TW201439470A - Lamp and method for manufacturing the same - Google Patents

Abstract

A lamp includes a head, a base connected to the head, a light source mounted on the base and a cover covering the light source. The cover has a plurality of elongated openings to allow light emitted from the light source to radiate out of the cover. The lamp has a high heat dissipation efficiency. A method for manufacturing the lamp is also provided.

Description

Lamp and its manufacturing method

The invention relates to a lighting device, in particular to a lighting fixture.

Conventional luminaires generally consist of a lamp holder, a lamp cover, a light source and a lamp holder. The light source is mounted on the lamp holder and electrically connected to the lamp cap. The lamp cover is fixed to the lamp holder and seals the light source. However, for some light sources that are sensitive to heat, such as light-emitting diodes, etc., since the light source is sealed in the lamp cover, the heat in the lamp cover is not easily dissipated from the lamp cover, which affects the normal operation of such a light source.

Therefore, it is necessary to provide a lamp having high heat dissipation efficiency and a method of manufacturing the same.

A lamp comprises a lamp holder, a light source mounted on the lamp holder, a lamp cap connecting the lamp holder and a lamp cover covering the light source, wherein the lamp cover is provided with an elongated opening.

A method of manufacturing a lamp, comprising: providing a plate; processing the plate to form a lamp cover having an elongated opening; and bonding the lamp cover to the lamp holder on which the light source is mounted.

Since the lamp cover is provided with an opening, the heat generated by the light source can be directly radiated outward through the opening of the lamp cover, thereby improving the heat dissipation efficiency of the entire lamp.

10. . . Lamp

20. . . Lamp head

twenty two. . . Side wall

220. . . Thread

twenty four. . . contact

26. . . Insulating tape

30. . . Lamp holder

300. . . space

32. . . Substrate

320. . . Top surface

322. . . Bottom

324. . . perforation

34. . . Sleeve

342. . . Bottom

36. . . Socket

360. . . Thread

38. . . Flange

380. . . Top surface

382. . . Bottom

40. . . light source

42. . . Light-emitting diode

44. . . Circuit board

50. . . lampshade

52. . . case

520. . . Opening

54. . . Folding

60. . . Drive module

70. . . wire

80. . . Light distribution curve

90. . . Light distribution curve

50a. . . Sheet metal

52a. . . model

54a. . . Plate body

56a. . . Side panel

50b. . . lampshade

51b. . . Connection

52b. . . case

520b. . . Opening

53b. . . Connection

54b. . . Folding

56b. . . Fin

Fig. 1 shows a perspective view of a lamp according to an embodiment of the present invention.

2 is an inverted view of the luminaire of FIG. 1.

3 is an exploded view of the luminaire of FIG. 1 with the light source removed for ease of viewing.

4 is an inverted view of the luminaire of FIG.

Figure 5 is a cross-sectional view of the luminaire of Figure 1.

Figure 6 is a light distribution curve of the lamp of Figure 1.

Figure 7 is a cross-sectional view of a lamp according to another embodiment of the present invention.

8-13 are various manufacturing steps of the luminaire of Fig. 1.

Figure 14 is a perspective view of a lampshade of a lamp according to still another embodiment of the present invention.

Referring to Figures 1 and 5, a light fixture 10 in accordance with one embodiment of the present invention is illustrated. The lamp 10 includes a lamp cap 20, a lamp holder 30, a light source 40, and a lamp cover 50.

