WO2019062069A1 - Led灯管及其制备方法 - Google Patents

Led灯管及其制备方法 Download PDF

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Publication number
WO2019062069A1
WO2019062069A1 PCT/CN2018/082526 CN2018082526W WO2019062069A1 WO 2019062069 A1 WO2019062069 A1 WO 2019062069A1 CN 2018082526 W CN2018082526 W CN 2018082526W WO 2019062069 A1 WO2019062069 A1 WO 2019062069A1
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WO
WIPO (PCT)
Prior art keywords
tube
lamp
led
cavity
lamp cap
Prior art date
Application number
PCT/CN2018/082526
Other languages
English (en)
French (fr)
Inventor
李远刚
罗杨洋
杨林
杨海涛
Original Assignee
深圳市豪恩智能物联股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 深圳市豪恩智能物联股份有限公司 filed Critical 深圳市豪恩智能物联股份有限公司
Priority to DE212018000107.3U priority Critical patent/DE212018000107U1/de
Publication of WO2019062069A1 publication Critical patent/WO2019062069A1/zh

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Classifications

    • 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
    • F21K9/20—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
    • F21K9/272—Details of end parts, i.e. the parts that connect the light source to a fitting; Arrangement of components within end parts
    • 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
    • F21K9/278—Arrangement or mounting of circuit elements integrated in the light source
    • 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
    • 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
    • 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
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/85—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems characterised by the material
    • F21V29/87—Organic material, e.g. filled polymer composites; Thermo-conductive additives or coatings therefor
    • 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
    • F21V31/00—Gas-tight or water-tight arrangements
    • F21V31/03—Gas-tight or water-tight arrangements with provision for venting
    • 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 present disclosure relates to the field of lighting technology, for example, to an LED lamp tube and a method of fabricating the same.
  • LED tube Light Emitting Diode (LED) tube, commonly known as LED tube, LED tube or LED tube, uses LED as the illuminator.
  • the traditional fluorescent tube is also called a fluorescent lamp. There is a filament at each end of the lamp.
  • the tube is filled with a small amount of argon and thin mercury vapor.
  • the inner wall of the tube is coated with phosphor, and the gas between the two filaments emits ultraviolet light when it conducts electricity. Let the phosphor emit visible light. Due to the heavy metal pollutant "mercury", the environmental pollution of the discarded fluorescent tubes is very serious.
  • the LED tube uses a light-emitting diode as a light source, which has higher luminous efficiency, is more energy-saving, has a longer service life, and is more environmentally friendly.
  • Some LED tubes have a sealed connection between the lamp cap and the tube body, and the tube may burst.
  • the present disclosure provides an LED lamp tube and a preparation method thereof, which have improved heat dissipation performance to the power module at the lamp cap, and have better gas permeability to prevent the lamp tube from bursting.
  • LED tube comprising:
  • tubular body having a hollow tubular structure in which a main light strip with LEDs is mounted in the lumen of the tubular body;
  • the lamp cap is disposed at the end of the pipe body and blocks the opening of the end of the pipe cavity.
  • the lamp cap is disposed at one end of the pipe body with a lamp cap accommodating cavity, and the power module is installed in the lamp cap accommodating cavity, and the power module and the main lamp strip are electrically connected.
  • the lamp cap is provided with a through hole, and the through hole is connected to the lamp cap receiving cavity;
  • a heat dissipating glue disposed in the lamp housing accommodating cavity and covering at least part of the power module
  • the heat-dissipating glue is provided with a venting hole, at least one venting hole communicates with the through-hole and the lumen, or a venting channel is formed between the heat-dissipating glue and the inner wall forming the accommodating cavity of the lamp cap, and the venting channel communicates with the through-hole and the lumen.
  • the power module is electrically connected to the main light bar through a flexible body, and the flexible body is a flexible light bar, a flexible circuit board or a soft wire;
  • the flexible body and the main light bar are integrated.
  • the number of the caps is two, and the two caps respectively block the openings at both ends of the lumen, and the cap cavities and lumens of the two caps are combined into a closed tubular lumen, the main strip and The power modules are respectively located on opposite sides of the inner cavity.
  • an end of the lamp head facing away from the pipe body is provided with a static electricity column, and a hollow cavity is disposed in the electric power column, and the hollow cavity is connected to the lamp cap receiving cavity;
  • the power module is provided with a power supply pin, and the power supply pin extends into the hollow cavity and is electrically connected to the over-voltage column.
  • the lamp cap is provided with two over-voltage posts, and one end of the lamp cap facing away from the pipe body is provided with a safety groove, and the safety groove is disposed between the two over-electric posts.
  • a safety flap is disposed in the cap accommodating chamber, and the safety rib is disposed between the openings of the two hollow cavities.
  • the cap accommodating cavity is divided into a first accommodating portion and a second accommodating portion in a direction toward the tube body;
  • a protrusion is disposed between the first accommodating portion and the second accommodating portion, and the second accommodating portion is sleeved at an end of the tube body, and an end surface of the tube body abuts the protrusion;
  • a part of the power module protrudes into the second receiving portion, and another portion is located in the first receiving portion, and the heat dissipating rubber is located in the first receiving portion.
  • the through hole is disposed at an end of the base that faces away from the tubular body.
  • the lamp cap is a plastic lamp cap and the tube body is a glass tube body.
  • the present disclosure also provides a method for preparing an LED tube, which is used for preparing the LED tube described above, and includes:
  • the anti-blocking fixture protrudes into the lamp cap accommodating cavity through the through hole, and the heat dissipating glue is poured into the lamp cap accommodating cavity from the opening of the lamp cap accommodating cavity to wrap at least part of the structure of the power module; when the heat dissipating glue is solidified, the anti-blocking is blocked
  • the fixture is extracted from the lamp housing, and a vent hole is formed at the insertion position of the anti-blocking fixture; the power module is electrically connected to the main light strip; and the lamp head filled with the heat-dissipating glue is installed at the end of the tube body.
  • the LED tube provided by the present disclosure and the preparation method thereof can connect the through hole with the lumen of the tube body by providing a venting hole or a venting passage, so that the internal and external air pressure and the air pressure at both ends are balanced during the operation of the lamp tube, and the heat is reduced.
  • the glue can be conveniently filled into the lamp housing, the heat dissipation function of the heat dissipation glue can be used to improve the heat dissipation capability of the power module, and the vent hole can be conveniently formed in the heat dissipation glue to protect the lumen. Balance with external air pressure to avoid bursting of the pipe body.
  • Embodiment 1 is an exploded perspective view of an LED lamp provided in Embodiment 1;
  • Embodiment 2 is an exploded perspective view showing one end of the LED tube provided in Embodiment 1;
  • Embodiment 3 is a schematic cross-sectional view showing one end of an LED lamp tube provided in Embodiment 1;
  • FIG. 4 is a schematic cross-sectional view of a lamp cap in the LED tube provided in Embodiment 1;
  • FIG. 5 is a schematic view 1 of a step of injecting glue in the LED lamp tube assembly method provided in Embodiment 1;
  • FIG. 6 is a schematic view 2 of a step of injecting glue in the LED lamp tube assembly method provided in Embodiment 1;
  • Figure 8 is a partial exploded view of the LED tube of Embodiment 2.
  • Figure 9 is a partial cross-sectional view of the LED tube of Embodiment 2.
  • FIG. 10 is a cross-sectional view of the lamp cap, the power module, and the heat sink according to Embodiment 2;
  • Figure 11 is a cross-sectional view of the base of the second embodiment
  • Figure 12 is a partial cross-sectional view showing the tube body, the main light bar and the flexible body according to the second embodiment
  • FIG. 13 is a schematic structural view of a main light bar and a flexible body according to Embodiment 2;
  • Figure 14 is a schematic view showing the structure of the anti-blocking jig and the lamp cap according to the second embodiment
  • Figure 15 is a cross-sectional view of Figure 14;
  • FIG. 16 is a schematic structural view of a lamp cap according to Embodiment 2;
  • FIG. 17 is a schematic structural view of another lamp cap according to Embodiment 2.
  • Figure 18 is a cross-sectional view of the base of Figure 17;
  • first, second, and the like are used for the purpose of description only, and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated.
  • features defining “first” and “second” may include one or more of the features, either explicitly or implicitly.
  • the meaning of "a plurality" is two or more unless specifically and specifically defined otherwise.
