WO2019114041A1 - Method for processing and manufacturing led disc lamp - Google Patents

Abstract

a method for processing and manufacturing an LED disc lamp, comprising: step (1) processing a reflecting plate (3): forming a curved surface of the reflecting plate (3) by press molding; forming a white reflecting layer on a reflecting surface by means of a powder spraying process; and coating a nanolayer on the white reflecting layer; Step (2) molding a mask (5) by using an injection molding machine, and pre-drying materials at a temperature of 115-125°C for 4-6 hours, the temperature zones of an injection molding machine barrel comprising: 230-260°C in the front section, 230~250°C in the middle section, and 220-240°C in the rear section; and a machine head temperature of 210-240°C; Step (3) processing a mounting base (6): forming bent mounting plates (62, 63) by press molding; forming a white reflecting layer on a reflecting surface by means of a powder spraying process; and coating a nanolayer on the white reflecting layer; and step (4) assembling the reflecting plate (3), a fixing plate (2), a power supply cap (1), the mask (5), and the mounting base 6 (6). Thus, LED light sources mounted on different mounting plates (62, 63) may emit light from different angles so that light emitted by a lamp is more uniform.

Description

Method for processing and manufacturing LED disk lamp Technical field

The invention relates to an LED lamp, in particular to a method for manufacturing and manufacturing an LED disk lamp.

Background technique

The LED panel light is an embedded indoor lighting fixture installed in the ceiling of the room. After installation and use, the structure of the lamp body is not leaked, and other parts of the lamp body are embedded in the ceiling to realize the overall coordination of the room. The lamp body of the LED lamp is directly installed on the roof, suitable for overall lighting, and is widely used in homes, shopping malls, banks, hospitals, hotels, restaurants. The existing LED lamp panel has a mounting base of an LED substrate, which is generally a flat panel, such as the Chinese patent, the LED lamp panel device disclosed in No. 203784772, including an anti-glare panel, a power supply and an LED strip, an LED strip and The power circuit connection is characterized in that: the LED lamp panel device comprises a panel and a single housing, wherein each housing is formed with a slot cavity, and the panel is provided with two or more recessed The slot cavity is fixed to each of the slots to form a light bar cavity, and each of the light bar cavity is provided with an LED light bar and an anti-glare plate. Since the plurality of LED substrates are in the same plane, the illumination directions of the plurality of LED light sources are equivalent, so that the illumination spot of the lamps is uneven, and the overall effect is that the illumination on both sides is weak, and the illumination in the middle is strong.

Summary of the invention

The technical problem to be solved by the present invention is to provide a method for processing and manufacturing an LED disk lamp, wherein the lamp panel emits light more uniformly.

In order to solve the above technical problem, the technical solution of the present invention is:

A method for manufacturing and manufacturing an LED disk lamp, the lamp panel comprising a power component, a light source component and a light distribution component;

The power component includes a fixing plate, a power source, and a power cover disposed at a top of the fixing plate;

The light source assembly includes a mounting seat fixed at a bottom of the fixing plate and an LED light bar fixed on the mounting seat, the mounting seat is located under the power cover, the mounting seat is formed by bending a metal plate, and includes a middle protrusion a mounting portion and mounting ears on both sides of the mounting portion, the mounting portion including a connecting plate in the middle, and a first mounting plate and a second mounting plate symmetrically disposed on both sides of the connecting plate, one side of the connecting plate One side of the first mounting board is connected, the other side of the first mounting board is connected to one side of the second mounting board, the other side of the second mounting board is connected to the mounting ear, and the connecting board is between the connecting board and the first mounting board. The angle is 170°, the angle between the first mounting plate and the second mounting plate is 160°, and the angle between the second mounting plate and the mounting ear is 150°; the LED light bar is fixed in the first installation a plate and a second mounting plate; the mounting ears and the fixing plate are connected and fixed to each other;

The light distribution assembly includes a reflective plate on both sides of the fixed plate and a mask under the mounting seat; the reflective surface of the reflective plate is a curved surface, and one side of the reflective plate is connected to the fixed plate through a connecting portion; The surface is sprayed with a white reflective layer, the curved surface is a hyperbolic tangent function, and the surface function relationship is as follows:

Where x represents the length of the lateral projection of the reflector, and f(x) represents the longitudinal height of the reflector in millimeters.

