WO2023178804A1 - 一种可任意方向折弯或扭曲的灯具及其制作方法 - Google Patents

一种可任意方向折弯或扭曲的灯具及其制作方法 Download PDF

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Publication number
WO2023178804A1
WO2023178804A1 PCT/CN2022/091170 CN2022091170W WO2023178804A1 WO 2023178804 A1 WO2023178804 A1 WO 2023178804A1 CN 2022091170 W CN2022091170 W CN 2022091170W WO 2023178804 A1 WO2023178804 A1 WO 2023178804A1
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Prior art keywords
pcba
neon
units
twisted
bent
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PCT/CN2022/091170
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English (en)
French (fr)
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李忠训
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四川蓝景光电技术有限责任公司
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Publication of WO2023178804A1 publication Critical patent/WO2023178804A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S4/00—Lighting devices or systems using a string or strip of light sources
    • F21S4/20—Lighting devices or systems using a string or strip of light sources with light sources held by or within elongate supports
    • F21S4/28—Lighting devices or systems using a string or strip of light sources with light sources held by or within elongate supports rigid, e.g. LED bars
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V15/00—Protecting lighting devices from damage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V15/00—Protecting lighting devices from damage
    • F21V15/01—Housings, e.g. material or assembling of housing parts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V19/00—Fastening of light sources or lamp holders
    • F21V19/001—Fastening of light sources or lamp holders the light sources being semiconductors devices, e.g. LEDs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V21/00—Supporting, suspending, or attaching arrangements for lighting devices; Hand grips
    • F21V21/005—Supporting, suspending, or attaching arrangements for lighting devices; Hand grips for several lighting devices in an end-to-end arrangement, i.e. light tracks
    • 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
    • F21V23/001—Arrangement of electric circuit elements in or on lighting devices the elements being electrical wires or cables
    • 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
    • F21V5/00—Refractors for light sources
    • F21V5/04—Refractors for light sources of lens shape
    • 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
    • F21V2200/00—Use of light guides, e.g. fibre optic devices, in lighting devices or systems
    • 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 invention relates to the technical field of LED lamps, and specifically, to a lamp that can be bent or twisted in any direction and a manufacturing method thereof.
  • the lamp referred to in the present invention is a long strip lamp with a waterproof casing and a uniform light output. Since its waterproof casing is made of soft materials, such as silica gel, PVC, etc., it is It has a certain degree of bendability. At present, this kind of lamps are generally called “silicone light strips” or “neon light strips” or similar names in the LED industry.
  • the conventional technical solution for this type of product in the industry is to use a (flexible) FPCBA light strip.
  • FPCBA uses a common The process of squeezing or casing, glue dispensing or casing filling makes the surface of the light strip form a soft waterproof shell, which can achieve different protection (IP) levels according to different processes.
  • IP protection
  • This type of product is generally used in the market for building outlines, urban lighting, landscape lighting, etc. It requires linear lighting to achieve the effect of brightening outlines and beautification. It belongs to a category of linear lighting products in the industry. At present, the linear scene applications of this type of industry products in the market are mainly linear applications, side-bending plane curve applications and top-bending plane curve applications. There are also some products for space curve applications. However, the current difficulties encountered by industry products in the market are The main ones are: 1.
  • the installation reliability of products for spatial curve applications is not good, and it is easy to cause functional failures such as the product not lighting up during the installation process.
  • the characteristics of products for flat curve applications with single side or top bends, to a certain extent. It constrains the installation behavior and requires installation according to product characteristics, which can improve the yield rate of the product installation process. However, it has certain limitations in application scenarios, and it still cannot be avoided when encountering installers who do not understand product characteristics. Installation failure.
  • the application scenarios of this type of urban edge lighting products are usually large, and once functional problems occur, it will cause troublesome after-sales service.
  • the present invention proposes a new product technical solution, which can not only bend side-bending or top-bending plane curves under the condition that the bending diameter is met, but also can bend space curves to a greater extent freely. Twisted to meet the needs of various existing application scenarios.
  • PCBA Printed Circuit Board Assembly refers to the entire process in which the PCB (Printed Circuit Board) empty board passes through SMT upper parts or DIP plug-ins, referred to as PCBA.
  • FPCBA Flexible Printed Circuit Board Assembly refers to the entire process in which the FPCB (Flexible Printed Circuit Board) empty board passes through the SMT upper part or the DIP plug-in.
