WO2015081809A1 - 防爆型led灯管及其制造方法 - Google Patents

防爆型led灯管及其制造方法 Download PDF

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Publication number
WO2015081809A1
WO2015081809A1 PCT/CN2014/092439 CN2014092439W WO2015081809A1 WO 2015081809 A1 WO2015081809 A1 WO 2015081809A1 CN 2014092439 W CN2014092439 W CN 2014092439W WO 2015081809 A1 WO2015081809 A1 WO 2015081809A1
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Prior art keywords
tube
explosion
led
proof
substrate
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Ceased
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PCT/CN2014/092439
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English (en)
French (fr)
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陈弘昌
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Individual
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V15/00—Protecting lighting devices from damage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S2/00—Systems of lighting devices, not provided for in main groups F21S4/00 - F21S10/00 or F21S19/00, e.g. of modular construction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20—Light sources comprising attachment means
    • F21K9/27—Retrofit light sources for lighting devices with two fittings for each light source, e.g. for substitution of fluorescent tubes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/90—Methods of manufacture
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V19/00—Fastening of light sources or lamp holders
    • F21V19/001—Fastening of light sources or lamp holders the light sources being semiconductors devices, e.g. LEDs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V19/00—Fastening of light sources or lamp holders
    • F21V19/001—Fastening of light sources or lamp holders the light sources being semiconductors devices, e.g. LEDs
    • F21V19/003—Fastening of light source holders, e.g. of circuit boards or substrates holding light sources
    • F21V19/005—Fastening of light source holders, e.g. of circuit boards or substrates holding light sources by permanent fixing means, e.g. gluing, riveting or embedding in a potting compound
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V23/00—Arrangement of electric circuit elements in or on lighting devices
    • F21V23/06—Arrangement of electric circuit elements in or on lighting devices the elements being coupling devices, e.g. connectors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V25/00—Safety devices structurally associated with lighting devices
    • F21V25/12—Flameproof or explosion-proof arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V3/00—Globes; Bowls; Cover glasses
    • F21V3/02—Globes; Bowls; Cover glasses characterised by the shape
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2101/00—Point-like light sources
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2103/00—Elongate light sources, e.g. fluorescent tubes
    • F21Y2103/10—Elongate light sources, e.g. fluorescent tubes comprising a linear array of point-like light-generating elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • the invention relates to an LED lamp, in particular to 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, and a manufacturing method thereof.
  • FIG. 1 is an exploded view of a conventional LED lamp.
  • 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 two end caps 15', wherein the circuit board 13' and the LED element 14' are placed on the heat dissipating aluminum extrusion 10', the LED driving module 12' It is placed in the accommodating space inside the heat-dissipating aluminum extrusion 10', and finally the lampshade 11' and the two end caps 15' are assembled to the heat-dissipating aluminum extrusion 10'.
  • 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
  • the above-mentioned LED lamp 1' is one of the currently common LED lamps; however, after long-term research, the inventors of the present invention found that the conventional LED lamp 1' shows several defects in use:
  • the structure is complicated: the structure of the conventional LED lamp 1' is relatively complicated, and 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 assembled onto the heat-dissipating aluminum extrusion 10', and such a complicated assembly process is very difficult to mass-produce by automation or semi-automation.
  • the conventional LED lamp 1' is mainly used for heat dissipation by heat-dissipating aluminum extrusion 10', but the heat-dissipating aluminum extrusion 10' is not only bulky, heavy, but more importantly, its production cost is very high, resulting in The cost of manufacturing the conventional LED lamp 1' is generally high.
  • 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, it can be imagined to be exposed.
  • the heat-dissipating aluminum extrusion 10' will probably result in poor insulation of the LED lamp 1'.
  • 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 above LED element 14' can only be half a week. Light ( ⁇ 180o) is emitted; it can be seen that the illumination range of the conventional LED lamp 1' is not large.
  • 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 directly 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.
  • 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 heat generated by the illumination of the LED element can be directly transferred to the air through the lamp tube, thereby enhancing the heat dissipation effect of the LED lamp.
  • the self-adhesive substrate is directly attached to the inner wall of the tube without passing through any aluminum base; therefore, the light emitted by the above-mentioned LED element can be emitted in a manner similar to full-circumference (greater than 300o).
  • the illumination range of the LED luminaire of the present invention is increased.
  • 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, which is guaranteed.
  • the safety of the LED tube of the present invention is used.
