WO2021120490A1 - 一种he方案的led球泡灯及其生产工艺 - Google Patents

一种he方案的led球泡灯及其生产工艺 Download PDF

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Publication number
WO2021120490A1
WO2021120490A1 PCT/CN2020/087832 CN2020087832W WO2021120490A1 WO 2021120490 A1 WO2021120490 A1 WO 2021120490A1 CN 2020087832 W CN2020087832 W CN 2020087832W WO 2021120490 A1 WO2021120490 A1 WO 2021120490A1
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Prior art keywords
board
led light
machine
led
automatic plug
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PCT/CN2020/087832
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English (en)
French (fr)
Inventor
王佩诚
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杭州泰格电子电器有限公司
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Publication of WO2021120490A1 publication Critical patent/WO2021120490A1/zh

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    • 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
    • F21K9/23—Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • F21K9/232—Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
    • 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
    • F21K9/23—Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • F21K9/237—Details of housings or cases, i.e. the parts between the light-generating element and the bases; Arrangement of components within housings or cases
    • 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
    • F21K9/23—Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • F21K9/238—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
    • 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 the field of lighting equipment, in particular to an LED bulb lamp of the HE scheme and a production process thereof.
  • EMC electromagnetic compatibility
  • EMC electromagnetic compatibility
  • one of the objectives of the present invention is to provide an LED bulb lamp of the HE scheme, and the second objective is to provide a production process of the LED bulb lamp of the HE scheme, which has a simple structure and is convenient Automated assembly.
  • An LED bulb lamp of the HE scheme comprising a lamp cap, an upper shell and a blister; the lamp cap, the upper shell and the blister form a bulb shell, and the bulb shell is provided with an LED light board, an insulating board, a capacitor, and an inductor And a power cord; the insulating board is plugged into the LED light board, and the capacitor, inductance, and power cord are arranged on the insulating board and electrically connected to the LED light board.
  • a fuse resistor is also arranged in the bulb shell, and the fuse resistor is arranged on the insulating board and is electrically connected to the LED light board.
  • a side of the insulating plate close to the LED light board is provided with a plurality of bosses along the thickness direction, and the LED light board is provided with insertion holes corresponding to the positions and numbers of the bosses.
  • the boss is provided with a through hole, and the pins of the capacitor, the inductor, the power line and the fuse resistor pass through the through hole and are electrically connected to the LED light board.
  • the inductor is an E-shaped inductor or an I-shaped inductor.
  • the insulating board is made of plastic material.
  • a production process of the LED bulb lamp of the HE scheme includes the following steps:
  • making the LED light board includes the following steps:
  • the solder paste is melted by reflow soldering so that the LED lamp beads are soldered on the LED light source board to form an LED lamp board.
  • inserting the insulating board and the LED light board through the first automatic plug-in machine includes the following steps:
  • the LED light board is transported to the LED light board receiving position of the first automatic plug-in machine through the automatic board suction machine.
  • the LED light board receiving position is provided with a first sensor to sense whether the LED light board is in place; if the sensor is in place, it will send out The LED light board in place signal is sent to the first automatic plug-in machine; if it is not in place, the LED light board is not in place signal is sent to the first automatic plug-in machine;
  • the insulating plate is transported to the insulating plate receiving position of the first automatic plug-in machine through the insulating plate vibrating plate, and the insulating plate receiving position is equipped with a second sensor to sense whether the insulating plate is in place; if the sensing is in place, the insulating plate is in place. Signal to the first automatic plug-in machine; if it is not in place, the insulation board is not in place signal to the first automatic plug-in machine;
  • the first automatic plug-in machine After the first automatic plug-in machine receives the LED light board in-position signal and the insulation board in-position signal, the first automatic plug-in machine inserts the insulation board into the LED light board through the manipulator of the first automatic plug-in machine, and transports the LED light board after the insertion is completed Go to the next process; the first automatic plug-in machine will shut down and alarm after receiving the signal that the LED light board is not in place or the insulation board is not in place.
