TWI586915B - Explosion - proof LED lamp manufacturing method - Google Patents

Description

Explosion-proof type LED lamp manufacturing method

The invention relates to an LED lamp, in particular to a method for manufacturing an explosion-proof LED lamp tube in which an inner wall surface and an outer wall surface of a lamp tube are respectively provided with a heat-conductive self-adhesive substrate and an explosion-proof protective film.

In recent years, Light-Emitting Diode (LED) has been widely used in lighting devices for everyday life. Please refer to the first figure, which is an exploded view of a conventional LED lamp. As shown in the first figure, the conventional LED lamp 1' includes: a heat dissipation aluminum extrusion 10', a lamp cover 11', a circuit board 13', a plurality of LED elements 14', an LED driving module 12', and a two-terminal cover 15', wherein the circuit board 13' and the LED elements 14' are placed on the heat-dissipating aluminum extrusion 10', the LED driving mode The group 12' is placed in the accommodating space inside the heat-dissipating aluminum extrusion 10', and finally the lampshade 11' and the two-end cover 15' are assembled to the heat-dissipating aluminum extrusion 10'. Moreover, the circuit board 13' is electrically connected to the LED driving module 12' for controlling the illumination of the plurality of LED elements 14'; further, each end cap 15' has a set of electrical terminals 151', To connect to the mains.

The above LED lamp 1' is one of the currently common LED lamps; However, after long-term research, the inventors of this case found that the conventional LED lamps 1' showed several defects in use:

1. The structure is complicated: the structure of the conventional LED lamp 1' is relatively complicated. On the assembly, the circuit board 13' must be placed on the heat-dissipating aluminum extrusion 10' and the LED driving module 12' is placed in the heat-dissipating aluminum extrusion 10'. The lampshade 11' and the end cap 15' are then assembled onto the heat-dissipating aluminum extrusion 10', and such a complicated assembly process is very difficult to mass-produce through automation or semi-automation.

2. High cost: The conventional LED lamp 1' mainly uses heat-dissipating aluminum to squeeze 10' to dissipate heat. However, the heat-dissipating aluminum extrusion 10' is not only bulky and heavy, but more importantly, its production cost is very high, resulting in conventional use. The overall cost of producing LED lamps 1' is high.

3. Insufficient insulation: The conventional LED lamp 1' has a large volume of heat-dissipating aluminum extrusion 10', and the bottom of the heat-dissipating aluminum extrusion 10' is exposed outside the lampshade 11'; therefore, the exposed heat dissipation can be imagined. Aluminum extrusion 10' will likely result in poor insulation of LED lamps 1'.

4. The illumination range is small: since the upper half of the conventional LED lamp 1' structure is the lamp cover 11', and the lower half is the heat dissipation aluminum extrusion 10', the light emitted by the LED elements 14' can only be half-circumferential. (~180o) is emitted; it can be seen that the illumination range of the conventional LED lamp 1' is not large.

Therefore, the inventors of the present invention have invented the invention in view of the shortcomings and disadvantages of the LED lamps currently in use, and finally developed an explosion-proof type LED lamp tube of the present invention and a manufacturing method thereof.

The main object of the present invention is to provide an explosion-proof type LED lamp tube and a manufacturing method thereof, which are particularly used for quickly attaching a self-adhesive substrate having a plurality of LED elements on a surface thereof to a lamp tube by using a substrate bonding tool. The inner wall; in this way, the heat generated by the illumination of the LED elements can be directly transferred to the air through the lamp tube, thereby enhancing the heat dissipation effect of the LED lamp. In addition, since the self-adhesive substrate is directly attached to the inner wall of the lamp tube without passing through any aluminum base; therefore, the light emitted by the LED elements can be similar to full-circumference (greater than 300o). Ejecting, in this way, increases the illumination range of the LED luminaire of the present invention. More importantly, in the present invention, the lamp tube is covered with an explosion-proof protective film in particular, so that once the (glass) lamp tube breaks, the explosion-proof protective film can effectively prevent the lamp tube from escaping. The safety of the LED tube of the present invention is ensured.

Therefore, in order to achieve the above object of the present invention, the inventor of the present invention proposes an explosion-proof LED lamp tube, comprising: a lamp tube; an explosion-proof protective film for covering the lamp tube to prevent the lamp tube from being broken and broken; a self-adhesive substrate is disposed on an inner wall of the lamp tube, and the self-adhesive substrate is formed with at least one circuit layer, and the circuit layer is electrically connected to an LED drive The LED module is disposed on the circuit layer and electrically connected to the LED driving module through the circuit layer, so that the LED driving module can control the illumination of the plurality of LED components; And two end covers are respectively connected to the two ends of the lamp tube, and the end cover has an electrical terminal set for electrically connecting an external power source.