Please refer to FIG. 2-4 together. The lamp holder 30 is made of a heat-conductive and insulating material such as ceramics and heat-conductive plastic. In this embodiment, the socket 30 is integrally formed of ceramic. The lamp holder 30 includes a substrate 32, a sleeve 34 extending from the periphery of the substrate 32 toward the base 20, and a sleeve portion 36 formed at the bottom end of the sleeve 34. The substrate 32 has a disk shape and includes a top surface 320 and a bottom surface 322 parallel to the top surface 320. The substrate 32 is provided with four through holes 324 extending from the top surface 320 thereof to the bottom surface 322. The four through holes 324 are evenly distributed on the substrate 32 and close to the outer periphery of the substrate 32. It can be understood that the number of the through holes 324 may also be two, three, etc., and the position thereof is not limited to the edge of the substrate 32. The sleeve 34 extends vertically downward from the outer periphery of the substrate 32. In the present embodiment, the sleeve 34 has a cylindrical shape with a thickness greater than the thickness of the substrate 32. The sleeve 34 is formed with a convex flange 38 at a position where its outer peripheral surface is close to the bottom. The flange 38 is annular in shape with a top surface 380 that is lower than the top surface 320 of the substrate 32 and a bottom surface 382 that is higher than the bottom surface 342 of the sleeve 34. Moreover, the spacing of the top surface 380 of the flange 38 from the top surface 320 of the substrate 32 is greater than the spacing of the bottom surface 382 of the flange 38 from the bottom surface 342 of the sleeve 34. In the present embodiment, the bottom surface 382 of the flange 38 is inclined and tapered toward the bottom surface 342 of the sleeve 34. The inner diameter of the sleeve 34 is uniform from top to bottom, and the outer diameter of the sleeve 34 at a position higher than the flange 38 is greater than the outer diameter at a position lower than the flange 38. The ferrule 36 connects the bottom end of the sleeve 34. The inner diameter of the socket portion 36 is the same as the inner diameter of the sleeve 34, and the outer diameter is smaller than the minimum outer diameter of the sleeve 34. The inner circumferential surface of the socket portion 36, the inner circumferential surface of the sleeve 34, and the bottom surface 322 of the substrate 32 collectively define a cylindrical space 300 for receiving a driving module 60. The space 300 communicates with the space above the substrate 32 through the four perforations 324 of the substrate 32. A thread 360 is formed on the outer circumferential surface of the socket portion 36 for screwing with the base 20.

The light source 40 includes a circuit board 44 and a light emitting diode 42 mounted on the circuit board 44. The circuit board 44 is preferably a metal-based circuit board (i.e., a metal is used as a substrate, and then an insulating layer and a circuit layer are sequentially formed on the metal substrate) to provide a strong thermal conductivity. The wafer (not shown) of the light-emitting diode 42 is directly mounted on the chip on board 44, whereby heat generated during operation of the wafer can be directly conducted to the circuit board 44, thereby improving heat transfer efficiency. The wafer of the light-emitting diode 42 is preferably made of a semiconductor light-emitting material such as gallium nitride, indium gallium nitride or aluminum indium gallium nitride, which emits blue light when excited by current. The two electrodes of the wafer are directly connected to the two electrodes (not shown) of the circuit board 44 through two wires or by flip chip technology, thereby being electrically connected to the circuit board 44. The LED 42 further includes an encapsulation layer (not shown) covering the wafer. The encapsulating layer is preferably made of a light transmissive material such as epoxy resin, silicone rubber or the like. The encapsulation layer is further doped with phosphor powder. The phosphor powder can be made of a fluorescent material such as yttrium aluminum garnet, citrate, oxide, oxynitride, etc., which can emit yellow light under excitation of the blue light of the wafer, and then mix with blue light to form white light. The two electrodes of circuit board 44 are coupled to drive module 60 by wires 70 that pass through holes 324 in substrate 32 to provide electrical energy to the wafer.

