CN107339300B - External heating equipment for manufacturing LED straight lamp - Google Patents
External heating equipment for manufacturing LED straight lamp Download PDFInfo
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- CN107339300B CN107339300B CN201710516766.9A CN201710516766A CN107339300B CN 107339300 B CN107339300 B CN 107339300B CN 201710516766 A CN201710516766 A CN 201710516766A CN 107339300 B CN107339300 B CN 107339300B
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- hot melt
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- lamp tube
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Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B11/00—Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding
- F16B11/006—Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding by gluing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
- B05D3/0254—After-treatment
- B05D3/0281—After-treatment with induction heating
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Non-Portable Lighting Devices Or Systems Thereof (AREA)
- Fastening Of Light Sources Or Lamp Holders (AREA)
Abstract
An external heating device for manufacturing an LED straight tube lamp comprises an induction coil, wherein the diameter of the induction coil is larger than the outer diameter of a lamp cap of the LED straight tube lamp, and the induction coil generates heat after being electrified and conducts the heat to the lamp cap of the LED straight tube lamp for installation; a lamp tube of an LED straight tube lamp using an external heating device and a lamp cap connecting method are synchronously disclosed.
Description
Technical Field
The invention relates to the field of manufacturing of lighting appliances, in particular to external heating equipment for manufacturing an LED straight lamp.
Background
LED lighting technology is rapidly advancing to replace traditional incandescent and fluorescent lamps. Compared with a fluorescent lamp filled with inert gas and mercury, the LED straight lamp does not need to be filled with mercury. Therefore, LED straight tube lamps have become a highly desirable lighting option unintentionally in various lighting systems for homes or work places dominated by lighting options such as traditional fluorescent bulbs and tubes. Advantages of LED straight lamps include improved durability and longevity and lower power consumption. Therefore, a LED straight tube lamp would be a cost effective lighting option, taking all factors into account.
The known LED straight lamp generally includes a lamp tube, a circuit board disposed in the lamp tube and having a light source, and lamp caps disposed at two ends of the lamp tube, wherein a power supply is disposed in the lamp caps, and the light source and the power supply are electrically connected through the circuit board. However, the existing LED straight lamp still has the following problems to be solved:
in the existing straight LED lamp, white glue is generally used when a lamp cap and a lamp tube are bonded, for example, as mentioned in the patent publication CN102052652A, an epoxy resin glue is used to seal the lamp cap of the LED lamp tube, and chinese patent application with publication No. CN102777788A discloses an LED fluorescent lamp tube, which comprises a lamp tube body and plugs installed at two ends of the lamp tube body for connecting a power supply, magnetic blocks are arranged on the surfaces of the two ends of the lamp tube body, a groove corresponding to the magnetic blocks is arranged inside the plugs, and the surface of the groove is an iron sheet, thereby achieving the effect of magnetic connection; however, the conventional white adhesive has poor adhesion and durability, and the magnetic connection effect is limited, so that the connection effect is not achieved through the adhesive medium. In addition, after the lamp tube is directly sleeved with the lamp cap, the condition that the viscose overflows is not easy to control, and if the redundant viscose is not removed, the appearance is influenced, and the shading problem is caused; if the excess glue is to be removed, a great deal of labor is required to wipe the excess glue during the manufacturing process, resulting in production obstacles and inefficiencies. In addition, the poor heat dissipation of the power supply element in the lamp holder easily leads to the formation of a high-temperature environment in the lamp holder, so that the service life of the hot melt adhesive is reduced, meanwhile, the adhesion between the lamp tube and the lamp holder is reduced, and the reliability of the LED straight tube lamp is reduced.
In view of the above, the present invention and embodiments thereof are set forth below.
Disclosure of Invention
The invention provides a novel external heating device for manufacturing an LED straight lamp and an LED straight lamp manufacturing method based on the external heating device, and aims to solve the problems.
The invention provides external heating equipment for manufacturing an LED straight lamp, which comprises an induction coil, wherein the diameter of the induction coil is larger than the outer diameter of a lamp cap of the LED straight lamp, and the induction coil generates heat after being electrified and conducts the heat to the lamp cap of the LED straight lamp for installation by inserting the lamp cap of the LED straight lamp into the external heating equipment.
Optionally, the induction coil of the external heating device is connected with a power supply to form an electromagnetic field after being powered on, and when the lamp cap enters the electromagnetic field, the induction power generates current, so that the lamp cap generates heat and conducts the heat to the hot melt adhesive.
Optionally, the induction coil is formed by curling a metal wire with a width of 5mm to 6mm into a ring shape, the diameter of the induction coil is about 30mm to 35mm, and the induction coil is made of red copper.
The invention also provides a lamp tube of the LED straight lamp and a lamp cap connecting method, which comprises the following steps: coating a hot melt adhesive on the inner surface of the lamp cap; sleeving the lamp holder on the end part of the lamp tube; and filling the hot melt adhesive between the inner surface of the lamp cap and the outer surface of the end part of the lamp tube after the hot melt adhesive is heated and expanded by an external heating device.
Optionally, the hot melt adhesive is located in the accommodating space. Preferably, the accommodating space is not completely filled with the hot melt adhesive. Preferably, part of the hot melt adhesive is located in the space between the inner surface of the second tube and the outer surface of the end zone.
Optionally, the position of the accommodating space filled with the hot melt adhesive passes through a first virtual plane perpendicular to the axial direction of the lamp tube, and the first virtual plane passes through the heat conducting portion, the hot melt adhesive and the outer circumferential surface of the lamp tube in sequence along the radial direction.
Optionally, the position of the accommodating space filled with the hot melt adhesive passes through a second virtual plane perpendicular to the axial direction of the lamp tube, and the second virtual plane passes through the heat conducting portion, the second tube, the hot melt adhesive and the tail end region in sequence along the radial direction.
Optionally, the position of the accommodating space filled with the hot melt adhesive passes through a first virtual plane perpendicular to the axial direction of the lamp tube, and the first virtual plane passes through the heat conducting part, the hot melt adhesive and the outer circumferential surface of the lamp tube in sequence along the radial direction; the position of the hot melt adhesive filled in the accommodating space is also passed through by a second virtual plane which is vertical to the axial direction of the lamp tube, and the second virtual plane passes through the heat conducting part, the second tube, the hot melt adhesive and the tail end area in sequence along the radial direction.
