CN106738608A - 塑包五金散热件的制备工艺及使用该散热件的灯具 - Google Patents
塑包五金散热件的制备工艺及使用该散热件的灯具 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/78—Measuring, controlling or regulating of temperature
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
- F21V29/85—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems characterised by the material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
- B29C2045/14245—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity using deforming or preforming means outside the mould cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76498—Pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76531—Temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76595—Velocity
- B29C2945/76605—Velocity rotational movement
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Abstract
本发明提供一种塑包五金散热件的制备工艺,包括以下步骤,(1)冲压成型散热基体:基于冷冲压工艺将五金耗材冲压成目标形状的五金件,五金件冲压成型的同时其上冲压形成有变形缓冲带,以此冲压成型获得散热基体;(2)塑包散热基体获得散热件:将步骤(1)中成型获得的散热基体置于注塑模具内,基于注塑工艺将散热塑料注塑包覆在散热基体的散热表面,以此注塑成型获得塑包五金散热件。本发明的塑包五金散热件的制备工艺,注塑完成后的散热件即为材料半成品,无需喷漆和二次加工,能够大幅度的提高生产效率和有效降低不良率;与此同时,有效解决注塑工艺中塑料和铝件因缩水率不同而造成的变形问题,确保散热件的散热效果和LED灯珠的使用寿命。
Description
技术领域
本发明属于灯具设计生产技术领域,具体涉及一种塑包五金散热件的制备工艺及使用该散热件的灯具。
背景技术
散热是影响LED灯具成本和使用寿命的主要因素,LED灯具的安装都需要配置散热件,铝是最好的散热材料。目前,LED灯具的散热件通过如下步骤获得,选取铝材为散热基材,基于压铸工艺将铝材成型为目标形状和尺寸的散热件,随后在散热件的一个表面喷漆形成绝缘面,与之相对的另一个表面形成安装LED灯具的散热面。如此工艺制备的散热件工艺复杂,二次加工介入太多,单价高,同时生产效率和良率都不能达到预期目标。
另,为了解决上述技术问题,业界也曾尝试基于注塑工艺制备塑包铝散热件,但是,由于塑料和铝两者材料的本身特性,在注塑工艺中两者的缩水率不同,塑料的缩水率大、铝的小,使得成型后的散热件变形严重,塑料和铝件之间产生气泡,最终影响散热效果,危及LED灯珠的使用寿命。
发明内容
为解决上述技术问题,本发明提供了一种塑包五金散热件的制备工艺,注塑完成后的散热件即为材料半成品,无需喷漆和二次加工,能够大幅度的提高生产效率和有效降低不良率;与此同时,有效解决注塑工艺中塑料和铝件因缩水率不同而造成的变形问题,确保散热件的散热效果和LED灯珠的使用寿命。
为达到上述目的,本发明的技术方案如下:一种塑包五金散热件的制备工艺,其特征在于:包括以下步骤,
(1)冲压成型散热基体:基于冷冲压工艺将五金耗材冲压成目标形状的五金件,所述五金件冲压成型的同时其上冲压形成有变形缓冲带,所述变形缓冲带贯穿五金件的两侧表面,以此冲压成型获得散热基体;
(2)塑包散热基体获得散热件:将步骤(1)中成型获得的散热基体置于注塑模具内,基于注塑工艺将散热塑料注塑包覆在所述散热基体的散热表面,以此注塑成型获得塑包五金散热件。
本发明的一个较佳实施例中,进一步包括所述散热基体的中心设有安装区域、围绕安装区域的四周均设有散热区域,所述安装区域和各散热区域内均冲压形成有所述变形缓冲带。
本发明的一个较佳实施例中,进一步包括所述变形缓冲带为贯穿五金件两侧表面的若干个变形缓冲槽,所述变形缓冲槽为长条状腰型槽结构。
本发明的一个较佳实施例中,进一步包括成型获得的塑包五金件的散热面积为(600~650)*Pmm2,P为发热元件的功率瓦数。
本发明的一个较佳实施例中,进一步包括所述散热塑料为聚对苯二甲酸丁二醇酯、或者聚对苯二甲酸四次甲基酯。
本发明的一个较佳实施例中,进一步包括
注塑前:在130~150℃的温度下干燥散热塑料3~4小时;
注塑过程中:控制熔胶温度为275~290℃、注射压力为145~160MPa、背压3~5MPa、回料转速95~100rpm。
本发明的一个较佳实施例中,进一步包括所述五金耗材为铝耗材。
为达到上述目的,本发明的技术方案如下:一种灯具,包括灯体,其特征在于:其还包括权利要求1-7任一项所述的塑包五金散热件,所述灯体的热源部位固定在塑包五金散热件上。
本发明的有益效果是:
其一、相较于传统的压铸工艺,本发明的制备工艺注塑完成后的散热件即为材料半成品,无需喷漆和二次加工,组成部件从传统的“两件套”优化为“一件套”,能够大幅度的提高生产效率和有效降低不良率;