  • An explosion-proof LED lamp tube according to the present invention includes:
  • An explosion-proof protective film for covering the lamp tube to prevent the lamp tube from being broken and broken;
  • the self-adhesive substrate is disposed on the inner wall of the lamp tube, and the self-adhesive substrate is at least formed with a circuit layer, and the circuit layer is electrically connected to the LED driving module;
  • a plurality of LED elements disposed on the circuit layer and electrically connected to the LED driving module through the circuit layer, such that the LED driving module can control the illumination of the plurality of LED elements;
  • Two end caps are respectively connected to the two ends of the lamp tube, and the end caps are provided with an electrical terminal set for electrically connecting an external power source.
  • the LED driving module is disposed inside the end cover.
  • the above-mentioned explosion-proof LED tube wherein the tube is any one of the following: a full glass tube or an all-plastic tube.
  • the above-mentioned explosion-proof type LED tube wherein the all-glass tube is any one of the following: a light diffusing glass tube or a transparent glass tube.
  • the above-mentioned explosion-proof LED lamp tube wherein the all-plastic lamp tube is any one of the following: a heat-conductive plastic and a light-diffusing plastic composite lamp tube, a light-diffusing plastic lamp tube, or a transparent plastic lamp tube.
  • explosion-proof protective film is any one of the following: a light diffusion explosion-proof protective film or a transparent explosion-proof protective film.
  • the self-adhesive substrate on which the circuit layer is formed is any one of the following: a heat-conductive self-adhesive substrate, a glass fiber board with a glue, an aluminum substrate with a glue, and a copper with a glue.
  • a substrate, a flexible circuit board with a glue (FPC soft board), a ceramic substrate with a glue, or a printed wiring board with a glue is any one of the following: a heat-conductive self-adhesive substrate, a glass fiber board with a glue, an aluminum substrate with a glue, and a copper with a glue.
  • a substrate, a flexible circuit board with a glue (FPC soft board), a ceramic substrate with a glue, or a printed wiring board with a glue is any one of the following: a heat-conductive self-adhesive substrate, a glass fiber board with a glue, an aluminum substrate with a glue, and a copper with a glue.
  • the above-mentioned glue is any one of the following: thermal conductive glue, silica gel, plexiglass glue, viscose, paste, or adhesive substance.
  • a method for manufacturing an explosion-proof LED lamp tube according to the present invention comprises the following steps:
  • the method for manufacturing an explosion-proof type LED lamp tube wherein the substrate bonding tool comprises: a rigid support member for supporting the lamp tube in the above step (4) to make the lamp tube float; and the soft joint member is The utility model is disposed on the rigid support material and has a plurality of LED recesses for accommodating the LED element when the self-adhesive substrate is placed on the substrate bonding tool.
  • the LED driving module is disposed in the end cover and electrically connected to the circuit layer for driving the LED element to emit light.
  • the LED driving module is disposed outside the end cover and electrically connected to the circuit layer for driving the LED element to emit light.
  • the method for manufacturing an explosion-proof LED lamp tube wherein the lamp tube is any one of the following: an all-glass tube or an all-plastic tube.
  • the all-glass tube is any one of the following: a light diffusing glass tube or a transparent glass tube.
  • the method for manufacturing an explosion-proof LED lamp tube wherein the all-plastic lamp tube is any one of the following: a heat-conductive plastic and a light-diffusing plastic composite lamp tube, a light-diffusing plastic lamp tube, or a transparent plastic lamp tube.
  • the method for manufacturing an explosion-proof LED lamp tube wherein the explosion-proof protective film is any one of the following: a light diffusion explosion-proof protective film or a transparent explosion-proof protective film.
  • the method for manufacturing an explosion-proof LED lamp tube wherein the self-adhesive substrate on which the circuit layer is formed is any one of the following: a heat-conductive self-adhesive substrate, a glass fiber board with a glue, an aluminum substrate with a glue, and a sticker Copper substrate with glue, flexible circuit board with adhesive (FPC soft board), ceramic with adhesive Substrate, printed circuit board with adhesive.
  • the method for manufacturing an explosion-proof LED lamp tube wherein the glue is any one of the following: a thermal conductive adhesive, a silica gel, an plexiglass adhesive, a viscose, a paste, or an adhesive.
  • the present invention has at least the advantages of enhancing the heat dissipation effect of the LED lamp, increasing the illumination range of the LED lamp, and ensuring the safety of the LED lamp.
  • 1 is an exploded view of a conventional LED lamp.
  • Figure 2 is an exploded view of an explosion-proof type LED tube of the present invention.
  • 3 is a side cross-sectional view of an explosion-proof type LED tube.
  • FIG. 4 is a cross-sectional view of an explosion-proof type LED tube.
  • Fig. 5 is a flow chart showing a method of manufacturing an explosion-proof type LED tube according to the present invention.