Optionally, the hot melt adhesive mainly comprises the following components: phenolic resin 2127#, shellac, rosin, calcite powder, zinc oxide and ethanol, wherein the volume of the hot melt adhesive expands 1 to 1.3 times at the temperature of 200-250 ℃.
Optionally, the hot melt adhesive has fluidity at a temperature of 200 to 250 ℃.
Optionally, the hot melt adhesive is heated to a temperature of 200 to 250 ℃ and then expands due to heating, and is cured after cooling.
Optionally, the hot melt adhesive is heated to a temperature of 200 to 250 ℃ and then cured.
Optionally, the external heating device is an induction coil, the induction coil is connected to a power supply, an electromagnetic field is formed after the induction coil is powered on, and when the magnetic conductive metal piece in the lamp holder enters the electromagnetic field, induction power is generated to generate current, so that the magnetic conductive metal piece generates heat, and the heat is conducted to the hot melt adhesive.
Optionally, the power supply passes through a power amplifying unit before flowing into the induction coil, and the power amplifying unit amplifies the alternating current electric power by 1 to 2 times.
Optionally, the induction coil is coiled by a metal wire with a width of 5mm to 6mm to form a ring-shaped coil structure, and the diameter of the ring-shaped coil structure is about 30mm to 35 mm.
Preferably, the induction coil is mainly made of red copper.
Optionally, the heating temperature of the magnetic metal piece can reach 250 to 300 ℃.
Optionally, the heating temperature of the hot melt adhesive can reach 200 to 250 ℃.
Optionally, the induction coil is placed at a fixed position and is not moved, the lamp head is moved and enters the induction coil, the hot melt adhesive expands and flows after being heated, then the lamp head is pulled out of the induction coil, and then the hot melt adhesive is cooled and solidified.
Optionally, the induction coil is placed at a fixed position and is not moved, the lamp head is moved and enters the induction coil, the hot melt adhesive is heated and cured, and then the lamp head is pulled out of the induction coil.
Optionally, the lamp head is placed in a fixed position and is not moved, the induction coil is moved and surrounds the lamp head, the hot melt adhesive is cured after being heated, and then the induction coil is moved to leave the lamp head.
Optionally, the lamp head is placed in a fixed position and is still, the induction coil is moved and surrounds the lamp head, the hot melt adhesive expands and flows after being heated, then the induction coil is moved away from the lamp head, and then the hot melt adhesive is cooled and solidified.
Optionally, the induction coil is placed at a fixed position and is not moved, the lamp head rolls and enters the induction coil, the hot melt adhesive is heated and cured or flows after being heated, and then the lamp head is pulled out of the induction coil.
Optionally, after the lamp cap and the lamp tube end region are bonded and fixed by the hot melt adhesive, the torque test of 1.5 to 5 newton-meters (Nt-m) can be performed.
Optionally, after the lamp cap and the tail end region of the lamp tube are bonded and fixed by the hot melt adhesive, the bending moment test can be performed by a bending moment of 5 to 10 newton-meters (Nt-m).
Furthermore, the magnetic conductive metal sheet is arranged on the lamp holder, when the lamp tube is bonded with the lamp holder, the solidification of the hot melt adhesive is realized through the electromagnetic induction technology, the bonding is convenient, and the efficiency is high.
Furthermore, the lamp tube is provided with a transition area which is connected with the body area and the tail end area, the lamp cap is adhered to the lamp tube in the transition area, and the height difference is formed between the tail end area and the body area of the lamp tube, so that the phenomenon that the adhesive overflows to the body area is avoided, the trouble of manual modification treatment is eliminated, and the yield is improved.
Furthermore, due to the insulation effect of the insulation tube on the lamp holder, danger caused by electric shock of people in high voltage is avoided; the insulating tube can be made of various insulating materials, such as a plastic tube, so that heat is not easy to conduct, and the heat is prevented from being conducted to the power supply module inside the lamp holder and affecting the performance of the power supply module.
Furthermore, through optimizing the design and use of the hot melt adhesive and the heating mode of the hot melt adhesive, the combination and fixation between the lamp tube and the lamp holder can be better executed, and the reduction of the reliability caused by the high temperature of the internal environment of the lamp holder in the hot melt adhesive bonding between the lamp tube and the lamp holder is avoided. In addition, the hot melt adhesive is used as an object for realizing the insulation effect between the lamp tube and the lamp holder, and the electric shock condition which possibly occurs when the lamp tube is damaged can be avoided.
Furthermore, when the external heating equipment adopts a hollow ring shape formed by using the upper and lower semicircular clamps, the problem that the induction coil and the lamp holder are damaged due to poor position precision control when being drawn in or drawn out from each other can be avoided, so that the problem of yield in manufacturing is reduced.
