CN114370613A - 一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺 - Google Patents
一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺 Download PDFInfo
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Abstract
本发明公开了一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,包括电源线以及间隔设置在电源线上的若干个灯泡,灯泡包括灯罩、灯芯主体以及至少一绝缘胶件。灯罩设置有插装部,灯芯主体插装于插装部且伸入灯罩的内部,灯芯主体设置有至少一LED灯丝,LED灯丝的两端分别连接有正极导电线和负极导电线,成为半成品毛泡。毛泡、正极导电线、负极导电线和灯罩是通过注塑与电源线一体式连接,注塑胶溶体与半成品毛泡经模具融合成一体,形成绝缘胶件。具有防水性强,结构简单,使用寿命长,无破损。无灯座少零件,减少人工扭装,便于加工,绝缘度高,故障率低,高防水;灯泡的绝缘保护头通过注塑与电源线一体式连接,加工工艺简单,成本低。
Description
技术领域
本发明涉及LED照明技术领域,尤其是涉及一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺。
背景技术
LED灯泡一般由铜制灯头、灯罩和LED灯芯组装而成,LED灯泡的生产需要经过多道工序才能完成。在现有技术中,LED灯丝灯泡首先加工一只与白炽灯内同的玻璃芯柱,通过半机械和半人工将灯丝焊接到玻璃芯柱上,形成LED灯芯;另外通过半机械和半人工将LED灯芯送入封口排气机,然后充入惰性气体后切断排气管,成为一只LED灯毛泡;接着再人工将毛泡的后端部固定安装在铜制灯头上形成一LED灯泡成品。
在上述的制作LED灯泡流程中存在如下问题:受限于传统灯泡的多配件结构,上述制作流程的玻璃芯柱和封口工艺过程中,需要使用高温火焰熔结成型,不仅对生产环境会造成污染,工作人员长期在该环境下对健康有一定的影响;铜制灯头越小其自动化生产的难度就越大;不防水,灯罩内产生水雾会导电,导致烧损电子元器件,甚至发生漏电,容易发生安全事故。
尤其是制作灯串时,传统的灯串是在电源线上间隔设置若干个灯座,每个灯座内还设有一个导电铜套,将灯泡扭装或卡接在灯座上,因此灯泡和灯座之间具有一定间隙,不具备防水性能,在使用时具有一定安全隐患,故障率高,使用寿命不长;而传统的一体化灯串结构复杂,加工难度大,防水等级仅为IP45以下,防水性能一般;并且灯泡串联数量少,无法多灯串连灯泡及长距离的进行串连,因此有必要予以大范围改进。
发明内容
针对现有技术存在的不足,本发明的目的是提供一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,具有防水性强,结构简单,使用寿命长,无破损,简化加工工艺,便于加工,不易破损,绝缘度高,故障率低,产量大,高防水。
为了实现上述目的,本发明所采用的技术方案是:一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,包括电源线以及间隔设置在电源线上的若干个灯泡,电源线包括正极电线和负极电线,灯泡包括灯罩、灯芯主体以及至少一绝缘胶件,灯罩设置有插装部,灯芯主体插装于插装部且伸入灯罩的内部,灯芯主体设置有至少一条LED灯丝,LED灯丝的两端部分别连接有正极导电线和负极导电线,正极导电线与正极电线电性连接,负极导电线与负极电线电性连接,成为半成品毛泡。半成品毛泡、正极导电线、负极导电线和灯罩是通过注塑与电源线一体式连接,注塑胶溶体与半成品毛泡经模具融合成一体,形成密封绝缘胶件头。
进一步的技术方案中,电源线与所述灯芯主体之间连接有延长电线,延长电线包括正极延长线和负极延长线,正极延长线的一端与所述正极电线电性连接、正极延长线的另一端与所述正极导电线电性连接,负极延长线的一端与所述负极电线电性连接、负极延长线的另一端与所述负极导电线电性连接,所述灯泡的所述插装部和所述电源线与延长电线的连接处分别注塑成型有一所述密封绝缘胶件头。
进一步的技术方案中,密封绝缘胶件头设置有用于固定所述灯泡的固定件,固定件固接或一体成型于密封绝缘胶件头的端部。
进一步的技术方案中,固定件为挂钩、吸盘、黏胶、夹子、挂设孔和魔术贴的其中一种。
