to the present invention;
FIG. 24 is a schematic perspective view of FIG. 23;
fig. 25 is a schematic diagram of a lampshade according to the present invention
Fig. 26 is a schematic view of a mutually spliced structure of the lamp covers in fig. 25;
FIG. 27 is a schematic view of a blank with a 90V-groove formed in the surface of the blank laterally adjacent to the body of the blank;
FIG. 28 is an enlarged view of a blank with a 90V-shaped groove formed in a portion of the surface of the blank that is laterally adjacent to the body of the blank.
Detailed Description
The present invention will be further described with reference to the accompanying drawings and specific embodiments so as to more clearly understand the technical ideas claimed in the present invention.
Embodiment one:
the embodiment is a sharp-edge right-angle integrated lamp shade production process method, which aims at a side butt joint structure and a seam sealing treatment process thereof, and comprises the following steps,
Step one, cutting:
1.1, cutting a PS (polystyrene) or PMMA (polymethyl methacrylate) or PC (polycarbonate) plastic plate by a numerical control engraving machine or punching a precise die into a rectangular blank 1, wherein a dispersing agent is added into the blank 1 and can be used as a diffusion plate with a light diffusion effect; in this embodiment, the blank 1 is a blank with a size of 0.6m1.2m, and the thickness of the blank 1 may be 1-4mm, and in this embodiment, 4mm;
1.2 referring to fig. 5 and 6, square notches 2 with a size of 30mm by 32mm are formed at four corners of the blank 1 (the size of the notches can be adjusted according to the height of the lampshade and the installation range, the size is only used as an example), two wall surfaces of the notches 2 keep straight edges and form right angles, four sides are formed by the blank 1 between adjacent notches 2, the four sides are divided into two groups of long sides 4 and short sides 3, and each pair of sides is one group;
1.3, please refer to fig. 7 in combination, a V-shaped crack-stopping groove 5 is opened at the bottom of the square notch 2, and two wall surfaces of the V-shaped crack-stopping groove 5 keep straight edges;
The straight edge in this embodiment means: when the blank 1 is flatly laid on the horizontal plane, the projection of the wall surfaces of the notch 2 and the V-shaped crack stop groove 5 on the horizontal plane is a straight line.
Bending:
2.1, referring to fig. 8, bending four sides formed by the blank 1 in the first step in sequence to form a square or special-shaped box-shaped semi-finished lampshade, wherein the bending angle range of the four sides is 80-90 degrees, and the bending inner radius R=0-3 MM; the bending angle of the embodiment is 90 degrees, and the bending inner radius is 0.2mm;
The concrete bending mode is cold bending or hot bending, the cold bending is performed by adopting a hydraulic bending machine, the blank 1 is horizontally arranged on a V-shaped machine, a hydraulic head is arranged above the blank, and the bending part is bent by pressing down; the hot bending is carried out by adopting an automatic hot bending machine, the blank 1 is flatly arranged on a machine table, the part to be bent is heated and softened, then is folded, and air cooling is carried out after the folding is finished, so that solidification and forming are carried out; the two bending modes are characterized in that overall, the hot bending process is complex, the bending process does not rebound, the cold bending process is simple, the bending process possibly has rebound, and different bending modes can be selected according to actual conditions;
2.2, after the side edges are bent, a side butt joint structure is formed between the adjacent side edges of the box-shaped semi-finished lampshade due to the existence of the V-shaped crack stop groove 5 and the long and short side edges (refer to fig. 9 and 10); and naturally creates an effect approaching sharp edges with right angles between adjacent sides. At this time, a gap 6 exists at the abutting position of the adjacent side edges, specifically: the gap 6 is formed between the outer end surfaces of the two end parts of the short side edge 3 and the inner side surfaces of the end parts of the long side edge 4;
The sharp edges and right angles referred to in this example are: the side outside the long side is a relatively sharp side, and the included angle between the long side and the end side is a right angle. Through sharp edge right angle's effect, can be finally convenient splice the polylith lamp shade, form the large-scale curtain wall that does not have the shade each other, no light loss.
