CN110199150B

CN110199150B - Manufacturing method of solid bulb, solid bulb and LED lamp

Info

Publication number: CN110199150B
Application number: CN201780068321.7A
Authority: CN
Inventors: 刘宁
Original assignee: Shenzhen Ep Culture & Technology Co ltd
Current assignee: Shenzhen Ep Culture & Technology Co ltd
Priority date: 2017-11-09
Filing date: 2017-11-09
Publication date: 2021-05-11
Anticipated expiration: 2037-11-09
Also published as: WO2019090597A1; CN110199150A

Abstract

A method of manufacturing a solid bulb (1), comprising the steps of, preparing (S1): mixing liquid unsaturated resin, a curing agent and an accelerant to prepare a resin mixed solution, and mixing color paste, the liquid unsaturated resin and the accelerant to prepare a color paste mixed solution; casting (S2): pouring the resin mixed liquid into a bulb mould; primary curing (S3): standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a viscous state; toning (S4): dipping the color paste mixed solution by using a stirring rod, extending the stirring rod into a bulb mould for stirring to mix and dissolve the color paste mixed solution and the resin mixed solution, and then taking out the stirring rod; final cure (S8): standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a solid state; demolding (S10): and (5) taking down the mold. The manufacturing method mainly utilizes different properties of resin in each flow of resin curing reaction and the characteristics of the curing reaction to manufacture the solid bulb (1) with complex illumination effect.

Description

Manufacturing method of solid bulb, solid bulb and LED lamp

Technical Field

The scheme belongs to the technical field of lighting lamps, particularly relates to a manufacturing method of a solid bulb, and further relates to the solid bulb and a corresponding LED lamp suitable for the manufacturing method.

Background

Because people pursue quality of life now, ornament lamp is more and more popular, no matter be city planning or house design, current ornament lamp mainly through the lamp shade of different grade type or bulb, realize the decorative effect of lamps and lanterns, for example set up the bulb of different shapes, or set up the line decorations in order to realize different illumination effects in the bulb.

Unsaturated resin is a material with stronger plasticity and light transmittance, the existing decorative lamp usually uses unsaturated resin materials as bulbs of the decorative lamp, wherein, some bulbs are solid bulbs made of resin materials, and the existing process is limited, and the solid bulbs are usually made of transparent materials or semi-transparent materials with single color, so that the illumination effect which can be presented by a lamp using the bulbs made of resin materials is limited, and only a monotonous illumination effect can be presented, and the expectation of people on the illumination effect of the decorative lamp cannot be met.

Disclosure of Invention

The technical scheme aims to provide a manufacturing method of a solid bulb, the corresponding solid bulb and an LED lamp, and aims to solve the problem that a bulb made of resin is single in illumination effect.

In order to realize the purpose, the technical scheme adopted by the scheme is as follows: a manufacturing method of a solid bulb is provided, which is characterized by comprising the following steps. Preparing: mixing liquid unsaturated resin, a curing agent and an accelerant to prepare a resin mixed solution, and mixing color paste, the liquid unsaturated resin and the accelerant to prepare a color paste mixed solution; pouring: pouring the resin mixed liquid into a bulb mould; primary curing: standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a viscous state; color matching: dipping the color paste mixed solution by using a stirring rod, extending the stirring rod into a bulb mould for stirring to mix and dissolve the color paste mixed solution and the resin mixed solution, and then taking out the stirring rod; and (3) final curing: standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a solid state; demolding: and taking down the mold to obtain the solid bulb.

Further, before the curing step and after the toning step, the following steps are also included. And (3) re-curing: standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a gel state; putting in an ornament: the ornaments are placed at the opening above the mould.

Further, before the step of placing the ornament and after the step of re-curing, the method further comprises the step of testing: and testing whether the resin mixed liquid in the mould reaches the gel state or not by using a needle bar, and returning to the re-curing step if the resin mixed liquid does not reach the gel state.

Further, before the demolding step and after the final curing step, a cooling step is further included: putting the whole mould into water at 10-25 ℃ to cool the mould.

Further, after the demolding step, a grinding step is also included: the surface of the solid bulb was polished with sandpaper.