进一步的技术方案中,灯芯主体包括灯芯柱、所述正极导电线、所述负极导电线、排气管、至少一条所述LED灯丝以及用于驱动LED灯丝发光的驱动元件,灯芯柱插装于所述灯泡的插装部,LED灯丝固定安装于灯芯柱,正极导电线的一端与LED灯丝的端部电性连接、正极导电线的另一端与所述正极电线电性连接,负极导电线的一端与LED灯丝的另一端电性连接、负极导电线的另一端与所述负极电线电性连接,驱动元件设置于正极导电线或负极导电线,驱动元件位于灯芯柱的内部或外围。
针对现有技术存在的不足,本发明的目的是提供一种无需传统灯座的高防水高绝缘简易注塑一体灯串制作工艺,灯泡的绝缘胶件通过注塑与电源线一体式连接,一体化程度高,加工工艺简单,成本低,防水性强,使用寿命长,便于加工,不易破损,绝缘度高,故障率低,产量大。
为了实现上述目的,本发明所采用的技术方案是:一种无需传统灯座的高防水高绝缘简易注塑一体灯串制作工艺,
S1步骤:通过剥皮机对如权利要求1所述的电源线进行局部剥皮,在所述正极电线和所述负极电线上分别形成一连接部;
S2步骤:将如权利要求1所述的灯芯主体的所述正极导电线和所述负极导电线分别与正极电线的连接部和负极电线的连接部电性连接,连接方式可以是卡接也可以是焊接;
S3步骤:将灯芯主体插装于如所述权利要求1所述的灯罩内;
S4步骤:将连接部放置在注塑机的模具上,通过注塑机对模具注塑,注塑形成如权利要求1所述的与所述灯罩一体式连接的所述绝缘防水胶件。
进一步的技术方案中,S2步骤还包括以下步骤
1)将如权利要求2所述的正极延长线和所述负极延长线的第一端分别与所述正极电线的所述连接部和所述负极电线的所述连接部电性连接,连接方式可以是卡接也可以是焊接;
2)将正极延长线和负极延长线的第二端分别与所述正极导电线和负极导电线电性连接,连接方式可以是卡接也可以是焊接;
进一步的技术方案中,S4步骤中将所述连接部和如权利要求2所述的延长电线与正极导电线和负极导电线的连接处分别放入所述注塑机的所述模具上,通过注塑机对模具注塑,形成两个所述密封绝缘胶件头。
进一步的技术方案中,S1步骤中,通过所述剥皮机在所述电源线上均匀等份的间隔剥皮处理,形成若干个间隔设置的所述连接部,在每个连接部分别设置一所述灯泡。
采用上述结构后,本发明和现有技术相比所具有的优点是:本发明的灯串结构巧妙,便于实现机械自动化生产,尤其是大小尺寸绝缘防水保护头产品的自动化生产,简化其生产过程,大大降低了生产成本,有效提高了灯串的日产量;采用灯芯插接灯罩的方式,减少传统多配件灯泡的手工扭装方式和人工组装的带来的成本压力,产品合格率高;灯芯主体、灯罩、电源线三者之间的一体式连接,减少了多个配件带来的成本,大大提高了灯串的密封绝缘性能和防水性能,延长了灯串的使用寿命,可单灯使用,更可成倍增加多灯串联使用,从而降低了多插头连接的不良成本。
附图说明
下面结合附图和实施例对本发明进一步说明。
图1是本发明的结构示意图;
图2是本发明的图1的A部放大图;
图3是本发明的延长电线的连接示意图;
图4是本发明的电源线与正极导电线和负极导电线的连接示意图;
图5是本发明的灯芯主体的结构示意图。
图中:
1电源线、11正极电线、12负极电线、13连接部;
2灯泡、21灯罩、211插装部、22灯芯主体、221LED灯丝、222正极导电线、223负极导电线、224灯芯柱、226驱动元件;
3密封绝缘胶件头、31固定件;
4延长电线;
5半成品毛泡。
具体实施方式
以下仅为本发明的较佳实施例,并不因此而限定本发明的保护范围。
一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,如图1至图5所示,包括电源线1以及间隔设置在电源线1上的若干个灯泡2,其特征在于:电源线1包括正极电线11和负极电线12,灯泡2包括灯罩21、灯芯主体22以及至少一密封绝缘胶件头3,灯罩21设置有插装部211,灯芯主体22插装于插装部211且伸入灯罩21的内部,灯芯主体22设置有至少一条LED灯丝221,LED灯丝221的两端部分别连接有正极导电线222和负极导电线223,正极导电线222与正极电线11电性连接,负极导电线223与负极电线12电性连接,成为半成品毛泡5。半成品毛泡5、正极导电线222、负极导电线223和灯罩21是通过注塑与电源线1一体式连接,注塑胶溶体与半成品毛泡5经模具融合成一体,形成密封绝缘胶件头3。
若干个灯泡2通过塑胶机注塑形成密封绝缘胶件头3,与电源线1一体式连接,组成该灯串,无需单独制作密封绝缘胶件头3,并且进行组装,简化灯泡组装工序的同时,提高电源线1与塑料灯泡2之间的连接强度,提高灯串的使用寿命。
具体地,如图3所示,电源线1与灯芯主体22之间连接有延长电线4,延长电线4包括正极延长线和负极延长线,正极延长线的一端与正极电线11电性连接、正极延长线的另一端与正极导电线222电性连接,负极延长线的一端与负极电线12电性连接、负极延长线的另一端与负极导电线223电性连接,灯泡2的插装部211和电源线1与延长电线4的连接处分别注塑成型有一密封绝缘胶件头3。通过延长电线4增加了灯泡2与电源线1之间的距离,使灯串形成梳子形状,便于隐藏电源线1,使其在装饰时更加美观,在延长电线4的两个连接处分别注塑成型一密封绝缘胶件头3,防水性能更佳。