Drawings
FIG. 1 is a perspective view showing an LED straight lamp according to an embodiment of the present invention;
FIG. 1A is a perspective view showing another embodiment of the present invention, in which the lamp caps at two ends of the tube have different sizes;
FIG. 2 is an exploded perspective view showing the LED straight tube lamp of FIG. 1;
FIG. 3 is a perspective view showing the front and top of the lamp cap of a LED straight lamp according to an embodiment of the present invention;
FIG. 4 is a perspective view showing the bottom of the base of the LED straight tube lamp of FIG. 3;
FIG. 5 is a sectional plan view showing a lamp cap and a lamp tube connecting portion of an LED straight lamp according to an embodiment of the present invention;
FIG. 6 is a perspective cross-sectional view showing an all-plastic lamp cap (with a magnetic metal part and a hot melt adhesive inside) of an LED straight tube lamp according to another embodiment of the invention;
FIG. 7 is a perspective view showing an all-plastic lamp cap (containing a magnetic metal part and a hot melt adhesive) and a lamp tube of a LED straight tube lamp according to another embodiment of the invention being heated and cured by an induction coil;
FIG. 8 is a perspective view showing another embodiment of the present invention, in which a support portion and a protrusion are formed on the inner peripheral surface of the insulation tube of the all-plastic lamp cap of the LED straight lamp;
FIG. 9 is a cross-sectional plan view showing the internal structure of the all-plastic base of FIG. 8 taken along the X-X direction;
FIG. 10 is a plan view showing a magnetic conductive metal member with holes on the surface inside the all plastic base of another embodiment of the LED straight tube lamp according to the invention;
FIG. 11 is a plan view showing an indentation or an embossment on the surface of the magnetic conductive metal member in the all-plastic base of the LED straight tube lamp according to another embodiment of the invention;
FIG. 12 is a cross-sectional plan view showing the structure of the lamp cap of FIG. 8 in which the insulating tube and the lamp tube are combined and the magnetic conductive metal member is a circular ring structure;
FIG. 13 is a cross-sectional plan view showing the structure of the lamp cap of FIG. 8 in which the insulating tube and the lamp tube are coupled together and the magnetic conductive metal member is an elliptical ring structure;
FIG. 14 is a perspective view showing a further structure of a lamp cap in a LED straight lamp according to still another embodiment of the present invention;
FIG. 15 is a sectional plan view showing the end structure of a lamp tube in an LED straight lamp according to an embodiment of the present invention;
FIG. 16 is a plan sectional view showing a partial structure of a transition region of an end portion of the lamp tube in FIG. 15;
fig. 17 is a plan sectional view showing an internal structure of a lamp tube of an LED straight lamp in the axial direction according to an embodiment of the present invention, in which two reflective films extend along the circumferential direction of the lamp tube on both sides of a lamp panel, respectively;
fig. 18 is a plan sectional view showing an internal structure of a lamp tube of an LED straight tube lamp in an axial direction according to another embodiment of the present invention, in which a reflective film extends only on one side of a lamp panel in a circumferential direction of the lamp tube;
FIG. 19 is a sectional plan view showing an inner structure of a lamp tube of an LED straight lamp according to still another embodiment of the present invention in an axial direction, in which a reflective film is provided under the lamp panel and extends in a circumferential direction of the lamp tube on both sides of the lamp panel;
FIG. 20 is a sectional plan view showing an inner structure of a lamp tube of an LED straight lamp according to still another embodiment of the present invention in an axial direction, in which a reflective film is provided under a lamp panel and extends in a circumferential direction of the lamp tube only on one side of the lamp panel;
fig. 21 is a plan sectional view showing an internal structure of a lamp tube of an LED straight lamp according to still another embodiment of the present invention in an axial direction, in which two reflective films are respectively adjacent to both sides of a lamp panel and extend in a circumferential direction of the lamp tube;
FIG. 22 is a cross-sectional plan view showing that the lamp panel of the LED straight lamp according to the embodiment of the present invention is a flexible circuit board, and the end of the flexible circuit board climbs over the transition portion of the lamp tube and is connected to the output end of the power supply in a welding manner;
FIG. 23 is a cross-sectional plan view showing a dual-layered structure of a flexible circuit board of a lamp panel of an LED straight lamp according to an embodiment of the present invention;
FIG. 24 is a perspective view showing a solder pad of a flexible circuit board of a lamp panel of an LED straight lamp according to an embodiment of the invention, the solder pad being connected to a printed circuit board of a power supply by soldering;
FIG. 25 is a plan view showing a pad configuration of a flexible circuit board of a lamp panel of an LED straight lamp according to an embodiment of the present invention;
FIG. 26 is a plan view showing a flexible circuit board of a lamp panel of a LED straight lamp according to another embodiment of the present invention, wherein the flexible circuit board has 3 pads arranged in a row;
FIG. 27 is a plan view showing a flexible circuit board of a lamp panel of a LED straight lamp according to still another embodiment of the present invention, wherein the flexible circuit board has 3 pads arranged in two rows;
FIG. 28 is a plan view showing a flexible circuit board of a lamp panel of a straight LED lamp according to another embodiment of the present invention, wherein the flexible circuit board has 4 pads arranged in a row;
FIG. 29 is a plan view showing that the flexible circuit board of the lamp panel of the LED straight lamp according to still another embodiment of the present invention has 4 pads arranged in two rows;
FIG. 30 is a plan view showing holes formed in bonding pads of a flexible circuit board of a lamp panel of a LED straight lamp according to an embodiment of the present invention;
FIG. 31 is a cross-sectional plan view illustrating a soldering process of a pad of a flexible circuit board and a printed circuit board of a power supply using the lamp panel of FIG. 30;
FIG. 32 is a sectional plan view illustrating a soldering process of a pad of a flexible printed circuit board using the lamp panel of FIG. 30 and a printed circuit board of a power supply, in which a hole of the pad is close to an edge of the flexible printed circuit board;
FIG. 33 is a plan view showing a solder pad of a flexible circuit board of a lamp panel of a LED straight lamp according to an embodiment of the invention, the solder pad having a notch;
FIG. 34 is a plan sectional view showing a partial enlarged section taken along line A-A' in FIG. 33;
FIG. 35 is a perspective view showing a flexible circuit board of a lamp panel of an LED straight lamp according to another embodiment of the present invention and a printed circuit board of a power supply being combined to form a circuit board assembly;
FIG. 36 is a perspective view showing another configuration of the circuit board assembly of FIG. 35;
FIG. 37 is a perspective view showing a structure of a holder for a light source of an LED straight lamp according to an embodiment of the present invention;
FIG. 38 is a perspective view of a power supply in a LED straight tube lamp in accordance with one embodiment of the present invention;
FIG. 39 is a perspective view showing another embodiment of the present invention, in which a circuit board of a power supply is vertically soldered to a rigid circuit board made of aluminum;
FIG. 40 is a perspective view showing a structure of a hot press head used for soldering a flexible printed circuit board of a lamp panel and a printed circuit board of a power supply according to an embodiment of the present invention;
FIG. 41 is a plan view showing a difference between the thickness of tin on the bonding pad before the FPC of the lamp panel and the PCB of the power supply are soldered according to an embodiment of the present invention;
FIG. 42 is a perspective view of a soldering carrier device for soldering a flexible printed circuit board of a lamp panel and a printed circuit board of a power supply according to an embodiment of the present invention;
fig. 43 is a plan view showing a rotation state of a rotary table on the welding carrier device of fig. 41;
FIG. 44 is a plan view showing an external heating apparatus for heating the hot melt adhesive in accordance with another embodiment of the present invention;
FIG. 45 is a cross-sectional view of a hot melt adhesive doped with uniformly distributed small-sized powder of high magnetic permeability material according to an embodiment of the present invention;
FIG. 46 is a cross-sectional view of another embodiment of the present invention, which is doped with non-uniformly distributed small-sized high magnetic permeability material powder to form a hot melt adhesive for closing a circuit;
FIG. 47 is a cross-sectional view of a thermal fuse that is doped with non-uniformly distributed large-grain-size high-permeability material powder to form a closed circuit according to yet another embodiment of the present invention;
FIG. 48 is a perspective view showing a flexible circuit board of a lamp panel with two circuit layers according to another embodiment of the present invention.