  • the present invention provides a lamp that can be bent or twisted in any direction and a preparation method thereof.
  • a lamp that can be bent or twisted in any direction and a preparation method thereof.
  • it can be made It can be bent and twisted in any direction to meet the product's application needs in spatial curve modeling and improve product reliability.
  • a lamp that can be bent or twisted in any direction including a neon sleeve, a silicone fixing strip, a PCBA unit and a welding wire.
  • the silicone fixing strip is provided with a plurality of holes at intervals along its extension direction. Each hole is A PCBA unit is sealed inside by glue dispensing or potting. Adjacent PCBA units are connected by welding wires with bending allowance. All PCBA units are connected in series. The interfaces of the PCBA units at both ends are configured as power cords with connection allowance.
  • the neon sleeve covers silicone fixing strips, welding wires and part of the power cord and is encapsulated by dispensing or potting glue;
  • the PCBA unit is made of LED light-emitting components and peripheral electronic components on a hard circuit board through SMT .
  • the neon sleeve is made of soft material, and its side corresponding to the LED light-emitting element is configured as a light guide surface.
  • the PCBA unit matches the hole size on the silicone fixing strip.
  • the silicone fixing strip is made of translucent soft material.
  • the welding wire is exposed on the back side of the silicone fixing strip and is wrapped in a neon sleeve.
  • the bonding wire between the designated two PCBA units is extended and leaked out of the neon sleeve as a shear connection line.
  • a light-emitting lens matched with the PCBA unit is provided in the hole.
  • the present invention also provides a method for manufacturing the above-mentioned lamp that can be bent or twisted in any direction, including the following steps:
  • Step 1 SMT the LED light-emitting components and peripheral electronic components on a single small piece of hard circuit board to make a PCBA unit;
  • Step 2 Two adjacent PCBA units are connected through soldering wires. Connect a specified number of strings according to the design. Power lines with connection margin are configured at both ends of the string PCBA units. The distance between two adjacent PCBA units is The length of the welding wire is greater than the spacing after placement, so that the welding wire maintains a certain bending allowance;
  • Step 3 Install the series of PCBA units into the silicone fixing strips with holes one by one in such a way that one PCBA unit corresponds to one hole;
  • Step 4 After completing the assembly of the PCBA unit, glue or pour glue on the back of the silicone fixing strip to fix and seal the PCBA unit and prevent the welding wires and power cords from leaking;
  • Step 5 Install the encapsulated silicone fixing strip and PCBA unit into the neon sleeve of matching length, so that the light-emitting surface of the PCBA unit corresponds to the light-guiding surface of the neon sleeve;
  • Step 6 Dispense or pour glue on the back of the neon sleeve, fix and seal the silicone fixing strip, the leaking welding wire and part of the power cord to complete the entire product. At this time, the power cord connector is leaking.
  • step 3 first assemble the luminous lens on each PCBA unit one by one, and then install the PCBA units with the luminous lens into the holes of the silicone fixing strip one by one.
  • step 5 when the length of the neon sleeve matches the length of multiple silicone fixing strips, the silicone fixing strips are installed into the neon sleeve one by one, and the power cords at the close ends of the adjacent silicone fixing strips are connected to connect in series. Connect the two series of PCBA units and make this part of the power cord leak out of the neon sleeve.
  • the present invention has the following beneficial effects:
  • this invention cleverly uses a single independent small hard circuit board as the carrier of the LED light-emitting element to form a PCBA unit, ensuring the use of the electronic device part Reliability, and use welding wires to connect multiple PCBA units in series to achieve the integrity of the LED electronic circuit.
  • the bendability between PCBA units is achieved, and the equal spacing between two lamp beads is ensured, so that the final
  • the formed long strip lighting product not only meets the needs of side bending or top bending, but also can be bent and twisted in any direction, realizing the product's modeling application requirements in space curves, and has low installation constraints during installation and construction. Or it is less likely to cause functional failure after installation, significantly improving the overall reliability of the product.
  • the invention has ingenious design, simple structure, convenient use and high reliability, and is suitable for application in neon light strips.
  • the present invention adopts the split independent component design of a small hard circuit board. Compared with ordinary LED strip lights, it has the characteristics of being able to be bent at will. Compared with ordinary FPCBA light strips, it has higher reliability in use. In the field of optoelectronics The technology of the parameters is actually more open and does not have the technical limitations of FPCBA. Combined with the stability and bendability of the silicone fixing strip, the product of the present invention is better than the FPCBA light strip product in terms of bendability and comprehensive technical parameters of the product.