The globe 50 is integrally formed of a metal material. Preferably, the present invention employs aluminum as the material of the lamp cover 50 to provide the lamp cover 50 with a high heat dissipation capability. The thickness of the globe 50 can be less than the thickness of the substrate 32. The lamp cover 50 includes a housing 52 and a flange 54 formed at a bottom end of the housing 52. The hem 54 extends vertically downward from the bottom of the housing 52. The hem 54 is annular and has an inner diameter greater than or equal to the outer diameter of the sleeve 34 above the flange 38. Thus, the flange 54 can be sleeved on the outer circumferential surface of the sleeve 34 to engage the lamp cover 50 with the socket 30. The outer diameter of the flange 54 is smaller than the outer diameter of the flange 38. Therefore, after the sleeve 54 is sleeved on the sleeve 34, it will abut against the top surface 380 of the flange 38, thereby preventing the entire socket 30 from falling into the lampshade. Within 50. Since the lamp cover 50 can be directly engaged with the lamp holder 30 through the flange 54, the assembly between the lamp cover 50 and the lamp holder 30 is very convenient, thereby simplifying the assembly process of the entire lamp 10. The upper half of the housing 52 has a hemispherical shape, and the lower half has a tapered shape that tapers downward. A plurality of openings 520 are defined in the housing 52. In the embodiment, the plurality of openings 520 are evenly formed on the housing 52. In this embodiment, each of the openings 520 has a circular shape. These openings 520 extend from the top of the housing 52 to a position near the bottom of the housing 52. These openings 520 are arranged in a plurality of rows on the entire outer circumferential surface of the casing 52. Wherein, the number of the openings 520 of the uppermost row is the smallest, and the number of the openings 520 of each row gradually increases from the top of the casing 52 toward the middle of the casing 52, and gradually decreases from the middle of the casing 52 toward the bottom of the casing 52. In other words, the number of rows of openings 520 is consistent with the outer diameter of the housing 52. In this embodiment, the height of the substrate 32 is flush with the height of the opening 520 of the lowermost row. Therefore, after the lampshade 50 is assembled with the lamp holder 30, the light-emitting diode 42 is higher than the opening 520 located at the lowermost row and is substantially flush with the opening 520 of the penultimate row below. Of course, for safety reasons, the height of the LED 42 can also be lower than the lower row of openings 520 (as shown in FIG. 7), thereby avoiding direct viewing of the LED 42 from the opening 520.

Since the lamp cover 50 is made of metal, its inner side wall surface has a high reflectance (of course, a high reflectance material may be further applied to the inner side wall surface of the lamp cover 50 to obtain a better reflection effect). A part of the light emitted from the LED 42 is directly emitted from the opening 520 of the lamp cover 50, and a part of the light is directly incident on the inner wall surface of the lamp cover 50, and then is emitted from the opening 520 of the lamp cover 50 through the reflection of the inner wall surface. Since the reflectance of the inner side wall surface of the lamp cover 50 is high, the light is less lost during the reflection process, so that the final light extraction efficiency is improved. Moreover, since the opening 520 is substantially distributed over the entire casing 52, and the light is reflected in various directions on the inner wall surface of the casing 52, the light emitted from the opening 520 can be directed to various angles and orientations. The exit is such that the entire luminaire 10 achieves a nearly 360 degree panoramic illumination effect. Preferably, the inner wall surface of the casing 52 is a diffuse reflection surface. In addition, the opening 520 is evenly disposed on the casing 52 to ensure the uniformity of the light output from the lamp cover 50, so that the light intensity of the lamps 10 at all angles is consistent (as shown in FIG. 6, in two mutually perpendicular directions). The light distribution curves 80, 90 are substantially coincident). Moreover, the lamp cover 50 is made of metal and directly sleeved on the lamp holder 30. Therefore, heat generated by the LED body 42 can be transmitted to the lamp cover 50 through the lamp holder 30, and then radiated to the external environment via the lamp cover 50, thereby lifting The heat dissipation efficiency of the entire luminaire 10. Of course, since the lamp holder 30 itself is also made of a heat conductive material and is also directly exposed to the external environment, the heat conducted by the light emitting diode 42 to the lamp holder 30 can also be directly radiated from the lamp holder 30 to the external environment. Finally, since the inner space of the lamp cover 50 is in communication with the external environment through the opening 520, the heat generated by the light-emitting diode 42 can be directly radiated into the air around the light-emitting diode 42, and then this portion is heated. Air is directly convected through the opening 520 to the outside environment. That is to say, the lamp 10 of the present invention has at least three heat dissipation paths: the first piece is transmitted to the lamp cover 50 via the lamp holder 30 to radiate heat outward, the second piece is directly radiated outward from the lamp holder 30, and the third piece is covered by the lamp cover. The air in 50 passes through the opening 520 to convect heat with the air outside the lamp cover 50.