  • LED lighting fixtures have significant advantages such as energy saving and long life. With the development of LED semiconductor technology, LED lamps will replace traditional gas discharge fluorescent tubes.
  • This solution is especially useful for small-diameter lamps.
  • LED tubes there are many types of LED tubes on the market, but in general, there are two main types of tubes for LED tubes, one is aluminum and polycarbonate. Polycarbonate, PC) cover, and the other is a PC full plastic tube.
  • the former pipe body is mainly composed of upper and lower parts, and the lower part is a semi-circular aluminum profile for heat dissipation.
  • the LED lamp plate is fixed on the aluminum profile, and the upper half is a semi-circular transparent PC cover, and the illumination angle thereof is Less than 180 degrees, the illumination angle is small, and the metal part is easy to leak during the installation and use.
  • a safety switch can be set in the lamp part.
  • the addition of a safety switch results in a complicated internal structure of the lamp cap, an increase in the volume of the lamp cap, and an increase in the production cost of the lamp tube; the latter is mainly composed of a PC extruded long tube.
  • the tube body is caused by the heat of the lamp tube. Deformation and bending phenomenon occurs. The longer the length of the lamp tube, the more obvious the bending is, and there is a certain safety hazard. Based on this, the present embodiment proposes an improvement to the LED tube.
  • the LED tube 1 comprises a glass tube body 11, two lamp holders 12, a driving power source (not labeled), an LED lamp panel 14, and two sets of conductive pins 15.
  • the accommodating groove 120 is formed on the base 12, and the two caps 12 are sleeved at both ends of the glass tube body 11, and the two caps 12 and the glass tube body 11 are formed to form a accommodating cavity 110.
  • the accommodating slot 120 and the accommodating cavity 110 are in communication with each other;
  • the driving power source includes a first power board 131 and a second power board 132; here, the first power board 131 and the second power board 132 are respectively accommodated in two
  • the LED lamp board 14 is housed in the accommodating cavity 120, and the LED lamp board 14 is fixedly disposed on the inner wall of the glass tube body 11; here, the LED light board 14 and the first power board
  • the 131 and the second power board 132 are electrically connected, and the two sets of conductive pins 15 are respectively disposed on the two bases 12.
  • one set of conductive pins 15 is connected to the first power board 131, the other set of conductive pins 15 is connected to the second power board 132, and one end of the conductive pins 15 extends into the receiving slot 120, and the conductive pins The other end of the 15 extends beyond the base 12.
  • the structure of the above LED tube 1 can be used on a T5, T6 or T8 tube, and the glass tube 11 included in the LED tube 1 can be replaced with a PC full plastic tube.
  • the LED lamp tube 1 provided in Embodiment 1 of the present disclosure has an advantage in that a conventional driving power source design is processed into a first power source board 131 and a second power board 132, and the first power board 131 and the second power board are used. 132 are respectively disposed in the lamp caps 12 at the two ends of the glass tube body 11, and the LED lamp board 14 is driven by the first power board 131 and the second power board 132 to reduce the volume of the lamp cap 12 and the installation and operation of the LED tube 1 is safer. .
  • the tube body is not easily deformed by high temperature, thereby effectively solving the problem that the tube of the LED tube is easily deformed by high temperature, the volume of the lamp is large, and it is easy to occur during installation and use.
  • the technical problem of leakage hazard realizes the miniaturization of LED tubes, reduces the production cost of LED tubes, and improves the safety and reliability of LED tubes.
  • a relay 1310 may be disposed on the first power board 131.
  • the relay 1310 is electrically connected to the LED board 14 and the conductive pin 15, which can effectively prevent the LED.
  • Lamp 1 is in danger of leakage during installation and use.
  • a first venting opening 121 may be defined in the lamp cap 12 , for example, two symmetrically disposed first venting holes are formed on the end surface of the lamp cap 12 .
  • 121 that is, four first vent holes 121 are opened in the two lamp caps 12 disposed at two ends of the glass tube body 11, and the four first vent holes 121 are connected to the accommodating cavity 110 through the two accommodating grooves 120. .
  • the air accommodating the cavity 110 communicates with the outside air of the LED tube 1 through the first vent hole 121, thereby allowing the inside and outside air of the LED tube 1 to circulate, thereby preventing the internal and external air pressure difference between the LED tube 1 during use. There is a danger of explosion of the glass tube body 11.
  • the LED lamp tube 1 may further include two heat dissipating gels 16 disposed in the receiving groove 120, and the two heat dissipating gels 16 are respectively filled in A gap between the first power board 131 and the inner wall of the base 12 and a gap between the second power board 132 and the inner wall of the base 12 are provided.
  • the heat dissipating gel 16 is formed by solidification of the heat dissipating glue, and the heat dissipating glue is injected into the gap between the first power board 131 and the inner wall of the lamp cap 12 and the gap between the second power board 132 and the inner wall of the lamp cap 12 through the first vent hole 121.
  • the heat dissipating gel 16 is solidified after a period of time in the air.
  • the heat dissipating gel 16 mainly serves to protect the first power board 131 and the second power board 132 and improve the heat dissipation efficiency of the first power board 131 and the second power board 132.
  • a second venting hole 160 may be defined in the heat dissipating colloid 16 , and the second venting hole 160 communicates with the accommodating cavity 110 and the first venting hole 121 , for example, for example.
  • the second venting hole 160 has a one-to-one correspondence with the first venting hole 121.
  • One end of the second venting hole 160 communicates with the first venting hole 121, and the other end of the second venting hole 160 communicates with the accommodating cavity 110.
  • the air accommodating the cavity 110 communicates with the outside air of the LED tube 1 through the second vent hole 160 and the first vent hole 121, thereby allowing the inside and outside air of the LED tube 1 to circulate, preventing the LED tube 1 from being in use.
  • the difference between the internal and external air pressure causes the glass tube body 11 to explode.
  • a heat dissipating layer 17 may be filled between the bottom surface of the LED lamp board 14 and the inner wall of the glass tube 11 .
  • the LED board 14 includes a printed circuit board. (Printed Circuit Board, PCB) 141 and a number of LED bead 142.
  • the PCB board is a rigid board, that is, has a certain rigidity, is not easy to flex, and is easy to protrude into the glass tube body 11, which is advantageous for sticking and fixing the PCB board and the inner wall of the glass tube body 11.
  • the PCB board can also be a flexible board depending on the specific use and needs.
  • the LED lamp bead 142 is connected to the top surface of the PCB board 141.
  • the bottom surface of the PCB board 141 is adhered to the inner wall of the glass tube body 11 by heat-dissipating glue.
  • the heat-dissipating glue layer 17 is formed.
  • the heat-dissipating rubber layer 17 serves to connect the LED light board 14 and the glass tube body 11 and to improve the heat-dissipating efficiency of the LED light board 14.
  • the LED tube 1 further includes two flexible connecting plates 18, for example, the flexible connecting plate 18 is received in the accommodating cavity 110, and the two flexible connecting plates 18 One end of each of the two flexible connecting plates 18 is respectively connected to one end of the first power board 131 and one end of the second power board 132, that is, the LED board 14 passes two flexible ends.
  • the connection board 18 is electrically connected to the first power board 131 and the second power board 132, respectively. Since the flexible connecting plate 18 has flexibility, the shape and length of the flexible connecting plate can be changed according to specific use conditions and requirements, so even if the length of the glass tube 11 is greater than the length of the LED light board 14, the LED light board 14 is flexible.
  • the connecting plate 18 can also be easily connected to the first power board 131 and the second power board 132.
  • a pin terminal 1300 may be disposed on the first power board 131 and the second power board 132, where the first power board 131 and the second power board 132 are disposed.
  • the pin terminal 1300 is connected to the flexible connecting plate 18.
  • the pin terminal 1300 includes a plurality of pin pins (a PIN pin, which is a metal substance in the connector for completing electrical (transmission) of electrical (signal)), and one end of the flexible connecting plate 18 is provided with The mounting hole is inserted into the mounting hole, and the flexible connecting plate 18 is connected to the first power board 131 and the second power board 132.
  • the flexible connecting board 18 and the first power board 131 and the second power source are reduced.
  • the difficulty in connecting the plates 132 improves the installation efficiency of the flexible connecting plate 18 and the first power board 131 and the second power board 132.
  • a diffusion film 19 may be attached on the inner wall of the glass tube 11 to replace the conventional phosphor, thereby increasing the divergence angle of the light and improving the divergence angle of the light.