  • the soldering wires between the PCBA units of the present invention are not directly embedded in the silicone fixing strips, but leak out with bending allowance on the back side of the silicone fixing strips, so that they will not be damaged by the soldering wires when bending.
  • Functional failure further ensures the reliability and integrity of the LED electronic circuit, and the neon sleeve as the overall shell uniformly covers and protects structures such as silicone fixing bars and welding wires, further improving product reliability.
  • the reliability performance of the product of the present invention is greatly improved compared to ordinary FPCBA light strips.
  • the structural design of the present invention also provides a smaller cuttable unit, which can better meet the length and size requirements of long strip lamps in various installation scenarios on the market.
  • the present invention can be designed according to the length of each silicone fixing strip to a standard cuttable length during production, that is, when the neon sleeve is covering multiple silicone fixing strips, the leakage power cord between the silicone fixing strips can be used as Independent connections after cutting.
  • each PCBA unit in the present invention is designed and installed independently, it can be cut directly between two PCBA units to achieve non-standard cuttable lengths of any length. At this time You only need to extend the cut welding wire and it can be used normally.
  • Figure 1 is a schematic diagram of the end face structure of Embodiment 1 of the present invention.
  • Figure 2 is a schematic diagram of the overall structure of Embodiment 1 of the present invention.
  • Figure 3 is a one-step exploded structural diagram of Embodiment 1 of the present invention.
  • Figure 4 is a schematic diagram of the two-step decomposition structure of Embodiment 1 of the present invention.
  • Figure 5 is a schematic diagram of the three-step decomposition structure of Embodiment 1 of the present invention.
  • Figure 6 is a schematic diagram of the overall structure of Embodiment 2 of the present invention.
  • Figure 7 is a schematic diagram of the end face structure of Embodiment 3 of the present invention.
  • Figure 8 is a schematic diagram of the exploded structure of Embodiment 3 of the present invention.
  • Figure 9 is a schematic diagram of the end face structure of Embodiment 4 of the present invention.
  • Figure 10 is a schematic diagram of the exploded structure of Embodiment 4 of the present invention.
  • this lamp that can be bent or twisted in any direction includes a neon sleeve 1, a silicone fixing strip 2, a PCBA unit 3 and a welding wire 4.
  • the silicone fixing strip is arranged along its extension direction.
  • the interface of the unit is configured as a power cord 5 with connection margin.
  • the neon sleeve covers the silicone fixing strip, welding wire and part of the power cord and is encapsulated by glue dispensing or potting 6;
  • the PCBA unit is composed of LED light-emitting elements and peripheral electronic components are made by SMT on hard circuit boards. Further, a light-emitting lens 7 matched with the PCBA unit is provided in the hole.
  • the neon sleeve is made of soft material, and its top surface corresponding to the LED light-emitting element is configured as the light guide surface 9 .
  • the PCBA unit matches the hole size on the silicone fixing strip.
  • the silicone fixing strip is made of translucent soft material.
  • the welding wire is exposed on the back side of the silicone fixing strip and is wrapped in a neon sleeve.
  • the bonding wire between the designated two PCBA units is extended and leaked out of the neon sleeve as a shear connection line 8.
  • This embodiment shows a section of neon sleeve with two silicone fixing strips built in. A series of PCBA units are placed on each silicone fixing strip. The connecting lines at the adjacent ends of the two silicone fixing strips are used as shearing connection lines.
  • the method for making the above-mentioned lamp that can be bent or twisted in any direction includes the following steps:
  • Step 1 SMT the LED light-emitting components and peripheral electronic components on a single small hard circuit board to form a PCBA unit.
  • a PCBA unit uses one LED lamp bead as the light-emitting component, and can also be configured into a small group according to application requirements. LED lamp beads;
  • Step 2 Two adjacent PCBA units are connected through soldering wires. Connect a specified number of strings according to the design. Power lines with connection margin are configured at both ends of the string PCBA units.
  • the distance between two adjacent PCBA units is The length of the welding wire is greater than the spacing after placement, so that the welding wire maintains a certain bending allowance; the number of the series of PCBA units matches the length and number of holes of a silicone fixing bar.