  • 6A to 6E are schematic views showing a manufacturing process of an explosion-proof type LED tube.
  • Explosion-proof protective film 13 Self-adhesive substrate
  • circuit layer 132 glue
  • Circuit board 14' LED element
  • the explosion-proof LED lamp tube 1 (hereinafter referred to as the LED tube 1) of the present invention includes a lamp tube 11, an explosion-proof protective film 111, a self-adhesive substrate 13, a plurality of LED elements 14, and Two end caps 15; wherein the lamp tube 11 is covered by a (light diffusing) explosion-proof protective film 111, and the explosion-proof protection The film is used to prevent the lamp tube 11 from being broken and broken.
  • the self-adhesive substrate 13 has a wiring layer 131 formed on its surface; and, 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 glued glass fiber board, an aluminum substrate with a glue, a copper substrate with a glue, a flexible circuit board with a glue (FPC soft board), a ceramic substrate with a glue, or a printed circuit board with a glue.
  • 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.
  • the adhesive 132 can be any of the following: heat conduction. Glue, silicone, plexiglass (acrylic) glue, glue, paste, adhesive, or any other adhesive.
  • the self-adhesive substrate 13 is adhered to the inner wall of the bulb 11 through the adhesive 132 on the back surface thereof, and the self-adhesive substrate 13 is formed at least with the wiring layer 131, wherein the wiring layer 131 may be a copper wiring layer.
  • the circuit layer 131 can also be presented by means of a circuit board.
  • 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, so that the LED driving module 152 can be controlled. Light emission of the plurality of LED elements 14.
  • the two end covers 15 are respectively connected to the two ends of the lamp tube 11, and the end cover 15 is an electrical terminal set 151 for electrically connecting an external power source.
  • the LED driving module 152 shown in FIG. 3 is disposed in the end cover 15, it is not limited to the setting position of the LED driving module 152; in terms of practical application, the LED driving Module 152 can also be disposed outside of end cap 15. Furthermore, as shown in the cross-sectional view of FIG. 4, 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 by self-adhesive coating 132 on the back surface of the substrate 13 The ground is attached to the inner wall of the bulb 11.
  • the heat generated by the illumination of the LED element 14 can be directly transferred to the air through the lamp tube 11, thereby enhancing the heat dissipation effect of the LED lamp 1.
  • 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 180o compared to a conventional LED tube.
  • the light emitted by the LED element 14 described above 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.
  • the present invention is also not limited to the embodiment of the lamp tube 11 and the explosion-proof protective film 111; wherein the lamp tube 11 may be a full transparent glass tube or a fully transparent plastic tube; and, in order to increase light scattering, the lamp The 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.
  • 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.
  • the protective film 111 Use of the protective film 111.
  • FIG. 5 is a flow chart of a method for manufacturing an explosion-proof LED tube according to the present invention.
  • FIG. 6A to FIG. 6E a schematic diagram of a manufacturing process of the manufacturing method.
  • the manufacturing method of the present invention mainly comprises the following steps:
  • the step (S01) is performed, the lamp tube 11 is provided, and the lamp tube 11 is covered with an explosion-proof protective film 111; then, as shown in FIG. 6B, the step (S02) is performed.
  • the self-adhesive substrate 13 on which the wiring layer 131 and the plurality of LED elements 14 are provided on the surface is placed on the substrate bonding tool 2 by the use of the release paper.
  • 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 When the adhesive substrate 13 is placed on the substrate bonding tool 2, the LED element 14 is housed.
  • the step (S03) is performed to remove the release paper, and the substrate bonding tool 2 is placed inside the tube 11.
  • 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 glue 132 of the bottom surface of the self-adhesive substrate 13 is made. It comes into full contact with the inner wall of the tube 11.
  • the step (S05) is performed, and the operation roller is rolled 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 inner wall of the lamp tube 11.
  • steps (S06) and (S07) are performed, the substrate bonding tool 2 is taken out, and the two end caps 15 are respectively combined to both ends of the tube 11.
  • the technical feature of the present invention is that the self-adhesive substrate 13 having the wiring layer 131 and the plurality of LED elements 14 provided on the surface thereof is directly attached to the inner wall of the bulb 11 by the adhesive 132. In this way, the heat generated by the illumination of the LED element 14 can be directly transferred to the air through the lamp tube 11, thereby enhancing the heat dissipation effect of the LED lamp 1.
  • the self-adhesive substrate 13 is directly attached to the inner wall of the bulb 11, it is not necessary to pass any aluminum base; therefore, the light emitted by the above-mentioned LED element 14 It can be emitted in a manner similar to full-circumference (greater than 300o), by which the illumination range of the LED lamp 1 of the present invention is increased.