  • the uniformity of brightness and brightness of the LED tube 1 improves the energy saving effect and safety of the LED tube 1.
  • a conductive pin 122 may be disposed on an end surface of the lamp cap 12 , and the conductive pin 122 is sleeved at one end of the conductive pin 15 .
  • one end of the conductive pin 15 extends into the conductive pin 122 through the end surface of the base 12, and the conductive pin 15 is electrically connected to the conductive pin 122.
  • the conductive pin 122 protects the conductive pin 15 and connects the LED lamp.
  • the tube 1 functions as a lamp holder (not shown) to which it is adapted.
  • an LED lamp tube assembly method provided by Embodiment 1 of the present disclosure includes the following steps:
  • step 10 the first power board 131 and the second power board 132 are respectively mounted in the two bases 12;
  • step 20 a heat dissipating glue is injected into the base 12;
  • step 30 one end of the two flexible connectors 18 is connected to both ends of the LED light board 14;
  • step 40 the LED light board 14 is attached to the inner wall of the glass tube body 11;
  • step 50 the other end of the second flexible connector 18 is connected to the first power board 131 and the second power board 132;
  • step 60 the two caps 12 are capped at both ends of the glass tube body 11.
  • the first power board 131 and the second power board 132 are respectively inserted into the accommodating slots 120 of the two caps 12, and then the heat dissipating glue is injected into the accommodating slots 120 through the slots of the accommodating slots 120 until the heat dissipating glue
  • the gap between the first power board 131 and the inner wall of the base 12 and the gap between the second power board 132 and the inner wall of the base 12 are filled.
  • one ends of the two flexible connecting members 18 are respectively connected to the two ends of the LED light board 14, and then the heat dissipating glue is coated on the bottom surface of the LED light board 14, and the LED light board 14 is pasted and fixed by the heat dissipating glue.
  • a positioning groove 123 is defined in the opening edge of the accommodating groove 120, and both ends of the glass tube 11 extend into the positioning groove 123 to form a positioning, so that the glass tube body is formed. 11 and the mounting position of the base 12 are more precise, and the connection between the glass tube 11 and the base 12 is improved and the appearance is improved.
  • An advantageous effect of the LED lamp tube assembling method provided by Embodiment 1 of the present disclosure is that the conventional driving power source design is processed into the first power board 131 and the second power board 132, and between the first power board 131 and the inner wall of the base 12 The gap and the gap between the second power board 132 and the inner wall of the lamp cap 12 are injected into the heat dissipating glue, so that the volume of the lamp cap 12 is reduced and the first power board 131 and the second power board 132 are operated safer and more reliable, and at the same time,
  • the tube body made of glass makes the tube body not easily deformed by high temperature, and the LED lamp board 14 needs to drive the first power board 131 and the second power board 132 together, thereby effectively solving the high temperature of the tube of the LED tube.
  • the glue-injecting jig 2 is firstly inserted into the accommodating groove 120 through the first vent hole 121, and then passed through the groove of the accommodating groove 120.
  • the heat sinking glue is injected into the mouth of the receiving groove 120.
  • one end of the glue-injecting jig 2 first passes through the first venting hole 121 and protrudes into the accommodating groove 120, and the glue-injecting jig 2 blocks the first venting hole 121 to avoid slurry leakage, and then the heat-dissipating glue is disposed.
  • the gap between the first power board 131 and the inner wall of the base 12 and the gap between the second power board 132 and the inner wall of the base 12 are injected through the slots of the receiving slot 120 until the heat sinking glue fills the gaps.
  • the end face of the injection jig 2 protrudes into the receiving groove 120 protrudes from the heat dissipating glue, and then waits for the heat dissipating gel to solidify to form the heat dissipating gel 16, the gluing jig 2 is retracted through the first vent hole 121.
  • the groove 120 further forms a second venting hole 160 in the heat dissipating gel 16.
  • the lamp cap 12 can be kept in an axially upright state during the process of injecting the heat-dissipating glue, that is, the end face of the lamp cap 12 faces downward, and the opening of the receiving groove 120 faces
  • the glue-injecting jig 2 is inserted into the accommodating groove 120 from the bottom to the top, and the top surface of the heat-dissipating glue is parallel to the horizontal plane and perpendicular to the central axis of the lamp cap 12 due to the self-leveling action of the liquid.
  • the above-mentioned glue-injecting jig 2 is a columnar member made of a hard material, and the outer wall surface of the columnar member is smooth.
  • the glue-injecting jig 2 has sufficient hardness to withstand the external force when it is pulled out from the heat-dissipating gel 16, and at the same time, since the outer wall surface of the glue-injecting jig 2 is smooth, the glue-injecting jig 2 is easily dialed from the heat-dissipating gel 16 And forming a smooth and complete second venting hole 160 in the heat dissipating gel 16.
  • the LED light bar is formed by assembling the LED on a strip-shaped circuit board, and is named after the shape of the product is like a tape.
  • LED light strips are generally divided into two types: flexible strips and hard strips.
  • the flexible strips are made of flexible printed circuit (FPC), which is formed by assembling LEDs on the patch.
  • the hard strips are A PCB (printed circuit board) hard board is used to assemble the circuit board, and an LED is assembled on the patch.
  • Embodiment 2 of the present disclosure provides an LED lamp tube including a tube body 31, two lamp caps 33, and a heat dissipating glue 35.
  • the tube body 31 is a hollow tubular structure, and the main light bar 32 with LEDs is attached to the cavity 311 of the hollow tubular structure through the glue 310.
  • the two lamp caps 33 are respectively disposed at the two ends of the pipe body 31, and the openings of the two ends of the pipe cavity 311 are blocked.
  • the lamp cap 33 is disposed at one end of the pipe body 31 with a lamp cap accommodating cavity 331.
  • the lamp cap accommodating cavity 331 is provided with a power module 34.
  • the power module 34 is electrically connected to the main light bar 32.
  • the heat dissipating glue 35 is disposed in the lamp cap accommodating cavity 331 and can be solidified by the heat dissipating glue.
  • the heat dissipating glue 35 at least partially encloses the power module 34 and at least partially contacts the inner wall forming the cap accommodating cavity 331 to conduct the heat of the power module 34 to the lamp cap 33 through the heat dissipating glue.
  • the heat dissipating rubber 35 can be filled into the entire cross section of the lamp cap accommodating cavity 331, that is, the inner wall forming the cap accommodating cavity 331 is in contact with the heat dissipating glue 35. At this time, the heat dissipating glue 35 can be provided with ventilation.
  • the hole 351 has at least one vent hole 351 communicating with the through hole 332 and the lumen 311.
  • a venting passage between the heat-dissipating glue 35 and the inner wall forming the cap-receiving cavity 331 is reserved, and the through-hole 332 and the lumen 311 are communicated through the venting passage.
  • the partial heat source module 34 is wrapped by the heat-dissipating glue 35, it can be connected to a part of the inner wall forming the lamp cap accommodating cavity 331 without filling the complete cap accommodating cavity 331 to form a venting passage.
  • the partition portion 336 may be disposed on the cap accommodating cavity 331 in advance.
  • the portion 336 divides the cap accommodating cavity 331 into different regions, and houses the power module 34 and the heat dissipating gel 35 in a part of the region, and the cap 33 can be provided with a through hole 332 in a region corresponding to the other region.
  • the heat-dissipating glue can be poured into the area of the lamp head 33 that houses the power module 34.
  • the heat-dissipating glue does not block the through-hole 332.
  • the 332 is in communication with the cap accommodating cavity 331 and is further connectable to the lumen 311.
  • the heat-dissipating glue 35 still forms a gas permeable passage with the inner wall forming the cap-receiving cavity 331.
  • the LED tube is equivalent to the LED tube in Embodiment 1.
  • the tube 31 may be the glass tube in Embodiment 1, or may be a tube made of other materials, such as polycarbonate. Made of materials.
  • the through hole 332 of the lamp cap 33 can be arranged, so that the anti-blocking fixture 3100 can be inserted into the through hole 332 from the outer end of the lamp cap 33 to prevent the heat sink rubber 35 from blocking the through hole 332 during the glue filling, and the anti-blocking treatment is prevented.
  • the 3100 can be a pin or the like.
  • the vent hole 351 can be formed on the heat dissipating rubber 35 by the anti-blocking jig 3100.
  • the vent hole 351 can be naturally formed on the cured heat-dissipating glue 35.