Detailed Description
The invention provides a novel LED straight lamp based on a glass lamp tube, which aims to solve the problems mentioned in the background technology and the problems. In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below. The following description of the various embodiments of the present invention is provided for illustration only and is not intended to represent all embodiments of the present invention or to limit the present invention to particular embodiments.
Referring to fig. 1 and 2, an embodiment of the invention provides an LED straight lamp, which includes: a fluorescent tube 1, a lamp plate 2 that locates in fluorescent tube 1 to and locate two lamp holders 3 at fluorescent tube 1 both ends respectively. The lamp tubes 1 can be plastic lamp tubes or glass lamp tubes, and the sizes of the lamp heads are the same or different. Referring to fig. 1A, in an embodiment where the sizes of the lamp bases are different, preferably, the size of the smaller lamp base is 30% to 80% of the size of the larger lamp base.
In one embodiment, the lamp tube 1 of the LED straight lamp is a glass lamp tube with a reinforced structure, so as to avoid the problems of the conventional glass lamp that the glass lamp is easy to crack and the electric shock accident is caused by electric leakage, and the plastic lamp is easy to age. In the embodiments of the present invention, the glass lamp 1 can be strengthened by a secondary process using a chemical method or a physical method.
The basic principle of chemically strengthening glass is to change the composition of the glass surface to improve the strength of the glass, and the method is to exchange other alkali metal ions with Na ions or K ions on the surface of the glass to form an ion exchange layer on the surface, and after cooling to normal temperature, the glass is in a state that the inner layer is pulled and the outer layer is compressed, thereby achieving the purpose of increasing the strength, including but not limited to a high temperature type ion exchange method, a low temperature type ion exchange method, a dealkalization method, a surface crystallization method, a sodium silicate strengthening method and the like, and further explained below.
1. High temperature type ion exchange method
In a temperature region between the softening point and the transition point of the glass, the glass containing Na2O or K2O is immersed in the lithium molten salt to exchange Na ions in the glass or Li ions in the molten salt having a small radius, and then cooled to room temperature, and the surface is strengthened by generating residual pressure due to the difference in expansion coefficient between the surface layer containing Li ions and the inner layer containing Na ions or K ions; when Al2O3, TiO2 and other components are neutralized in the glass, crystals having an extremely low expansion coefficient are generated by ion exchange, and a large pressure is generated on the surface of the cooled glass, whereby a glass having a strength as high as 700MPa can be obtained.
2. Low temperature type ion exchange method
A low-temperature ion exchange method for making K ions enter a surface layer by ion exchange between Na ions and monovalent cations (such as K ions) having a larger ion radius than alkali ions (such as Na ions) in the surface layer in a temperature region lower than the strain point of glass. For example, Na2O + CaO + SiO2 system glass can be immersed in a molten salt of more than four hundred degrees for more than ten and several hours. The low-temperature ion exchange method can easily obtain high strength, and has the characteristics of simple treatment method, no damage to the transparency of the glass surface, no deformation and the like.
3. Dealkalization method
The alkali removal method is a method in which a glass is treated with a Pt catalyst in a high-temperature atmosphere containing sulfurous acid gas and water, Na + ions are exuded from the surface layer of the glass and react with sulfurous acid, and the surface layer becomes a SiO 2-rich layer, and as a result, the surface layer becomes a low-expansion glass, and a compressive stress is generated during cooling.
4. Surface crystallization method
The surface crystallization method is different from the high-temperature type ion exchange, but it is a method of forming microcrystals with a low expansion coefficient on the surface layer by heat treatment alone to strengthen the surface layer.
5. Sodium silicate strengthening process
The sodium silicate strengthening method is to treat an aqueous solution of sodium silicate (water glass) at 100 ℃ or higher under several atmospheres to obtain high-strength glass whose surface layer is not easily scratched.
The means for physically strengthening the glass may include, but is not limited to, the use of coatings or the modification of the structure of the article. The coating determines the type and state of the coating according to the substrate needing to be sprayed, can be a ceramic tile reinforced coating, an acrylic coating or a glass coating and the like, and can be coated in a liquid state or a gas state during coating. The structure of the article is changed, for example, a structural reinforcing design is made at the position which is easy to break.
The above methods, whether chemical or physical, are not limited to single implementation, and may be mixed in physical or chemical ways to be combined in any combination.
Referring to fig. 2 and 15, a glass lamp tube of a straight LED tube lamp according to an embodiment of the present invention has a structurally strengthened end portion, which is described below. The glass lamp 1 includes a body region 102, end regions 101 respectively located at two ends of the body region 102, and lamp caps respectively sleeved outside the end regions 101. The outer diameter of the at least one end region 101 is smaller than the outer diameter of the body region 102. In this embodiment, the outer diameters of the two end regions 101 are smaller than the outer diameter of the body region 102, and the cross section of the end region 101 is a plane and parallel to the body region 102. Specifically, the two ends of the lamp 1 are reinforced, the end region 101 forms a reinforced structure, the base 3 is sleeved on the reinforced end region 101, and the difference between the outer diameter of the base 3 and the outer diameter of the lamp body region 102 is reduced or even completely leveled, i.e. the outer diameter of the base 3 is equal to the outer diameter of the body region 102 and no gap is generated between the base 3 and the body region 102. The advantage that sets up like this lies in, and in the transportation, the packing bearing thing can not only contact lamp holder 3, and it can contact lamp holder 3 and fluorescent tube 1 simultaneously for whole LED straight tube lamp atress is even, and can not make lamp holder 3 become only stress point, avoids lamp holder 3 and the position that the terminal district 101 of fluorescent tube is connected to take place to break because stress concentration, improves the quality of product, and has pleasing to the eye effect concurrently.
In one embodiment, the outer diameter of the base 3 is substantially equal to the outer diameter of the body region 102 to a tolerance within plus or minus 0.2mm (millimeters) and up to plus or minus 1 mm. In order to achieve the purpose that the outer diameter of the lamp cap 3 is substantially equal to the outer diameter of the body region 102, the difference between the outer diameters of the strengthened end region 101 and the body region 102 can be 1mm to 10mm according to the thicknesses of different lamp caps 3; or preferably, the difference between the outer diameters of the reinforced tip region 101 and the body region 102 may be relaxed to 2mm to 7 mm.