The base 20 is a universal bulb-type base that can be mated with conventional bulb sockets (not shown). The base 20 includes an annular side wall 22, a contact 24, and an insulating strip 26 connecting the contacts 24 and the side walls 22. The outer circumferential surface and the inner circumferential surface of the side wall 22 form corresponding threads 220. The side wall 22 is sleeved on the sleeve portion 36 of the socket 30, and the internal thread 220 is interference-fitted with the thread 360 of the socket portion 36 to fix the base 20 to the socket 30. The external threads 220 of the side walls 22 are adapted to mate with the internal threads of a conventional bulb socket to securely attach the luminaire 10 to the bulb socket. Both the side wall 22 and the contact 24 are made of a metal material, and the insulating tape 26 is connected to the side wall 22 and the contact 24 to insulate the two. The driving module 60 is connected to the side wall 22 and the contact 24 through the two wires 70 to receive the electric energy input from the lamp cap 20. Since the lamp holder 30 is made of an insulating ceramic material, the metal lamp cover 50 can be insulated from the lamp cap 20 by the lamp holder 30, thereby preventing the lamp cover 50 from being charged.

As shown in FIG. 8-13, the present invention further provides a manufacturing method of the lamp 10, which mainly includes the following steps:

First, a metal plate 50a is provided as shown in FIG. The sheet metal 50a is preferably an aluminum sheet to provide better ductility for subsequent manufacturing processes. The top surface of the metal sheet 50a is parallel to the bottom surface.

Then, a plurality of cup-shaped molds 52a (only one shown in Fig. 8) as shown in Fig. 9 were produced by punching from the metal plate 50a. Each of the molds 52a includes a circular plate body 54a and a side plate 56a extending downward from the outer peripheral edge of the plate body 54a. The side plate 56a is annular and surrounds the plate body 54a, and the thickness of the side plate 56a is equal to the thickness of the plate body 54a. Each of the models 52a corresponds to a region of the metal sheet 50a (the A region as shown in the drawing). During the stamping process, the A region of the metal sheet 50a is gradually separated from the other portions of the metal sheet 50a, wherein the middle portion of the A region maintains the original level state to form the plate body 54a, and the side of the A region is depressed by the pressure of the mold. The side plates 56a are formed by bending. During the stamping process, the thickness of the metal sheet 50a does not substantially change, that is, the thickness of the finally formed mold 52a is equal to the thickness of the metal sheet 50a.

Thereafter, the side plate 56a of the mold 52a is stretched as shown in Fig. 10 to increase its length. Due to the good ductility of aluminum, the side plates 56a are less prone to breakage during stretching, thereby ensuring the reliability of the manufacturing process. After stretching, the side plate 56a has an increased length and a reduced thickness. That is, the thickness of the stretched side plate 56a is smaller than the thickness of the plate body 54a.

Subsequently, the plate body 54a of the mold 52a is again pressed as shown in Fig. 11 to form a hemispherical structure. During the pressing process, the plate body 54a is changed from a flat plate shape to a hemispherical shape, so that the area is increased and the thickness is reduced. Finally, the thickness of the plate body 54a tends to coincide with the thickness of the side plate 56a. It can be understood that the shape of the plate body 54a is determined by the shape of the stamped mold, that is, the hemispherical mold can manufacture the hemispherical plate body 54a, and therefore, if necessary, a plate body 54a of other shapes (such as an ellipse) can be manufactured. Shape, cone, etc.), only need to use a mold with a corresponding shape.

Then, an opening 520 is formed in the surface of the mold 52a as shown in FIG. There may be various ways of opening the surface of the model 52a. For example, an inner mold having a pre-drilled hole may be firstly sleeved inside the model 52a, and then a pre-drilled position on the model 52a with a metal drill bit outside the model 52a. Drilling inwardly at the location of the hole; or inserting a hollow inner mold into the mold 52a to support the mold 52a, then placing the drill bit into the mold 52a, drilling from the inside to the outside; or using a hollow first The inner mold is placed in the mold 52a to support the mold 52a, and then the tool is placed in the mold 52a, stamped from the inside to the outside, thereby forming a projection on the outer surface of the mold 52a, and finally the convex edge is passed through the cutter outside the mold 52a. The surface of the model 52a is removed.