  • the structure of the LED luminaire 1 of the present invention is relatively simple, and the substrate affixing tool 2 can be used to complete the automatic/semi-automatic mass production of the LED luminaire 1 of the present invention, and further display The integrity of the techniques of the present invention.
  • 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.
  • the LED lamp 1 of the present invention does not use any aluminum base, 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 LED lamps 1.
  • the glass bulb 11 is covered with the explosion-proof protective film 111 in particular, so that the explosion-proof protective film 111 can effectively prevent the lamp from being broken when the glass bulb 11 is broken.
  • the tube fragments are scattered to ensure the safety of the LED tube 1 of the present invention.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Optics & Photonics (AREA)
  • Manufacturing & Machinery (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Fastening Of Light Sources Or Lamp Holders (AREA)

Abstract

一种防爆型LED灯管及其制造方法。该LED灯管包括：灯管（11）、防爆保护膜（111）、自粘基板（13）、多个LED元件（14）、以及二个端盖（15）。使用基板贴合制具快速地将表面设置有多个LED元件（14）的自粘基板（13）直接地贴附至灯管（11）的内壁。LED元件（14）的热量通过灯管（11）传递到空气中以加强散热效果。由于不需要铝基座，可以增加LED灯具的照明范围。

Description

防爆型LED灯管及其制造方法 技术领域
本发明是关于一种LED灯具，尤指其灯管内壁面与外壁面分别设置有导热自粘基板与防爆保护膜的一种防爆型LED灯管及其制造方法。
背景技术
近年来，发光二极管(Light-Emitting Diode，LED)是广泛地被应用于日常生活的照明装置上。请参阅图1，是现有习用的一种LED灯具的分解图，如图1所示，现有习用的LED灯具1’是包括：散热铝挤10’、灯罩11’、电路板13’、多个LED元件14’、LED驱动模块12’、以及二个端盖15’，其中，电路板13’与上述LED元件14’是放置于该散热铝挤10’上，该LED驱动模块12’是放置于散热铝挤10’内部的容置空间内，最后再将灯罩11’与该二个端盖15’组装至散热铝挤10’。并且，该电路板13’是电性连接至LED驱动模块12’，用以控制该多个LED元件14’的发光；此外，每个端盖15’具有一组电性端子151’，用以连接至市电。
上述的LED灯具1’为目前常见的LED灯具的一种；然，本案的发明人经长期研究后发现，现有习用的LED灯具1’是显现了几个使用上的缺陷：
结构复杂：现有习用的LED灯具1’的结构较为复杂，组装上必须将电路板13’置于散热铝挤10’之上并将LED驱动模块12’置于散热铝挤10’内，再将灯罩11’与端盖15’组装至该散热铝挤10’之上，而这样复杂的组装过程非常难以通过自动化或半自动化实现量产化。
2.成本高：现有习用的LED灯具1’主要通过散热铝挤10’来进行散热，但，散热铝挤10’不但体积大、重量重，更重要的是其生产成本非常的高，导致现有习用的LED灯具1’整体的制作费用偏高。