  • the venting hole 351 or the venting passage, and the lumen 311 are connected, the internal and external air pressure and the air pressure at both ends can be balanced when the lamp is in operation, thereby reducing the hidden danger of the lamp burst caused by thermal expansion and contraction.
  • two through holes 332 are provided to prevent the passage of the lumen 311 from the outside when one of the through holes 332 is blocked, thereby improving reliability.
  • the number of the through holes 332 may also be one or not less than three, and may be adjusted according to actual needs.
  • power module 34 is electrically coupled to main light strip 32 by flexible body 36, which is a flexible light strip, flexible circuit board, or flexible wiring.
  • the main light bar 32 can be a hard light bar or a soft light bar.
  • the main light bar 32 and the flexible body 36 may be of a unitary structure, that is, the main light bar 32 and the flexible body 36 are an entire flexible light bar.
  • the power module 34 and the main light bar 32 are connected through the flexible circuit board, so that the flexible light strip can be used as a patch component, and the main light bar 32 is directly connected through the reflow soldering point, thereby solving the lamp fitting terminal or the soldering silicone wire.
  • the difficult problem is that the main light bar 32 and the tube body 31 can be glued normally.
  • the power module 34 is provided with a plurality of connecting ends at one end, and one end of the flexible body 36 is provided with a mounting hole corresponding to the connecting end, and the connecting end is disposed in the mounting hole to realize the flexible body 36.
  • the electrical connection with the power module 34 reduces the difficulty of connecting the flexible body 36 to the power module 34, and improves the installation efficiency of the flexible body 36 and the power module 34.
  • one end of the base 33 away from the tubular body 31 is vertically disposed with two over-electrodes 333.
  • the over-clamped post 333 is provided with a hollow cavity 3331, and the hollow cavity 3331 communicates with the cap-receiving cavity 331.
  • the power module 34 is provided with two power supply pins 341.
  • the two power supply pins 341 extend into the two hollow chambers 3331 respectively, and are electrically connected to the power transmission post 333.
  • the two through holes 332 are respectively opened on the two power posts.
  • On both sides of the 333 On both sides of the 333.
  • the arrangement of the above-mentioned over-powered column 333 can effectively protect the power supply pin 341 of the power module 34 while ensuring reliable power supply of the power module 34.
  • one end of the lamp cap 33 facing away from the tubular body 31 is provided with a safety groove 334 disposed between the two overhanging posts 333.
  • the arrangement of the safety slot 334 above increases the creepage distance between the two over-voltage posts 333, which improves the safety and reliability of the lamp.
  • the cap 331 is provided with a safety flap 335 disposed between the openings of the two hollow cavities 3331.
  • the above-mentioned safety flap 335 is arranged to cooperate with the safety groove 334 to increase the creepage distance between the two over-electrodes 333, thereby improving the safety and reliability of the lamp.
  • the cap accommodating cavity 331 is sequentially divided into a first accommodating portion 3311 and a second accommodating portion 3312 from the inside to the outside.
  • a protrusion 3313 is disposed between the second accommodating portion 3312 of the first accommodating portion 3311.
  • the second accommodating portion 3312 is sleeved at an end of the tube body 31, and an end surface of the tube body 31 abuts against the protrusion 3313.
  • the projections 3313 may be continuously disposed around the inner wall forming the cap accommodating chamber 3311 to form a stepped structure.
  • the protrusions 3313 may also be spaced around the inner wall forming the cap accommodation cavity 3311 to form a constrained bone structure.
  • a portion of the power module 34 extends into the second receiving portion 3312, and another portion is located in the first receiving portion 3311.
  • the heat sink 35 is located in the first receiving portion 3311.
  • the first receiving portion 3311 is disposed such that the lamp cap 33 can be fixed to one end of the tubular body 31 by simply applying glue, and the convenience of connecting the terminals of the power module 34 to the main light bar 32 is improved.
  • the two cap cavities 331 and the lumen 311 are combined into a closed tubular lumen, with the main ledge 32 and the power module 34 on opposite sides of the lumen, respectively.
  • the above arrangement makes reasonable use of the space of the inner cavity, facilitates the heat dissipation of the glue filling, and makes the main light bar 32 easy to be connected with the terminal of the power module 34.
  • the LED lamp tube structure provided in this embodiment can be applied to a T5, T6 or T8 lamp tube.
  • a T5 type lamp tube is taken as an example.
  • a relay is used instead of the button switch in the lamp tube as a safety control component, and the overall processing and assembly is more convenient, and the risk of electric leakage of the LED tube during installation and use is effectively prevented.
  • the lamp cap 33 is a plastic lamp cap
  • the pipe body 31 is a glass pipe body. Since the tube body 31 made of glass is used, the tube body 31 is not easily deformed by high temperature. It is also possible to attach a diffusion film on the inner wall of the tube body 31, which replaces the conventional phosphor powder, increases the divergence angle of the light, improves the brightness and brightness uniformity of the LED tube, and improves the LED. The energy saving effect and safety of the lamp. Of course, phosphor powder may also be disposed on the inner wall of the tube body 31.
  • the LED tube of the embodiment can adopt a double-ended power mode, and the dark area is reduced.
  • the circuit diagram is divided into two halves in the PCB design, and the power module 34 at one end includes electromagnetic compatibility (EMC) and electromagnetic interference (Electromagnetic Interference). , EMI) and the circuit of the rectification and filtering section, and the other end of the power supply module 34 includes a circuit of the power conversion output section.
  • EMC electromagnetic compatibility
  • EMI electromagnetic interference
  • the LED lamp tube provided in this embodiment processes the conventional driving power supply into two power supply boards, and arranges two power supply boards in two lamp holders 33 at two ends of the glass tube body, and drives the main lamps through the two power supply boards.
  • the strip 32 operates to reduce the volume of the cap 33 and to make the installation and operation of the LED tube safer.
  • the arrangement of the relay, the two lamp caps 33 and the glass body 31 of the glass material effectively solves the problem that the tube body 31 of the LED lamp tube is easily deformed by high temperature, the volume of the lamp cap is large, and the risk of electric leakage is likely to occur during installation and use.
  • the miniaturization of the LED tube reduces the production cost of the LED tube and improves the safety and reliability of the LED tube.
  • the present disclosure also provides a method for preparing an LED lamp tube, which is used for preparing the above LED lamp tube, and the method comprises the following steps:
  • the anti-blocking fixture 3100 extends from the outer end of the cap 33 into the cap accommodating cavity 331 through the through hole 332, and the heat-dissipating glue 35 is poured into the cap-receiving cavity 331 from the open end of the cap-receiving cavity 331 to wrap the fixed power module. 34.
  • the power module 34 is first secured within the base 33.
  • the anti-blocking jig 3100 is withdrawn from the outer end of the cap 33, and a vent hole 351 is formed at the insertion position of the anti-blocking jig 3100.
  • vent hole 351 is formed on the cured heat-dissipating gel 35 by the anti-blocking jig 3100.
  • the power modules 34 in the two caps 33 are electrically connected to both ends of the main strip 32 in the tube body 31, respectively.
  • the power module 34 and the main light bar 32 are connected using a flexible strip.
  • Two lamp caps 33 filled with the heat-dissipating glue 35 are attached to both ends of the pipe body 31.
  • the method for preparing the LED lamp tube provided by the present disclosure can facilitate the anti-blocking fixture 3100 to inject the heat-dissipating glue 35 by providing the through-hole 332 on the lamp cap 33, and when the anti-blocking jig 3100 is removed after the filling is completed, A venting hole 351 is naturally formed on the solidified heat-dissipating glue 35, so that the internal and external air pressure and the air pressure at both ends are balanced when the lamp is in operation, thereby reducing the hidden danger of the lamp burst caused by thermal expansion and contraction.
  • the LED lamp tube provided by the present disclosure and the preparation method thereof use the heat dissipating glue to improve the heat dissipation performance of the lamp cap to the power module, and the ventilating hole or the ventilating passage is arranged to balance the internal and external air pressure and the air pressure at both ends when the lamp is working, thereby reducing the heat.
  • the hidden danger of the tube burst caused by expansion and contraction, the heat dissipation is good, the air pressure inside and outside the lamp tube can be kept balanced, and the lamp head space is greatly saved.