Moreover, in order to achieve the above object of the present invention, the inventor of the present invention proposes a method for manufacturing an explosion-proof LED lamp tube, which comprises the following steps: (1) providing a lamp tube and coating the lamp tube with an explosion-proof protective film; (2) placing a self-adhesive substrate having a circuit layer and a plurality of LED elements on a substrate bonding tool by using a release paper; (3) removing the release paper, and removing the substrate The bonding tool is placed in the lamp tube; (4) the lamp tube is suspended, and the lamp tube is supported by the substrate bonding tool, so that a glue on the bottom surface of the self-adhesive substrate and the inner wall of the lamp tube (5) operating a roller to roll over the outer wall of the lamp tube, so that the glue on the bottom surface of the self-adhesive substrate can be closely attached to the inner wall of the lamp tube; (6) taking out the substrate bonding And (7) combining the two end caps to the ends of the tube.

<present invention>

1‧‧‧LED tube

11‧‧‧Light tube

111‧‧‧Explosion-proof protective film

13‧‧‧ Self-adhesive substrate

131‧‧‧Line layer

132‧‧‧Glue

14‧‧‧LED components

15‧‧‧End cover

151‧‧‧Electrical terminal block

152‧‧‧LED driver module

S01~S07‧‧‧ method steps

<知知>

1'‧‧‧Used LED lamps

10'‧‧‧Solid aluminum extrusion

11’‧‧‧shade

12'‧‧‧LED driver module

13’‧‧‧ boards

14'‧‧‧LED components

15’‧‧‧End cover

151'‧‧‧Electrical terminals

The first figure is an exploded view of an LED lamp used in the prior art; the second figure is an exploded view of an explosion-proof type LED lamp of the present invention; the third figure is a side sectional view of the explosion-proof type LED lamp; the fourth figure is an explosion-proof type LED The cross-sectional view of the lamp tube; the fifth figure is a flow chart of the manufacturing method of the explosion-proof type LED lamp tube of the present invention; and the process diagrams of the explosion-proof type LED lamp tube of the sixth to sixth E-pictures.

In order to more clearly describe an explosion-proof type LED lamp tube and a method of manufacturing the same according to the present invention, a preferred embodiment of the present invention will be described in detail below with reference to the drawings.

Please refer to the second and third figures, which are an exploded view and a side cross-sectional view of an explosion-proof LED tube of the present invention. As shown in the second and third figures, the explosion-proof LED tube 1 (hereinafter referred to as the LED tube 1) of the present invention comprises: a tube 11, an explosion-proof protective film 111, a self-adhesive substrate 13, and a plurality of The LED element 14 and the two-end cover 15 are covered by a (light-diffusing) explosion-proof protective film 111, and the explosion-proof protective film is used to prevent the lamp tube 11 from being broken and broken.

The self-adhesive substrate 13 has a circuit layer 131 formed on the surface thereof. Moreover, in the present invention, the surface is formed with a self-adhesive substrate 13 of the wiring layer 131, which may be any of the following: a thermally conductive self-adhesive substrate, having a sticker Glued fiberglass board, aluminum substrate with adhesive, copper substrate with adhesive, FPC with adhesive A flexible board, a ceramic substrate with a glue, or a printed wiring board with a glue. As shown in the figure, the adhesive 132 is located on the back surface of the self-adhesive substrate 13. The type or form of the adhesive 132 is not particularly limited. Therefore, the adhesive 132 can be any of the following: thermal adhesive , silicone, acrylic, adhesive, adhesive, adhesive, or any other adhesive. Thus, the self-adhesive substrate 13 is adhered to the inner wall of the lamp tube 11 through a glue 132 on the back surface thereof, and the self-adhesive substrate 13 is formed with at least one circuit layer 131. The circuit layer 131 may be copper. The circuit layer; or the circuit layer 131 can also be presented through the circuit board. In addition, the plurality of LED elements 14 are disposed on the circuit layer 131, and are electrically connected to the LED driving module 152 disposed in the end cover 15 through the circuit layer. Thus, the LED driving module 152 is configured. The illumination of the plurality of LED elements 14 can be controlled. Finally, the two end caps 15 are respectively connected to the two ends of the lamp tube 11, and the end cap 15 has an electrical terminal set 151 for electrically connecting an external power source.