3.无法有效绝缘：现有习用的LED灯具1’因具有大体积的散热铝挤10’，且该散热铝挤10’的底部是露出于灯罩11’之外；因此，可想而知外露的散热铝挤10’将可能导致LED灯具1’的绝缘效果不佳。
4.光照范围小：由于现有习用的LED灯具1’结构的上半部为灯罩11’，且下半部为散热铝挤10’，因此上述LED元件14’所发出的光只能以半周光(～180o)的方式射出；由此可知现有习用的LED灯具1’的光照范围并不大。
因此，本案的发明人有鉴于目前所习用的LED灯具仍具有缺点与不足，故极力加以研究发明，终于研发完成本发明的一种防爆型LED灯管及其制造方法。
发明内容
本发明的主要目的，在于提供一种防爆型LED灯管及其制造方法，是特别使用基板贴合制具来快速地将表面设置有多个LED元件的自粘基板直接地贴附至灯管的内壁；如此一来，上述LED元件发光所产生的热便可透过灯管直接地热传递至空气之中，借此方式加强LED灯具的散热效果。此外，由于自粘基板是直接地贴附至灯管的内壁，而不需要通过任何铝基座；因此，上述LED元件所发出的光便能够以类似全周光(大于300o)的方式射出，借此方式增加本发明的LED灯具的光照范围。更重要的是，在本发明之中，特别以防爆保护膜包覆灯管，如此，一旦发生(玻璃)灯管破碎的事情，则防爆保护膜便可有效防止灯管碎片爆散，是能够保证本发明的LED灯管使用上的安全性。
因此，为了达成本发明上述的目的，本发明的目的及解决其技术问题是采用以下技术方案来实现的。依据本发明提出的一种防爆型LED灯管，是包括：
灯管；
防爆保护膜，用以包覆该灯管以防止该灯管破损碎裂；
自粘基板，是设置于该灯管的内壁上，且该自粘基板至少形成有线路层，并且该线路层是电性连接于LED驱动模块；
多个LED元件，是设置于该线路层之上，并通过该线路层而与该LED驱动模块电性连接，使得该LED驱动模块可控制该多个LED元件的发光；以及
二个端盖，是分别连接至该灯管的两端，且该端盖是具有用以电性连接外部电源的电性端子组。
本发明的目的及解决其技术问题还可采用以下技术措施进一步实现。
前述的防爆型LED灯管，其中该LED驱动模块是设置于该端盖之内。
前述的防爆型LED灯管，其中该LED驱动模块是置于该端盖之外。
前述的防爆型LED灯管，其中该灯管为下列任一种：全玻璃灯管或全塑胶灯管。
前述的防爆型LED灯管，其中所述的全玻璃灯管为下列任一种：光扩散玻璃灯管或透明玻璃灯管。
前述的防爆型LED灯管，其中所述的全塑胶灯管为下列任一种：导热塑胶与光扩散塑胶复合灯管、光扩散塑胶灯管、或透明塑胶灯管。
前述的防爆型LED灯管，其中该防爆保护膜为下列任一种：光扩散防爆保护膜或透明防爆保护膜。
前述的防爆型LED灯管，其中形成有该线路层的该自粘基板为下列任一种：导热自粘基板、具有贴胶的玻纤板、具有贴胶的铝基板、具有贴胶的铜基板、具有贴胶的柔性电路板(FPC软板)、具有贴胶的陶瓷基板、或者具有贴胶的印刷线路板。
前述的防爆型LED灯管，其中所述的贴胶为下列任一种：导热胶、硅胶、有机玻璃胶、粘胶、粘膏、或粘着物质。
并且，为了达成本发明上述的目的，本发明的目的及解决其技术问题还采用以下技术方案来实现。依据本发明提出的一种防爆型LED灯管的制造方法，是包括以下步骤：
(1)提供灯管，并以防爆保护膜包覆该灯管；
(2)通过离型纸的使用，将表面设置有线路层与多个LED元件的自粘基板置于基板贴合制具之上；
(3)移除该离型纸，并将该基板贴合制具置入该灯管之内；
(4)使灯管悬空，并以该基板贴合制具支撑该灯管，使得该自粘基板底面的贴胶与该灯管的内壁达到完全接触；
(5)操作滚轮滚过该灯管的外壁，借此方式使得该自粘基板底面的该贴胶能够紧密贴合于灯管的内壁；
(6)取出该基板贴合制具；以及
(7)将二个端盖分别组合至该灯管的两端。
本发明的目的及解决其技术问题还可采用以下技术措施进一步实现。
前述的防爆型LED灯管的制造方法，其中该基板贴合制具是包括：刚性支撑材，用以在上述步骤(4)支撑该灯管以使得灯管悬空；以及软质结合件，是设置于该刚性支撑材之上，并具有多个LED凹槽，用以在该自粘基板被置于该基板贴合制具之上时，容置上述LED元件。
前述的防爆型LED灯管的制造方法，其中LED驱动模块是设置于该端盖之内，并电性连接于该线路层，用以驱动上述LED元件发光。
前述的防爆型LED灯管LED灯具，其中该LED驱动模块是置于该端盖之外，并电性连接于该线路层，用以驱动上述LED元件发光。
前述的防爆型LED灯管的制造方法，其中该灯管为下列任一种：全玻璃灯管或全塑胶灯管。
前述的防爆型LED灯管的制造方法，其中所述的全玻璃灯管为下列任一种：光扩散玻璃灯管或透明玻璃灯管。