具体地,密封绝缘胶件头3设置有用于固定灯泡2的固定件31,固定件31固接或一体成型于密封绝缘胶件头3的端部。
具体地,固定件31为挂钩、吸盘、黏胶、夹子、挂设孔和魔术贴的其中一种。
固定件31开设有一挂设孔,通过挂设孔可将各个灯泡2固定在挂钩上;或者固定件31为夹子,通过夹子固定各个灯泡2;或者固定件31为挂钩,通过挂钩将各个灯泡2挂设在孔内进行固定;或者固定件31为吸盘,通过吸盘将各个灯泡2吸附在平面上;或者固定件31为黏胶,通过粘贴的方式将各个灯泡2粘贴在相应的位置上;或者固定件31为魔术贴,通过魔术贴将各个灯泡2粘贴在毛面上,通过固定件31固定各个灯泡2,安装灯串更加便捷。
具体地,灯芯主体22包括灯芯柱224、正极导电线222、负极导电线223、排气管225、至少一条LED灯丝221以及用于驱动LED灯丝221发光的驱动元件226,灯芯柱224插装于灯泡2的插装部211,LED灯丝221固定安装于灯芯柱224,正极导电线222的一端与LED灯丝221的端部电性连接、正极导电线222的另一端与正极电线11电性连接,负极导电线223的一端与LED灯丝221的另一端电性连接、负极导电线223的另一端与负极电线12电性连接,驱动元件226设置于正极导电线222或负极导电线223,驱动元件226位于灯芯柱224的内部或外围。驱动元件226设置在灯芯柱224内的空间,保护驱动元件226,提升产品质量,降低故障率。
较佳地,灯芯柱224采用玻璃材质或塑料材质。灯芯柱224采用玻璃材质时,灯芯柱224的顶端通过高温熔结的方式将正极导电线222、负极导电线223、LED灯丝221以及灯芯柱224连成一体,能保证自动化或人工生产过程中灯芯柱主体2位置的固定,从而保证产品的合格率。
具体地,S1步骤:通过剥皮机对如权利要求1的电源线1进行局部剥皮,在正极电线11和负极电线12上分别形成一连接部13;
S2步骤:将如权利要求1的灯芯主体22的正极导电线222和负极导电线223分别与正极电线11的连接部13和负极电线12的连接部13电性连接,连接方式可以是卡接也可以是焊接;
S3步骤:将灯芯主体22插装于如权利要求1的灯罩21内;
S4步骤:将连接部13放置在注塑机的模具上,通过注塑机对模具注塑,注塑形成如权利要求1的与灯罩21一体式连接的绝缘防水胶件。
绝缘胶件3直接注塑在连接部13上,无需传统的铜制灯头,一体化连接,密封性更强,较传统的灯串防水等级IP45,本发明的灯串防水性至少可达到IP68;无需在传统的铜制灯头的底部加设绝缘件隔绝正负极,结构简单,加工工艺更加简单,成本更低,无需人手工扭装,可靠性高,提高了产品合格率。
具体地,S2步骤还包括以下步骤
1)将如权利要求2的正极延长线和负极延长线的第一端分别与正极电线11的连接部13和负极电线12的连接部13电性连接,连接方式可以是卡接也可以是焊接;
2)将正极延长线和负极延长线的第二端分别与正极导电线222和负极导电线223电性连接,连接方式可以是卡接也可以是焊接;
具体地,S4步骤中将连接部13和如权利要求2的延长电线4与正极导电线222和负极导电线223的连接处分别放入注塑机的模具上,通过注塑机对模具注塑,形成两个密封绝缘胶件头3。
在电源线1和灯泡2之间增设延长电线4,然后对延长电线4的两个端部的连接处分别注塑成型一密封绝缘胶件头3,进一步提高其防水性。
具体地,S1步骤中,通过剥皮机在电源线1上均匀等份的间隔剥皮处理,形成若干个间隔设置的连接部13,在每个连接部13分别设置一灯泡2。根据实用场景在电源线1上设置数量不同的灯泡2,更加美观、实用,可长距离、多灯泡串连,使用场景更为广泛。
以上内容仅为本发明的较佳实施例,对于本领域的普通技术人员,依据本发明的思想,在具体实施方式及应用范围上均会有改变之处,本说明书内容不应理解为对本发明的限制。
Claims (9)
1.一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,包括电源线(1)以及间隔设置在电源线(1)上的若干个灯泡(2),其特征在于:电源线(1)包括正极电线(11)和负极电线(12),灯泡(2)包括灯罩(21)、灯芯主体(22)以及至少一绝缘胶件(3),灯罩(21)设置有插装部(211),灯芯主体(22)插装于插装部(211)且伸入灯罩(21)的内部,灯芯主体(22)设置有至少一LED灯丝(221),LED灯丝(221)的两端部分别连接有正极导电线(222)和负极导电线(223),正极导电线(222)与正极电线(11)电性连接,负极导电线(223)与负极电线(12)电性连接,成为半成品毛泡(5)。半成品毛泡(5)、正极导电线(222)、负极导电线(223)和灯罩(21)是通过注塑与电源线(1)一体式连接,注塑胶溶体与半成品毛泡(5)经模具融合成一体,形成密封绝缘胶件头(3)。