The disc lamp manufacturing method comprises the following steps:

(1) Process steps for processing the reflector:

(1.1) stamping and forming the surface of the reflector;

(1.2) forming a white reflective layer on the surface of the reflecting surface by a dusting process;

(1.3) plating a nano layer on the white reflective layer;

(2) Using the injection molding machine to form the mask, the material is pre-dried for 4-6 hours before processing, and the pre-drying temperature is 115-125 °C. The temperature range of the injection molding machine barrel includes: the front section 230-260 ° C, the middle section 230-250 °C, the rear section is 220-240 ° C; the head temperature is 210-240 ° C;

(3) Process for processing the mount:

(3.1) a stamping and bending installation plate;

(3.2) forming a white reflective layer on the surface of the reflecting surface by a dusting process;

(3.3) plating a nano layer on the white reflective layer;

(4) A process of assembling a reflector, a fixing plate, a power cover, a mask, and a mount.

The mounting portion of the lamp panel of the present invention is composed of mounting plates arranged at multiple angles, and the mounting plates are arranged in different directions in a substantially arc shape, corresponding to the reflecting plates of the special curved surface, so that they are mounted on different mounting plates. The LED light source can be illuminated at different angles to make the light output of the luminaire more uniform.

As an improvement, the top of the mounting seat forms a lower recess, the fixing plate is provided with a communication hole corresponding to the position of the power supply cover, and the power supply cover and the lower recess form a receiving cavity, and the power source is disposed in the receiving Inside the cavity.

As a modification, the mounting seat is provided with a first card hole, and the LED light bar is correspondingly provided with a second card hole, and the LED light bar is fixed on the mounting seat by the buckle.

As an improvement, the connecting portion is L-shaped, and includes a first connecting piece and a second connecting piece. The first connecting piece is connected to the fixing plate by a bolt, and the first connecting piece is connected to the reflecting plate through the second connecting piece, first The connecting piece and the second connecting piece are formed by bending.

As a modification, an angle between the first connecting piece and the second connecting piece is an acute angle to form a defensive groove, and both ends of the mask are provided with a hook portion, and the hook portion is disposed in the detachment preventing groove.

As an improvement, the mask is made of a flame-retardant polycarbonate resin and has a tension of 30 N to 50 N.

The beneficial effects of the present invention compared to the prior art are:

The mounting portion of the lamp panel of the present invention is composed of mounting plates arranged at multiple angles, and the mounting plates are arranged in different directions in a substantially arc shape, corresponding to the reflecting plates of the special curved surface, so that they are mounted on different mounting plates. The LED light source can be illuminated at different angles to make the light output of the luminaire more uniform.

DRAWINGS

Figure 1 is a schematic view of the structure of a lamp panel.

Figure 2 is a schematic view of the end face of the lamp panel.

Figure 3 is a schematic diagram of the mounting seat.

Fig. 4 is an enlarged view showing the position of a connecting portion of the reflecting plate.

Fig. 5 is a schematic view of the cover hook portion in a natural state.

Figure 6 is a schematic view of the cover hook portion in the assembled state.

Figure 7 is a schematic view of the end face of the mount.

Figure 8 is a graph of the light distribution of indoor lamps.

Fig. 9 is a graph showing the light intensity of a lamp or the like.

Figure 10 is a graph of the plane iso-illuminance.

Figure 11 is a graph of the plane illuminance.

Figure 12 is a graph of a reflecting plate.

Detailed ways

The invention will now be further described with reference to the drawings of the specification.

As shown in FIG. 1, an LED curved reflector lamp includes a power component, a light source component, and a light distribution component.