And step three, sealing joints:
The L-shaped or triangular side strips 7 (plastic strips) are adhered to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade by using glue or the adjacent sides are welded by using plastic welding rods 8, the gaps 6 are sealed, and the two sides of the side strips 7 are adhered to the adjacent sides, so that the contact surface is increased, the adhesive force is enhanced, and the glue can naturally permeate into the gaps 6;
3.1, glue coating process: fixing a semi-finished lampshade product on a concave positioning clamp 40, ensuring that the relative positions of four side edges are kept stable, coating adhesive on the inner side of a gap and the areas with the same width as the side strips 7 on the side edges, adhering the side strips 7 on a gluing area (refer to fig. 11 and 12), standing and curing for 1-24 hours or UV (ultraviolet) curing for 10-60S or heating and curing for 1-30 minutes under the normal temperature condition; or directly coating the sticky adhesive on the gap for filling treatment.
3.2, A hot melt welding process: the semi-finished product of the lampshade is placed on a positioning fixture 40 (refer to fig. 13), a triangle, round or square plastic welding rod 8 is welded to the four corner gaps 6 of the lampshade blank 1 by a hot-melting plastic welding gun in a hot-melting mode, and a triangle plastic filling welding seam effect is formed, so that the purpose of sealing welding is achieved.
The positioning fixture 40 of the present embodiment is a fixture specifically designed for the present application, and includes a support platform 401 for supporting a lampshade main body, and an L-shaped clamping seat 402, which is identical to the side edge of the lampshade, is disposed around the support platform 401.
And fourthly, repairing and polishing fillets:
And (3) carrying out fillet or bevel angle repair polishing treatment on the outer sides of the four corners of the semi-finished product of the lampshade after the sealing treatment by using a chamfering machine or a gong machine, removing residual glue, burrs, flash, stains and the like at the corners, and ensuring that the glue thickness at the corners is basically consistent with that of the sides and is smooth.
Referring to fig. 27 and 28, before the bending step, a 90 ° V-groove 70 may be formed on the portion to be bent of the side edge of the surface of the blank, where the 90 ° V-groove 70 means that two groove edges are right-angled, and four side edges are bent along the 90 ° V-groove in sequence, and the depth of the 90 ° V-groove may be generally half of the thickness of the blank, and the milling cutter or the cutting tool is controlled by a numerical control or a common machine tool to perform the grooving operation.
The embodiment also provides a lampshade manufactured according to the above technical method, referring to fig. 23 and 24, which includes a planar quadrilateral lampshade main body 50, wherein four lampshade edges 501 are formed by bending the edge of the lampshade main body 50 in the same direction, the four lampshade edges 501 are divided into two groups of long lampshade edges and short lampshade edges, and each pair of lampshade edges is one group; the cover edges 501 and the lampshade main body 50 form 90 degrees, the bending inner radius R=0.2MM, and right angles are formed between the adjacent cover edges 501; the connecting strip 502 is arranged at the joint of the adjacent cover edges 501, the connecting strip 502 can be a plastic strip, and two sides of the connecting strip 502 are respectively connected with the adjacent cover edges 501 through glue or thermal welding. The cover edge 501 is an angle formed by bending the cover body 50 with a 90V-shaped groove 70 provided on the surface of the cover body 50.
Further, the connecting strip 502 is L-shaped or triangular, and two wall surfaces thereof are respectively adhered to the surfaces of the adjacent cover edges 501 by glue. Finally, a plurality of quadrilateral lamp covers can be spliced conveniently, each lamp cover is not physically connected, the lamp covers can be fixed on a curtain wall or a ceiling by using metal sheet metal parts respectively and are abutted together, and the whole lamp covers emit light to form a square large-screen curtain wall which is free of shadows and no light loss.