2.根据权利要求1所述的一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,其特征在于:所述电源线(1)与所述灯芯主体(22)之间连接有延长电线(4),延长电线(4)包括正极延长线和负极延长线,正极延长线的一端与所述正极电线(11)电性连接、正极延长线的另一端与所述正极导电线(222)电性连接,负极延长线的一端与所述负极电线(12)电性连接、负极延长线的另一端与所述负极导电线(223)电性连接,所述灯泡(2)的所述插装部(211)和所述电源线(1)与延长电线(4)的连接处分别注塑成型有一所述密封绝缘胶件头(3)。
3.根据权利要求1所述的一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,其特征在于:所述密封绝缘胶件头(3)设置有用于固定所述灯泡(2)的固定件(31),固定件(31)固接或一体成型于密封绝缘胶件头(3)的端部。
4.根据权利要求3所述的一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,其特征在于:所述固定件(31)为挂钩、吸盘、黏胶、夹子、挂设孔和魔术贴的其中一种。
5.根据权利要求1所述的一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,其特征在于:所述灯芯主体(22)包括灯芯柱(224)、所述正极导电线(222)、所述负极导电线(223)、至少一条所述LED灯丝(221)以及用于驱动LED灯丝(221)发光的驱动元件(226),灯芯柱(224)插装于所述灯泡(2)的插装部(211),LED灯丝(221)固定安装于灯芯柱(224),正极导电线(222)的一端与LED灯丝(221)的端部电性连接、正极导电线(222)的另一端与所述正极电线(11)电性连接,负极导电线(223)的一端与LED灯丝(221)的另一端电性连接、负极导电线(223)的另一端与所述负极电线(12)电性连接,驱动元件(226)设置于正极导电线(222)或负极导电线(223),驱动元件(226)位于灯芯柱(224)的内部或外围。
6.一种无需传统灯座的高防水高绝缘简易注塑一体灯串的制作工艺,其特征在于:
S1步骤:通过剥皮机对如权利要求1所述的电源线(1)进行局部剥皮,在所述正极电线(11)和所述负极电线(12)上分别形成一连接部(13);
S2步骤:将如权利要求1所述的灯芯主体(22)的所述正极导电线(222)和所述负极导电线(223)分别与正极电线(11)的连接部(13)和负极电线(12)的连接部(13)电性连接,连接方式可以是卡接也可以是焊接;
S3步骤:将灯芯主体(22)插装于如所述权利要求1所述的灯罩(21)内;
S4步骤:将连接部(13)放置在注塑机的模具上,通过注塑机对模具注塑,注塑形成如权利要求1所述的与所述灯罩(21)一体式连接的所述绝缘防水胶件。
7.根据权利要求6所述的一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,其特征在于:所述S2步骤还包括以下步骤
1)将如权利要求2所述的正极延长线和所述负极延长线的第一端分别与所述正极电线(11)的所述连接部(13)和所述负极电线(12)的所述连接部(13)电性连接,连接方式可以是卡接也可以是焊接;
2)将正极延长线和负极延长线的第二端分别与所述正极导电线(222)和负极导电线(223)电性连接,连接方式可以是卡接也可以是焊接;
8.根据权利要求7所述的一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,其特征在于:所述S4步骤中将所述连接部(13)和如权利要求2所述的延长电线(4)与正极导电线(222)和负极导电线(223)的连接处分别放入所述注塑机的所述模具上,通过注塑机对模具注塑,形成两个所述密封绝缘胶件头(3)。
9.根据权利要求7所述的一种无需传统灯座的高防水高绝缘简易注塑一体灯串及其制作工艺,其特征在于:所述S1步骤中,通过所述剥皮机在所述电源线(1)上均匀等份的间隔剥皮处理,形成若干个间隔设置的所述连接部(13),在每个连接部(13)分别设置一所述灯泡(2)。
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