  • the silicone fixing bar is produced according to the standard 0.5m is one piece to facilitate the production of ingredients, and usually the neon strip is made into a roll of 10m or 20m. Therefore, in actual production, multiple silicone fixing strips will be loaded into one neon sleeve. This embodiment only uses Take two as an example;
  • Step 3 First assemble the luminescent lens on each PCBA unit one by one, and then install the PCBA unit with the luminous lens into each hole of the silicone fixing strip with holes one by one in such a way that one PCBA unit corresponds to one hole;
  • Step 4 After completing the assembly of the PCBA unit, apply glue or pour glue on the back of the silicone fixing strip to fix and seal the PCBA unit and prevent the welding wires and power cords from leaking; when you want to connect the PCBA units in two adjacent silicone fixing strips At this time, the power cord at the adjacent end can be replaced by an extended welding wire; at this time, after the PCBA unit is sealed in the hole by dispensing glue or pouring glue, the solder joints between the welding wire and the hard circuit board are also wrapped and fixed by glue. , ensuring the stability of the circuit connection point. At the same time, because the leaking welding wire has a bending allowance, the welding wire will not be damaged when the product is bent, effectively improving product reliability;
  • Step 5 Put the encapsulated silicone fixing strips and PCBA units into the neon sleeve of matching length one by one, so that the light-emitting surface of the PCBA unit corresponds to the light guide surface of the neon sleeve; the power cord at the close end of the adjacent silicone fixing strip Butt connection to connect the two series of PCBA units in series, and make this part of the power cord leak out of the neon casing;
  • Step 6 Dispense or pour glue on the back of the neon sleeve, fix and seal the silicone fixing strip, the leaking welding wire and part of the power cord to complete the entire product.