Referring to fig. 15, the end region 101 and the body region 102 of the lamp 1 are smoothly transitioned to form a transition region 103. In one embodiment, both ends of the transition region 103 are cambered, that is, the cross section of both ends of the transition region 103 along the axial direction is cambered. Further, one of the arc surfaces at the two ends of the transition region 103 is connected to the body region 102, and the other is connected to the tail region 101. The arc angle of the arc surface is greater than ninety degrees, and the outer surface of the end region 101 is a continuous surface and remains parallel to the outer surface of the body region 102 when viewed in cross section. In other embodiments, the transition region 103 may not be curved or arcuate in shape. The length of the transition zone 103 is 1mm to 4mm, and if less than 1mm, the strength of the transition zone is insufficient; if it is larger than 4mm, the length of the body region 102 is reduced, the light emitting surface is reduced, and the length of the base 3 is required to be increased correspondingly to match the body region 102, resulting in an increase in the material of the base 3. In other embodiments, the transition region 103 may not be curved.
Referring to fig. 5 and 16, in the present embodiment, the lamp tube 1 is a glass lamp tube, the transition region 103 between the body region 102 and the end region 101 is a slightly inverted S-shaped curved surface formed by two consecutive curved surfaces with curvature radii R1 and R2, the curved surface of the transition region 103 near the body region 102 is convex outward, and the curved surface of the transition region 103 near the end region 101 is concave inward. Generally, the relationship between the curvature radii R1 and R2 of the two curved surfaces is R1< R2, the ratio of R1 to R2 is in the range of R1: R2 from 1:1.5 to 1:10, preferably in the range of 1:2.5 to 1:5, and most preferably in the range of 1:3 to 1:4, in this embodiment, R1: R2 is about 1:3, so that the transition region 103 near the end region 101 is strengthened to make the glass in a state where the inner layer is in tension and the outer layer is in compression; the transition region 103 close to the body region 102 is strengthened to enable the glass to be in a state that the inner layer is pressed and the outer layer is pulled; thereby achieving the purpose of increasing the strength of the transition region 103 of the glass lamp tube 1.
Taking the standard lamp of T8 as an example, the outer diameter of the reinforced end zone 101 ranges from 20.9mm to 23mm, and if less than 20.9mm, the inner diameter of the end zone 101 is too small to allow power supply components to be inserted into the lamp 1. The outer diameter of the body region 102 ranges from 25mm to 28mm, and if the outer diameter is smaller than 25mm, the two ends of the body region are inconvenient to be treated by strengthening parts under the existing process conditions, and if the outer diameter is larger than 28mm, the body region does not meet the industrial standard.
Referring to fig. 3 and 4, in an embodiment of the invention, the lamp head 3 of the LED straight tube lamp includes an insulating tube 302, a heat conducting portion 303 fixed on an outer circumferential surface of the insulating tube 302, and two hollow conductive pins 301 disposed on the insulating tube 302. The heat conducting portion 303 may be a tubular metal ring.
Referring to fig. 5, in an embodiment, one end of the heat conducting portion 303 extends out of the end of the insulating tube 302 facing the lamp tube, and the extending portion (the portion extending out of the insulating tube) of the heat conducting portion 303 and the lamp tube 1 are bonded by a hot melt adhesive 6. Further, the lamp cap 3 extends to the transition region 103 through the heat conducting portion 303, and the heat conducting portion 303 is in close contact with the transition region 103, so that when the heat conducting portion 303 and the lamp tube 1 are bonded through the hot melt adhesive 6, the hot melt adhesive 6 does not overflow the lamp cap 3 and remain in the main body region 102 of the lamp tube 1. Furthermore, the end of the insulating tube 302 facing the lamp vessel 1 does not extend into the transition region 103, i.e. a certain distance is maintained between the end of the insulating tube 302 facing the lamp vessel and the transition region 103. In this embodiment, the material of the insulating tube 302 is not limited to plastic, ceramic, or the like, and may be a good conductor that is not electrically conductive in a general state.
Furthermore, the hot melt adhesive 6 is a composition comprising a material of solder paste powder, preferably having the following composition: phenolic resin 2127#, shellac, rosin, calcite powder, zinc oxide, ethanol, and the like. In this embodiment, rosin is a tackifier, and has the property of being soluble in ethanol but insoluble in water. The hot melt adhesive 6 can change the physical state of the hot melt adhesive to greatly expand under the condition of high-temperature heating, achieves the curing effect, and additionally has the viscosity of the material, so that the lamp holder 3 can be in close contact with the lamp tube 1, and the LED straight tube lamp can be conveniently and automatically produced. In one embodiment, the hot melt adhesive 6 will expand and flow after being heated at a high temperature, and then will solidify after being cooled, and when the hot melt adhesive 6 is heated from room temperature to a temperature of 200 to 250 degrees celsius, the volume of the hot melt adhesive will expand to 1 to 1.3 times the original volume. Of course, the selection of the hot melt adhesive composition of the present invention is not limited thereto, and the composition can be selected to be cured after being heated to a predetermined temperature. Because the hot melt adhesive 6 disclosed by the invention cannot cause reliability reduction due to the high-temperature environment formed by heating of heating components such as a power supply module and the like, the bonding performance of the lamp tube 1 and the lamp cap 3 can be prevented from being reduced in the use process of the LED straight tube lamp, and the long-term reliability is improved.
Further, an accommodating space is formed between the inner peripheral surface of the protruding portion of the heat conducting portion 303 and the outer peripheral surface of the lamp tube 1, and the hot melt adhesive 6 is filled in the accommodating space, as shown by the dotted line B in fig. 5. In other words, the location where the hot melt adhesive 6 is filled passes through a first virtual plane (a plane as drawn by the dotted line B in fig. 5) perpendicular to the axial direction of the lamp tube 1: in the radially inward direction, at the position of the first virtual plane, the heat conduction portion 303, the hot melt adhesive 6, and the outer peripheral surface of the lamp tube 1 are arranged in this order. The hot melt adhesive 6 may be applied to a thickness of 0.2mm to 0.5mm, and the hot melt adhesive 6 is cured after being expanded, thereby contacting the lamp tube 1 and fixing the lamp cap 3 to the lamp tube 1. And because the height difference exists between the outer peripheral surfaces of the tail end area 101 and the body area 102, the hot melt adhesive can be prevented from overflowing to the body area 102 part of the lamp tube, the subsequent manual wiping process is omitted, and the yield of the LED straight tube lamp is improved. During processing, heat is conducted to the heat conducting part 303 through external heating equipment, then conducted to the hot melt adhesive 6, and the hot melt adhesive 6 is cooled and solidified after expansion, so that the lamp holder 3 is fixedly bonded on the lamp tube 1.