前述的防爆型LED灯管的制造方法，其中所述的全塑胶灯管为下列任一种：导热塑胶与光扩散塑胶复合灯管、光扩散塑胶灯管、或透明塑胶灯管。
前述的防爆型LED灯管的制造方法，其中该防爆保护膜为下列任一种：光扩散防爆保护膜或透明防爆保护膜。
前述的防爆型LED灯管的制造方法，其中形成有该线路层的该自粘基板为下列任一种：导热自粘基板、具有贴胶的玻纤板、具有贴胶的铝基板、具有贴胶的铜基板、具有贴胶的柔性电路板(FPC软板)、具有贴胶的陶瓷 基板、具有贴胶的印刷线路板。
前述的防爆型LED灯管的制造方法，其中所述的贴胶为下列任一种：导热胶、硅胶、有机玻璃胶、粘胶、粘膏、或粘着物质。
借由上述技术方案，本发明至少具有加强LED灯具的散热效果、增加LED灯具的光照范围和保证LED灯管使用上的安全性等优点。
上述说明仅是本发明技术方案的概述，为了能够更清楚了解本发明的技术手段，而可依照说明书的内容予以实施，并且为了让本发明的上述和其他目的、特征和优点能够更明显易懂，以下特举较佳实施例，并配合附图，详细说明如下。
附图说明
图1是现有习用的一种LED灯具的分解图。
图2是本发明的一种防爆型LED灯管的分解图。
图3是防爆型LED灯管的侧面剖视图。
图4是防爆型LED灯管的剖视图。
图5是本发明的一种防爆型LED灯管的制造方法流程图以及。
图6A至图6E是防爆型LED灯管的制造过程示意图。
【主要元件符号说明】
1：LED灯管                            11：灯管
111：防爆保护膜                       13：自粘基板
131：线路层                           132：贴胶
14：LED元件                           15：端盖
151：电性端子组                       152：LED驱动模块
S01～S07：方法步骤
1’：现有习用的LED的灯具              10’：散热铝挤
11’：灯罩                            12’：LED驱动模块
13’：电路板                          14’：LED元件
15’：端盖                            151’：电性端子
具体实施方式
为了能够更清楚地描述本发明所提出的一种防爆型LED灯管及其制造方法，以下将配合图式，详尽说明本发明的较佳实施例。
请参阅图2与图3，是本发明的一种防爆型LED灯管的分解图与侧面剖视图。如图2与图3所示，本发明的防爆型LED灯管1(以下简称LED灯管1)是包括：灯管11、防爆保护膜111、自粘基板13、多个LED元件14、以及二个端盖15；其中，该灯管11是由(光扩散)防爆保护膜111所包覆，且该防爆保护 膜是用以防止该灯管11破损碎裂。
该自粘基板13，其表面形成有线路层131；并且，在本发明中，所述的表面形成有线路层131的自粘基板13，其可为下列任一种：导热自粘基板、具有贴胶的玻纤板、具有贴胶的铝基板、具有贴胶的铜基板、具有贴胶的柔性电路板(FPC软板)、具有贴胶的陶瓷基板、或者具有贴胶的印刷线路板。如图所示，所述的贴胶132是位于自粘基板13的背面，在此，对于贴胶132的种类或者形式并不特别加以限制，因此，贴胶132可为下列任一种：导热胶、硅胶、有机玻璃(压克力)胶、粘胶、粘膏、粘着剂、或其它任何粘着物质。如此，自粘基板13是通过其背面的贴胶132而贴粘于该灯管11的内壁之上，且该自粘基板13至少形成有线路层131，其中，线路层131可以是铜线路层；或者，线路层131也可以通过电路板的方式呈现。另，该多个LED元件14是设置于线路层131之上，进而通过该线路层而与设置在端盖15内的LED驱动模块152电性连接，如此，是使得该LED驱动模块152可控制该多个LED元件14的发光。最后，该二个端盖15是分别连接至该灯管11的两端，且该端盖15是具有用以电性连接外部电源的电性端子组151。
在此，必须特别说明的是，虽然图3所示的LED驱动模块152是设置于该端盖15内，但并非以此限制LED驱动模块152的设置位置；就实务应用面来说，LED驱动模块152也可以设置在端盖15之外。再者，如图4的剖视图所示，本发明的技术特征在于，通过自粘基板13背面的贴胶132而将而将表面设置有线路层131与多个LED元件14的自粘基板13直接地贴附至该灯管11的内壁。如此一来，上述LED元件14发光所产生的热便可透过灯管11直接地热传递至空气之中，借此方式加强LED灯具1的散热效果。此外，更重要的是，由于自粘基板13是直接地贴附至灯管11的内壁，而不需要通过任何铝基座；因此，相比于传统LED灯管仅具有180o左右的光照范围，上述LED元件14所发出的光便能够以类似全周光(大于300o)的方式射出，借此方式增加本发明的LED灯具1的光照范围。