  • inserting the capacitor, the inductor, the power line and the fuse resistor into the through hole of the insulating plate through the corresponding automatic plug-in machine in no particular order includes the following steps:
  • the capacitor After sorting and distinguishing the positive and negative poles and cutting the feet through the first vibrating plate, the capacitor is delivered to the manipulator of the capacitor automatic plug-in machine.
  • the manipulator of the capacitor automatic plug-in machine inserts the capacitor into the corresponding through hole on the insulating plate and places it in the capacitor's Bent the foot after the pin passes through the through hole;
  • the inductance is delivered to the manipulator of the inductance automatic plug-in machine through the second vibrating plate, and the manipulator of the inductance automatic plug-in machine inserts the inductance into the corresponding through hole on the insulation board, and then the inductance pin passes through the through hole to bend the foot ;
  • the power cord is transported to the manipulator grab area of the power cord automatic plug-in machine through the conveyor belt, and the manipulator of the power cord automatic plug-in machine grabs it and inserts it into the corresponding through hole on the insulation board, and passes it through the pin of the power cord. Bent the foot after exiting the through hole;
  • the fuse resistor is transported to the manipulator grabbing area of the fuse resistor automatic plug-in machine through the conveyor belt, and the manipulator of the fuse resistor automatic plug-in machine grabs and rotates it and inserts it into the corresponding through hole on the insulation board. Bend the foot after passing through the through hole.
  • the present invention has the beneficial effects that the insulating board is plugged into the LED lamp board, which can facilitate assembly and improve production efficiency.
  • the insulating board itself can insulate the LED light board from the capacitors and inductors, eliminating the need for printed circuit boards used to install capacitors and inductors in traditional LED bulbs, and the printed circuit boards are not environmentally friendly materials. , Cannot be recycled
  • Figure 1 is a perspective view of the LED bulb lamp of the HE scheme of the present invention
  • Figure 2 is an exploded view of the LED bulb lamp of the HE scheme of the present invention
  • FIG. 3 is a schematic diagram of the LED bulb of the HE scheme of the present invention with the lamp cap, the upper shell and the bulb shell removed from the first perspective;
  • FIG. 4 is a schematic diagram of a second perspective view of the LED bulb lamp of the HE scheme of the present invention with the lamp cap, the upper shell and the bulb shell removed;
  • Figure 5 is an exploded view of the LED bulb of the HE scheme of the present invention with the lamp cap, the upper shell and the bulb shell removed;
  • Fig. 6 is a schematic diagram of an insulating plate.
  • the HE solution refers to a series of products formed on the insulating plate technology of this patent. It uses a plastic insulating plate as a carrier to insulate electronic components such as electrolytic capacitors, inductors, fuse resistors, power lines, and aluminum substrates. The boards are cleverly combined, and the fully automatic plug-in line is used for production, thereby greatly reducing labor costs, reducing raw material costs, and making product quality and performance more stable and reliable.
  • the LED bulb lamp of the HE solution provided by the embodiment of the present invention is shown, which at least includes a lamp cap 1, an upper shell 2 and a bulb 3.
  • the lamp holder 1, the upper shell 2 and the blister 3 form a bulb shell.
  • the bulb shell is provided with an LED light board 4, an insulating board 5, a capacitor 6, an inductor 7 and a power cord 8; the insulating board 5 is plugged into the LED light board 4,
  • the capacitor 6, the inductor 7 and the power line 8 are arranged on the insulating board 5 and electrically connected to the LED light board 4.
  • the inductor 7 can be an E-shaped inductor or an I-shaped inductor.
  • the material of the insulating board 5 can be made of plastic.
  • the number of capacitors 6 can be specifically set to two according to requirements. Capacitor 6 can be an electrolytic capacitor.
  • the insulating board 5 is plugged into the LED lamp board 4, which can facilitate assembly and improve production efficiency.
  • the insulating plate 5 itself can insulate the LED light board 4 from the capacitor 6 and the inductor 7, eliminating the need for a circuit board for arranging capacitors and inductors in the traditional LED bulb lamp.
