EA019873B1 - Method for producing a led lamp, led lamp obtained by said method, and radiator for said lamp - Google Patents

Abstract

The invention relates to LED lamps, and the technical result of the invention is an increase in the structure workability and a simpler assembly of the article that can be achieved due to a firm connection made between the hollow annular radiator (4), the light-emitting shell (1), and the transition cone (10), using a two-link closing mechanism including catches (3, 11), protrusions (12) and openings (7) that are formed during the production step of these parts of the lamp.

Description

The invention relates to lighting engineering, and in particular to the manufacturing technology and design of LED lighting devices intended for use as part of equipment for external and internal lighting.

State of the art

It is known that the complexity of assembly operations is up to 50% of the total complexity of the production of devices. Optimization of the assembly process reduces the price of products and creates competitive advantages. Among the most time-consuming include operations associated with the mechanical connection of parts and assemblies, in particular during the final assembly of the finished product.

In relation to LED lamps, assembly operations mean an integral fixed connection of assembly units - individual structural functional parts of the lamp: a radiator (cooling device), a light-emitting shell, a source of radiation sources, an electronic converter assembly, means of connecting to an electric current source (in particular, an electric base) . Obviously, for the installation, the assembly units must be equipped with the appropriate technological means of connection, allowing to successfully complete the assembly operations. Such tools include technological holes, guide grooves, technological protrusions, which, although they are part of the assembly units, are intended solely for assembly operations and do not participate in the operation of the light source.

The following identified methods for manufacturing electronic devices are known in the art.

The method of mounting a receiving-amplifying lamp is described in detail in the book of E.I. Schehmeister Assembly operations in electrovacuum production, Moscow, Higher School, 1987, p. 14-25, in which electrodes, traverses, leads and plate springs are fixed in mica insulator provided with teeth along the edges in pre-cut holes. The assembled electrode assembly is placed in a glass bulb in such a way that the said teeth on the mica insulator are deformed against the calibrated surface of the bulb and, due to the elasticity of the material, provide a sufficient density of the electrode assembly in the bulb of the lamp. It should be noted that the mentioned insulator teeth and leaf springs do not participate in the operation of the receiving-amplifying lamp, but are absolutely necessary for the assembly operation of the product, i.e. these elements are technological.

Known methods for connecting parts and assemblies of an LED lamp, in which the light-emitting sheath and the base are fixed to the lamp housing using only a threaded connection (Chinese application € N2760382, MKI E21B 6/00, published 02.22.2006) or threaded connection and latch (Chinese application SI201106814 , MKI E21U 17/00, published August 27, 2008).

The screwing operation is itself quite time-consuming, and in relation to plastic parts it requires the application of normalized forces, most often controlled by a special tool. The connection of the light-emitting casing with a latch made around the entire perimeter of the casing, equipped with an annular protrusion on the lamp housing, also located around the entire perimeter of the casing, not only complicates the installation, but can also deform the casing during assembly.

Known LED lamp, in which the nodes and parts are provided with means for their connection. So, a case with an electronic converter is performed with latches on the outer surface, and the end panel of the metal cast radiator is provided with holes for accommodating the tabs of the latch. The connection of these assembly units is carried out by fixing the latches in the holes of the front panel of the radiator (patent EP2077415, MKI E21U 29/00, published 08.07.2009).

A disadvantage of the known solution is the low-tech design of the LED lamp due to the placement of the electronic converter in a closed case made up of two parts to be connected by means of a special technological operation; increased requirements for the accuracy of manufacturing the elements of the latches on the halves of the case, necessary for guaranteed fixation on the radiator disk. In addition, in a closed case, efficient cooling of the electronic converter cannot be ensured, apparently, therefore, a powerful but single LED is used as a radiation source.

The closest analogue to the method of manufacturing an LED lamp is the solution according to EP2077415.

As the prior art for the construction of an LED lamp, the already mentioned solutions for applications of € .'N2760382 and € N201106814 can be indicated. In addition to the above disadvantages of these solutions, it should be noted a large number of parts that must be pre-connected before the final assembly of the LED lamp, which allows us to talk about the low-tech design of the lamp.

The closest analogue of the LED lamp is the solution according to EP2077415, an exhaustive criticism of which is set out on page 3 of this description.

The prior art for a hollow radiator can be characterized by the following identified analogues.

- 1 019873

Known hollow radiator for an LED lamp, containing a ribbed side surface, a top panel with a podium for accommodating LEDs, equipped with ventilation holes, a wall around the perimeter of the upper panel with a thread, apparently for attaching a light-scattering sheath (application for utility model SI201059520, MKI R21U 29/00 published on 05/14/2008).