As shown in Fig. 13, the side plate 56a of the mold 52a is further molded to form a taper which gradually decreases in diameter from top to bottom, and at the same time, an annular flange 54 is formed at the bottom of the side plate 56a. The side plate 56a may be formed by extrusion rotation, such as placing the side plate 56a into a rotating mold whose opening is tapered. By gradually pressing the side plate 56a into the rotary mold, the side plate is deformed by being pressed by the tapered opening, thereby A tapered structure with an annular flange 54 is formed. So far, the lamp cover 50 of the luminaire 10 has been manufactured.

Finally, the lamp holder 30, which has been pre-assembled with the lamp holder 20, the light source 40 and the driving module 60, is aligned with the flange 54 of the lamp cover 50, and penetrates into the lamp cover 50 from bottom to top until the flange 54 of the lamp cover 50 is sleeved to the lamp holder. The outer peripheral surface of the sleeve 34 of 30 abuts against the top surface 380 of the flange 38. Thereby, the assembly process of the entire luminaire 10 is completed.

Since the present invention uses metal as the material of the lamp cover 50, the manufacturing process is significantly different from the manufacturing process of the conventional glass or plastic lamp cover. In particular, the entire process of the metal lampshade 50 is simpler than the conventional glass or plastic lampshade, and there is no need to pay special attention to the lampshade 50 during manufacturing and assembly (the traditional glass lampshade requires special attention to lightness due to fragility). Therefore, the mass production is faster, and the output of the lamp 10 in a unit time can be effectively increased. In addition, the metal lampshade 50 is more cost-effective than the glass lampshade, and can effectively reduce the total cost of the entire lamp 10, thereby facilitating the market promotion and application.

It can be understood that after narrowing the side plate 56a of the mold 52a, the outer surface of the lamp cover 50 can be further processed to form a smooth surface to give the lamp cover 50 a better appearance; or in the lamp cover 50. A highly reflective reflective layer is formed by electroplating to enhance the reflective effect.

The present invention still further provides a luminaire 10 having a shape of different apertures 520b. Referring to Figure 14, a lamp cover 50b of a luminaire 10 in accordance with another embodiment of the present invention is illustrated. The components of the lamp 10 other than the lamp cover 50b are the same as those of the previous embodiment, and are not shown in FIG. The shape of the lamp cover 50b of the lamp 10 is also the same as that of the lamp cover 50 of the previous embodiment, except for the shape and arrangement of the opening 520b. These openings 520b are each elongated and are evenly spaced along the circumferential direction of the casing 52b of the globe 50b. Each opening 520b extends from a first position of the shade 50b toward a second position of the shade 50b. The first position of the shade 50b is closer to the socket 30 than the second position. Preferably, the first position is located adjacent to the socket 30 and the second position is located away from the socket 30. That is, the first position is near the bottom of the lamp cover 50b, and the second position is near the top of the lamp cover 50b. Of course, the first position may also be located in the middle of the lamp cover 50b, and the second position is close to the top of the lamp cover 50b; or the first position may be close to the bottom of the lamp cover 50b, the second position may be located in the middle of the lamp cover 50b; or other lower facing faces Even the diagonally opposite position. In addition, the extending direction of the opening 520b in this embodiment can also be understood to coincide with the extending direction of the folded edge 54b of the lamp cover 50b or the axial direction of the lamp cover 50b. The bottom of each opening 520b terminates above the bottom of the housing 52b of the lamp cover 50b, and the top terminates below the top of the housing 52b of the lamp cover 50b; thus, the lamp cover 50b is at the top of the housing 52b to which the opening 520b does not extend and A dome-shaped connecting portion 51b and a circular connecting portion 53b are formed at the bottom. A portion of the lamp cover 50b located between each of the adjacent two openings 520b forms a vertically long fin 56b. The width of each fin 56b increases first and then decreases from top to bottom. The top and bottom of each fin 56b are respectively connected by the two connecting portions 51b, 53b of the housing 52b, thereby forming an integral structure to increase the strength of the lamp cover 50b. The heat of the lamp cover 50b can be radiated to the outside through the fins 56b, thereby improving the heat dissipation effect of the lamp 10. Moreover, since the opening 520b is elongated, the convection between the air in the lamp cover 50b and the outside air will be more smooth, thereby further improving the heat dissipation effect of the lamp cover 50b. Further, since the opening 520b is elongated, the forming step of the opening 520b can be performed after punching to form the cup-shaped mold 52a, and can be formed in advance even before the metal sheet 50a is punched. During the subsequent stretching of the side panels 56a, the openings 520b are stretched together with the side panels 56a. Since the required opening 520b itself is elongated, the shape requirement can be satisfied even if it is stretched. Also, the elongated shape of the opening 520b is not substantially affected during the narrowing of the subsequent side plate 56a. Thereby, the manufacturing process of the lampshade 50b having the elongated opening 520b is more flexible, and the manufacturing steps can be arranged according to actual needs.