Abstract

一种LED灯管及其制备方法。其中，LED灯管包括管体（31）、灯头（33）和散热胶（35）。管体（31）的管腔（311）内安装有带有LED的主灯条（32）。灯头（33）设置于管体（31）的端部，且封堵管腔（311）端部的开口，灯头（33）朝向管体（31）的一端设置有灯头容置腔（331），灯头容置腔（331）内安装有电源模块（34），灯头（33）开设有通孔（332），通孔（332）连通灯头容置腔（331）。散热胶（35）设置于灯头容置腔（331）内，且包覆至少部分电源模块（34）。散热胶（35）上设置有透气孔（351），至少一个透气孔（351）连通通孔（332）和管腔（311），或者，散热胶（35）与形成灯头容置腔（331）的内壁之间形成有透气通道，透气通道连通通孔（332）和管腔（311）。所述LED灯管的制备方法用于制备上述LED灯管。

Description

LED灯管及其制备方法 技术领域
本公开涉及照明技术领域，例如涉及一种LED灯管及其制备方法。
背景技术
发光二极管(Light Emitting Diode，LED)灯管，俗称LED光管、LED日光灯管或LED日光灯，其光源采用LED作为发光体。传统的日光灯管又称荧光灯，灯两端各有一灯丝，灯管内充有微量的氩和稀薄的汞蒸气，灯管内壁上涂有荧光粉，两个灯丝之间的气体导电时发出紫外线，使荧光粉发出可见光。由于含有重金属污染物质“汞”，使得报废的荧光灯管对环境的污染十分严重。而LED灯管采用发光二极管作为光源，光效更高、更为节能、使用寿命更长，而且更为环保。
对于超过一定功率的LED灯管而言，可能出现在灯管工作时温度过高，影响电源模块的性能，甚至发生安全事故。有些LED灯管的灯头和管体采用密封连接，可能出现管体炸裂。
发明内容
本公开提供一种LED灯管及其制备方法，在灯头处提高了对电源模块的散热性能，又具有较好的透气性，避免灯管炸裂。
本公开提供一种LED灯管，包括：
呈空心管状结构的管体，管体的管腔内安装有带有LED的主灯条；
灯头，设置于管体的端部，且封堵管腔端部的开口，灯头朝向管体的一端设置有灯头容置腔，灯头容置腔内安装有电源模块，电源模块与主灯条电连接，灯头开设有通孔，通孔连通灯头容置腔；
散热胶，设置于灯头容置腔内，且包覆至少部分电源模块；
其中，散热胶上设置有透气孔，至少一个透气孔连通通孔和管腔，或散热胶与形成灯头容置腔的内壁之间形成有透气通道，透气通道连通通孔和管腔。
在一实施例中，电源模块通过柔性体电连接于主灯条，柔性体为软灯条、柔性线路板或软接线；
当主灯条为软灯条时，柔性体与主灯条为一体结构。
在一实施例中，灯头的数量为两个，两个灯头分别封堵管腔的两端的开口，两个灯头的灯头容置腔和管腔组合成一个封闭的管状内腔，主灯条和电源模块分别位于内腔径向相对的两侧。
在一实施例中，灯头背离管体的一端设置有过电柱，过电柱内设置有空心腔，空心腔连通于灯头容置腔；
电源模块上设置有供电插针，供电插针伸入空心腔内，与过电柱电连接。
在一实施例中，灯头设置有两个过电柱，灯头背离管体的一端设置有安全槽，安全槽设置于两个过电柱之间。
在一实施例中，灯头容置腔内设置有安全挡片，安全挡片设置于两个空心腔的开口之间。
在一实施例中，灯头容置腔沿朝向管体的方向分为第一容置部和第二容置部；
第一容置部和第二容置部之间设有凸起，第二容置部套设于管体的端部，管体的端面抵靠凸起；
电源模块一部分伸入第二容置部内，另一部分位于第一容置部内，散热胶位于第一容置部内。
在一实施例中，通孔设置于灯头的背离管体的一端。
在一实施例中，灯头为塑胶灯头，管体为玻璃管体。
本公开还提供一种LED灯管的制备方法，用于制备上述的LED灯管，包括：
将防堵治具通过通孔伸入灯头容置腔内，从灯头容置腔的开口向灯头容置腔内灌注散热胶，包裹电源模块的至少部分结构；当散热胶固化后，将防堵治具从灯头容置腔中抽出，在防堵治具的插放位置处形成透气孔；将电源模块与 主灯条电连接；将灌注完散热胶的灯头安装于管体的端部。
本公开提供的LED灯管及其制备方法，通过设置透气孔或透气通道，可以将通孔与管体的管腔连通，以使灯管工作时内外气压、两端气压保持平衡，降低了热胀冷缩造成的灯管爆裂的隐患。通过上述的制备方法，即可以方便地向灯头容置腔中灌胶，利用散热胶的导热作用提升对电源模块的散热能力，还能很方便地在散热胶中形成透气孔，保护管腔内和外部气压平衡，避免管体炸裂。
附图说明
图1为实施例1提供的LED灯管的分解示意图；
图2为实施例1提供的LED灯管的一端分解放大示意图；
图3为实施例1提供的LED灯管的一端剖面示意图；
图4为实施例1提供的LED灯管中灯头的剖面示意图；
图5为实施例1提供的LED灯管组装方法中注胶步骤示意图一；
图6为实施例1提供的LED灯管组装方法中注胶步骤示意图二；
图7为实施例1提供的LED灯管组装方法流程图；
图8为实施例2所述的LED灯管的局部爆炸图；
图9为实施例2所述的LED灯管的局部剖视图；
图10为实施例2所述的灯头、电源模块和散热胶相配合的剖视图；
图11为实施例2所述的灯头的剖视图；
图12为实施例2所述的管体、主灯条和柔性体相配合的局部剖视图；
图13为实施例2所述的主灯条和柔性体相配合的结构示意图；
图14为实施例2所述的防堵治具与灯头相配合的结构示意图；
图15为图14的剖视图；
图16为实施例2所述的一种灯头的结构示意图；
图17为实施例2所述的另一种灯头的结构示意图；
图18为图17所示灯头的剖视图。
其中，图1-图7中的附图标记如下：
1-LED灯管、2-注胶治具、11-玻璃管体、12-灯头、14-LED灯板、15-导电插针、16-散热胶体、17-散热胶层、18-柔性连接件、19-扩散膜、110-容置腔、120-容置槽、121-第一透气孔、122-导电针脚、123-定位槽、131-第一电源板、132-第二电源板、141-PCB板、142-LED灯珠、160-第二透气孔、1300-拼针端子、1310-继电器；
图8-图18中的附图标记如下：
31-管体、311-管腔、32-主灯条(等同于图1中的LED灯板)、33-灯头(等同于图1中的灯头)、331-灯头容置腔、3311-第一容置部、3312-第二容置部、3313-凸起、332-通孔(等同于图1中的第一透气孔)、333-过电柱(等同于图1中的导电针角)、3331-空心腔、334-安全槽、335-安全挡片、336-隔离部，34-电源模块、341-供电插针(等同于图1中的拼针端子)、35-散热胶(等同于图1中的散热胶体)、351-透气孔(等同于图1中的第二透气孔)、36-柔性体(等同于图1中的柔性连接件)、310-胶水、3100-防堵治具(等同于图1中的注胶治具)。
具体实施方式
本公开中相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，用于解释本公开。
当元件被称为“固定于”或“设置于”另一个元件，它可以直接在另一个元件上或者间接在该另一个元件上。当一个元件被称为是“连接于”另一个元件，它可以是直接连接到另一个元件或间接连接至该另一个元件上。
术语“长度”、“宽度”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”、“内”和“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本公开和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作。
此外，术语“第一”、“第二”等仅用于描述目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二” 的特征可以明示或者隐含地包括一个或者更多个该特征。在本公开的描述中，“多个”的含义是两个或两个以上，除非另有明确具体的限定。
实施例1
LED照明灯具具有节能、寿命长等显著优点，随着LED半导体技术发展，LED灯管将取代传统气体放电日光灯管。