Further, in the polishing step, a plurality of pieces of sandpaper from low to high are sequentially used for polishing.

Further, in the preparation step, the weight fraction ratio of the liquid unsaturated resin, the curing agent and the accelerator in the resin mixed solution is 100: 0.3-0.4: 0.4-0.5.

Further, the operation temperature from the preparation step to the final curing step is controlled to be 16-35 ℃.

Further, the preliminary curing step lasts 20-45 minutes.

Further, the stirring time in the toning step is controlled within 20 seconds to 100 seconds.

Further, the stirring rod is cylindrical, and the diameter of the stirring rod is 3-10 mm.

Further, in the preparation step, the weight fraction ratio of the liquid unsaturated resin, the accelerator and the color paste in the color paste mixture is 100: 0.3-0.4: 0.2-0.3.

Further, the mold is a glass bulb.

Further, in the demolding step, the solid bulb is taken out by breaking the glass bulb.

Another object of this scheme is to provide a solid bulb, adopt above-mentioned solid bulb manufacturing approach to produce.

Another object of this scheme is to provide an LED lamp, is equipped with above-mentioned solid bulb.

The scheme mainly utilizes different properties presented by the resin in each flow of the curing reaction of the resin and the characteristics of the curing reaction to manufacture the solid bulb with complex illumination effect, and meanwhile, the solid bulb adopts the resin material, so that the solid bulb has better heat radiation performance and impact toughness.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the embodiments or the prior art descriptions will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without inventive exercise.

Fig. 1 is a schematic flow chart of a manufacturing method of a solid bulb according to an embodiment of the present disclosure;

fig. 2 is a schematic view of a solid bulb and an LED lamp provided in the present embodiment.

In the drawings, the reference numbers:

1-solid bulb; 11-texture; 12-decorations; 2-LED lamp panel; 3-lamp holder.

Detailed Description

In order to make the technical problems, technical solutions and beneficial effects to be solved by the present disclosure more clearly understood, the present disclosure is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present solution and are not intended to limit the present solution.

Referring to fig. 1, the present disclosure provides a method for manufacturing a solid bulb, including the steps of:

s1, preparation: mixing liquid unsaturated resin, a curing agent and an accelerant to prepare a resin mixed solution, and mixing color paste, the liquid unsaturated resin and the accelerant to prepare a color paste mixed solution;

s2, pouring: pouring the resin mixed liquid into a bulb mould;

s3, primary curing: standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a viscous state;

s4, color mixing: dipping the color paste mixed solution by using a stirring rod, extending the stirring rod into a bulb mould for stirring to mix and dissolve the color paste mixed solution and the resin mixed solution, and then taking out the stirring rod;

s8, final curing: standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a solid state;

s10, demolding: and taking down the mold to obtain the solid bulb.

The curing reaction of the unsaturated resin refers to a process that the liquid unsaturated resin is gradually converted into a solid state under the action of a curing agent or other conditions, and the mechanical state of the unsaturated resin is changed from an initial liquid state (which may be a non-Newtonian fluid or a Newtonian fluid) to a gel stage, a hardening stage and a complete curing stage to the solid state. The liquid resin is viscous but retains a certain fluidity before reaching the gel stage, in which the state of the resin is called viscous state, and the liquid resin loses fluidity and is converted into a gel state in the gel stage. The scheme mainly utilizes different properties of the resin in each flow of the curing reaction of the resin and the characteristics of the curing reaction to manufacture the solid bulb with complex illumination effect.

Specifically, in this embodiment, it is necessary to prepare the resin mixture and the color paste mixture in the preliminary step S1. The resin mixed solution is liquid unsaturated resin, a fixing agent and an accelerating agent are added into the liquid unsaturated resin, the liquid unsaturated resin is generally thermosetting resin, the liquid unsaturated resin is crosslinked and cured into insoluble substances under the action of a curing agent, and the accelerating agent can accelerate the curing process of the liquid unsaturated resin. The main component of the color paste mixed liquid is also liquid unsaturated resin, the color paste mixed liquid is enabled to be in the color of the color paste as a whole by adding the color paste, and the color paste mixed liquid is reacted with the curing agent in the resin mixed liquid and can be cured into solid resin. And because the volume of the unsaturated resin is increased after the unsaturated resin undergoes the curing reaction, if the curing speed of each part of the resin in the die is not consistent, the cured resin is cracked, so that an accelerant needs to be added into the color paste mixed liquid to ensure that the curing speed of the color paste mixed liquid is consistent with the curing speed of the resin mixed liquid.