  • the present invention also adds an inductor 7 in addition to the capacitor 6, which can further improve the electromagnetic compatibility (EMC) capability.
  • EMC electromagnetic compatibility
  • a fuse resistor 9 is also provided in the bulb housing, and the fuse resistor 9 is provided on the insulating board 5 and is electrically connected to the LED light board 4.
  • the fuse resistor 9 will be blown first when the current is too large, so that damage to the LED light board 4 can be avoided.
  • the insulating board 5 is provided with a plurality of bosses 51 along the thickness direction on the side close to the LED light board 4, and the LED light board 4 is provided with plugs corresponding to the position and number of the bosses 51 ⁇ 41. That is, the insertion of the insulating board 5 and the LED light board 4 is realized through the cooperation of the boss 51 on the insulating board 5 and the insertion hole 41 on the LED light board 4. Specifically, in order to achieve the effect of fastening, the boss 51 and the insertion hole 41 can be interference fit.
  • the boss 51 is provided with a through hole 511, and the pins of the capacitor 6, the inductor 7, the power line 8 and the fuse resistor 9 pass through the through hole 511 and are electrically connected to the LED light board 4.
  • the through hole 511 on the boss 51 By opening the through hole 511 on the boss 51, the electrical connection between the capacitor 6, the inductor 7, the power line 8, and the fuse resistor 9 and the LED light board 4 can be facilitated.
  • the way of opening the through hole 511 in this way is also more convenient for assembly.
  • the pins passing through the through hole 511 need to be bent to make them correspond to the corresponding ones on the LED light board 4.
  • the soldering points are contacted, and then the pins are fixed on the LED light board 4 by soldering, thereby achieving conductivity and a certain fixing effect.
  • the invention also discloses a production process of the LED bulb lamp of the HE scheme, which includes the following steps: S1, making the LED light board 4; S2, inserting the insulating board 5 and the LED light board 4 through the first automatic plug-in machine; S3. Insert the capacitor 6, the inductor 7, the power cord 8 and the fuse resistor 9 into the through hole 511 of the insulating plate 5 through the corresponding automatic plug-in machine in no particular order; S4, the LED light board after the step S3 4 Assemble with the lamp holder 1, the upper shell 2 and the bulb 3. This can increase the degree of automation of the LED bulb lamp production, thereby improving production efficiency and reducing labor costs.
  • the LED light board 4 and the insulating board 5 are set in a simple plug-in form that can be matched with the boss 51 and the plug hole 41, the difficulty of automatic plug-in is also reduced; and the capacitor 6, the inductor 7, the power cord 8, and The matching form of the fuse resistor 9 and the through hole 511 on the boss 51 also reduces the difficulty of automatic insertion.
  • making the LED light board 4 includes the following steps: brushing solder paste on the front of the LED light source board; attaching the LED lamp beads 42 to the solder paste of the LED light source board by an automatic placement machine; melting the solder paste through reflow soldering to make The LED lamp beads 42 are welded on the LED light source board to form the LED lamp board 4.
  • inserting the insulating board 5 with the LED light board 4 through the first automatic plug-in machine includes the following steps: the LED light board 4 is transported to the receiving position of the LED light board 4 of the first automatic plug-in machine by an automatic suction machine, and the LED
  • the receiving position of the light board 4 is provided with a first sensor to sense whether the LED light board 4 is in place; if the sensor is in place, the LED light board 4 in-position signal is sent to the first automatic plug-in machine; if the sensor is not in place, the LED is sent out
  • the light board 4 is not in place signal to the first automatic plug-in machine; the insulating plate 5 is conveyed to the insulating board 5 receiving position of the first automatic plug-in machine through the vibration plate of the insulating plate 5, and the insulating plate 5 receiving position is provided with a second sensor to Sensing whether the insulating board 5 is in place; if it is sensed, it sends a signal that the insulating board 5 is in place to the first automatic plug-in machine;
  • a third sensor can be provided on the receiving position of the LED light board 4 in the next process to sense whether the LED light board 4 is in place after the insertion is completed, and if it is not in place, it will send a stop signal to the automatic suction.