Neither the description nor the graphic materials of the known solution contain information about the means of connection with other parts and components of the LED lamp. A visible drawback of the solution is the presence on the panel of a separately placed podium for the radiation source, which increases the complexity of assembly operations.

The closest analogue of the cooling device for an LED lamp is the solution described in EP2077415, MKI E21U 29/00, published on 08.07.2009. As the closest option, shown in FIG. 4 of this patent, which is a hollow radiator with double walls, the outer of which is provided with longitudinal ventilation holes, and the end panel is provided with holes for connecting with the latches of the case of the electronic converter. The design flaws of the radiator are a consequence of the general design flaws of the LED lamp according to the known patent, which are set forth on pages 3 and 4 of this description.

Disclosure of invention

The technical result of the invention is to increase the manufacturability of the design, the possibility of using interchangeable parts and assemblies in the assembly process without additional processing and without the use of fasteners, improving the cooling conditions of radiation sources, as well as reducing the complexity and cost of assembly of the LED lamp.

A method of manufacturing a LED lamp according to the invention includes the following operations: manufacturing a light-emitting shell with the simultaneous formation of discrete latches on its remote surface;

the manufacture of the transition cone with the simultaneous formation of discrete latches and ventilation holes on its surface;

the manufacture of an annular radiator, including the formation of the end panel of the housing; the formation of the side along the perimeter of the end panel;

forming holes on the side with the possibility of placing discrete latches of the light-emitting shell in them;

the formation on the common axis of the holes on the end panel, slots on the housing and protrusions on the inner conical surface of the cavity of the housing, while the protrusions form with the possibility of connection with discrete latches of the transition cone;

the formation of guide grooves on the inner surface of the radiator cavity to accommodate the electronic converter board;

placement of the electronic converter by translating its board along the groove guides on the inner surface of the radiator cavity;

fixing the latches of the light-emitting shell in the holes of the rim of the end panel of the radiator body;

fixing the latches of the transition cone on the protrusions of the inner surface of the conical cavity of the radiator body;

placement and fixation on the transitional cone of a means of connection with a current source (base).

The creation of a guaranteed connection between these assembly units is ensured by the use of a two-link locking mechanism, the first link of which is a latch made on the first assembly unit, and the second link, a protrusion, a through or blind hole, is made on the surface of the second assembly unit. The surface shape of these links of the castle is performed with the possibility of pairing and eliminating spontaneous opening without special force. The number of locking mechanisms on assembly units is selected depending on the requirements for bond strength. Obviously, the minimum number of locking mechanisms cannot be less than one.

The condition on the conical shape of the surface of the radiator cavity is due, on the one hand, to the need to form slots on the housing and protrusions on the inner surface of the housing on one axis, and on the other hand, to technological requirements for the injection mold that implements the method.

On the mating surfaces of the transition cone and the radiator, to prevent their rotation relative to each other, additional fixation means are possible, which are made in the form of protruding elements on one of the parts to be joined and corresponding recesses on the mating part, for example, a pin on the radiator and recesses on the transition cone.

To achieve this goal, a material having a coefficient of elasticity, on the one hand, sufficient to establish the elements of the lock, but on the other hand, providing reliable fixation of the connected parts, is used as the material of the latches. In this case, the formation of latches at the same time as the manufacture of the light-emitting shell and the transition cone is optimal. The formation of the structural elements of the radiator case is advisable to be carried out simultaneously with the manufacture of the case in one technological operation, taking into account the subsequent

- 2 019873 connections of assembly units and clutch links of locking mechanisms.

It is preferable to form limiters on the end panel, preventing the radial movement of the light-emitting shell and capable of simultaneously serving as a guide link when connecting assembly units. These stops should preferably be formed concentrically on the rim on the front of the radiator.

The sequence of joining the assembly units is not significant and depends on the specific conditions of the assembly production. For example, the operation of connecting the light-emitting shell and the radiator may precede the connection of the radiator and the transition cone.

As mentioned above, the formation of all structural elements of the radiator casing is advisable to produce at the same time. Based on these conditions, in the case of receiving a radiator by casting, the injection mold at the time of the operation should already contain all the molds necessary to obtain structural elements of the radiator. So, in order to achieve this goal, a body of a given configuration, its end panel, all openings in the end panel, slots in the body and protrusions at the end of each slot, longitudinal grooves on the conical surface of the body cavity, and other elements must be formed during the casting process. For a specialist it should be clear that this is possible only if there is such an injection mold on which there are all forming inserts necessary to obtain a casting containing the elements necessary for the subsequent operations of manufacturing an LED lamp.