Next, in the pouring step S2, the prepared resin mixture is poured into a bulb mold, and then the preliminary curing step S3 is performed to allow the mold to stand for a while to wait for the resin mixture in the mold to be cured into a viscous state. Next, in the color mixing step S4, the stirring rod is dipped in a small amount of color paste mixture, and then the stirring rod is inserted into the mold, so that the remaining color paste mixture is immersed in the resin mixture in the viscous state, at this time, the molecules of the resin mixture are not polymerized, the color paste mixture can be mixed with the resin mixture, and the molecules of the color paste mixture slowly diffuse to form complex textures. Finally, in the final curing step S8, the mold is allowed to stand for a period of time to complete the curing reaction, at this time, the solid bulb is molded, the molecules of the color paste mixed liquid are not diffused any more, the texture is fixed, and then the mold is taken down and the solid bulb is taken out through the demolding step S10.

Further, as a specific implementation manner of this embodiment, the method for manufacturing a solid bulb further includes a re-curing step S5 and a decoration placing step S7, where the re-curing step S5 is immediately followed by the color adjusting step S4, and the mold is left standing to wait for the resin mixture in the viscous state in the mold to be converted into a gel state. When the resin mixed liquid is converted into a gel state, the resin mixed liquid still has certain plasticity, and at the moment, an object can be placed in the resin mixed liquid and the resin mixed liquid can keep the integrity of the resin mixed liquid. The incorporation of decorative elements can allow solid bulbs to exhibit more complex lighting effects.

Further, as a specific embodiment of this embodiment, after the re-curing step S5, before the putting of the ornament step S7, a detecting step S6 of detecting whether the conversion state of the resin mixture liquid reaches the gel state using a needle bar is further included. Whether the resin reaches the gel state is difficult to be directly judged by naked eyes, so that the state of the resin mixed solution needs to be tested by using a needle bar to ensure that the resin mixed solution reaches the gel state, and decorations are conveniently placed.

Further, as a specific embodiment of this embodiment, before the step of demolding S10 and after the step of final curing S8, a step of cooling S9 is further included, and the mold is cooled by putting the entire mold into water at 10-25 ℃. After complete solidification, the resin material will adhere to the inner wall of the mold, making the solid bulb difficult to demould, so the bulb needs to be cooled to shrink and separate from the inner wall of the mold, and the mold is convenient to take out

Further, as a specific embodiment of this embodiment, after the step of demolding S10, a step of grinding S11 is further included, in which the surface of the solid bulb is ground and polished by using sandpaper. After the bulb is produced, a plurality of flaws still exist on the surface, and the surface needs to be polished to be smooth, so that the use requirement of the bulb is met.

Further, as a specific embodiment of this example, several sheets of sandpaper from low to high were used in sequence in the polishing step. Specifically, in the present embodiment, the surface of the solid bulb is ground with 300-8000 mesh sandpaper. The lower grit sandpaper can quickly smooth the larger ridges or indentations on the surface of the solid bulb, while the higher grit sandpaper can smooth the surface of the solid bulb.

Further, as a specific embodiment of this embodiment, in the preliminary step S1, the weight ratio of the liquid unsaturated resin, the curing agent, and the accelerator in the resin mixture is 100: 0.3-0.4: 0.4-0.5. The proportion of the fixing agent and the accelerator in the resin mixed solution determines the curing speed of the unsaturated resin and the completeness of the curing reaction; if the proportion of the curing agent to the accelerator is too high, the curing reaction is too fast and a large amount of heat is released, which may cause resin sintering; if the ratio of the curing agent to the accelerator is too small, the curing reaction may be incomplete and the resin may not be cured. Preferably, the weight ratio of the liquid unsaturated resin, the curing agent and the accelerator in the resin mixture in this embodiment is 100:0.4: 0.3.