  • the trigger and the insulating plate 5 vibrate the plate.
  • inserting the capacitor 6, the inductor 7, the power line 8, and the fuse resistor 9 into the through hole 511 of the insulating plate 5 through the corresponding automatic plug-in machine in no particular order includes the following steps: After distinguishing the positive and negative poles and cutting the feet, transfer the capacitor 6 to the manipulator of the capacitor 6 automatic plug-in machine.
  • the manipulator of the capacitor 6 automatic plug-in machine inserts the capacitor 6 into the corresponding through hole 511 on the insulating plate 5, and inserts the capacitor 6 into the corresponding through hole 511 on the insulating plate 5.
  • the pin passes through the through hole 511 and then bends the foot; the inductor 7 is transported to the manipulator of the inductor 7 automatic plug-in machine through the second vibration plate, and the inductor 7 is inserted into the corresponding through hole on the insulating plate 5 by the manipulator of the inductor 7 automatic plug-in machine.
  • the power cord 8 is transported to the manipulator grabbing area of the power cord 8 automatic plug-in machine through the conveyor belt, and the power cord 8 is automatically plugged in by the power cord 8
  • the manipulator grabs it and inserts it into the corresponding through hole 511 on the insulating plate 5, and bends the foot after the pin of the power cord 8 passes through the through hole 511; the fuse resistor 9 is transported to the fuse resistor 9 through the conveyor belt.
  • the manipulator grabbing area of the machine is grabbed and rotated by the manipulator of the fuse resistor 9 automatic plug-in machine, and inserted into the corresponding through hole 511 on the insulating plate 5, and punched after the pin of the fuse resistor 9 passes through the through hole 511 Bent feet.