The LED lamp made according to the method comprises a hollow annular radiator with an end panel and through cuts on the side surface; a radiation source mounted on the end panel and a light emitting shell; a transition element between the radiator and the means of connection to the current source; an electronic converter and means for connecting parts and assemblies, characterized in that the light-emitting shell and the transition cone are provided with discrete latches; the end panel has technological holes located on the same axis with slots on the case and protrusions on the conical cavity cavity surface tapering to the panel, on which the electronic converter board is mounted in longitudinal grooves, and latches of the transition cone equipped with ventilation holes are fixed on the protrusions.

The preferred option is the formation of limiters on the end panel, preventing the radial movement of the light-emitting shell and capable of simultaneously serve as a guide link when connected. These stops must be formed concentrically on the side on the front of the radiator.

The shape of the outer and inner surfaces of a real hollow annular radiator in any embodiment can be characterized as a conical surface formed by an η-angled guide and with an angle ψ between the generators, the value of which is selected from the expressions:

<η <x and <ψ <180, where η is the number of vertices of the polygon of the guide line;

ψ is the angle between the generators of the conical surface.

The meaning of choosing the boundary values of the indicated parameters of the conical surface should be clear to the specialist and does not need special justifications. It is only worthwhile to note that the choice of the value of ψ essentially determines the height of the hollow ring-shaped radiator, and the small value of ψ at the maximum value of η corresponds to the choice of shape in the form of a conical surface.

According to the invention, an optically transparent component is used as a binder material for the light-emitting sheath, which can be supplemented with particles of a certain type of phosphor or with a mixture of phosphors of different colors and / or afterglow.

The end surface of the radiator, designed to interface with the surface of the transition cone, can be equipped with additional fixation means, eliminating the possibility of rotation of the transition cone around the axis of the radiator. In this case, the configuration of the fixing elements is not of fundamental importance. As a special case of their implementation, you can specify pairs of pins - hole, radial protrusion - radial groove or the execution of both mating surfaces with a toothed profile.

An embodiment of an LED lamp comprises a transition cone configured to fasten a threaded base to it. For this, the cylindrical part of the transition cone may be provided with a screw guide.

To improve the cooling conditions of the electronic converter and create a cooling air flow through the radiator cavity, create a ventilation channel formed by through cuts on the side surface of the radiator and holes in the transition cone and / or the gap between the transition cone and the radiator.

The radiator for the LED lamp manufactured in the above-described manner comprises an annular body with a developed external surface, one of the end sides of which is provided with a panel,

- 3 019873 having a perimeter rim with connection elements with latches of the light-emitting shell; wherein said panel is provided with technological holes located on the same axis with slots on the radiator body and with protrusions on the tapered surface of the radiator cavity tapering to the panel, on which grooves are made with the possibility of placing the electronic converter board in them.

The surface of the radiator, designed to interface with the surface of the transition cone, can be equipped with additional fixation means, eliminating the possibility of rotation of the radiator relative to the axis of the transition cone, for example, in the form of a pin formed on the end of the radiator.

A variant of the developed surface of the radiator may be transverse and / or longitudinal cooling fins. In the latter case, the slots on the housing are located in the plane of the cooling fin so that the formed ventilation openings do not create conditions for unauthorized entry to the current-carrying elements of the electronic converter. The number of slots made in this way depends on the type of electronic converter used.

Means for connecting the radiator to the light-emitting shell can be made in the form of holes, recesses or protrusions formed in the rim with the possibility of interaction with the latches of the light-emitting shell.

The end panel, in addition to these holes, may have at least one hole adapted to accommodate current conductors and / or to fix the radiation source board with a collet latch.

For efficient cooling of radiation sources, a hollow radiator should be made of highly heat-conducting material, for example, copper, aluminum, their alloys, or ceramic based on aluminum oxide. An important condition for the accurate manufacture of a hollow radiator is the good molding ability of the selected material.

Brief Description of the Drawings

The invention is illustrated by the following graphic materials, which show:

in FIG. 1 is a side view of an LED lamp;

in FIG. 2 is a three-dimensional image of the LED lamp in the parsing shown in FIG. one;

in FIG. 3 - three-dimensional image of the radiator from the top side;

in FIG. 4 - three-dimensional image of the radiator bottom side;

in FIG. 5 - a three-dimensional image of the cross section of the radiator and the transition cone in an exploded view.