As shown in FIG. 1, the power supply assembly includes a fixed plate 2, a power source, and a power supply cover 1 disposed at the top of the fixed plate 2. The fixing plate 2 is a flat plate and has a rectangular shape. The power supply cover 1 is disposed at an intermediate position of the fixed plate 2. The fixed plate 2 is provided with a slot on one side of the power supply cover 1 and is disposed on the other side of the power supply cover 1. a first screw hole is provided; a mounting plate is disposed on two sides of the power cover 1 , and a mounting plate is disposed on the mounting plate opposite to the slot, the insert corresponding to the slot; and the mounting plate opposite to the first screw hole The second screw hole is arranged, and the mounting plate is connected to the fixing plate 2 by bolts; when the power cover 1 is installed, only one side of the bolt can be screwed, thereby improving assembly efficiency. The two sides of the fixing plate 2 are respectively provided with a third screw hole for mounting the light source assembly and a fourth screw hole for mounting the light distribution assembly.

As shown in FIGS. 1 and 2, the light source assembly includes a mount 6 fixed to the bottom of the fixed plate 2 and a plurality of LED strips 8 fixed to the mount 6. The mounting seat 6 is located below the power supply cover 1, and the mounting base 6 is formed by bending a metal plate. As shown in FIG. 7, it includes a centrally protruding mounting portion and mounting ears 64 on both sides of the mounting portion. The mounting ears 64 are horizontal, and are attached to the bottom surface of the fixing plate 2, and the mounting ears 64 are fixedly connected to the fixing plate 2 by bolts. The mounting portion includes a connecting plate 61 in an intermediate horizontal state, and a first mounting plate 62 and a second mounting plate 63 symmetrically disposed on both sides of the connecting plate 61, one side of the connecting plate 61 and the first mounting plate 62 One side is connected, the other side of the first mounting plate 62 is connected to one side of the second mounting plate 63, and the other side of the second mounting plate 63 is connected to the mounting ears. As shown in FIG. 3, the angle between the connecting plate 61 and the first mounting plate 62 is 170°, the angle between the first mounting plate 62 and the second mounting plate 63 is 160°, and the second mounting plate 63 is The angle between the mounting ears is 150°; the angle between the LED beads on the adjacent LED strips 8 is 20°. The width of the connecting plate 61 is 19 mm, the width of the first mounting plate 62 is 26 mm, and the width of the second mounting plate 63 is 25 mm. The LED light bar 8 is fixed on the first mounting plate 62 and the second mounting plate 63. To achieve rapid assembly, the mounting seat 6 is provided with a first card hole, and the LED light bar 8 is correspondingly provided with a first Two card holes, the LED light bar 8 is fixed on the mounting seat 6 by a snap. Since the mounting seat 6 is downwardly convex, that is, a lower recess 7 is formed at the top of the mounting base 6, the fixing plate 2 is provided with a communication hole corresponding to the position of the power supply cover 1, the power supply cover 1 and the lower recess 7 The accommodating cavity is formed, and the power source is disposed in the accommodating cavity; the invention fully utilizes the structure of the mounting seat 6 to solve the problem that the conventional lamp power supply is disposed at the top to form a convexity, resulting in an excessive thickness.

As shown in FIG. 2, the light distribution assembly includes a reflection plate 3 on both sides of the fixed plate 2 and a mask 5 located below the mount 6. The reflecting surface of the reflecting plate 3 is a curved surface, and one side of the reflecting plate 3 is connected to the fixing plate 2 through a connecting portion. As shown in FIG. 4, the connecting portion is L-shaped, and includes a first connecting piece 31 and a second connecting piece 32. The first connecting piece 31 is connected to the fixing plate 2 by bolts, and the first connecting piece 31 passes through the second connection. The sheet 32 is connected to the reflecting plate 3, and the first connecting piece 31 and the second connecting piece 32 are formed by bending, and the angle between the first connecting piece 31 and the second connecting piece 32 is an acute angle to form the anti-drop groove 33. The surface of the reflecting plate 3 is sprayed with a white reflective layer that increases the reflectance. As shown in FIG. 12, the surface is a hyperbolic tangent function, and the surface function relationship is as follows:

Where x represents the length of the lateral projection of the reflector 3, and f(x) represents the longitudinal height of the reflector 3 in millimeters.