Referring to fig. 5, in an embodiment, the insulating tube 302 includes a first tube 302a and a second tube 302b connected along an axial direction, an outer diameter of the second tube 302b is smaller than an outer diameter of the first tube 302a, and a difference between the outer diameters of the two tubes ranges from 0.15mm to 0.3 mm. The heat conducting part 303 is arranged on the outer peripheral surface of the second tube 302b, and the outer surface of the heat conducting part 303 is flush with the outer peripheral surface of the first tube 302a, so that the outer surface of the lamp holder 3 is flat and smooth, and the stress of the whole LED straight tube lamp in the packaging and transportation processes is uniform. The ratio of the length of the heat conducting part 303 in the axial direction of the lamp holder to the axial length of the insulating tube 302 is 1:2.5 to 1:5, namely the length of the heat conducting part: the length of the insulating tube is 1: 2.5-1: 5.
In one embodiment, to ensure the bonding firmness, the second tube 302b is at least partially sleeved outside the lamp tube 1, and the accommodating space further includes a space between the inner surface of the second tube 302b and the outer surface of the end region 101 of the lamp tube. The hot melt adhesive 6 is partly filled between the second tube 302b and the lamp vessel 1, which are superimposed on one another (position indicated by the broken line a in fig. 5), i.e. part of the hot melt adhesive 6 is located between the inner surface of the second tube 302b and the outer surface of the end region 101. In other words, the position where the hot melt adhesive 6 is filled in the accommodating space passes through a second virtual plane (a plane drawn by a dotted line a in fig. 5) perpendicular to the axial direction of the lamp tube: in the radially inward direction, at the position of the second virtual plane, the heat conduction portion 303, the second tube 302b, the hot melt adhesive 6, and the end region 101 are arranged in this order.
In this embodiment, the hot melt adhesive 6 does not need to completely fill the accommodating space (e.g., the accommodating space may also include a space between the heat conducting portion 303 and the second tube 302 b). When the hot melt adhesive 6 is applied between the heat conductive portion 303 and the end region 101 at the time of manufacture, the amount of the hot melt adhesive can be increased as appropriate so that the hot melt adhesive can flow between the second tube 302b and the end region 101 due to expansion during the subsequent heating, and then be cooled and solidified to thereby adhesively join the two.
When the LED straight tube lamp is manufactured, after the end region 101 of the lamp tube 1 is inserted into the lamp cap 3, the axial length of the part of the end region 101 of the lamp tube 1 inserted into the lamp cap 3 occupies between one third and two thirds of the axial length of the heat conducting portion 303, which is beneficial: on one hand, the hollow conductive needle 301 and the heat conducting part 303 are ensured to have enough creepage distance, and the hollow conductive needle and the heat conducting part are not easy to be short-circuited when being electrified, so that people are electric shock and danger is caused; on the other hand, due to the insulating effect of the insulating tube 302, the creepage distance between the hollow conductive needle 301 and the heat conducting part 303 is increased, and the test which causes danger due to electric shock when high voltage passes is easier to pass.
Further, with respect to the hot melt adhesive 6 on the inner surface of the second pipe 302b, the second pipe 302b is interposed between the hot melt adhesive 6 and the heat conductive portion 303, and therefore the effect of heat conduction from the heat conductive portion 303 to the hot melt adhesive 6 is impaired. To solve this problem, referring to fig. 4, in the present embodiment, a plurality of circumferentially arranged notches 302c are disposed at an end of the second tube 302b facing the lamp tube 1 (i.e., an end away from the first tube 302 a), so as to increase a contact area between the heat conducting portion 303 and the hot melt adhesive 6, thereby facilitating heat to be rapidly conducted from the heat conducting portion 303 to the hot melt adhesive 6, and accelerating a curing process of the hot melt adhesive 6. Meanwhile, when the user touches the heat conduction part 303, the lamp tube 1 is not damaged to cause electric shock due to the insulation effect of the hot melt adhesive 6 between the heat conduction part 303 and the lamp tube 1.
The heat conducting portion 303 may be made of various materials that easily conduct heat, such as a metal sheet in this embodiment, and has a good appearance, such as an aluminum alloy. The heat conducting portion 303 is tubular (or ring-shaped) and is sleeved outside the second tube 302 b. The insulating tube 302 may be made of various insulating materials, but it is preferable that the insulating tube is not easy to conduct heat, so as to prevent the heat from being conducted to the power module inside the lamp head 3 and affecting the performance of the power module, and the insulating tube 302 in this embodiment is a plastic tube. In other embodiments, the heat conducting portion 303 may also be composed of a plurality of metal sheets arranged at intervals or not along the circumference of the second tube 302 b.
The lamp cap of the LED straight lamp can be designed to have other structures or contain other elements. Referring to fig. 6, in another embodiment of the present invention, the lamp cap 3 further includes a magnetic conductive metal member 9 besides the insulating tube 302, but does not include the aforementioned heat conducting portion. The magnetic conductive metal member 9 is fixedly disposed on the inner circumferential surface of the insulating tube 302, and at least a portion of the magnetic conductive metal member is located between the inner circumferential surface of the insulating tube 302 and the end region of the lamp tube, and has an overlapping portion with the lamp tube 1 along the radial direction. In this embodiment, the entire magnetic conductive metal member 9 is located in the insulating tube 302, and the hot melt adhesive 6 is coated on the inner surface of the magnetic conductive metal member 9 (the surface of the magnetic conductive metal member 9 facing the lamp tube 1) and is adhered to the outer circumferential surface of the lamp tube 1. In order to increase the bonding area and improve the bonding stability, the hot melt adhesive 6 preferably covers the entire inner surface of the magnetically permeable metal member 9.