  • the product of the present invention Compared with existing FPCBA light strip products, the product of the present invention has better bending performance, can meet the application requirements of spatial curves, and has higher reliability. According to the analysis of the application difficulties of existing FPCBA light strips, although conventional flexible circuit boards have a certain degree of flexibility, they are limited by material properties. Repeated bending will still cause local damage to the printed circuit on the flexible circuit board. Moreover, the built-in flexible circuit boards of light strip products are usually set according to the length of the product itself, and excessively long flexible circuit boards reduce product reliability.
  • the structural design of the present invention may seem simple, but it innovatively solves the pain points of existing neon strip products from the source and principle, making significant progress.
  • this embodiment provides a simplified structural design compared to Embodiment 1, that is, no shear connection line 8 is provided, which can also be understood as setting the silicone fixing strip and the neon sleeve to the same length. , and the middle welding wire will not be lengthened or leaked. It can also meet the requirements of bending in any direction and cutting to any length. It only needs to extend the connecting line to the cut welding wire after cutting.
  • this embodiment provides a simplified structural design compared to Embodiment 1, that is, the light-emitting lens 7 is not provided.
  • the light-emitting lens is not installed on the PCBA unit in Step 3 during production, and the light-emitting lens is directly installed on the PCBA unit.
  • the PCBA units can be installed into the holes of the silicone fixing strip one by one to meet the needs of different lighting applications. Other usage methods and effects are the same as those in Embodiment 1.
  • this embodiment provides a structural design similar to that of Embodiment 3. The difference is that the LED light-emitting elements used on the PCBA unit are different. This embodiment is configured for RGB light-emitting, that is, during the production step The electronic components used in Step 1 are configured accordingly to meet different lighting application requirements. Other usage methods and effects are the same as those in Embodiment 3.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Fastening Of Light Sources Or Lamp Holders (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