Abstract

本发明公开了一种HE方案的LED球泡灯及其生产工艺，其中HE方案的LED球泡灯包括灯头、上壳以及泡壳；灯头、上壳以及泡壳组成灯泡壳体，灯泡壳体内设置有LED灯板、绝缘板、电容、电感以及电源线；绝缘板与LED灯板插接，电容、电感以及电源线设置在绝缘板上且与LED灯板电连接。HE方案的LED球泡灯的生产工艺包括一下步骤，S1、制作LED灯板；S2、通过第一自动插件机将绝缘板与LED灯板插接；S3、通过对应的自动插件机不分先后顺序的将电容、电感、电源线以及保险电阻插接在绝缘板的通孔中；S4、将经过S3步骤后的LED灯板与灯头、上壳以及泡壳组装。本发明的HE方案的LED球泡灯，其结构简单，便于自动化装配。

Description

一种HE方案的LED球泡灯及其生产工艺 技术领域
本发明涉及照明设备领域，尤其涉及一种HE方案的LED球泡灯及其生产工艺。
背景技术
目前，LED球泡灯是照明领域内出货量最大，使用最广泛的产品，但同时其质量也是参差不齐。其中不含电磁兼容(EMC)的产品比比皆是，这是因为含有电磁兼容(EMC)会增加产品的成本。所谓电磁兼容(EMC)是指电子设备在电磁环境中符合要求运行并且不对其环境中的任何其他设备产生电磁干扰的能力。
在LED球泡灯的生产成本中，材料与人工这两项成本能占到总成本的70％，其中电磁兼容(EMC)对材料和人工的成本都有较大的影响，一般来说含有电磁兼容(EMC)的LED球泡灯比不含电磁兼容(EMC)的球泡灯成本会高出10-15％左右，其中人工成本占了大部分。而人工成本主要是因为现有的LED球泡灯结构相对比较复杂，不利于自动化生产装配。
发明内容
为了克服现有技术的不足，本发明的目的之一在于提供一种HE方案的LED球泡灯，其目的之二在于提供一种HE方案的LED球泡灯的生产工艺，其结构简单，便于自动化装配。
本发明的目的之一采用如下技术方案实现：
一种HE方案的LED球泡灯，包括灯头、上壳以及泡壳；所述灯头、上壳以及泡壳组成灯泡壳体，所述灯泡壳体内设置有LED灯板、绝缘板、电容、电 感以及电源线；所述绝缘板与所述LED灯板插接，所述电容、电感以及电源线设置在所述绝缘板上且与所述LED灯板电连接。
进一步地，所述灯泡壳体内还设置有保险电阻，所述保险电阻设置在所述绝缘板上且与所述LED灯板电连接。
进一步地，所述绝缘板靠近所述LED灯板的一面设置有多个沿厚度方向的凸台，所述LED灯板上设置有与所述凸台的位置以及数量对应的插接孔。
进一步地，所述凸台上开设有通孔，所述电容、电感、电源线以及保险电阻的引脚穿过所述通孔与所述LED灯板电连接。
进一步地，所述电感为E字型电感或工字型电感。
进一步地，所述绝缘板为塑料材质。
本发明的目的之二采用如下技术方案实现：
一种HE方案的LED球泡灯的生产工艺，包括以下步骤：
S1、制作LED灯板；
S2、通过第一自动插件机将绝缘板与LED灯板插接；
S3、通过对应的自动插件机不分先后顺序的将电容、电感、电源线以及保险电阻插接在绝缘板的通孔中；
S4、将经过S3步骤后的LED灯板与灯头、上壳以及泡壳组装。
进一步地，制作LED灯板包括以下步骤：
在LED光源板的正面刷锡膏；
通过自动贴片机将LED灯珠贴到LED光源板的锡膏上；
通过回流焊将锡膏融化使LED灯珠焊接在LED光源板上形成LED灯板。
进一步地，通过第一自动插件机将绝缘板与LED灯板插接包括以下步骤：
通过自动吸板机将LED灯板输送到第一自动插件机的LED灯板接收位，LED灯板接收位设置有第一感应器以感知LED灯板是否就位；若感应就位，则发出LED灯板就位信号给第一自动插件机；若没有感应到位，则发出LED灯板未就位信号给第一自动插件机；
通过绝缘板振动盘将绝缘板输送到第一自动插件机的绝缘板接收位，绝缘板接收位设置有第二感应器以感知绝缘板是否就位；若感应就位，则发出绝缘板就位信号给第一自动插件机；若未感应就位，则发出绝缘板未就位信号给第一自动插件机；