Referring to fig. 7, in the manufacture of the LED straight tube lamp of the present embodiment, the insulating tube 302 of the lamp cap 3 is inserted into an external heating device, which is preferably an induction coil 11, such that the induction coil 11 is located above the magnetic metal member 9 and is opposite to the magnetic metal member 9 along the radial direction of the insulating tube 302. When processing, with induction coil 11 circular telegram, induction coil 11 forms the electromagnetic field after circular telegram, and the electromagnetic field converts the electric current into behind magnetic conduction metalwork 9 for magnetic conduction metalwork 9 generates heat, uses electromagnetic induction technique to make magnetic conduction metalwork 9 generate heat promptly, and heat conduction to hot melt adhesive 6, and hot melt adhesive 6 absorbs the heat back inflation and flows, makes hot melt adhesive 6 solidification after the cooling, in order to realize being fixed in the purpose of fluorescent tube 1 with lamp holder 3. The main material of the induction coil 11 may be red copper and is a ring coil formed by rolling a metal wire with a width of 5mm to 6mm, the diameter of the ring coil is about 30mm to 35mm, and the lower limit of the diameter of the ring coil is slightly larger than the outer diameter of the lamp cap 3. On the premise that the outer diameter of the lamp cap 3 is the same as that of the lamp tube 1, the outer diameter of the lamp cap 3 will have different outer diameters with different lamp tubes 1, so that different types of lamp tubes can use different diameters of the induction coil 11. For example, the diameter of a T12 lamp tube is 38.1mm, the diameter of a T10 lamp tube is 31.8mm, the diameter of a T8 lamp tube is 25.4mm, the diameter of a T5 lamp tube is 16mm, the diameter of a T4 lamp tube is 12.7mm, and the diameter of a T2 lamp tube is 6.4 mm.
Furthermore, the induction coil 11 can be used with a power amplification unit to amplify the power of the ac power store by 1 to 2 times. The induction coil 11 is preferably coaxial with the insulating tube 302 so that the energy transfer is relatively uniform. Preferably, the deviation between the induction coil 11 and the central axis of the insulating tube 302 is not more than 0.05 mm. When the gluing is completed, the lamp cap 3 together with the lamp vessel 1 will be pulled away from the induction coil 11. The hot melt adhesive 6 will then expand and flow after absorbing heat, and then cool to a solidified effect. In one embodiment, the heating temperature of the magnetic metal piece 9 can reach 250 to 300 ℃, and the heating temperature of the hot melt adhesive 6 can reach 200 to 250 ℃. Of course, the selection of the components of the hot melt adhesive of the present invention is not limited thereto, and components which absorb heat and then solidify can be selected.
In one embodiment, after the manufacturing process of the lamp 1 is completed, the induction coil 11 is not moved, and then the lamp 1 and the lamp cap 3 are pulled away from the induction coil 11. However, in other embodiments, the induction coil 11 may be detached from the lamp tube after the lamp tube 1 is fixed. In an embodiment, the heating device of the magnetic conductive metal member 9 may adopt a device having a plurality of induction coils 11, that is, when the lamp caps 3 of the plurality of lamp tubes 1 are to be heated, only the plurality of lamp tubes 1 need to be placed at the default position, then the heating device moves the corresponding induction coil 11 to the lamp cap position of the lamp tube 1 to be heated, and after the heating is completed, the plurality of induction coils 11 are taken out from the corresponding lamp tube 1 to complete the heating of the magnetic conductive metal member 9. However, since the length of the lamp tube 1 is much longer than that of the lamp cap 3, or even the length of the lamp tube 1 can reach 240cm or more in some special applications, when the lamp tube 1 and the lamp cap 3 are linked, the connection and fixation between the lamp cap 3 and the lamp tube 1 may be damaged due to the position error when the induction coil 11 and the lamp cap 3 are drawn in or out relative to each other in the front-back direction as described above.
Referring to fig. 44, the induction coil 11 of the present embodiment may also adopt an external heating device 110 composed of a plurality of upper and lower semicircular clamps 11a to achieve the same effect as the induction coil, and reduce the possibility of damage to the connection and fixation of the lamp head 3 and the lamp tube 1 caused by the position error due to the relative movement in the front-back direction. The upper and lower semicircular clamps 11a are respectively provided with semicircular coils formed by curling the metal wires with the width of 5mm to 6mm, and when the upper and lower semicircular clamps are contacted, a hollow ring with a diameter of about 30mm to 35mm is formed, and a closed circuit is formed inside the hollow ring to form the induction coil 11. In this embodiment, the upper and lower semicircular clamps 11a are used to form a hollow ring, and the lamp head 3 of the lamp tube 1 enters the hollow ring not in a forward and backward movement manner, but in a rolling manner, so as to avoid the problem of damage caused by poor position accuracy control when the induction coil 11 and the lamp head 3 are drawn in or out from each other. In detail, the lamp 1 is on a rolling production line, the lamp head 3 of the lamp 1 is rolled and placed on the notch of the lower semicircular fixture, the upper semicircular fixture and the lower semicircular fixture are contacted to form a closed circuit, and after the heating is finished, the upper semicircular fixture is separated, so that the requirement for position precision control can be reduced, and the yield problem in manufacturing can be reduced.
Referring to fig. 6, in order to better support the magnetic conductive metal member 9, the inner diameter of the first tube portion 302d of the insulating tube 302 for supporting the magnetic conductive metal member 9 is larger than the inner diameter of the remaining second tube portions 302e, a step is formed at the junction of the first tube portion 302d and the second tube portion 302e, one axial end of the magnetic conductive metal member 9 abuts against the step, and the inner surface of the entire lamp holder is flush after the magnetic conductive metal member 9 is disposed. The magnetic conductive metal fitting 9 may have various shapes, for example, a sheet shape or a tubular shape arranged in the circumferential direction, and here, the magnetic conductive metal fitting 9 is provided in a tubular shape coaxial with the insulating tube 302.
Referring to fig. 8 and 9, in another embodiment, the inner circumferential surface of the insulating tube 302 may support the magnetic conductive metal fitting 9 as follows: the insulating tube 302 has on its inner peripheral surface a support portion 313 protruding toward the inside of the insulating tube 302 so that the magnetic conductive metal member 9 abuts against the upper edge of the support portion 313 in the axial direction (i.e., the end surface of the support portion on the side facing the projection). Preferably, the thickness of the support portion 313 protruding inward from the inner circumferential surface of the insulating tube 302 is 1mm to 2 mm. The inner circumferential surface of the insulating tube 302 is further provided with a projection 310, so that the magnetic metal fitting 9 is circumferentially abutted against the inner side in the radial direction of the projection 310, and a gap is formed between the outer circumferential surface of the magnetic metal fitting 9 and the inner circumferential surface of the insulating tube 302. The radial thickness of the protruding portion 310 is smaller than that of the supporting portion 313, and in one embodiment, is preferably 0.2mm to 1 mm.