In addition, it should be noted that the term "long shape" in the present invention means that the length of the shape is larger than the width, and is not limited to the definition of the rectangle. For example, elongated strips having semicircles, triangles or other shapes at both ends are all elongated as defined in the present invention.

The technical and technical features of the present invention have been disclosed as above, and those skilled in the art can still make various substitutions and modifications without departing from the spirit and scope of the invention. Therefore, the scope of the present invention should be construed as being limited by the scope of the appended claims

50b. . . lampshade

51b. . . Connection

52b. . . case

520b. . . Opening

53b. . . Connection

54b. . . Folding

56b. . . Fin

Claims (20)

A lamp comprising a lamp holder, a light source mounted on the lamp holder, a lamp cap connected to the lamp holder, and a lamp cover covering the light source, wherein the lamp cover is provided with an elongated opening. The luminaire of claim 1, wherein the luminaire is a light bulb. The luminaire of claim 1, wherein the light source comprises a light emitting diode. The luminaire of claim 1, wherein a part of the light emitted by the light source is directly emitted from the opening, and another part of the light emitted by the light source is reflected from the inner side wall surface of the lamp cover and then emerges from the opening. The luminaire of claim 1, wherein the lampshade is made of an opaque material. The luminaire of claim 1, wherein the lampshade is made of a thermally conductive material. The luminaire of claim 1, wherein the lampshade is made of a metal material. The luminaire of any one of claims 1 to 7, wherein the opening of the lamp cover extends from the first position of the lamp cover to the second position of the lamp cover, the first position being closer to the lamp holder than the second position. The luminaire of claim 8 wherein the second position is adjacent to the top of the lampshade and the first position is adjacent to the bottom of the lampshade. The luminaire of claim 1, wherein the number of the openings is plural, and fins are formed between the adjacent openings. The lamp of claim 10, wherein the lamp cover forms a connecting portion above and below the opening, and the top and bottom of the fin are connected by corresponding connecting portions. The luminaire of claim 11, wherein a width of a middle portion of the fin is greater than a width of both ends. The lamp of claim 1, wherein the lamp cover comprises a casing and a flange extending downward from the casing, and the opening is formed on the casing, and the lampshade is sleeved on the lamp socket by the flange. The lamp of claim 13, wherein the lamp holder comprises a substrate supporting the light source, a sleeve extending downward from the periphery of the substrate, and a flange formed on the outer circumferential surface of the sleeve, the flange being sleeved on the sleeve And abut the top of the flange. A method of manufacturing a luminaire according to any one of claims 1 to 7, comprising:
Provide plates;
Processing the sheet to form a lampshade having an elongated opening;
The lamp cover is joined to a socket on which the light source is mounted. The manufacturing method according to claim 15, wherein the step of processing the sheet material comprises the step of stamping the sheet material to form a cup-shaped mold, the mold comprising the plate body and the side plate surrounding the plate body. The manufacturing method of claim 16, wherein the step of processing the sheet material comprises the step of stretching the side panels of the mold. The manufacturing method according to claim 17, wherein the step of processing the sheet material comprises the step of narrowing the side panel after stretching toward a direction away from the sheet body. The manufacturing method according to claim 17, wherein the step of processing the sheet material comprises the step of punching the mold before stretching the side panel, and the formed opening is stretched together during the stretching of the side panel. The manufacturing method according to claim 18, wherein in the process of narrowing the side plate, a flange is formed at the bottom of the side plate, and the lamp cover is sleeved on the lamp holder.