Embodiment two:
The embodiment is a sharp-edge right-angle integrated lamp shade production process method, which aims at 45-degree inclined plane butt joint and seam sealing treatment process, and comprises the following steps,
Step one, cutting:
1.1, cutting a PS (polystyrene) or PMMA (polymethyl methacrylate) or PC (polycarbonate) plastic plate by a numerical control engraving machine or punching a precise die into a square blank 1, wherein a dispersing agent is added into the blank 1 and can be used as a diffusion plate with a light diffusion effect; in the embodiment, the blank 1 is a blank with the size of 0.6m by 0.6m, the thickness of the blank 1 is 1-3mm, and the embodiment is 3mm;
1.2, referring to fig. 14 and 15, square notches 20 (the size of which can be adjusted according to the height and installation range of the lampshade, the size of which is only an example) of 28mm are formed at four corners of the blank 1, 45-degree chamfers are milled on the wall surface 200 of the square notch 20, four equal-length side edges 30 are formed on the blank 1 between adjacent square notches 20, and arc-shaped bending process inclined surfaces 51 are arranged at the bottoms of the square notches 20; referring to fig. 27 and 28 in combination, a 90 ° V-groove 70 is formed on the surface of the blank, the side of which is connected with the main body of the blank, so that the subsequent bending step is more facilitated, and a better sharp edge effect at the side can be achieved, the depth of the 90 ° V-groove in this embodiment can be generally one third of the thickness of the blank, and the milling cutter or the cutting tool is controlled to perform slotting operation by a numerical control or common machine tool;
the 45 ° chamfer milled out of the wall 200 of the square notch 20 in this embodiment means: when the blank 1 is laid on a horizontal plane, the wall surface of the square notch 20 is projected to the horizontal plane to form a rectangle, and two sides of the two wall surfaces are respectively right angles.
Bending:
2.1, bending four equal-length side edges 30 of the blank 1 in sequence at room temperature to form a square or special-shaped box-shaped semi-finished lampshade; the four equal-length side edges 30 are bent at an angle ranging from 80 degrees to 90 degrees, the inner radius of bending is R=0-3 MM, the bending angle of the embodiment is 80 degrees, and the inner radius of bending is 1.5MM; the same cold or hot pressing procedure as in example one was used; the end surfaces of four adjacent equal-length side edges 30 of the box-shaped semi-finished lampshade form a 45-degree inclined surface butt joint structure (see fig. 16 and 17 and 18);
2.2, after four sides are bent, a 45-degree inclined surface butt joint structure is formed between four adjacent sides of the box-shaped semi-finished lampshade due to the existence of the arc bending process inclined surface 51 and the wall surface 200 of the square notch 20; and naturally forms an effect approaching sharp edges; at this time, a gap 61 exists between 45 ° bevel faces of adjacent sides.
The sharp edges and right angles referred to in this example are: the outer sides of the equal-length side edges are relatively sharp edges, and the included angle between the adjacent equal-length side edges is a right angle. Through sharp edge right angle's effect, can be finally convenient splice the polylith lamp shade, form the large-scale curtain wall that does not have the shade each other, no light loss.
And step three, sealing joints:
The L-shaped or triangular side strips 7 (plastic strips) are adhered to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade by using glue or the adjacent sides are welded by using plastic welding rods, the gaps 61 are sealed, the two sides of the side strips 7 are adhered to the adjacent sides, the purpose is to increase the contact surface, strengthen the adhesive force and enable the glue to naturally permeate into the gaps 61;
3.1, glue coating process: fixing the semi-finished lampshade product on a concave positioning fixture 40, ensuring that the relative positions of four equal-length side edges are kept stable, then coating the inner side of a gap 61 and the side edges of the gap with adhesive in the same width as the edge strip 7, and then adhering the edge strip 7 to a gluing area (fig. 19 and 20); standing and curing for 1-24 hours or UV curing for 10-6 seconds or heating and curing for 1-30 minutes under the normal temperature condition.
3.2, A hot melt welding process: the semi-finished lampshade is placed on the positioning fixture 40, and a triangular, round or square plastic welding rod is welded to the four corner gaps 61 of the lampshade blank 1 by a hot-melting plastic welding gun in a hot-melting mode, so that a plastic filling welding effect is achieved, and the purpose of sealing welding is achieved.
And fourthly, repairing and polishing fillets:
the step is the same as that of the first embodiment, the outer sides of the four corners of the lampshade after the sealing treatment are subjected to fillet or bevel repairing and polishing treatment by using a chamfering machine or a gong machine, and the residual glue, burrs, flash, stains and the like at the corners are removed, so that the glue thickness at the corners is ensured to be basically consistent with that of the sides, and the corners are smooth.