一种可任意方向折弯或扭曲的灯具，包括霓虹套管（1）、硅胶固定条（2）、PCBA单元（3）和焊线（4），硅胶固定条（2）上沿其延伸方向间隔设有多个穴孔，每个穴孔内通过点胶或灌胶封闭安置一PCBA单元（3），相邻PCBA单元（3）之间通过具有弯曲余量的焊线（4）连接，霓虹套管（1）包覆硅胶固定条（2）、焊线（4）并通过点胶或灌胶封装，PCBA单元（3）由LED发光元件在硬质电路板上通过SMT制成。

Description

一种可任意方向折弯或扭曲的灯具及其制作方法 技术领域
本发明涉及LED灯具技术领域，具体地讲，是涉及一种可任意方向折弯或扭曲的灯具及其制作方法。
背景技术
LED行业内有多种照明产品，本发明所指的灯具从外形上来看，是具有防水外壳的出光均匀的长条状灯具，由于其防水外壳是采用软质材质，如硅胶、PVC等，因此其具有一定的可弯折性。目前这类灯具在LED行业内一般称为“硅胶灯带”或“霓虹灯带”或类似名称。行业内这类产品的常规技术方案是采用一条(柔性)FPCBA灯带，灯带上面有LED灯、电阻、二极管、三极管、IC等电子元器件通过合理的电子布线图实现电流回路，FPCBA通过共挤或套管或滴胶或套管灌胶的工艺使得灯带表面形成软质防水外壳，根据工艺的不同可以达到不同的防护(IP)等级。这类产品在市场上一般应用于建筑勾边、城市亮化、景观亮化等，需要线状点亮，取得亮化勾边及美化的效果，在行业内属于一类线性照明类产品，而目前行业这类产品在市场上的线性场景应用主要表现为直线应用、侧弯平面曲线应用和顶弯平面曲线应用，也有部分空间曲线应用的产品，但是目前行业产品在市场运用遇到的困难点主要有：1.空间曲线应用的产品安装可靠性不好，在安装过程中容易造成产品一截不亮等功能性故障，2.单一侧弯或顶弯的平面曲线应用的产品特性，一定程度上约束了安装行为，要求按产品特性实施安装，能提升产品的安装过程的良率，但在应用场景有一定局限性，并且在遇到不懂产品特性的安装人员时依然不能较好的避免安装失效的现象。这类城市勾边亮化产品的应用场景规模通常较大，一旦出现功能性问题，会带来很麻烦的售后。因此，基于上述行业痛点，本发明提出一种新的产品技术方案，在满足弯曲直径的情况下不仅能够侧弯或顶弯的平面曲线的折弯，而且可以在空间曲线上较大程度的随意扭曲，来满足现有多种应用场景的需求。
名词解释：
PCBA：Printed Circuit Board Assembly，是指PCB(印刷电路板)空板经过SMT上件，或经过DIP插件的整个制程，简称PCBA。
FPCBA：Flexible Printed Circuit Board Assembly，是指FPCB(柔性印刷电路板)空板经过SMT上件，或经过DIP插件的整个制程。
SMT：Surface Mounted Technology，表面贴装技术。
发明内容
针对上述现有技术存在的问题，本发明提供一种可任意方向折弯或扭曲的灯具及其制备方法，针对现有同类灯具产品的应用缺陷，通过对灯具结构和工艺的设计改进，使其可以任意方向弯折扭曲，满足产品在空间曲线的造型方面的应用需要，并提升了产品可靠性。
为了实现上述目的，本发明采用的技术方案如下：
一种可任意方向折弯或扭曲的灯具，包括霓虹套管、硅胶固定条、PCBA单元和焊线，所述硅胶固定条上沿其延伸方向间隔设有多个穴孔，每个穴孔内通过点胶或灌胶封闭安置一PCBA单元，相邻PCBA单元之间通过具有弯曲余量的焊线连接，所有PCBA单元串接，两端的PCBA单元的接口配置为具有连接余量的电源线，所述霓虹套管包覆硅胶固定条、焊线和部分电源线并通过点胶或灌胶封装；所述PCBA单元由LED发光元件和外围电子元件在硬质电路板上通过SMT制成。
具体地，所述霓虹套管由软质材料制成，其对应LED发光元件的侧面配置为导光面。
具体地，所述PCBA单元与硅胶固定条上的穴孔大小匹配。
具体地，所述硅胶固定条为透光软质材质。
具体地，所述焊线在硅胶固定条背侧外露，并被包覆于霓虹套管内。
具体地，每间隔设定数量的PCBA单元，将指定两个PCBA单元之间的焊线 延长并外漏于霓虹套管，作为剪切连接线。
进一步地，所述穴孔内设有与PCBA单元匹配安置的发光透镜。
基于上述构造，本发明还提供了上述可任意方向折弯或扭曲的灯具的制作方法，包括以下步骤：
Step1、将LED发光元件和外围电子元件在单小块的硬质电路板上SMT，制成PCBA单元；
Step2、两两相邻的PCBA单元之间通过焊线连接，按设计连接规定数量的一串，在该串PCBA单元两端配置具有连接余量的电源线，相邻两个PCBA单元之间的焊线长度大于其安置后的间距，使焊线保持一定的弯曲余量；
Step3、将该串PCBA单元按一个PCBA单元对应一个穴孔的方式逐个装入带穴孔的硅胶固定条；
Step4、完成PCBA单元装配后在硅胶固定条背面点胶或灌胶，以固定和密封PCBA单元，并使焊线和电源线外漏；
Step5、将完成封装的硅胶固定条和PCBA单元装入匹配长度的霓虹套管，使PCBA单元的发光面对应霓虹套管的导光面；
Step6、在霓虹套管背面点胶或灌胶，固定并密封硅胶固定条以及外漏的焊线和部分电源线，完成整个产品，此时电源线接头外漏。
进一步地，所述步骤Step3中，先在每个PCBA单元上逐个装配发光透镜，再将带发光透镜的PCBA单元逐个装入硅胶固定条的穴孔中。