第一自动插件机在接收到LED灯板就位信号和绝缘板就位信号后，通过第一自动插件机的机械手将绝缘板插入LED灯板中，并将插接完成后的LED灯板输送到下一工序；第一自动插件机在接收到LED灯板未就位信号或绝缘板未就位信号后，会停机报警。
进一步地，通过对应的自动插件机不分先后顺序的将电容、电感、电源线以及保险电阻插接在绝缘板的通孔中包括以下步骤：
通过第一振动盘排序并区分正负极以及剪脚后将电容输送到电容自动插件机的机械手上，由电容自动插件机的机械手将电容插入绝缘板上对应的通孔中，并在电容的引脚穿出通孔后打弯脚；
通过第二振动盘将电感输送到电感自动插件机的机械手上，由电感自动插件机的机械手将电感插入绝缘板上对应的通孔中，并在电感的引脚穿出通孔后打弯脚；
通过输送带将电源线输送到电源线自动插件机的机械手抓取区，由电源线 自动插件机的机械手将其抓取并插入绝缘板上对应的通孔中，并在电源线的引脚穿出通孔后打弯脚；
通过输送带将保险电阻输送到保险电阻自动插件机的机械手抓取区，由保险电阻自动插件机的机械手将其抓取并旋转后插入绝缘板上对应的通孔中，并在保险电阻的引脚穿出通孔后打弯脚。
相比现有技术，本发明的有益效果在于：绝缘板与LED灯板插接，可以便于装配，提高生产效率。并且绝缘板本身而言可以起到对LED灯板与电容、电感的绝缘作用，省去了传统的LED球泡灯中用于安置电容、电感的印刷线路板，并且印刷线路板属于不环保材料，无法回收再利用
附图说明
图1为本发明HE方案的LED球泡灯的立体图；
图2为本发明HE方案的LED球泡灯的爆炸图；
图3为本发明HE方案的LED球泡灯去除灯头、上壳以及泡壳的第一视角示意图；
图4为本发明HE方案的LED球泡灯去除灯头、上壳以及泡壳的第二视角示意图；
图5为本发明HE方案的LED球泡灯去除灯头、上壳以及泡壳的爆炸图；
图6为绝缘板的示意图。
图中：1、灯头；2、上壳；3、泡壳；4、LED灯板；41、插接孔；42、LED灯珠；5、绝缘板；51、凸台；511、通孔；6、电容；7、电感；8、电源线；9、保险电阻。
具体实施方式
为了便于理解本发明，下面将参照相关附图对本发明进行更全面的描述。附图中给出了本发明的较佳的实施例。但是，本发明可以用许多不同的形式来实现，并不限于本文所描述的实施例。相反地，提供这些实施例的目的是使对本发明的公开内容的理解更加透彻全面。
需要说明的是，当元件被称为“固定于”另一个元件，它可以直接在另一个元件上或者也可以存在居中的元件。当一个元件被认为是“连接”另一个元件，它可以是直接连接到另一个元件或者可能同时存在居中元件。本文所使用的术语“垂直的”、“水平的”、“左”、“右”以及类似的表述只是为了说明的目的。
除非另有定义，本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。本文中在本发明的说明书中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本发明。本文所使用的术语“及/或”包括一个或多个相关的所列项目的任意的和所有的组合。
需要说明的是，HE方案指的是在本专利的绝缘板技术上形成的系列产品，采用塑料绝缘板作为载体，将电解电容，电感，保险电阻，电源线等电子元器件跟铝基板通过绝缘板巧妙结合，采用全自动插件线进行生产，从而大幅减少人工成本，减少原材料成本，并使产品质量性能更加稳定可靠。
如图1-6所示，示出了本发明实施例提供的HE方案的LED球泡灯，其至少包括灯头1、上壳2以及泡壳3。灯头1、上壳2以及泡壳3组成灯泡壳体，灯泡壳体内设置有LED灯板4、绝缘板5、电容6、电感7以及电源线8；绝缘板5与LED灯板4插接，电容6、电感7以及电源线8设置在绝缘板5上且与LED灯板4电连接。其中电感7可以选用E字型电感或工字型电感。绝缘板5的材料可以选用塑料材质。根据需要可以将电容6的数量具体设置为两个。电 容6可以选用电解电容。
绝缘板5与LED灯板4插接，可以便于装配，提高生产效率。并且绝缘板5本身而言可以起到对LED灯板4与电容6、电感7的绝缘作用，省去了传统的LED球泡灯中用于安置电容、电感的线路板。另外，本发明除了使用电容6之外还增加了电感7，可以进一步地提升电磁兼容(EMC)能力。