The embodiment also provides a lampshade manufactured according to the above technical method, referring to fig. 23 and 24 specifically, the lampshade comprises a planar quadrilateral lampshade main body 50, four lampshade edges 501 are formed by bending the edge of the lampshade main body 50 in the same direction, and in the embodiment, the four lampshade edges 501 are equal in length; the cover edges 501 and the lampshade main body 50 form an angle of 80 degrees, the bending inner radius R=1.5MM, and the adjacent cover edges 501 form a right angle; the connecting strip 502 is arranged at the joint of the adjacent cover edges 501, the connecting strip 502 can be a plastic strip, and two sides of the connecting strip 502 are respectively connected with the adjacent cover edges 501 through glue or thermal welding. The cover edge 501 is an angle formed by bending the cover body 50 with a 90V-shaped groove 70 provided on the surface of the cover body 50.
Further, the connecting strip 502 is L-shaped or triangular, and two wall surfaces thereof are respectively adhered to the surfaces of the adjacent cover edges 501 by glue. Finally, a plurality of quadrilateral lamp covers can be spliced conveniently, each lamp cover is not physically connected, the lamp covers can be fixed on a curtain wall or a ceiling by using metal sheet metal parts respectively and are abutted together, and the whole lamp covers emit light to form a square large-screen curtain wall which is free of shadows and no light loss.
Embodiment III:
The embodiment is a sharp-edge right-angle integrated hexagonal lampshade production process method, which aims at 60-degree inclined plane butt joint and seam sealing treatment process, and comprises the following steps,
Step one, cutting:
1.1, cutting a PS (polystyrene) or PMMA (polymethyl methacrylate) or PC (polycarbonate) plastic plate by a numerical control engraving machine or punching a precise die into a hexagonal blank 1, wherein a dispersing agent is added into the blank 1 and can be used as a diffusion plate for light diffusion; in the embodiment, the blank 1 is a blank with the size of 0.8m by 0.8m, the thickness of the blank 1 is 1-4mm, and 2mm is selected in the embodiment;
1.2, please refer to fig. 21, there are 25mm triangle notches 600 (this notch size can be adjusted according to the height of the lamp shade and installation scope, the size here is merely as an example), the wall of triangle notch 600 mills out 60 ° chamfer, blank 1 part between adjacent triangle notches 600 forms six equal length side edges 60, the bottom in triangle notch 600 has arc bending technological inclined plane; referring to fig. 28 in combination, a 90 ° V-groove 70 is formed on the surface of the blank where each side edge is connected to the main body of the blank, which is more beneficial to the subsequent bending step, and can achieve better edge sharpening effect at the side edge, the depth of the 90 ° V-groove in this embodiment can be generally between one half and one third of the thickness of the blank, and the milling cutter or the cutting tool is controlled by a numerical control or a common machine tool to perform slotting operation;
bending:
2.1, referring to fig. 22, bending six sides 60 of the blank 1 in turn at room temperature to form a hexagonal box-shaped semi-finished lampshade; the bending angle range of the six equal-length side edges 60 is 80-90 degrees, the bending inner radius is R=0-3 MM, the bending angle of the embodiment is 90 degrees, and the bending inner radius is 3MM; the same cold or hot pressing procedure as in example one was used; the end faces of four adjacent equal-length side edges 30 of the box-shaped semi-finished lampshade form a 60-degree inclined plane;
2.2, after the six sides are bent, a 60-degree inclined surface butt joint structure is formed between six adjacent sides of the box-shaped semi-finished lampshade due to the existence of the arc bending process inclined surface and the wall surface of the triangular notch 600; and naturally forms an effect approaching sharp edges; at this time, a gap exists between 60-degree inclined planes of adjacent sides;
The sharp edge in this example is: the edges outside the side edges are sharp edges, and the included angle between the adjacent side edges is 120 degrees.
And step three, sealing joints:
The step is the same as that of the first and second embodiments, the L-shaped or triangular edge strips (plastic strips) are adhered to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade by using glue or the adjacent sides are welded by using plastic welding rods, and the gaps are sealed, so that the two sides of the edge strips are adhered to the adjacent sides, the contact surface is increased, the adhesive force is enhanced, and the glue can naturally permeate into the gaps;
3.1, glue coating process: fixing a semi-finished product of the lampshade on a concave positioning clamp, ensuring that the relative positions of six side edges are kept stable, coating the inner side of a gap and the area on the side edges, which is equal to the width of the side edges, with adhesive, and adhering the side edges to a gluing area; and standing and curing for 1-24 hours or UV curing for 10-6 seconds or heating and curing for 1-30 minutes at normal temperature, or directly coating the viscous adhesive on the gaps for filling treatment.