The LED lamp comprises a light emitting shell 1, on a remote surface 2 of which latches 3 of a locking mechanism are made; a hollow radiator 4 provided with an end panel 5, along the perimeter of which a rim 6 is formed with holes 7 for accommodating latches 3 of the light-emitting shell 1; a cluster 8 of radiation sources 9 mounted on a board and mounted on said panel 5 of a hollow radiator 4; a transition cone 10 provided with latches 11 for connection with the protrusions 12 made on the inner surface 13 of the hollow radiator 4; an electronic transducer 14 mounted in longitudinal grooves (not shown) formed on the surface 13 of the cavity 15 of the radiator 4 and electrically connected to a cluster 8 of radiation sources 9 and means 16 for connecting to an electric current source.

The radiator 4, in the optimal embodiment, which is essentially a complex casting part, consists of an annular body, one of the end sides of which is provided with a panel 5 containing technological holes 17 and having a perimeter 6 along which the through holes 7 are formed with the possibility of connection with latches 3 of the light emitting shell 1; the outer surface 18 of the housing is made developed, for example, in the form of longitudinal ribs 18, and its inner cavity 15 is formed by a conical surface 13, tapering to the panel 5, and provided with ventilation slots 19, protrusions 12 for fixing the latches 11 of the transition cone 10 and longitudinal guide grooves ( not shown) to accommodate the electronic converter.

The end surface 20 of the radiator 4, designed to interface with the surface of the transition cone 10, may be provided with additional fixing means, for example in the form of a pin 21, eliminating the possibility of rotation of the transition cone 10 around the axis of the radiator 4.

An embodiment of the invention

A method of manufacturing an LED lamp is as follows:

form a light-emitting shell 1 and latches 3 on it in one injection operation. The material used to obtain the light-emitting shell 1 may include phosphor particles, the composition and quantity of which are not considered in this invention;

form a transition cone 10 with latches 11 in one injection operation;

molten metal is cast, for example, in a metal mold (not shown) to form a molding part, including an annular radiator casing 4, panel 5 with technological holes 17, side 6, stops 22, holes 7 for connecting with latches 3 of the light-emitting shell 1 and the hole 23 for fastening with a collet latch 24 of the cluster board 8 radiation sources 9, slots 19 and protrusions 12 on the inner conical surface 13 of the cavity 15

- 4 019873 of the radiator housing 4. The relative location of these radiator elements is determined by the injection mold, taking into account the subsequent connection of parts and components of the LED lamp;

place the cluster board 8 radiation sources 9 on the end panel 5 of the hollow radiator 4 and fix the collet latch 24;

place the light-emitting shell 1 between the side 6 and the limiters 22 on the end panel 5 of the radiator body 4 and fix the latches 3 in the holes 7 of the side 6 of the end panel 5 of the hollow body of the radiator 4;

the latches 11 of the transition cone 10 are fixed on the protrusions 12 formed on the conical surface 13 of the cavity 15 of the annular body of the radiator 4.

In an embodiment of the method of manufacturing an LED lamp on a transition cone 10, a surface helical guide 26 is formed for fixing the threaded base.

LED lamp manufactured in the described manner operates as follows.

A cluster 8 of radiation sources 9, under the action of a supply voltage created by an electronic converter 14, electrically connected to a source of electric energy (not shown) by means of a threaded cap 16, generates a light flux of the ultraviolet or blue spectral region, which excites the luminescence of phosphor particles embedded in the mass of the light-emitting shell 1 made of optically transparent material. The heat generated by the radiation sources 9 is transferred through heat conduction to the radiator panel 5, the surface of which is in thermal contact with the radiation sources 9, and dissipated from the ribbed outer surface 18 of the radiator body 4. The heat generated by the electronic converter 14 located in the cavity 15 of the radiator body 4 is removed from the board by heat transfer through the housing and dissipated from its surface into the environment, and is also diverted by convection flow flowing through the ventilation holes 25 in the transition cone 10 through the cavity 15, and is carried out of the housing through the slots 19 in the side surface of the radiator 4.

Industrial applicability

Parts and assemblies for LED lamps can be manufactured by known methods of casting metals, ceramics and plastics. Board mounting with radiation sources can be easily automated. The final assembly of the product does not require highly qualified personnel, which can significantly reduce the cost of manufacturing an LED lamp. The information set forth in the description is sufficient for a specialist to understand the manufacturing order and design features of the device.