此方案特别对小管径灯管更实用，如市场上LED灯管产品种类繁多，但总体来说，LED灯管的管体主要存在两种主流结构，一种是铝型材加聚碳酸酯(Polycarbonate，PC)罩，另一种则是PC全塑管体。前者管体主要由上下两部分组成，下部分为半圆形的起散热作用的铝型材，LED灯板固定在铝型材上，上半部分为半圆形的透光PC罩，其发光角度为小于180度，发光角度小，并且金属部分容易在安装使用过程中发生漏电危险，为了解决漏电危险，可以在灯头部分设置安全开关。然而增设安全开关导致灯头内部结构复杂，灯头体积增大，灯管的生产成本增加；后者灯体主要构成是PC挤塑成型长管，在实际使用过程中，由于灯管热量会引起管体发生变形弯曲现象，灯管长度越长，弯曲越明显，存在一定的安全隐患。基于此，本实施例对LED灯管提出了改进。
请参阅图1至图4，对本公开的实施例1提供的LED灯管进行说明。该LED灯管1包括玻璃管体11、两个灯头12、驱动电源(未标注)、LED灯板14以及两组导电插针15。其中，在灯头12上开设有容置槽120，两个灯头12套设玻璃管体11的两端，并且两个灯头12与玻璃管体11合围形成有容置腔110。此处，容置槽120与容置腔110相互连通；驱动电源包括第一电源板131和第二电源板132；此处，第一电源板131和第二电源板132分别容置在两个灯头12的容置槽120内，LED灯板14容置在容置腔120内，并且LED灯板14固定设置在玻璃管体11的内壁上；此处，LED灯板14与第一电源板131和第二电源板132电连接，两组导电插针15分别穿设在两个灯头12上。例如，其中一组导电插针15与第一电源板131连接，另一组导电插针15与第二电源板132连接，并且导电插针15的一端伸入容置槽120内，导电插针15的另一端伸出灯头12外。
上述LED灯管1的结构可用在T5、T6或T8灯管上，LED灯管1包括的玻璃管体11可以替换为PC全塑管体。
本公开的实施例1提供的LED灯管1，有益效果在于：采用了将传统驱动电源设计加工成第一电源板131和第二电源板132，并且将第一电源板131和第二电源板132分别布置在位于玻璃管体11两端的灯头12内，通过第一电源板131和第二电源板132驱动LED灯板14工作，使得灯头12的体积缩小以及LED灯管1的安装运行更加安全。同时，由于采用了玻璃材质的管体，使得管体不容易因受高温发生变形，从而有效地解决了LED灯管的管体受高温容易发生变形、灯头体积大以及在安装使用过程中容易发生漏电危险的技术问题，实现了LED灯管的小型化，降低了LED灯管的生产成本，提升了LED灯管的安全可靠性。
在一实施例中，请参阅图1和图2，可以在上述第一电源板131上设置有继电器1310，例如，继电器1310与LED灯板14和导电插针15电连接，可以有效地防止LED灯管1在安装使用过程中发生漏电危险。
在一实施例中，请参阅图1、图2和图4，可以在上述灯头12上开设有第一透气孔121，例如，在灯头12的端面上开设有两个对称设置的第一透气孔121，即在套设于玻璃管体11两端的两个灯头12上一共开设有四个第一透气孔121，并且四个第一透气孔121通过两个容置槽120与容置腔110连通。如此，容置腔110的空气通过第一透气孔121与LED灯管1的外部空气连通，进而使得LED灯管1的内外空气流通，防止了LED灯管1在使用过程中产生内外气压差导致玻璃管体11发生爆炸的危险。
在一实施例中，请参阅图1至图3，上述LED灯管1还可以包括两个散热胶体16，该散热胶体16容置在容置槽120内，并且两个散热胶体16分别填充在第一电源板131与灯头12内壁之间的间隙和第二电源板132与灯头12内壁之间的间隙中。例如，散热胶体16由散热胶浆凝固形成，散热胶浆通过上述第一透气孔121注入第一电源板131与灯头12内壁之间的间隙和第二电源板132与灯头12内壁之间的间隙中，在空气中经过一段时间后凝固形成散热胶体16。 此处，散热胶体16主要起到保护第一电源板131和第二电源板132以及提高第一电源板131和第二电源板132散热效率的作用。
在一实施例中，请参阅图2和图6，可以在上述散热胶体16上开设有第二透气孔160，该第二透气孔160与上述容置腔110和第一透气孔121连通，例如，第二透气孔160与第一透气孔121一一对应，第二透气孔160的一端与第一透气孔121连通，第二透气孔160的另一端与容置腔110连通。如此，容置腔110的空气通过第二透气孔160和第一透气孔121与LED灯管1的外部空气连通，进而使得LED灯管1的内外空气流通，防止了LED灯管1在使用过程中产生内外气压差导致玻璃管体11发生爆炸危险。
在一实施例中，请参阅图3，可以在上述LED灯板14的底面与上述玻璃管体11的内壁之间填充有一个散热胶层17，例如，LED灯板14包括一个印制电路板(Printed Circuit Board，PCB)141和若干LED灯珠142。此处，PCB板为硬性板，即具有一定的刚性，不易曲挠，便于伸入玻璃管体11内，有利于PCB板与玻璃管体11的内壁进行粘贴固定。根据具体的使用情况和需求，PCB板还可为软性板。LED灯珠142连接在PCB板141的顶面上，PCB板141的底面通过散热胶浆粘贴在玻璃管体11的内壁上，当该散热胶浆凝固后形成散热胶层17。此处，散热胶层17既起到连接LED灯板14和玻璃管体11的作用，又有利于提高LED灯板14的散热效率。
在一实施例中，请参阅图2和图3，上述LED灯管1还包括两个柔性连接板18，例如，柔性连接板18容置在容置腔110内，并且两个柔性连接板18的一端分别与LED灯板14的两端连接，两个柔性连接板18的另一端分别与第一电源板131的一端和第二电源板132的一端连接，即LED灯板14通过两个柔性连接板18分别与第一电源板131和第二电源板132电连接。由于柔性连接板18具有柔性，可根据具体的使用情况和需求改变柔性连接板的形状和长度，因此即使在玻璃管体11的长度大于LED灯板14的长度情况下，LED灯板14借助柔性连接板18也可轻易地与第一电源板131和第二电源板132连接。
在一实施例中，请参阅图1至图3，可以在上述第一电源板131和第二电源 板132上设置有拼针端子1300，此处，第一电源板131和第二电源板132通过拼针端子1300与柔性连接板18连接。例如，拼针端子1300包括若干拼针(PIN针，是连接器中用来完成电(信号)的导电(传输)的一种金属物质)，柔性连接板18的一端上开设有与该拼针对应的安装孔，拼针与安装孔插接，实现柔性连接板18与第一电源板131和第二电源板132连接，如此，降低了柔性连接板18与第一电源板131和第二电源板132连接的难度，提高了柔性连接板18与第一电源板131和第二电源板132的安装效率。
在一实施例中，请参阅图1，可以在上述玻璃管体11的内壁上贴覆有一层扩散膜19，该扩散膜19取代了传统的荧光粉，增大了光线的发散角，提高了LED灯管1的亮度及亮度均的匀性，提升了LED灯管1的节能效果及使用安全性。
在一实施例中，请参阅图1至图4，可以在上述灯头12的端面上设置有导电针脚122，该导电针脚122套设在导电插针15的一端。例如，导电插针15的一端穿过灯头12的端面伸入导电针脚122内，并且导电插针15与导电针脚122电连接，如此，导电针脚122起到保护导电插针15，以及连接LED灯管1与其相适配的灯座(未图示)的作用。
请参阅图7，本公开的实施例1提供的LED灯管组装方法，包括以下步骤：
在步骤10中，将第一电源板131和第二电源板132分别装入二灯头12内；
在步骤20中，向灯头12内注入散热胶浆；
在步骤30中，将二柔性连接件18的一端连接于LED灯板14的两端；
在步骤40中，将LED灯板14贴固于玻璃管体11的内壁上；
在步骤50中，将二柔性连接件18的另一端连接于第一电源板131和第二电源板132上；
在步骤60中，将二灯头12封盖于玻璃管体11的两端。
将第一电源板131和第二电源板132分别装入两个灯头12的容置槽120内，接着通过容置槽120的槽口向容置槽120内注入散热胶浆，直至散热胶浆填满第一电源板131与灯头12内壁之间的间隙和第二电源板132与灯头12内壁之 间的间隙。同时，将两个柔性连接件18的一端分别连接在LED灯板14的两端，接着在LED灯板14的底面上涂覆散热胶浆，并且通过散热胶浆将LED灯板14粘贴固定在玻璃管体11的内壁上，直至注入在第一电源板131与灯头12内壁之间的间隙和第二电源板132与灯头12内壁之间的间隙中散热胶浆凝固形成散热胶体16，接着将两个柔性连接件18的另一端分别与第一电源板131的一端和第二电源板132的一端连接，然后将玻璃管体11的两端伸入两个灯头12的容置槽120内，打胶固定。