Therefore, it should be particularly noted that although the LED driving module 152 shown in the third figure is disposed in the end cover 15, it is not limited to the setting position of the LED driving module 152; The LED driver module 152 can also be disposed outside the end cap 15. Furthermore, as shown in the cross-sectional view of the fourth figure, the technical feature of the present invention is that the self-adhesive substrate 13 having the circuit layer 131 and the plurality of LED elements 14 disposed on the surface of the self-adhesive substrate 13 is provided with the adhesive 132. Attached directly to the inner wall of the tube 11. In this way, the heat generated by the LED elements 14 can be directly transmitted through the tube 11 for heat transfer. It is delivered to the air, thereby enhancing the heat dissipation effect of the LED lamp 1. In addition, more importantly, since the self-adhesive substrate 13 is directly attached to the inner wall of the bulb 11 without passing through any aluminum base; therefore, it has only an illumination range of about 180° compared to the conventional LED tube. The light emitted by the LED elements 14 can be emitted in a manner similar to full-circumference (greater than 300o), thereby increasing the illumination range of the LED lamp 1 of the present invention.

Similarly, the present invention is not limited to the implementation of the lamp tube 11 and the explosion-proof protective film 111; wherein the lamp tube 11 may be a fully transparent glass tube or a fully transparent plastic tube; and, in order to increase light scattering, The lamp tube 11 can be a light diffusing glass tube or a light diffusing plastic tube. Therefore, it can be inferred that when the lamp tube 11 is a fully transparent glass tube, the light diffusion explosion-proof protective film can be used to cover the full transparent glass tube; conversely, if the tube 11 is a light diffusing glass lamp When used, it is used with a fully transparent explosion-proof protective film and cover protection. Furthermore, if the lamp tube 11 is a heat-conductive plastic and a light-diffusing plastic composite lamp tube, a fully transparent plastic lamp tube, or a light-diffusing plastic lamp tube, since the plastic lamp tube does not suddenly burst, the explosion-proof can be omitted. Use of the protective film 111.

Thus, through the above, the structure and technical features of the explosion-proof LED lamp of the present invention are clearly and completely described. Next, the explosion-proof LED lamp of the present invention will be further described below with the aid of the method flow chart. Production method. Please refer to the fifth figure, which is a flow chart of a method for manufacturing an explosion-proof type LED tube of the present invention; and, please refer to the sixth figure A to the same Figure 6 is a schematic diagram of the process of the manufacturing method. The manufacturing method of the present invention mainly comprises the following steps. First, as shown in FIG. 5 and FIG. 6A, the step (S01) is performed to provide a lamp tube 11 and the lamp tube 11 is covered with an explosion-proof protective film 111. Then, as shown in FIG. B, the step (S02) is performed to place a self-adhesive substrate 13 having a circuit layer 131 and a plurality of LED elements 14 on a substrate through a use of a release paper. Above the tooling 2. The substrate bonding tool 2 is composed of a rigid supporting member 21 and a soft bonding member 22. The rigid support member 21 is configured to support the lamp tube 11 so that the lamp tube 11 is suspended. The soft joint member 22 is disposed on the rigid support member 21 and has a plurality of LED recesses 221 for self-adhesive When the substrate 13 is placed on the substrate bonding tool 2, the LED elements 14 are housed.

Continuing, as shown in FIG. C, the step (S03) is performed to remove the release paper, and the substrate bonding tool 2 is placed inside the tube 11. Then, in step (S04), the lamp tube 11 is suspended by the rigid support member 21, and the lamp tube 11 is supported by the substrate bonding tool 2, so that the surface of the self-adhesive substrate 13 is pasted 132. It is in full contact with the inner wall of the tube 11. Then, as shown in FIG. 6D, the step (S05) is performed to operate a roller to roll over the outer wall of the lamp tube 11, so that the glue 132 on the bottom surface of the self-adhesive substrate 13 can be closely attached to the lamp tube. Finally, as shown in FIG. 6E, steps (S06) and (S07) are performed, the substrate bonding tool 2 is taken out, and the two end caps 15 are respectively combined to the lamp tube 11. Both ends.

Thus, the above-mentioned system has completely and clearly explained the explosion-proof type LED lamp of the present invention and the manufacturing method thereof, and, through the above, we can know that the present invention has the following advantages: the technical feature of the present invention is that the glue is applied The substrate 13 on which the wiring layer 131 and the plurality of LED elements 14 are provided is directly attached to the inner wall of the bulb 11. In this way, the heat generated by the LED elements 14 can be directly transferred to the air through the lamp tube 11, thereby enhancing the heat dissipation effect of the LED lamp 1.