Claims (19)

1. A method of manufacturing a LED lamp, including the manufacture of a light-emitting shell with the simultaneous formation of discrete latches on its remote surface; the manufacture of the transition cone with the simultaneous formation of discrete latches on its surface; the manufacture of an annular radiator, including the formation of an end panel on its body; the formation of the side along the perimeter of the end panel; the formation on the side of the fastening elements of the light-emitting shell; the formation on one axis of the holes on the end panel, slots on the case and protrusions on the inner surface of the conical cavity of the radiator, while the protrusions form with the possibility of connection with discrete latches of the transition cone; the formation of guide grooves on the inner surface of the radiator cavity with the possibility of placing the electronic converter board; fixing the latches of the light-emitting shell on the edge of the end panel; fixing the latches of the transition cone on the protrusions of the inner surface of the conical cavity of the radiator body; placement and fixation on the transition cone of a means of connection with a current source. 2. The method of manufacturing the LED lamp according to claim 1, characterized in that on the end surface of the transition cone and on the end surface of the radiator, additional fixing means are formed in the form of protruding elements and / or recesses. 3. The method of manufacturing the LED lamp according to claim 2, characterized in that the additional fixing means is in the form of, for example, a pin or a radial protrusion on the end surface of the radiator and a corresponding recess on the end surface of the transition cone or in the form of both mating surfaces with a toothed profile. 4. The method of manufacturing the LED lamp according to claim 2, characterized in that the limiters of the radial movement of the light-emitting shell are formed on the front panel of the radiator. 5. A method of manufacturing an LED lamp according to claim 4, characterized in that the limiters concentrically form a side on the end panel of the radiator. 6. LED lamp containing a housing in the form of an annular radiator, equipped with an end panel and through cuts on the side surface; a radiation source and a light emitting shell mounted on the end panel; electronic converter; transition cone between the radiator and means for connecting to a current source, characterized in that the transition cone and - 5 019873 a radiant shell mounted on the end panel, equipped with discrete latches; the end panel has a perimeter around the perimeter with connection elements with latches of the light-emitting shell and is equipped with holes located on the same axis with slots in the housing and protrusions on the inner conical surface of the cavity of the housing, on which the electronic converter board is mounted in longitudinal grooves, and latches are fixed on the said protrusions transition cone. 7. The LED lamp according to claim 6, characterized in that the mating end surfaces of the transition cone and the radiator are provided with additional fixing means in the form of protruding elements and / or recesses. 8. The LED lamp according to claim 7, characterized in that the additional means of fixation are made in the form, for example, of a pin or a radial protrusion on the end surface of the radiator and a corresponding recess on the end surface of the transition cone; or in the form of both mating surfaces with a gear profile. 9. The LED lamp according to claim 7, characterized in that the end panel of the radiator is equipped with limiters for the radial movement of the light-emitting shell. 10. The LED lamp according to claim 9, characterized in that the limiters are located concentrically to the side of the end panel of the radiator. 11. The LED lamp according to claim 6, characterized in that the end panel is provided with at least one hole made with the possibility of placing means for mounting the board of radiation sources and / or current conductors. 12. The LED lamp according to claim 11, characterized in that the means for attaching the board of radiation sources is made in the form of a collet latch. 13. The LED lamp according to claim 6, characterized in that the radiator is provided with transverse and / or longitudinal cooling fins. 14. The LED lamp according to item 13, wherein the slot on the housing is located in the plane of the longitudinal cooling fin of the radiator. 15. A radiator for an LED lamp, comprising an annular body with a developed external surface, one of the end sides of which is provided with a panel having a perimeter around the rim with elements of connection with latches of the light-emitting shell; the end panel is provided with holes located on the same axis with slots in the housing, and protrusions made on the inner conical surface of the cavity of the housing with the possibility of connection with the latches of the transition cone, while on the conical surface of the cavity of the housing there are longitudinal grooves with the possibility of placing an electronic converter board in them . 16. The radiator for the LED lamp according to clause 15, characterized in that the developed surface of the radiator is made in the form of transverse and / or longitudinal cooling fins. 17. The radiator for the LED lamp according to clause 15, characterized in that the slot on the housing is located in the plane of the longitudinal cooling fins. 18. The radiator for the LED lamp according to clause 15, characterized in that the end surface of the radiator is equipped with additional fixing means in the form of protruding elements and / or recesses. 19. The radiator for the LED lamp according to claim 18, characterized in that the additional fixing means are made in the form of, for example, a pin or a radial protrusion or in the form of a surface with a gear profile.