进一步地，所述步骤Step5中，当霓虹套管长度匹配多个硅胶固定条长度时，将硅胶固定条逐个装入该霓虹套管内，相邻硅胶固定条的靠近端的电源线对接以串接该两串PCBA单元，并使该部分电源线外漏于霓虹套管。
与现有技术相比，本发明具有以下有益效果：
(1)本发明针对现有FPCBA灯带在市场应用中的痛点，巧妙地采用了单一独立的小块硬质电路板作为LED发光元件的承载体，形成PCBA单元，保证了 电子器件部分的使用可靠性，并利用焊线将多个PCBA单元串接实现LED电子电路的完整性，同时结合硅胶固定条实现了PCBA单元之间的可折弯性，并保证两两灯珠等间距，使得最终形成的长条状灯具产品既满足侧弯或顶弯需要，并可以任意方向弯折扭曲，实现了产品在空间曲线的造型应用需求，而且在安装施工时对安装的约束条件较低，安装时或安装后不容易产生功能失效，使产品整体的可靠性得到明显提升。本发明设计巧妙，结构简单，使用方便，可靠性高，适于在霓虹灯带中应用。
(2)本发明采用小块硬质电路板的分体独立式元件设计，相比普通LED条灯具有可任意弯折的特性，相比普通FPCBA灯带具有更高的使用可靠性，在光电参数的技术现实上更开放，没有FPCBA的技术局限性，结合硅胶固定条的稳固和可弯曲作用，使得本发明产品在可弯曲程度上、在产品综合技术参数上都更优于FPCBA灯带产品，而且本发明的PCBA单元之间的焊线并非嵌入硅胶固定条内的直连，而且带有弯曲余量地外漏在硅胶固定条背侧，使其在弯折时不会因焊线损坏而功能失效，进一步保证了LED电子电路的可靠性和完整性，并且作为整体外壳的霓虹套管更是统一包覆和保护了硅胶固定条和焊线等结构，进一步提高了产品可靠性，最终使得本发明产品的可靠性能相比普通FPCBA灯带大幅提升。
(3)本发明的该种结构设计还提供了更小的可剪单元，能够更好地满足市场上各类安装场景对长条状灯具的长度尺寸的要求。一方面，本发明在制作中可按每根硅胶固定条的长度设计为标准可剪长度，即在霓虹套管包覆又多根硅胶固定条时硅胶固定条之间的外漏电源线作为剪切后的独立连线，另一方面，由于本发明中每个PCBA单元是独立设计安置，可直接在两个PCBA单元之间剪切来实现任意长度的非标可剪长度使用，此时也仅需将剪断的焊线外连延长即可正常使用。
附图说明
图1为本发明-实施例1的端面结构示意图。
图2为本发明-实施例1的整体结构示意图。
图3为本发明-实施例1的一步分解结构示意图。
图4为本发明-实施例1的二步分解结构示意图。
图5为本发明-实施例1的三步分解结构示意图。
图6为本发明-实施例2的整体结构示意图。
图7为本发明-实施例3的端面结构示意图。
图8为本发明-实施例3的分解结构示意图。
图9为本发明-实施例4的端面结构示意图。
图10为本发明-实施例4的分解结构示意图。
具体实施方式
下面结合附图和实施例对本发明作进一步说明，本发明的实施方式包括但不限于下列实施例。
实施例1
如图1至图5所示，该可任意方向折弯或扭曲的灯具，包括霓虹套管1、硅胶固定条2、PCBA单元3和焊线4，所述硅胶固定条上沿其延伸方向间隔设有多个穴孔，每个穴孔内通过点胶或灌胶封闭安置一PCBA单元，相邻PCBA单元之间通过具有弯曲余量的焊线连接，所有PCBA单元串接，两端的PCBA单元的接口配置为具有连接余量的电源线5，所述霓虹套管包覆硅胶固定条、焊线和部分电源线并通过点胶或灌胶6封装；所述PCBA单元由LED发光元件和外围电子元件在硬质电路板上通过SMT制成。进一步地，所述穴孔内设有与PCBA单元匹配安置的发光透镜7。具体地，所述霓虹套管由软质材料制成，其对应LED发光元件的顶面配置为导光面9。所述PCBA单元与硅胶固定条上的穴孔大小匹配。所述硅胶固定条为透光软质材质。所述焊线在硅胶固定条背侧外露，并被包覆于霓虹套管内。
具体地，每间隔设定数量的PCBA单元，将指定两个PCBA单元之间的焊线延长并外漏于霓虹套管，作为剪切连接线8。本实施例展示的一段霓虹套管内置两根硅胶固定条，每根硅胶固定条上安置一串PCBA单元，将该两根硅胶固定条相邻端的连接线作为剪切连接线。
上述可任意方向折弯或扭曲的灯具的制作方法，包括以下步骤：
Step1、将LED发光元件和外围电子元件在单小块的硬质电路板上SMT，制成PCBA单元；一般一个PCBA单元就以一个LED灯珠作为发光元件，也可根据应用需求配置为一小组LED灯珠；
Step2、两两相邻的PCBA单元之间通过焊线连接，按设计连接规定数量的一串，在该串PCBA单元两端配置具有连接余量的电源线，相邻两个PCBA单元之间的焊线长度大于其安置后的间距，使焊线保持一定的弯曲余量；该一串PCBA单元的数量与一根硅胶固定条的长度和穴孔数量匹配，一般在生产中硅胶固定条按照标准的0.5m为一根，以便于生产配料，而通常霓虹灯带按10m或20m为一卷一个整体，因此在实际生产中一个霓虹套管内会装入多根硅胶固定条，本实施例仅以装入两根为例；
Step3、先在每个PCBA单元上逐个装配发光透镜，再将带发光透镜的PCBA单元按一个PCBA单元对应一个穴孔的方式逐个装入带穴孔的硅胶固定条的每个穴孔中；
Step4、完成PCBA单元装配后在硅胶固定条背面点胶或灌胶，以固定和密封PCBA单元，并使焊线和电源线外漏；当要连接两根相邻的硅胶固定条内的PCBA单元时，该相邻端的电源线可以用加长的焊线替代；此时通过点胶或灌胶将PCBA单元密封在穴孔内后，焊线与硬质电路板的焊点也同时被胶包裹固定，保证了电路连接点位的稳固，同时由于外漏的焊线具有弯曲余量，在产品弯折时也不会使得焊线损坏，有效提高了产品可靠性；