The mask 5 is made of a flame-retardant polycarbonate resin and has characteristics such as high diffusion, ultraviolet resistance, corrosion resistance, and good toughness, and the mask 5 has a tension of 30N to 50N. The hooks 51 are provided at both ends of the mask 5, and the hooks 51 are disposed in the retaining grooves 33. As shown in FIG. 5, in the natural state, the hooks 51 are in a barbed state, and are inclined. The direction is substantially at an angle of 15° to the horizontal plane; as shown in FIG. 6 , in the assembled state, since the mask 5 is deformed, the hook portion 51 is substantially horizontal, so that it is fastened with the anti-drop groove 33, so that the lamp cover can bear its own weight. Extra downward gravity of more than 100N; the lampshade will not naturally detach from the lamp under the harsh conditions of use and transportation.

As shown in Fig. 1, a light shielding plate 4 is further provided at both ends of the mounting seat 6, and the light shielding plate 4 and the fixing plate 2 are perpendicular to each other to have an embedded mounting structure.

The mounting portion of the present invention is composed of mounting plates arranged at various angles, and the mounting plates are arranged in different directions in a substantially arc-shaped manner, corresponding to the reflecting plates 3 of the special curved surface, so that the LEDs mounted on different mounting plates are arranged. The light source can be illuminated at different angles to make the light output of the luminaire more uniform.

As shown in Figure 8-11, the horizontal direction (C0/180°) of the lamp of the present invention is tested by the matching of the curved surfaces of the two sides and the lampshade, so that the luminous intensity curve is approximately circular, and the beam angle is about 110°; The luminous intensity curve in the vertical direction (C90/270°) approximates the heart shape with a beam angle of about 140°. Under such a design, the luminaire is used indoors, and when the installation interval is less than 1 m, the illuminance uniformity of the light emitted by the luminaire to the working surface is greater than 0.8 (the illuminance uniformity is calculated as the minimum illuminance divided by the average illuminance).

The method for manufacturing a lamp panel of the present invention comprises the following steps:

(1) Process steps for processing the reflector:

(1.1) stamping and forming the surface of the reflector;

(1.2) forming a white reflective layer on the surface of the reflecting surface by a dusting process;

(1.3) plating a nano layer on the white reflective layer;

(2) Using the injection molding machine to form the mask, the material is pre-dried for 4-6 hours before processing, and the pre-drying temperature is 115-125 °C. The temperature range of the injection molding machine barrel includes: the front section 230-260 ° C, the middle section 230-250 °C, the rear section is 220-240 ° C; the head temperature is 210-240 ° C;

(3) Process for processing the mount:

(3.1) a stamping and bending installation plate;

(3.2) forming a white reflective layer on the surface of the reflecting surface by a dusting process;

(3.3) plating a nano layer on the white reflective layer;

(4) A process of assembling a reflector, a fixing plate, a power cover, a mask, and a mount.

The above process of plating the nano layer:

(1) Put the parylene powder into the sublimation furnace, the working temperature in the sublimation furnace is 150-200 ° C, and the vacuum degree is 1 Torr;

(2) Peililin enters the cracking furnace after gasification of the sublimation furnace, the working temperature in the cracking furnace is 650-700 ° C, and the vacuum degree is 0.5 Torr;

(3) The gasified parylene is cracked in a cracking furnace to form monomeric para-xylene vapor and enters the coating space in the deposition tank, and the LED strip on the tray is painted. The working temperature of the deposit tank is 35 to 45 ° C, the degree of vacuum is 0.5 Torr;

(4) The excess monomer p-xylene vapor in the deposition tank enters the cold trap through the residual material output port, and the working temperature of the cold trap is -(80-60) ° C, and the vacuum degree is 0.001-0.01 Torr.