在一实施例中，请参阅图4，在上述容置槽120的开口边缘上开设有定位槽123，上述玻璃管体11的两端伸入定位槽123内形成定位，如此，使得玻璃管体11与灯头12的安装位置更加精确，并且提升了玻璃管体11与灯头12连接的牢固度以及外观美观度。
本公开的实施例1提供的LED灯管组装方法的有益效果在于：将传统驱动电源设计加工成第一电源板131和第二电源板132，并且在第一电源板131与灯头12内壁之间的间隙和第二电源板132与灯头12内壁之间的间隙中注入散热胶浆，使得灯头12的体积缩小以及第一电源板131和第二电源板132运行更加安全可靠，同时，由于采用了玻璃材质的管体，使得管体不容易因受高温发生变形，并且LED灯板14需要第一电源板131和第二电源板132一起驱动，从而有效地解决了LED灯管的管体受高温容易发生变形、灯头体积大以及在安装使用过程中容易发生漏电危险的技术问题，实现了LED灯管的小型化，降低了LED灯管的生产成本，提升了LED灯管的安全可靠性。
在一实施例中，请参阅图5和图6，在上述步骤20中，先将注胶治具2穿过第一透气孔121伸入容置槽120内，接着通过容置槽120的槽口向容置槽120内注入散热胶浆。例如，注胶治具2的一端先穿过第一透气孔121伸入容置槽120内，并且注胶治具2将第一透气孔121封堵，避免发生漏浆，接着将散热胶浆通过容置槽120的槽口注入第一电源板131与灯头12内壁之间的间隙和第二电源板132与灯头12内壁之间的间隙中，直至散热胶浆填满上述两处间隙，此时，注胶治具2的伸入容置槽120内的一端端面突出散热胶浆外，接着等待散 热胶浆凝固形成散热胶体16后，注胶治具2经过第一透气孔121退出容置槽120，进而在散热胶体16上形成第二透气孔160。为了不让散热胶浆外溢或散热胶浆顶面倾斜，在注入散热胶浆的过程中，可以将灯头12保持轴向竖立状态，即灯头12的端面朝下，容置槽120的开口朝上，注胶治具2自下向上插入容置槽120内，由于液体自流平的作用，使得散热胶浆的顶面与水平面平行并且垂直于灯头12的中心轴。
在一实施例中，请参阅图6，上述注胶治具2为由硬质材料制成的柱状件，该柱状件的外壁面光滑。如此，注胶治具2具有足够的硬度承受从散热胶体16中拨出时的外部作用力，同时，由于注胶治具2的外壁面光滑，便于注胶治具2从散热胶体16中拨出，并在散热胶体16中形成光滑完整的第二透气孔160。
实施例2
LED灯条，简称灯条，是指把LED组装在带状的线路板上而形成的，因产品形状像一条带子一样而得名。LED灯条常规分为软灯条和硬灯条两种，其中软灯条采用柔性线路板(Flexible Printed Circuit，FPC)做组装线路板，在其上贴片组装LED而形成，硬灯条是用PCB(印制电路板)硬板做组装线路板，在其上贴片组装LED而形成。
如图8-图16所示，本公开的实施例2提供了一种LED灯管，包括管体31、两个灯头33以及散热胶35。其中，管体31为空心管状结构，空心管状结构的管腔311内通过胶水310贴装有带有LED的主灯条32。两个灯头33分别设置于管体31的两端，封堵管腔311两端的开口，灯头33朝向管体31的一端设置有灯头容置腔331，灯头容置腔331内安装有电源模块34，电源模块34与主灯条32电连接，灯头33背离管体31的一端开设有用于透气的通孔332，通孔332连通灯头容置腔331。散热胶35设置于灯头容置腔331内，可以由散热浆胶固化而成。散热胶35至少包裹部分电源模块34，并且与形成灯头容置腔331的内壁至少部分接触，以将电源模块34的热量通过散热胶向灯头33传导出去。
在本实施例中，可以将散热胶35填充灯头容置腔331的整个横截面，即，形成灯头容置腔331的内壁均与散热胶35接触，此时，可以在散热胶35上设 置透气孔351，至少一个透气孔351连通通孔332和管腔311。
此外，还可以在填充散热胶35时，预留出散热胶35与形成灯头容置腔331的内壁之间的透气通道，通过透气通道将通孔332和管腔311连通。比如，可以通过打胶的方式，将散热胶35包裹部分电源模块34后，与形成灯头容置腔331的内壁的一部分连接，而不填充完整的灯头容置腔331，从而形成透气通道。
如图17和图18所示，在散热胶35与形成灯头容置腔331的内壁之间预留透气通道的实施方式中，还可以预先在灯头容置腔331上设置隔离部336，通过隔离部336将灯头容置腔331分隔为不同的区域，将电源模块34和散热胶35容置在其中一部分区域中，而灯头33在另外的区域对应的区域可以设置通孔332。此种方案中，可以将散热胶灌入到灯头33的容纳有电源模块34的区域，由于通孔332并未在电源模块34所在的区域，散热胶不会阻挡通孔332，此时通孔332与灯头容置腔331连通，进而可以与管腔311连通。此种实施方式中，散热胶35仍然与形成灯头容置腔331的内壁之间形成了透气通道。
本实施例中，LED灯管相当于实施例1中的LED灯管，管体31可以是实施例1中的玻璃管体，也可以是其他的材料制成的管体，比如采用聚碳酸酯的材料制成。
本实施例中，灯头33上通孔332的设置，可以方便防堵治具3100从灯头33的外端插入通孔332中，防止在灌胶时散热胶35堵住通孔332，防堵治具3100可以是插针等。并且，对于散热胶35完全填充灯头容置腔331的横截面的实施方式而言，还可以利用防堵治具3100在散热胶35上形成透气孔351。灌胶完成后，取下防堵治具3100时，可在固化的散热胶35上自然形成透气孔351。通孔332、透气孔351或透气通道、以及管腔311连通后，可以使得灯管工作时内外气压、两端气压保持平衡，降低了热胀冷缩造成的灯管爆裂的隐患。
在本实施例中，通孔332设置有两个，以避免有一个通孔332被堵时而无法将管腔311与外部连通，提高可靠性。当然，通孔332的数量也可以是一个或不少于三个，可以根据实际需要进行调整。
在一实施例中，电源模块34通过柔性体36电连接于主灯条32，该柔性体 36为软灯条、柔性线路板或软接线。主灯条32可以是硬灯条，也可以是软灯条。当主灯条32为软灯条时，主灯条32与柔性体36可以为一体结构，即，主灯条32和柔性体36为一整条软灯条。上述通过柔性线路板连接电源模块34和主灯条32，使得软灯条可以作为贴片元器件，通过回流焊点直接贴合连接主灯条32，解决了灯管贴合端子或焊硅胶线困难的问题，使得主灯条32和管体31可以正常打胶。
在本实施例中，电源模块34一端设置有多个连接端头，柔性体36的一端开设有与该连接端头相对应的安装孔，连接端头穿设于安装孔内，实现柔性体36与电源模块34的电连接，如此，降低了柔性体36与电源模块34连接的难度，提高了柔性体36与电源模块34的安装效率。
在一实施例中，灯头33背离管体31的一端垂直设置有两个过电柱333，过电柱333内设置有空心腔3331，该空心腔3331连通于所述灯头容置腔331。电源模块34上设置有两个供电插针341，两个供电插针341分别伸入两个空心腔3331内，与过电柱333电连接，两个通孔332分别开设于两个过电柱333的两侧。上述过电柱333的设置，在保证电源模块34可靠供电的同时，能够有效对电源模块34的供电插针341进行保护。
在一实施例中，灯头33背离管体31的一端设置有安全槽334，该安全槽334设置于两个过电柱333之间。上述安全槽334的设置，增加了两个过电柱333之间的爬电距离，提高了灯管的安全性和可靠性。
在一实施例中，灯头容置腔331内设置有安全挡片335，该安全挡片335设置于两个空心腔3331的开口之间。上述安全挡片335的设置，与安全槽334相配合，增加了两个过电柱333之间的爬电距离，提高了灯管的安全性和可靠性。
在本实施例中，灯头容置腔331从里向外依次分为第一容置部3311和第二容置部3312。其中，第一容置部3311第二容置部3312之间设有凸起3313，第二容置部3312套设于管体31的端部，管体31的端面抵靠凸起3313。凸起3313可以环绕形成灯头容置腔3311的内壁连续设置，形成台阶结构。凸起3313也可以环绕形成灯头容置腔3311的内壁间隔设置，形成限位的骨位结构。电源模 块34的一部分伸入第二容置部3312内，另一部分位于第一容置部3311内，散热胶35位于第一容置部3311内。上述第一容置部3311的设置，使得灯头33可以简单可靠地通过打胶固定于管体31的一端，并且提高了电源模块34的端子与主灯条32连接的便捷性。