同样地，本发明对于灯管11与防爆保护膜111的实施例也没有加以限定；其中，灯管11可以是全透明玻璃灯管或全透明塑胶灯管；并且，为了增加光的散射，灯管11可以是光扩散玻璃灯管或者光扩散塑胶灯管。由此，可以推得而知，当灯管11为全透明玻璃灯管之时，可搭配使用光扩散防爆保护膜来覆盖全透明玻璃灯管；相反地，若灯管11为光扩散玻璃灯管之时，便搭配使用全透明防爆保护膜与以覆盖保护。再者，若灯管11为导热塑胶与光扩散塑胶复合灯管、全透明塑胶灯管、或者光扩散塑胶灯管时，由于塑胶灯管不会有突然爆裂的事情产生，因此可省去防爆保护膜111的使用。
如此，经由上述，本发明的防爆型LED灯管的结构与技术特征是已清楚且完整的被说明；接着，以下将通过方法流程图的辅助，进一步地详述本 发明防爆型LED灯管的制造方法。请参阅图5，是本发明的一种防爆型LED灯管的制造方法的流程图；并且，请同时参阅图6A至图6E，是该制造方法的制造过程示意图。本发明的制造方法主要包括以下步骤：
首先，如图5与图6A所示，是执行步骤(S01)，提供灯管11，并以防爆保护膜111包覆该灯管11；接着，如图6B所示，是执行步骤(S02)，通过离型纸的使用，将表面设置有线路层131与多个LED元件14的自粘基板13置于基板贴合制具2之上。其中，该基板贴合制具2是由刚性支撑材21与软质结合件22所构成。该刚性支撑材21用以在支撑该灯管11以使得灯管11悬空，该软质结合件22则设置于刚性支撑材21之上，并具有多个LED凹槽221，用以在该自粘基板13被置于该基板贴合制具2之上时，容置上述LED元件14。
继续地，如图6C所示，是执行步骤(S03)以移除该离型纸，并将该基板贴合制具2置入该灯管11之内。接着，在步骤(S04)之中，便可通过刚性支撑材21而使得灯管11悬空，并以该基板贴合制具2支撑该灯管11，使得该自粘基板13底面的贴胶132与该灯管11的内壁达到完全接触。然后，如图6D所示，是执行步骤(S05)，操作滚轮滚过该灯管11的外壁，借此方式使得该自粘基板13底面的贴胶132能够紧密贴合于灯管11的内壁；最后，如图6E所示，是执行步骤(S06)与步骤(S07)，取出该基板贴合制具2，并将二个端盖15分别组合至该灯管11的两端。
如此，上述是已完整且清楚地说明本发明的防爆型LED灯管及其制造方法，并且，经由上述，可以得知本发明是具有下列的优点：
本发明的技术特征在于，通过贴胶132而将表面设置有线路层131与多个LED元件14的自粘基板13直接地贴附至该灯管11的内壁。如此一来，上述LED元件14发光所产生的热便可透过灯管11直接地热传递至空气之中，借此方式加强LED灯具1的散热效果。
承上述第1点，此外，更重要的是，由于自粘基板13是直接地贴附至灯管11的内壁，而不需要通过任何铝基座；因此，上述LED元件14所发出的光便能够以类似全周光(大于300o)的方式射出，借此方式增加本发明的LED灯具1的光照范围。
再者，不同于现有习用的LED灯具，本发明的LED灯具1的结构相当简单，并且可利用基板贴合制具2完成本发明的LED灯具1的自动/半自动化的量产，更显示了本发明技术的完整性。
承上述第3点，由于本发明的LED灯具1的结构相当简单，并可利用基板贴合制具2完成其自动/半自动化的量产，可想而知，本发明的LED灯具1的材料成本、制造成本是非常低廉。
承上述第2点，由于本发明的LED灯具1不使用任何铝基座，因此，全玻璃材质的灯管11或者全塑胶材质的灯管11能够有效地达到绝缘效果，且其 绝缘效果是符合LED灯具1的相关安全规定。
更重要的是，在本发明之中，特别以防爆保护膜111包覆玻璃材质的灯管11，如此，一旦发生玻璃材质的灯管11破碎的事情，则防爆保护膜111便可有效防止灯管碎片爆散，是能够保证本发明的LED灯管1使用上的安全性。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发明，任何熟悉本专业的技术人员，在不脱离本发明技术方案范围内，当可利用上述揭示的技术内容作出些许更动或修饰为等同变化的等效实施例，但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (19)

  1. 一种防爆型LED灯管，其特征在于是包括：
    灯管；
    防爆保护膜，是包覆该灯管，以防止该灯管破损碎裂；