3.2, A hot melt welding process: and placing the semi-finished lampshade on a positioning clamp, and performing hot-melting welding on the triangular, circular or square plastic welding rods to the gaps at the four corners of the lampshade blank 1 by using a hot-melting plastic welding gun to form a plastic filling welding seam effect, so that the aim of sealing welding is fulfilled.
And fourthly, repairing and polishing fillets:
the step is the same as that of the first and second embodiments, the outer sides of the four corners of the lampshade after the sealing treatment are subjected to fillet or bevel repairing and polishing treatment by using a chamfering machine or a gong machine, and the residual glue, burrs, flash, stains and the like at the corners are removed, so that the glue thickness at the corners is ensured to be basically consistent with that of the sides, and the corners are smooth.
The embodiment also provides a lampshade manufactured according to the above technical method, referring to fig. 25, which includes a planar hexagonal lampshade main body 50, wherein six lampshade edges 501 are formed by bending the edges of the lampshade main body 50 in the same direction, and the six lampshade edges 501 are equal in length; the cover edges 501 and the lampshade main body 50 form 90 degrees, the bending inner radius R=3MM, and the adjacent cover edges 501 form 120 degrees; the connecting strip 502 is arranged at the joint of the adjacent cover edges 501, the connecting strip 502 can be a plastic strip, and two sides of the connecting strip 502 are respectively connected with the adjacent cover edges 501 through glue or thermal welding. The cover edge 501 is an angle formed by bending the cover body 50 with a 90V-shaped groove 70 provided on the surface of the cover body 50.
Further, the connecting strip 502 is L-shaped or triangular, and two wall surfaces thereof are respectively adhered to the surfaces of the adjacent cover edges 501 by glue. Referring to fig. 26, a plurality of hexagonal lamp covers can be spliced conveniently, each lamp cover is not physically connected, and the lamp covers can be fixed on a curtain wall or a ceiling by metal sheet metal parts and are close together, so that the whole lamp covers emit light, and a honeycomb large-screen curtain wall without shadows and no light loss is formed.
Of course, the present embodiment is not necessarily limited to a quadrilateral or a hexagon, and according to the process of the present invention, various special-shaped lampshade structures such as pentagons, octagons, triangles and the like can be derived by the scheme of the present invention.
The foregoing detailed description is directed to embodiments of the present invention which are not intended to limit the scope of the invention, and other various modifications and variations may be made by those skilled in the art in light of the above teachings without departing from the scope of the invention as defined by the appended claims.
Claims (10)
1. A process for producing a sharp-edged integrated lampshade is characterized by comprising the following steps aiming at a side butt joint structure and a seam sealing treatment process thereof,
Step one, cutting:
1.1, milling or punching a plastic plate into a rectangular blank, wherein a diffusing agent is added in the blank and can serve as a diffusing plate for light diffusion;
1.2, square notches are formed in four corners of the blank, two wall surfaces of the notches keep straight edges and form right angles, four sides are formed in the blank part between adjacent notches, the four sides are divided into two groups of long sides and short sides, and each pair of sides is one group;
1.3, a V-shaped crack-stopping groove is formed in the bottom of the square notch, and two wall surfaces of the V-shaped crack-stopping groove keep straight edges;
bending:
2.1, sequentially bending four side edges formed by the blank in the first step to form a box-shaped semi-finished lampshade, wherein the bending angle range of the four side edges is 80-90 degrees, and the bending inner radius R=0-3.0 MM;
2.2, after the side edges are bent, a side butt joint structure is formed between adjacent side edges of the box-shaped semi-finished lampshade, and right angles are formed between the adjacent side edges; gaps exist at the butt joint positions of the adjacent side edges, and the specific is that: the gap is formed between the outer end surfaces of the two end parts of the short side edge and the inner side surfaces of the end parts of the long side edge;
And step three, sealing joints:
Bonding the edge strips to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade or welding the adjacent sides by using a plastic welding rod, sealing the gaps, and bonding the two sides of the edge strips with the adjacent sides; or directly coating the sticky adhesive on the gap for filling treatment;
3.1, glue coating process: fixing the semi-finished lampshade on a concave positioning clamp to ensure that the relative positions of four side edges are kept stable, coating the adhesive on the inner side of a gap and the area on the side edges, which is equal to the width of the edge strip, adhering the edge strip to a gluing area, and curing at normal temperature;
3.2, a hot melt welding process: placing the semi-finished lampshade on a positioning clamp, and performing hot-melting welding on the plastic welding rods to the four-corner gaps of the lampshade blank by using a hot-melting plastic welding gun to form a triangular plastic filling welding seam effect;
And fourthly, repairing and polishing fillets:
And (3) carrying out fillet or bevel angle repair polishing treatment on the outer sides of the four corners of the semi-finished product of the lampshade after the sealing treatment by using a chamfering machine or a gong machine, removing residual glue, burrs, flash and stains at the corners, and ensuring that the glue thickness at the corners is basically consistent with that of the sides and is smooth.