Further, as a specific embodiment of this embodiment, the operation temperature is controlled to be 16 to 35 degrees Celsius from the preliminary step S1 to the final curing step S8. The operation temperature is directly related to the curing reaction speed, the curing reaction speed is faster at higher operation temperature, if the operation temperature is too high, the time of each process flow is reduced, in the subsequent color mixing step S4 and the decoration placing step S7, workers do not have enough operation time, the quality of the solid bulb is reduced, and if the operation temperature is too low, the time of the whole process flow is too long, and the efficiency is lower.

Further, as a specific embodiment of this embodiment, the preliminary curing step S3 lasts for 20 to 45 minutes. The purpose of the preliminary curing step S3 is to make the resin mixture liquid in a viscous state, which is a state between a gel state and a liquid state, and in the actual process flow, the resin mixture liquid is in the viscous state from the time when the curing agent is added to the time when the resin is changed into the gel state, and in this process, the dynamic viscosity of the resin mixture liquid increases with the time of standing. The dynamic viscosity of the resin mixed liquid has a great influence on the color mixing step S4, and specifically, when the dynamic viscosity of the resin mixed liquid is too high, the color paste mixed liquid cannot be slowly diffused, and complex textures cannot be formed inside the solid bulb to realize the illumination effect; on the contrary, if the dynamic viscosity of the resin mixed liquid is too low, the color paste mixed liquid and the resin mixed liquid are completely mixed and dissolved, the whole solid bulb presents a single color tone, and complex textures cannot be formed inside the solid bulb to realize the illumination effect. In conclusion, it is necessary to define a specific preliminary curing step standing time in order to achieve a good effect in the toning step S4.

Further, as a specific embodiment of this embodiment, the stirring time in the toning step S4 is controlled within 20 to 100 seconds. In the toning step S4, a stirring rod needs to be inserted into the resin mixture, which may affect the final curing effect of the resin, and in order to avoid cracks in the finally formed solid bulb, the toning step S4 needs to be completed within a certain time.

Further, as a specific embodiment of this example, the stirring rod has a cylindrical shape with a diameter of 3 to 10 mm. If the diameter of the stirring rod used in the color mixing step S4 is too large, a large amount of bubbles and cracks may be left in the resin mixed liquid, which is not favorable for curing and molding the resin mixed liquid, and if the diameter of the stirring rod used is too small, the stirring rod may not be dipped in a sufficient amount of the color paste mixed liquid, thereby limiting the diameter of the stirring rod to 3-10 mm; in addition, the cylindrical stirring rod is less resistant to stirring.

Further, as a specific implementation manner of this embodiment, in the preparation step, the weight fraction ratio of the liquid unsaturated resin, the accelerator, and the color paste in the color paste mixture is 100: 0.3-0.4: 0.2-0.3. The proportion of the accelerator in the color paste mixed liquid determines the curing speed of the color paste mixed liquid, the curing speed is higher when the proportion of the accelerator is larger, and if the curing speed of the color paste mixed liquid is far higher or lower than the curing speed of the liquid unsaturated resin, cracks can appear in the cured solid bulb. Preferably, the weight ratio of the liquid unsaturated resin, the accelerator and the color paste in the color paste mixture is 100:0.4: 0.3.

Further, as a specific embodiment of this example, the mold used was a glass bulb. The glass bulb is a mold which is low in cost and easy to obtain, the glass bulbs on the market are various in types, the glass bulb can be used for manufacturing various solid bulbs, the glass material is smooth, and the solidified solid bulbs are not easy to stick to the inner wall of the mold.

Further, as a specific embodiment of this example, in the mold releasing step, the solid bulb was taken out by breaking the glass bulb. The diameter of the opening of the glass bulb is smaller than the diameter of the outline, so that the glass bulb cannot be taken down by adopting a common method, in addition, the cost of the glass bulb is lower, and the molded solid bulb can be taken out by adopting a direct smashing method.