    自粘基板，是设置于该灯管的内壁之上，且该自粘基板至少形成有线路层，并且该线路层是电性连接于LED驱动模块；
    多个LED元件，是设置于该线路层之上，并通过该线路层而与该LED驱动模块电性连接，使得该LED驱动模块能控制该多个LED元件的发光；以及
    二个端盖，是分别连接至该灯管的两端，且该端盖是具有用以电性连接外部电源的电性端子组。
  2. 根据权利要求1所述的防爆型LED灯管，其特征在于其中该LED驱动模块是设置于该端盖之内。
  3. 根据权利要求1所述的防爆型LED灯管，其特征在于其中该LED驱动模块是置于该端盖之外。
  4. 根据权利要求1所述的防爆型LED灯管，其特征在于其中该灯管为下列任一种：全玻璃灯管或全塑胶灯管。
  5. 根据权利要求4所述的防爆型LED灯管，其特征在于其中所述的全玻璃灯管为下列任一种：光扩散玻璃灯管或透明玻璃灯管。
  6. 根据权利要求4所述的防爆型LED灯管，其特征在于其中所述的全塑胶灯管为下列任一种：导热塑胶与光扩散塑胶复合灯管、光扩散塑胶灯管、或透明塑胶灯管。
  7. 根据权利要求1所述的防爆型LED灯管，其特征在于其中该防爆保护膜为下列任一种：光扩散防爆保护膜或透明防爆保护膜。
  8. 根据权利要求1所述的防爆型LED灯管，其特征在于其中形成有该线路层的该自粘基板为下列任一种：导热自粘基板、具有贴胶的玻纤板、具有贴胶的铝基板、具有贴胶的铜基板、具有贴胶的柔性电路板、具有贴胶的陶瓷基板、或者具有贴胶的印刷线路板。
  9. 根据权利要求8所述的防爆型LED灯管，其特征在于其中所述的贴胶为下列任一种：导热胶、硅胶、有机玻璃胶、粘胶、粘膏、或粘着物质。
  10. 一种具有防爆型LED灯管的制造方法，其特征在于是包括以下步骤：
    (1)提供灯管，并以防爆保护膜包覆该灯管；
    (2)通过离型纸的使用，将表面设置有线路层与多个LED元件的自粘基板置于基板贴合制具之上；
    (3)移除该离型纸，并将该基板贴合制具置入该灯管之内；
    (4)使灯管悬空，并以该基板贴合制具支撑该灯管，使得该自粘基板底 面的贴胶与该灯管的内壁达到完全接触；
    (5)操作滚轮滚过该灯管的外壁，借此方式使得该自粘基板底面的该贴胶能够紧密贴合于灯管的内壁；
    (6)取出该基板贴合制具；以及
    (7)将二个端盖分别组合至该灯管的两端。
  11. 根据权利要求10所述的防爆型LED灯管的制造方法，其特征在于其中该基板贴合制具是包括：
    刚性支撑材，用以在上述步骤(4)支撑该灯管以使得灯管悬空；以及
    软质结合件，是设置于该刚性支撑材之上，并具有多个LED凹槽，用以在该自粘基板被置于该基板贴合制具之上时，容置上述LED元件。
  12. 根据权利要求10所述的防爆型LED灯管的制造方法，其特征在于其中LED驱动模块是设置于该端盖之内，并电性连接于该线路层，用以驱动上述LED元件发光。
  13. 根据权利要求10所述的防爆型LED灯管LED灯具，其特征在于其中该LED驱动模块是置于该端盖之外，并电性连接于该线路层，用以驱动上述LED元件发光。
  14. 根据权利要求10所述的防爆型LED灯管的制造方法，其特征在于其中该灯管为下列任一种：全玻璃灯管或全塑胶灯管。
  15. 根据权利要求14所述的防爆型LED灯管的制造方法，其特征在于其中所述的全玻璃灯管为下列任一种：光扩散玻璃灯管或透明玻璃灯管。
  16. 根据权利要求14所述的防爆型LED灯管的制造方法，其特征在于其中所述的全塑胶灯管为下列任一种：导热塑胶与光扩散塑胶复合灯管、光扩散塑胶灯管、或透明塑胶灯管。
  17. 根据权利要求10所述的防爆型LED灯管的制造方法，其特征在于其中该防爆保护膜为下列任一种：光扩散防爆保护膜或透明防爆保护膜。
  18. 根据权利要求10所述的防爆型LED灯管的制造方法，其特征在于其中形成有该线路层的该自粘基板为下列任一种：导热自粘基板、具有贴胶的玻纤板、具有贴胶的铝基板、具有贴胶的铜基板、具有贴胶的柔性电路板、具有贴胶的陶瓷基板、具有贴胶的印刷线路板。
  19. 根据权利要求10所述的防爆型LED灯管的制造方法，其特征在于其中所述的贴胶为下列任一种：导热胶、硅胶、有机玻璃胶、粘胶、粘膏、或粘着物质。
PCT/CN2014/092439 2013-12-06 2014-11-28 防爆型led灯管及其制造方法 Ceased WO2015081809A1 (zh)

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