2. A process for producing a sharp-edged unitary lamp shade according to claim 1, wherein: the specific bending mode in the second step is cold bending or hot bending, wherein the cold bending is performed by adopting a hydraulic bending machine, a blank is horizontally arranged on a V-shaped machine, a hydraulic head is arranged above the blank, and a bending part is bent by pressing down; the hot bending is carried out by adopting an automatic hot bending machine, the blank is flatly arranged on a machine table, the part to be bent is heated and softened, then the blank is folded, and air cooling is carried out after the folding is finished, so that the blank is solidified and formed.
3. A process for producing a sharp-edged unitary lamp shade according to claim 1, wherein: before the bending step, a 90-degree V-shaped groove is formed in the part to be bent of the side edge of the surface of the blank, and the side edge is bent along the 90-degree V-shaped groove in sequence.
4. A process for producing a sharp-edged integrated lampshade is characterized by comprising the following steps of aiming at 45-degree inclined plane butt joint and seam sealing treatment processes,
Step one, cutting:
1.1, milling or punching a plastic plate into square blanks, wherein a dispersing agent is added in the blanks and can be used as a diffusion plate for light diffusion;
1.2, square notches are formed in four corners of the blank, 45-degree chamfers are milled on the wall surfaces of the square notches, four equal-length side edges are formed in the blank part between adjacent square notches, and arc-shaped bending process inclined planes are formed in the bottoms of the square notches; forming a 90-degree V-shaped groove on the surface of the blank with the side edge connected with the blank main body;
bending:
2.1, bending four equal-length side edges of the blank in sequence to form a box-shaped semi-finished lampshade; the bending angles of the four equal-length side edges are 80-90 degrees, and the inner radius of bending is R=0-3.0 MM;
2.2, after four sides are bent, 45-degree inclined surface butt joint structures are formed among four adjacent sides of the box-shaped semi-finished lampshade; gaps exist between 45-degree inclined planes of adjacent sides;
And step three, sealing joints:
bonding the edge strips to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade or welding the adjacent sides by using a plastic welding rod, sealing the gaps, and bonding the two sides of the edge strips with the adjacent sides; or directly coating the sticky adhesive on the gap for filling treatment;
3.1, glue coating process: fixing the semi-finished lampshade on a concave positioning fixture, ensuring that the relative positions of four equal-length side edges are kept stable, coating the adhesive on the inner side of a gap and the area on the side edges, which is equal to the width of the side edges, and then adhering the side edges to a gluing area for curing at normal temperature;
3.2, a hot melt welding process: placing the semi-finished lampshade on a positioning clamp, and performing hot-melting welding on the plastic welding rods to the four-corner gaps of the lampshade blank by using a hot-melting plastic welding gun to form a triangular plastic filling welding seam effect;
And fourthly, repairing and polishing fillets:
And (3) carrying out fillet or bevel angle repair polishing treatment on the outer sides of the four corners of the lampshade after the sealing treatment by using a chamfering machine or a gong machine, removing residual glue, burrs, flash and stains at the corners, and ensuring that the glue thickness at the corners is basically consistent with that of the sides and is smooth.