作为优选地实施方式，灯泡壳体内还设置有保险电阻9，保险电阻9设置在绝缘板5上且与LED灯板4电连接。通过设置保险电阻9，在电流过大时会先烧断保险电阻9，从而可以避免对LED灯板4产生损坏。
优选地，参照图5-6，绝缘板5靠近LED灯板4的一面设置有多个沿厚度方向的凸台51，LED灯板4上设置有与凸台51的位置以及数量对应的插接孔41。即绝缘板5与LED灯板4的插接是通过绝缘板5上的凸台51与LED灯板4上的插接孔41配合实现的。具体地，为了达到紧固的效果，可以让凸台51与插接孔41过盈配合。
优选地，参照图6，凸台51上开设有通孔511，电容6、电感7、电源线8以及保险电阻9的引脚穿过通孔511与LED灯板4电连接。通过在凸台51上开设通孔511，可以方便电容6、电感7、电源线8以及保险电阻9与LED灯板4的电连接，同样，这样开设通孔511的方式也更加便于装配。具体地，当电容6、电感7、电源线8以及保险电阻9的引脚穿过通孔511后，需要将穿过通孔511的引脚弯折，使其与LED灯板4上相应的焊接点接触，然后通过锡焊将引脚固定在LED灯板4上，从而实现导电以及一定的固定作用。
本发明还公开了一种HE方案的LED球泡灯的生产工艺，包括以下步骤：S1、制作LED灯板4；S2、通过第一自动插件机将绝缘板5与LED灯板4插接；S3、通过对应的自动插件机不分先后顺序的将电容6、电感7、电源线8以及保 险电阻9插接在绝缘板5的通孔511中；S4、将经过S3步骤后的LED灯板4与灯头1、上壳2以及泡壳3组装。这样可以提高对LED球泡灯生产的自动化程度，从而提高生产效率，降低人工成本。并且由于LED灯板4以及绝缘板5设置成了可以凸台51与插接孔41配合的简单插接形式，所以也降低了自动插接的难度；而电容6、电感7、电源线8以及保险电阻9与凸台51上的通孔511的配合形式，同样也降低了自动插接的难度。
具体地，制作LED灯板4包括以下步骤：在LED光源板的正面刷锡膏；通过自动贴片机将LED灯珠42贴到LED光源板的锡膏上；通过回流焊将锡膏融化使LED灯珠42焊接在LED光源板上形成LED灯板4。
具体地，通过第一自动插件机将绝缘板5与LED灯板4插接包括以下步骤：通过自动吸板机将LED灯板4输送到第一自动插件机的LED灯板4接收位，LED灯板4接收位设置有第一感应器以感知LED灯板4是否就位；若感应就位，则发出LED灯板4就位信号给第一自动插件机；若没有感应到位，则发出LED灯板4未就位信号给第一自动插件机；通过绝缘板5振动盘将绝缘板5输送到第一自动插件机的绝缘板5接收位，绝缘板5接收位设置有第二感应器以感知绝缘板5是否就位；若感应就位，则发出绝缘板5就位信号给第一自动插件机；若未感应就位，则发出绝缘板5未就位信号给第一自动插件机；第一自动插件机在接收到LED灯板4就位信号和绝缘板5就位信号后，通过第一自动插件机的机械手将绝缘板5插入LED灯板4中，并将插接完成后的LED灯板4输送到下一工序；第一自动插件机在接收到LED灯板4未就位信号或绝缘板5未就位信号后，会停机报警。通过设置第一感应器以及第二感应器，可以保证插接的安全性，避免在工件未就位时就插接导致的工件损坏。更具体地，还可以在下一工序的LED灯板4接收位上设置第三感应器，用于感应插接完成后的LED灯 板4是否就位，若没有就位则发送停机信号给自动吸板机以及绝缘板5振动盘。
具体地，通过对应的自动插件机不分先后顺序的将电容6、电感7、电源线8以及保险电阻9插接在绝缘板5的通孔511中包括以下步骤：通过第一振动盘排序并区分正负极以及剪脚后将电容6输送到电容6自动插件机的机械手上，由电容6自动插件机的机械手将电容6插入绝缘板5上对应的通孔511中，并在电容6的引脚穿出通孔511后打弯脚；通过第二振动盘将电感7输送到电感7自动插件机的机械手上，由电感7自动插件机的机械手将电感7插入绝缘板5上对应的通孔511中，并在电感7的引脚穿出通孔511后打弯脚；通过输送带将电源线8输送到电源线8自动插件机的机械手抓取区，由电源线8自动插件机的机械手将其抓取并插入绝缘板5上对应的通孔511中，并在电源线8的引脚穿出通孔511后打弯脚；通过输送带将保险电阻9输送到保险电阻9自动插件机的机械手抓取区，由保险电阻9自动插件机的机械手将其抓取并旋转后插入绝缘板5上对应的通孔511中，并在保险电阻9的引脚穿出通孔511后打弯脚。