Another object of the present embodiment is to provide a solid bulb 1 produced by the above solid bulb production method, referring to fig. 2, the whole solid bulb 1 is formed by curing a resin mixture, and the inside thereof has a texture 11 formed by curing a color paste mixture, and the inside thereof also has an ornament 12. The solid bulb has a complex illumination effect, and has good heat dispersion and impact toughness due to the adoption of the resin material.

Another object of the present embodiment is to provide an LED lamp using the solid bulb, please refer to fig. 2, a lamp holder 3 is installed on the upper portion of the solid bulb 1, and an LED lamp panel 2 is installed in the lamp holder.

The above description is only exemplary of the present invention and should not be taken as limiting the present invention, and any modifications, equivalents, improvements, etc. made within the spirit and principle of the present invention should be included in the scope of the present invention.

Claims

1. A method for manufacturing a solid bulb is characterized by comprising the following steps:

preparing: mixing liquid unsaturated resin, a curing agent and an accelerant to prepare a resin mixed solution, and mixing color paste, the liquid unsaturated resin and the accelerant to prepare a color paste mixed solution;

pouring: pouring the resin mixed liquid into a bulb mould;

primary curing: standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a viscous state;

color matching: dipping the color paste mixed solution by using a stirring rod, extending the stirring rod into a bulb mould for stirring to mix and dissolve the color paste mixed solution and the resin mixed solution, and then taking out the stirring rod;

and (3) final curing: standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a solid state;

demolding: taking down the mold to obtain a solid bulb;

the primary curing step lasts 20-45 minutes.

2. A method of making a solid bulb as claimed in claim 1, further comprising, before said final curing step and after said toning step, the steps of:

and (3) re-curing: standing the mold, and waiting for the resin mixed liquid in the mold to be solidified into a gel state;

putting in an ornament: the ornaments are placed at the opening above the mould.

3. A method of making a solid core light bulb as claimed in claim 2 further comprising, before said placing step and after said re-curing step, the step of testing: and testing whether the resin mixed solution in the mould reaches a gel state or not by using a needle bar, and repeating the re-curing step if the resin mixed solution does not reach the gel state.

4. A method of manufacturing a solid bulb as claimed in any one of claims 1 to 3, further comprising, before the demoulding step and after the final curing step, a cooling step of: putting the whole mould into water at 10-25 ℃ to cool the mould.

5. A method of making a solid bulb as claimed in any one of claims 1 to 3, further comprising, after said demolding step, a grinding step: and (4) grinding and polishing the surface of the solid bulb by using sand paper.

6. A method of making a solid bulb as claimed in claim 5 wherein in the grinding step, a plurality of low to high mesh sandpaper are used in sequence.

7. The method for manufacturing a solid bulb as claimed in any one of claims 1 to 3, wherein in the preliminary step, the weight ratio of the liquid unsaturated resin, the curing agent and the accelerator in the resin mixture is 100:0.3 to 0.4:0.4 to 0.5.

8. A method for making a solid bulb as claimed in claim 7, wherein the operating temperature is controlled from 16 to 35 ℃ from the preliminary step to the final curing step.

9. A method of manufacturing a solid bulb as claimed in any one of claims 1 to 3 wherein the stirring time in the toning step is in the range of 20 to 100 seconds.

10. A method of manufacturing a solid bulb as claimed in any one of claims 1 to 3 wherein the stirring rod is cylindrical and has a diameter of 3 to 10 mm.

11. The method for manufacturing a solid bulb as claimed in any one of claims 1 to 3, wherein in the preliminary step, the weight fraction ratio of the liquid unsaturated resin, the accelerator and the color paste in the color paste mixture is 100: 0.3-0.4: 0.2-0.3.

12. A method of manufacturing a solid bulb as claimed in any one of claims 1 to 3 wherein the mould is a glass bulb.

13. A method of making a solid bulb as claimed in claim 12 wherein in said step of demolding, said solid bulb is removed by breaking said glass bulb.

14. A solid bulb produced by the method of producing a solid bulb according to any one of claims 1 to 13.

15. An LED lamp comprising the solid bulb of claim 14.