Step5、将完成封装的硅胶固定条和PCBA单元逐个装入匹配长度的霓虹套 管，使PCBA单元的发光面对应霓虹套管的导光面；相邻硅胶固定条的靠近端的电源线对接以串接该两串PCBA单元，并使该部分电源线外漏于霓虹套管；
Step6、在霓虹套管背面点胶或灌胶，固定并密封硅胶固定条以及外漏的焊线和部分电源线，完成整个产品。
本发明的产品相比现有的FPCBA灯带产品，弯折性能更好，能够满足空间曲线应用需求，并且可靠性更高。根据对现有FPCBA灯带应用困难点的分析，常规的柔性电路板虽然具有一定的柔性，但是受限于材料特性，反复多次弯曲仍然会导致柔性电路板上的印制电路出现局部损坏，而且灯带类产品的内置柔性电路板通常都是按照产品本身的长度匹配设置，过长的柔性电路板更是降低了产品可靠性。本发明的结构设计看似简单，但从源头和原理上创新性地解决现有霓虹灯带类产品的痛点问题，具有显著的进步。
实施例2
如图6所示，本实施例提供了一种相比实施例1简化的结构设计，即未设置剪切连接线8，也可以理解为将硅胶固定条和霓虹套管设置为一致的长度，并且不对中部的焊线进行加长和外漏。其同样可以满足任意方向弯折和任意长度剪切的要求，只需在剪切后对剪断的焊线部分外延连接线即可。
实施例3
如图7和图8所示，本实施例提供了一种相比实施例1简化的结构设计，即未设置发光透镜7，相应地制作时步骤Step3中不在PCBA单元上安装发光透镜，直接将PCBA单元逐个装入硅胶固定条的穴孔内即可，以满足不同的发光应用需求。其他使用方式和效果与实施例1相同。
实施例4
如图9和图10所示，本实施例提供了一种与实施例3相似的结构设计，区别在于PCBA单元上采用的LED发光元件不同，该实施例配置为RGB发光，即在制作时步骤Step1中采用的电子元器件做相应的配置，以满足不同的发光应用 需求。其他使用方式和效果与实施例3相同。
上述实施例仅为本发明的优选实施例，并非对本发明保护范围的限制，但凡采用本发明的设计原理，以及在此基础上进行非创造性劳动而做出的变化，均应属于本发明的保护范围之内。

Claims (10)

  1. 一种可任意方向折弯或扭曲的灯具，其特征在于，包括霓虹套管、硅胶固定条、PCBA单元和焊线，所述硅胶固定条上沿其延伸方向间隔设有多个穴孔，每个穴孔内通过点胶或灌胶封闭安置一PCBA单元，相邻PCBA单元之间通过具有弯曲余量的焊线连接，所有PCBA单元串接，两端的PCBA单元的接口配置为具有连接余量的电源线，所述霓虹套管包覆硅胶固定条、焊线和部分电源线并通过点胶或灌胶封装；所述PCBA单元由LED发光元件和外围电子元件在硬质电路板上通过SMT制成。
  2. 根据权利要求1所述的可任意方向折弯或扭曲的灯具，其特征在于，所述霓虹套管由软质材料制成，其对应LED发光元件的侧面配置为导光面。
  3. 根据权利要求1所述的可任意方向折弯或扭曲的灯具，其特征在于，所述PCBA单元与硅胶固定条上的穴孔大小匹配。
  4. 根据权利要求1所述的可任意方向折弯或扭曲的灯具，其特征在于，所述硅胶固定条为透光软质材质。
  5. 根据权利要求1所述的可任意方向折弯或扭曲的灯具，其特征在于，所述焊线在硅胶固定条背侧外露，并被包覆于霓虹套管内。
  6. 根据权利要求1所述的可任意方向折弯或扭曲的灯具，其特征在于，每间隔设定数量的PCBA单元，将指定两个PCBA单元之间的焊线延长并外漏于霓虹套管，作为剪切连接线。
  7. 根据权利要求1～6任一项所述的可任意方向折弯或扭曲的灯具，其特征在于，所述穴孔内设有与PCBA单元匹配安置的发光透镜。
  8. 根据权利要求1～7任一项所述的可任意方向折弯或扭曲的灯具的制作方法，其特征在于，包括以下步骤：
    Step1、将LED发光元件和外围电子元件在单小块的硬质电路板上SMT，制成PCBA单元；
    Step2、两两相邻的PCBA单元之间通过焊线连接，按设计连接规定数量的 一串，在该串PCBA单元两端配置具有连接余量的电源线，相邻两个PCBA单元之间的焊线长度大于其安置后的间距，使焊线保持一定的弯曲余量；
    Step3、将该串PCBA单元按一个PCBA单元对应一个穴孔的方式逐个装入带穴孔的硅胶固定条；
    Step4、完成PCBA单元装配后在硅胶固定条背面点胶或灌胶，以固定和密封PCBA单元，并使焊线和电源线外漏；
    Step5、将完成封装的硅胶固定条和PCBA单元装入匹配长度的霓虹套管，使PCBA单元的发光面对应霓虹套管的导光面；
    Step6、在霓虹套管背面点胶或灌胶，固定并密封硅胶固定条以及外漏的焊线和部分电源线，完成整个产品，此时电源线接头外漏。
  9. 根据权利要求8所述的可任意方向折弯或扭曲的灯具的制作方法，其特征在于，所述步骤Step3中，先在每个PCBA单元上逐个装配发光透镜，再将带发光透镜的PCBA单元逐个装入硅胶固定条的穴孔中。
  10. 根据权利要求8所述的可任意方向折弯或扭曲的灯具的制作方法，其特征在于，所述步骤Step5中，当霓虹套管长度匹配多个硅胶固定条长度时，将硅胶固定条逐个装入该霓虹套管内，相邻硅胶固定条的靠近端的电源线对接以串接该两串PCBA单元，并使该部分电源线外漏于霓虹套管。
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