以上仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (10)

  1. 一种HE方案的LED球泡灯，包括灯头、上壳以及泡壳；所述灯头、上壳以及泡壳组成灯泡壳体，其特征在于：所述灯泡壳体内设置有LED灯板、绝缘板、电容、电感以及电源线；所述绝缘板与所述LED灯板插接，所述电容、电感以及电源线设置在所述绝缘板上且与所述LED灯板电连接。
  2. 如权利要求1所述的HE方案的LED球泡灯，其特征在于：所述灯泡壳体内还设置有保险电阻，所述保险电阻设置在所述绝缘板上且与所述LED灯板电连接。
  3. 如权利要求2所述的HE方案的LED球泡灯，其特征在于：所述绝缘板靠近所述LED灯板的一面设置有多个沿厚度方向的凸台，所述LED灯板上设置有与所述凸台的位置以及数量对应的插接孔。
  4. 如权利要求3所述的HE方案的LED球泡灯，其特征在于：所述凸台上开设有通孔，所述电容、电感、电源线以及保险电阻的引脚穿过所述通孔与所述LED灯板电连接。
  5. 如权利要求1所述的HE方案的LED球泡灯，其特征在于：所述电感为E字型电感或工字型电感。
  6. 如权利要求1所述的HE方案的LED球泡灯，其特征在于：所述绝缘板为塑料材质。
  7. 一种HE方案的LED球泡灯的生产工艺，其特征在于，包括以下步骤：
    S1、制作LED灯板；
    S2、通过第一自动插件机将绝缘板与LED灯板插接；
    S3、通过对应的自动插件机不分先后顺序的将电容、电感、电源线以及保 险电阻插接在绝缘板的通孔中；
    S4、将经过S3步骤后的LED灯板与灯头、上壳以及泡壳组装。
  8. 如权利要求7所述的HE方案的LED球泡灯的生产工艺，其特征在于：制作LED灯板包括以下步骤：
    在LED光源板的正面刷锡膏；
    通过自动贴片机将LED灯珠贴到LED光源板的锡膏上；
    通过回流焊将锡膏融化使LED灯珠焊接在LED光源板上形成LED灯板。
  9. 如权利要求7所述的HE方案的LED球泡灯的生产工艺，其特征在于：
    通过第一自动插件机将绝缘板与LED灯板插接包括以下步骤：
    通过自动吸板机将LED灯板输送到第一自动插件机的LED灯板接收位，LED灯板接收位设置有第一感应器以感知LED灯板是否就位；若感应就位，则发出LED灯板就位信号给第一自动插件机；若没有感应到位，则发出LED灯板未就位信号给第一自动插件机；
    通过绝缘板振动盘将绝缘板输送到第一自动插件机的绝缘板接收位，绝缘板接收位设置有第二感应器以感知绝缘板是否就位；若感应就位，则发出绝缘板就位信号给第一自动插件机；若未感应就位，则发出绝缘板未就位信号给第一自动插件机；
    第一自动插件机在接收到LED灯板就位信号和绝缘板就位信号后，通过第一自动插件机的机械手将绝缘板插入LED灯板中，并将插接完成后的LED灯板输送到下一工序；第一自动插件机在接收到LED灯板未就位信号或绝缘板未就位信号后，会停机报警。
  10. 如权利要求8所述的HE方案的LED球泡灯的生产工艺，其特征在于：通过对应的自动插件机不分先后顺序的将电容、电感、电源线以及保险电阻插接在绝缘板的通孔中包括以下步骤：
    通过第一振动盘排序并区分正负极以及剪脚后将电容输送到电容自动插件机的机械手上，由电容自动插件机的机械手将电容插入绝缘板上对应的通孔中，并在电容的引脚穿出通孔后打弯脚；
    通过第二振动盘将电感输送到电感自动插件机的机械手上，由电感自动插件机的机械手将电感插入绝缘板上对应的通孔中，并在电感的引脚穿出通孔后打弯脚；
    通过输送带将电源线输送到电源线自动插件机的机械手抓取区，由电源线自动插件机的机械手将其抓取并插入绝缘板上对应的通孔中，并在电源线的引脚穿出通孔后打弯脚；
    通过输送带将保险电阻输送到保险电阻自动插件机的机械手抓取区，由保险电阻自动插件机的机械手将其抓取并旋转后插入绝缘板上对应的通孔中，并在保险电阻的引脚穿出通孔后打弯脚。
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