5. A process for producing a sharp-edged unitary lamp shade according to claim 4, wherein: the specific bending mode in the second step is cold bending or hot bending, wherein the cold bending is performed by adopting a hydraulic bending machine, a blank is horizontally arranged on a V-shaped machine, a hydraulic head is arranged above the blank, and a bending part is bent by pressing down; the hot bending is carried out by adopting an automatic hot bending machine, the blank is flatly arranged on a machine table, the part to be bent is heated and softened, then the blank is folded, and air cooling is carried out after the folding is finished, so that the blank is solidified and formed.
6. A process for producing a sharp-edged integrated lampshade is characterized by comprising the following steps of aiming at 60-degree inclined plane butt joint and seam sealing treatment processes,
Step one, cutting:
1.1, milling or punching a plastic plate into a hexagonal blank, wherein a diffusing agent is added in the blank and can serve as a diffusing plate for light diffusion;
1.2, forming triangular notches at corners of the blank, milling 60-degree chamfer angles on wall surfaces of the triangular notches, forming six side edges on the blank part between adjacent triangular notches, and arranging arc-shaped bending process inclined planes at the bottoms in the triangular notches; forming a 90-degree V-shaped groove on the surface of the blank with the side edge connected with the blank main body;
bending:
2.1, bending six sides of the blank in sequence to form a box-shaped semi-finished lampshade; the bending angle range of the six side edges is 80-90 degrees, and the inner radius of bending is R=0-3.0 MM;
2.2, after bending six sides, forming a 60-degree inclined plane butt joint structure between six adjacent sides of the box-shaped semi-finished lampshade; gaps exist between 60-degree inclined planes of adjacent sides;
And step three, sealing joints:
bonding the edge strips to the inner surfaces of the adjacent sides of the box-shaped semi-finished lampshade or welding the adjacent sides by using a plastic welding rod, sealing the gaps, and bonding the two sides of the edge strips with the adjacent sides; or directly coating the sticky adhesive on the gap for filling treatment;
3.1, glue coating process: fixing the semi-finished lampshade on a concave positioning clamp to ensure that the relative positions of the side edges are kept stable, coating the adhesive on the inner side of a gap and the area on the side edges, which is equal to the width of the side edges, and then adhering the side edges to a gluing area for curing at normal temperature;
3.2, a hot melt welding process: placing the semi-finished lampshade on a positioning clamp, and performing hot-melting welding on the plastic welding rods to the four-corner gaps of the lampshade blank by using a hot-melting plastic welding gun to form a triangular plastic filling welding seam effect;
And fourthly, repairing and polishing fillets:
And (3) carrying out fillet or bevel angle repair polishing treatment on the outer side edges of the corners of the lampshade after the sealing treatment by using a chamfering machine or a gong machine, removing residual glue, burrs, flash and stains at the corners, and ensuring that the glue thickness at the corners is basically consistent with that of the side edges and is smooth.
7. A lamp shade made by the process of claim 1, 4 or 6, wherein: the lampshade comprises a planar lampshade body (50), wherein the edge of the lampshade body (50) is bent in the same direction to form a lampshade edge (501), 80-90 degrees are formed between the lampshade edge (501) and the lampshade body (50), the bending inner radius R=0-3 MM, and right angles or 120-degree included angles are formed between the adjacent lampshade edges (501); the connecting strip (502) is arranged at the joint of the adjacent cover edges (501), and two sides of the connecting strip (502) are respectively connected with the adjacent cover edges (501) through glue or thermal fusion welding or directly coated to gaps between the adjacent cover edges through sticky adhesive for filling treatment.
8. The lamp shade of claim 7, wherein: the connecting strip (502) is L-shaped or triangular, and two wall surfaces of the connecting strip are respectively attached to the surfaces of the adjacent cover edges (501) through glue.
9. The lamp shade of claim 7, wherein: the lampshade main body (50) is square, rectangular or hexagonal.
10. The lamp shade of claim 7, wherein: the cover edge (501) is bent with the lampshade main body (50) through a 90-degree V-shaped groove arranged on the surface of the lampshade main body (50) to form an included angle.
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| JP5445299B2 (en) * | 2010-04-13 | 2014-03-19 | 東芝ライテック株式会社 | lighting equipment |
| CN204083864U (en) * | 2014-06-11 | 2015-01-07 | 常州天禄光电科技有限公司 | A kind of new structure flat illumination light fixture |
| CN106217827A (en) * | 2016-07-12 | 2016-12-14 | 金敏 | A kind of production process and production equipment of light box lampshade |
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