The nanolayer has good water resistance and can improve the reflectivity of the white reflective layer.

Claims (6)

1. A method of manufacturing a LED disk lamp, the disk lamp comprising a power component, a light source component and a light distribution component; wherein:

   The power component includes a fixing plate, a power source, and a power cover disposed at a top of the fixing plate;

   The light source assembly includes a mounting seat fixed at a bottom of the fixing plate and an LED light bar fixed on the mounting seat, the mounting seat is located under the power cover, the mounting seat is formed by bending a metal plate, and includes a middle protrusion a mounting portion and mounting ears on both sides of the mounting portion, the mounting portion including a connecting plate in the middle, and a first mounting plate and a second mounting plate symmetrically disposed on both sides of the connecting plate, one side of the connecting plate One side of the first mounting board is connected, the other side of the first mounting board is connected to one side of the second mounting board, the other side of the second mounting board is connected to the mounting ear, and the connecting board is between the connecting board and the first mounting board. The angle is 170°, the angle between the first mounting plate and the second mounting plate is 160°, and the angle between the second mounting plate and the mounting ear is 150°; the LED light bar is fixed in the first installation a plate and a second mounting plate; the mounting ears and the fixing plate are connected and fixed to each other;

   The light distribution assembly includes a reflective plate on both sides of the fixed plate and a mask under the mounting seat; the reflective surface of the reflective plate is a curved surface, and one side of the reflective plate is connected to the fixed plate through a connecting portion; The surface is sprayed with a white reflective layer, the curved surface is a hyperbolic tangent function, and the surface function relationship is as follows:

   

   Where x represents the length of the lateral projection of the reflector, and f(x) represents the longitudinal height of the reflector in millimeters;

   The disc lamp manufacturing method comprises the following steps:

   (1) Process steps for processing the reflector:

   (1.1) stamping and forming the surface of the reflector;

   (1.2) forming a white reflective layer on the surface of the reflecting surface by a dusting process;

   (1.3) plating a nano layer on the white reflective layer;

   (2) Using the injection molding machine to form the mask, the material is pre-dried for 4-6 hours before processing, and the pre-drying temperature is 115-125 °C. The temperature range of the injection molding machine barrel includes: the front section 230-260 ° C, the middle section 230-250 °C, the rear section is 220-240 ° C; the head temperature is 210-240 ° C;

   (3) Process for processing the mount:

   (3.1) a stamping and bending installation plate;

   (3.2) forming a white reflective layer on the surface of the reflecting surface by a dusting process;

   (3.3) plating a nano layer on the white reflective layer;

   (4) A process of assembling a reflector, a fixing plate, a power cover, a mask, and a mount.
2. The method of manufacturing and manufacturing an LED disk lamp according to claim 1, wherein a top surface of the mounting seat forms a lower recess, and the fixing plate is provided with a communication hole corresponding to the position of the power supply cover, the power supply. The cover and the lower recess form an accommodating cavity, and the power source is disposed in the accommodating cavity.
3. The method of manufacturing and manufacturing an LED disk lamp according to claim 1, wherein the mounting seat is provided with a first card hole, and the LED light bar is correspondingly provided with a second card hole, and the LED light bar Secured to the mount by snaps.
4. The method of manufacturing and manufacturing an LED disk lamp according to claim 1, wherein the connecting portion is L-shaped, and comprises a first connecting piece and a second connecting piece, wherein the first connecting piece passes through the bolt and the fixing plate. The first connecting piece is connected to the reflecting plate through the second connecting piece, and the first connecting piece and the second connecting piece are formed by bending.
5. The method for manufacturing and manufacturing an LED disk lamp according to claim 4, wherein an angle between the first connecting piece and the second connecting piece is an acute angle to form an anti-drop groove, and both ends of the mask are provided a hook portion, the hook portion being disposed in the detachment preventing groove.
6. The method of manufacturing and manufacturing an LED disk lamp according to claim 1, wherein the mask is made of a flame-retardant polycarbonate resin and has a tension of 30 N to 50 N.

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