在一实施例中，两个灯头容置腔331和管腔311组合成一个封闭的管状内腔，主灯条32和电源模块34分别位于该内腔径向相对的两侧。上述设置，合理地利用了内腔的空间，方便灌胶散热，并且使得主灯条32易于与电源模块34的端子相连接。
本实施例提供的LED灯管结构可以应用在T5、T6或T8灯管上，本实施例以T5型号的灯管为例。
本实施例的LED灯管的电源模块34中，使用继电器代替灯管中的按钮开关作为安全控制部件，整体加工组装更加方便，有效地防止LED灯管在安装使用过程中发生漏电危险。
本实施例中，灯头33为塑胶灯头，管体31为玻璃管体。由于采用了玻璃材质的管体31，使得管体31不容易因受高温发生变形。还可以在管体31的内壁上贴覆有一层扩散膜，该扩散膜取代了传统的荧光粉，增大了光线的发散角，提高了LED灯管的亮度及亮度的均匀性，提升了LED灯管的节能效果及使用安全性。当然，管体31的内壁上也可以设置荧光粉。
本实施例的LED灯管可以采用双端电源模式，减少了暗区，在PCB设计中把电路图分成两半，一端的电源模块34包括电磁兼容性(Electromagnetic Compatibility，EMC)、电磁干扰(Electromagnetic Interference，EMI)和整流滤波部分的电路，另一端电源模块34包括功率转换输出部分的电路。本实施例提供的LED灯管，将传统驱动电源设计加工成两块电源板，并且将两块电源板分别布置在位于玻璃管体两端的两个灯头33内，通过两个电源板驱动主灯条32工作，使得灯头33的体积缩小，并且使得LED灯管的安装运行更加安全。
继电器、两个灯头33和玻璃材质的管体31的设置，有效地解决了LED灯管的管体31受高温容易发生变形、灯头体积大以及在安装使用过程中容易发生 漏电危险的问题，实现了LED灯管的小型化，降低了LED灯管的生产成本，提升了LED灯管的安全可靠性。
本公开还提供了一种LED灯管的制备方法，用于制备上述的LED灯管，该方法包括如下步骤：
将防堵治具3100从灯头33的外端由通孔332伸入灯头容置腔331内，从灯头容置腔331的开口一端向灯头容置腔331内灌注散热胶35，包裹固定电源模块34。
在进行此步骤之前，先将电源模块34固定于灯头33内。
当散热胶35固化后，将防堵治具3100从灯头33的外端抽出，在防堵治具3100的插放位置处形成透气孔351。
此步骤中，通过防堵治具3100在固化的散热胶35上形成透气孔351。
将两个灯头33内的电源模块34分别电连接于管体31内的主灯条32的两端。
在此步骤中，使用软灯条连接电源模块34和主灯条32。
将灌注完散热胶35的两个灯头33安装于管体31的两端。
在此步骤中，通过打胶的方式将两个灯头33安装于管体31的两端，完成LED灯管的制备。
本公开提供的LED灯管的制备方法，通过在灯头33上设置通孔332，能够方便防堵治具3100灌注散热胶35，并且在灌胶完成后，取下防堵治具3100时，可在固化的散热胶35上自然形成透气孔351，以使灯管工作时内外气压、两端气压保持平衡，降低了热胀冷缩造成的灯管爆裂的隐患。
工业实用性
本公开提供的LED灯管及其制备方法，利用散热胶提高了灯头对电源模块的散热性能，通过设置透气孔或透气通道，使灯管工作时内外气压和两端气压保持平衡，降低了热胀冷缩造成的灯管爆裂的隐患，散热好，可保持灯管内外气压平衡，并大大节省灯头空间。

Claims (10)

  1. 一种LED灯管，包括：
    呈空心管状结构的管体(31)，所述管体(31)的管腔(311)内安装有带有发光二极管LED的主灯条(32)；
    灯头(33)，设置于所述管体(31)的端部，且封堵所述管腔(311)端部的开口，所述灯头(33)朝向所述管体(31)的一端设置有灯头容置腔(331)，所述灯头容置腔(331)内安装有电源模块(34)，所述电源模块(34)与所述主灯条(32)电连接，所述灯头(33)开设有通孔(332)，所述通孔(332)连通所述灯头容置腔(331)；
    散热胶(35)，设置于所述灯头容置腔(331)内，且包覆至少部分所述电源模块(34)；
    其中，所述散热胶(35)上设置有透气孔(351)，至少一个所述透气孔(351)连通所述通孔(332)和所述管腔(311)，或
    所述散热胶(35)与形成所述灯头容置腔(331)的内壁之间形成有透气通道，所述透气通道连通所述通孔(332)和所述管腔(311)。
  2. 根据权利要求1所述的LED灯管，其中，所述电源模块(34)通过柔性体(36)电连接于所述主灯条(32)，所述柔性体(36)为软灯条、柔性线路板或软接线；
    当所述主灯条(32)为软灯条时，所述柔性体(36)与所述主灯条(32)为一体结构。
  3. 根据权利要求1所述的LED灯管，其中，所述灯头(33)的数量为两个，两个所述灯头(33)分别封堵所述管腔(311)的两端的开口，两个所述灯头(33)的所述灯头容置腔(331)和所述管腔(311)组合成一个封闭的管状内腔，所述主灯条(32)和所述电源模块(34)分别位于所述内腔径向相对的两侧。
  4. 根据权利要求1所述的LED灯管，其中所述灯头(33)背离所述管体(31)的一端设置有过电柱(333)，所述过电柱(333)内设置有空心腔(3331)，所述空心腔(3331)连通于所述灯头容置腔(331)；
    所述电源模块(34)上设置有供电插针(341)，所述供电插针(341)伸入所述空心腔(3331)内，与所述过电柱(333)电连接。
  5. 根据权利要求4所述的LED灯管，其中，所述灯头(33)设置有两个所述过电柱(333)，所述灯头(33)背离所述管体(31)的一端设置有安全槽(334)，所述安全槽(334)设置于两个所述过电柱(333)之间。
  6. 根据权利要求5所述的LED灯管，其中，所述灯头容置腔(331)内设置有安全挡片(335)，所述安全挡片(335)设置于两个所述空心腔(3331)的开口之间。
  7. 根据权利要求1所述的LED灯管，其中，所述灯头容置腔(331)沿朝向所述管体(31)的方向分为第一容置部(3311)和第二容置部(3312)；
    所述第一容置部(3311)和所述第二容置部(3312)之间设有凸起(3313)，所述第二容置部(3312)套设于所述管体(31)的端部，所述管体(31)的端面抵靠所述凸起(3313)；
    所述电源模块(34)一部分伸入所述第二容置部(3312)内，另一部分位于第一容置部(3311)内，所述散热胶(35)位于所述第一容置部(3311)内。
  8. 根据权利要求1-7任一所述的LED灯管，其中，所述通孔(332)设置于所述灯头(33)的背离所述管体(31)的一端。
  9. 根据权利要求1-7任一所述的LED灯管，其中，所述灯头(33)为塑胶灯头，所述管体(31)为玻璃管体。
  10. 一种LED灯管的制备方法，用于制备权利要求1-9任一项所述的发光二极管LED灯管，所述方法包括：
    将防堵治具(3100)通过所述通孔(332)伸入所述灯头容置腔(331)内，从所述灯头容置腔(331)的开口向所述灯头容置腔(331)内灌注所述散热胶(35)，包裹所述电源模块(34)的至少部分结构；
    当所述散热胶(35)固化后，将所述防堵治具(3100)从所述灯头容置腔(331)中抽出，在所述防堵治具(3100)的插放位置处形成所述透气孔(351)；
    将所述电源模块(34)与所述主灯条(32)电连接；
    将灌注完所述散热胶(35)的所述灯头(33)安装于所述管体(31)的端部。
PCT/CN2018/082526 2017-09-30 2018-04-10 Led灯管及其制备方法 WO2019062069A1 (zh)

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