In addition to the above first point, and more importantly, since the self-adhesive substrate 13 is directly attached to the inner wall of the bulb 11, without passing through any aluminum base; therefore, the LED elements 14 are emitted. The light can be emitted in a manner similar to full-circumference (greater than 300o), thereby increasing the illumination range of the LED lamp 1 of the present invention.

Furthermore, unlike the conventional LED luminaire, the structure of the LED luminaire 1 of the present invention is relatively simple, and the automatic/semi-automatic mass production of the LED luminaire 1 of the present invention can be completed by using a substrate affixing tool 2, and the display is further shown. The integrity of the technology of the present invention.

According to the above third point, since the structure of the LED lamp 1 of the present invention is relatively simple, and the automatic/semi-automatic mass production can be completed by using the substrate bonding tool 2, it is conceivable that the material of the LED lamp 1 of the present invention is obtained. Cost and manufacturing costs are very low.

In accordance with point 2 above, since the LED lamp 1 of the present invention does not use any The aluminum base, therefore, the all-glass lamp 11 or the all-plastic lamp 11 can effectively achieve the insulation effect, and the insulation effect is in line with the relevant safety regulations of the LED lamp 1.

More importantly, in the present invention, the glass tube 11 is covered with an explosion-proof protective film 111. Thus, when the glass tube 11 is broken, the explosion-proof protective film 111 can be effectively prevented. The collapse of the lamp fragments ensures the safety of the LED lamp 1 of the present invention.

It is to be understood that the foregoing detailed description of the embodiments of the present invention is not intended to Both should be included in the scope of the patent in this case.

1‧‧‧LED tube

11‧‧‧Light tube

111‧‧‧Explosion-proof protective film

13‧‧‧ Self-adhesive substrate

131‧‧‧Line layer

14‧‧‧LED components

15‧‧‧End cover

151‧‧‧Electrical terminal block

152‧‧‧LED driver module

Claims (10)

The invention discloses a method for manufacturing an explosion-proof LED lamp tube, comprising the steps of: (1) providing a lamp tube; (2) placing a self-adhesive substrate with a circuit layer and a plurality of LED elements on the surface through use of a release paper; (3) removing the release paper and placing the substrate bonding tool into the lamp tube; (4) vacating the lamp tube and bonding the substrate Supporting the lamp tube such that a glue on the bottom surface of the self-adhesive substrate is in full contact with the inner wall of the lamp tube; (5) operating a roller to roll over the outer wall of the lamp tube, thereby making the bottom surface of the self-adhesive substrate The glue can be closely attached to the inner wall of the lamp tube; (6) the substrate bonding tool is taken out; and (7) the two end covers are respectively combined to the two ends of the lamp tube. The method for manufacturing an explosion-proof type LED lamp according to the above aspect of the invention, wherein the substrate bonding device comprises: a rigid supporting member for supporting the lamp in the step (4) to make the lamp The tube is suspended; and a soft joint is disposed on the rigid support material and has a plurality of LED recesses for receiving the self-adhesive substrate when the substrate is placed on the substrate bonding tool Some LED components. The method for manufacturing an explosion-proof type LED tube according to the first aspect of the invention, wherein an LED driving module is disposed in the end cover and electrically connected to the circuit layer for driving the LEDs. The component emits light. The explosion-proof LED tube LED lamp of claim 1, wherein the LED driving module is disposed outside the end cover and electrically connected to the circuit layer for The LED elements are driven to emit light. The method for manufacturing an explosion-proof type LED tube according to claim 1, wherein the tube can be any one of the following: an all-glass tube or an all-plastic tube. The method for manufacturing an explosion-proof type LED tube according to the invention of claim 5, wherein the all-glass tube can be any one of the following: a light diffusing glass tube or a transparent glass tube. The method for manufacturing an explosion-proof type LED lamp according to the invention of claim 5, wherein the all-plastic lamp tube can be any one of the following: a heat conductive plastic and a light diffusing plastic composite lamp tube, a light diffusing plastic lamp tube, Or transparent plastic tube. The method for manufacturing an explosion-proof type LED tube according to claim 1, wherein the tube is covered with an explosion-proof protective film, and the explosion-proof protective film can be any of the following: a light diffusion explosion-proof protective film or a transparent film. Explosion-proof protective film. The method for manufacturing an explosion-proof type LED tube according to the first aspect of the invention, wherein the self-adhesive substrate on which the circuit layer is formed is an FPC flexible board having a glue. The method for manufacturing an explosion-proof type LED tube according to claim 1, wherein the glue can be any one of the following: thermal conductive adhesive, silicone rubber, acrylic adhesive, adhesive, adhesive, or adhesive. substance.