其二、有效解决传统塑包铝注塑工艺中塑料和铝件因缩水率不同而造成的变形问题,确保散热件的散热效果和LED灯珠的使用寿命。
附图说明
为了更清楚地说明本发明实施例技术中的技术方案,下面将对实施例技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
图1是本发明优选实施例散热基体的结构示意图。
其中:2-散热基体,4-变形缓冲带,6-变形缓冲槽。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例一
如图1所示,本实施例中公开了一种塑包五金散热件的制备工艺,包括以下步骤,
(1)冲压成型散热基体2:基于冷冲压工艺将五金耗材冲压成目标形状和目标尺寸的五金件,优选五金耗材为铝耗材,其热传导率为236W/m.K,散热效果好,所述五金件冲压成型的同时其上冲压形成有变形缓冲带4,所述变形缓冲带4贯穿五金件的两侧表面,以此冲压成型获得散热基体2;
(2)塑包散热基体获得散热件:将步骤(1)中成型获得的散热基体2置于注塑模具内,基于注塑工艺将散热塑料注塑包覆在所述散热基体2的散热表面,以此注塑成型获得塑包五金散热件。注塑成型后的散热件,其没有包覆塑料的一面与发热件直接接触,包覆有塑料的一面形成向外传导热量的表面。
如此,相较于传统的压铸工艺,本发明的制备工艺注塑完成后的散热件即为材料半成品,无需喷漆和二次加工,组成部件从传统的“两件套”优化为“一件套”,能够大幅度的提高生产效率和有效降低不良率。
本发明在冷冲压形成铝散热基体2过程中在散热基体2上一体冲压形成变形缓冲带4,有效解决塑料和铝质散热基体2两者在高温注塑时因缩水率不同而出现的注塑变形问题,两种材质在高温注塑过程中能够紧密贴合,注塑过程中不会产生气泡,确保散热件的散热效果,使得配置有本发明散热件的灯具能够确保使用寿命。
具体的,所述散热基体2的中心设有安装区域21、围绕安装区域21的四周均设有散热区域22,所述安装区域21和各散热区域22内均冲压形成有所述变形缓冲带4,所述变形缓冲带4为贯穿五金件两侧表面的若干个变形缓冲槽6,所述变形缓冲槽6为长条状腰型槽结构;通过不间断的试验,最终获得如图1所示形状、位置和数量的变形缓冲槽6的效果最好,能够最大限度的确保塑料和铝质散热基体2在注塑成型过程中的服帖度,以此来最大程度的确保散热件的散热效果,由此成型获得的塑包五金件的散热面积为(600~650)*Pmm2,P为发热元件的功率瓦数,使得发热件产生热量的95%以上都能够传导出去。
作为本发明的进一步改进,所述散热塑料为热塑性塑料,优选聚对苯二甲酸丁二醇酯、或者聚对苯二甲酸四次甲基酯,其具有优良的包括绝缘性能、介电系数和耐电弧性在内的电气性能,以及具有优良的散热性能,能够进一步提高散热件的散热性能。
进一步的,优选聚对苯二甲酸丁二醇酯、或者聚对苯二甲酸四次甲基酯作为本发明散热塑料时,为了避免其在高温下水解,注塑前在130~150℃的温度下干燥散热塑料3~4小时;考虑聚对苯二甲酸丁二醇酯、或者聚对苯二甲酸四次甲基酯从熔融状态一经冷却,则会立即凝固结晶,为了避免结晶堵塞喷嘴,注塑过程在“高速、中压、中温”条件下进行,具体是:控制熔胶温度为275~290℃、注射压力为145~160MPa、背压3~5MPa、回料转速95~100rpm。
实施例二
本发明提供一种一种灯具,包括灯体和上述的塑包五金散热件,所述灯体的热源部位固定在塑包五金散热件上。灯体的发热件紧贴安装在散热件的没有包覆塑料的表面,如此设计的灯具能够确保安全温度内的使用寿命。
对所公开的实施例的上述说明,使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下,在其它实施例中实现。因此,本发明将不会被限制于本文所示的这些实施例,而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (8)
1.一种塑包五金散热件的制备工艺,其特征在于:包括以下步骤,
(1)冲压成型散热基体:基于冷冲压工艺将五金耗材冲压成目标形状的五金件,所述五金件冲压成型的同时其上冲压形成有变形缓冲带,所述变形缓冲带贯穿五金件的两侧表面,以此冲压成型获得散热基体;
(2)塑包散热基体获得散热件:将步骤(1)中成型获得的散热基体置于注塑模具内,基于注塑工艺将散热塑料注塑包覆在所述散热基体的散热表面,以此注塑成型获得塑包五金散热件。
2.根据权利要求1所述的塑包五金散热件的制备工艺,其特征在于:所述散热基体的中心设有安装区域、围绕安装区域的四周均设有散热区域,所述安装区域和各散热区域内均冲压形成有所述变形缓冲带。
3.根据权利要求2所述的塑包五金散热件的制备工艺,其特征在于:所述变形缓冲带为贯穿五金件两侧表面的若干个变形缓冲槽,所述变形缓冲槽为长条状腰型槽结构。
4.根据权利要求1所述的塑包五金散热件的制备工艺,其特征在于:成型获得的塑包五金件的散热面积为(600~650)*Pmm2,P为发热元件的功率瓦数。
5.根据权利要求1所述的塑包五金散热件的制备工艺,其特征在于:所述散热塑料为聚对苯二甲酸丁二醇酯、或者聚对苯二甲酸四次甲基酯。
6.根据权利要求5所述的塑包五金散热件的制备工艺,其特征在于,
注塑前:在130~150℃的温度下干燥散热塑料3~4小时;
注塑过程中:控制熔胶温度为275~290℃、注射压力为145~160MPa、背压3~5MPa、回料转速95~100rpm。
7.根据权利要求1所述的塑包五金散热件的制备工艺,其特征在于:所述五金耗材为铝耗材。
8.一种灯具,包括灯体,其特征在于:其还包括权利要求1-7任一项所述的塑包五金散热件,所述灯体的热源部位固定在塑包五金散热件上。
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