As shown in fig. 9, the protruding portion 310 is connected to the support portion 313 in the axial direction, and the magnetic conductive metal member 9 abuts against the upper edge of the support portion 313 (i.e., the end surface of the support portion on the side facing the protruding portion) in the axial direction and abuts against the radially inner side of the protruding portion 310 in the circumferential direction, so that at least a part of the protruding portion 310 is located between the magnetic conductive metal member 9 and the inner circumferential surface of the insulating tube 302. The protrusion 310 may be a ring shape extending along the circumferential direction of the insulating tube 302, or a plurality of protrusions arranged at intervals along the circumferential direction around the inner circumferential surface of the insulating tube 302, and furthermore, the protrusions may be arranged at equal intervals or at unequal intervals along the circumferential direction, as long as the contact area between the outer surface of the magnetic conductive metal member 9 and the inner circumferential surface of the insulating tube 302 is reduced, and the function of holding the hot melt adhesive 6 is achieved. In other embodiments, the lamp cap 3 may be made of all metal, and an insulator needs to be added below the hollow conductive pin to withstand high voltage.
Referring to fig. 10, in other embodiments, the surface of the magnetic metal piece 9 facing the insulating tube 302 has at least one hole 91, and the shape of the hole 91 is circular, but not limited to circular, and may be, for example, oval, square, star-shaped, etc., as long as the contact area between the magnetic metal piece 9 and the inner circumferential surface of the insulating tube 302 can be reduced, and the function of heat curing, i.e., heating the hot melt adhesive 6 can be provided. Preferably, the area of the empty hole 91 accounts for 10% to 50% of the area of the magnetic conductive metal piece 9. The holes 91 may be arranged at equal intervals in the circumferential direction or at unequal intervals.
Referring to fig. 11, in another embodiment, the surface of the magnetic metal member 9 facing the insulating tube 302 has an indentation/embossment 93, and the indentation/embossment 93 may be an embossment protruding from the inner surface of the magnetic metal member 9 to the outer surface, but may also be an indentation recessed from the outer surface of the magnetic metal member 9 to the inner surface, so as to form a protrusion or a recess on the outer surface of the magnetic metal member 9, so as to reduce the contact area between the outer surface of the magnetic metal member 9 and the inner circumferential surface of the insulating tube 302. That is, the surface shape of the magnetic metal member 9 may be selected from one structural shape of the group consisting of a hole, an embossment, an indentation and a combination thereof, so as to reduce the contact area between the outer surface of the magnetic metal member 9 and the inner circumferential surface of the insulating tube 302. It should be noted, however, that the magnetically conductive metal piece 9 and the lamp tube should be ensured to be stably bonded to each other at the same time, so as to realize the function of the thermosetting hot melt adhesive 6.
Referring to fig. 12, in an embodiment, the magnetic conductive metal member 9 is a circular ring. Referring to fig. 13, in other embodiments, the magnetically permeable metal member 9 is a non-circular ring, such as but not limited to an elliptical ring, and when the lamp tube 1 and the lamp cap 3 are elliptical, the minor axis of the elliptical ring is slightly larger than the outer diameter of the end region of the lamp tube, so as to reduce the contact area between the outer surface of the magnetically permeable metal member 9 and the inner circumferential surface of the insulating tube 302, but to achieve the function of thermally curing the hot melt adhesive 6. In other words, since the insulating tube 302 has the support portion 313 on the inner peripheral surface thereof and the non-circular ring-shaped magnetic metal fitting 9 is provided on the support portion 313, the contact area between the magnetic metal fitting 9 and the inner peripheral surface of the insulating tube 302 can be reduced, and the function of solidifying the hot melt adhesive 6 can be realized. It should be noted that, in other embodiments, the magnetic conductive metal member 9 may be disposed outside the lamp cap 3, instead of the heat conducting portion 303 shown in fig. 5, and the function of curing the hot melt adhesive 6 may also be realized by the electromagnetic induction principle.
Referring to fig. 45 to 47, in other embodiments, the lamp cap 3 does not need to be additionally provided with the magnetic metal member 9, and only the hot melt adhesive 6 mentioned above needs to be directly doped with the high magnetic permeability material powder 65 in a predetermined ratio, and the relative magnetic permeability thereof is between 102 and 106. The high magnetic conductivity material powder 65 may be used to replace the original amount of calcite powder added in the hot melt adhesive 6, that is, the volume ratio of the high magnetic conductivity material powder 65 to the calcite powder is about 1:1 to 1: 3. Preferably, the material of the high magnetic conductivity material powder 65 is selected from one of the group of mixtures of iron, nickel, cobalt and alloys thereof, the weight percentage of the high magnetic conductivity material powder 65 in the hot melt adhesive 6 is 10% to 50%, and the average particle size of the high magnetic conductivity material powder 65 is 1 micrometer to 30 micrometers. After the lamp holder 3 and the lamp tube 1 are bonded by the hot melt adhesive 6 with the high-permeability material powder 65, the bending moment test standard of the lamp holder and the torque test standard of the lamp holder can be met simultaneously through the destructive test of the lamp holder. Generally speaking, the bulb bending moment test standard of a straight tube lamp needs to be more than 5 Newton-meters (Nt-m), and the bulb torque test standard of the straight tube lamp needs to be more than 1.5 Newton-meters (Nt-m). The different proportions of the powder 65 of the high magnetic permeability material doped into the hot melt adhesive 6 and the different magnetic fluxes applied to the lamp cap can pass a bending moment test of 5 to 10 Newton-meters (Nt-m) and a torque test of 1.5 to 5 Newton-meters (Nt-m). When processing, the induction coil 11 is powered on, and after the induction coil 11 is powered on, the high magnetic conductivity material powder 65 uniformly distributed in the hot melt adhesive 6 is electrified, so that the hot melt adhesive 6 generates heat, and the hot melt adhesive 6 absorbs heat, expands and flows, and is solidified after cooling, so that the lamp holder 3 is fixed on the lamp tube 1.
As shown in fig. 45 to 47, the distribution states of the powders 65 made of different high magnetic permeability materials in the hot melt adhesive 6 are shown. As shown in fig. 45, the average particle size of the high magnetic conductivity material powder 65 is 1 to 5 microns and is uniformly distributed in the hot melt adhesive 6, when the hot melt adhesive 6 is coated on the inner surface of the lamp holder 3, although a closed circuit cannot be formed by the uniform distribution of the high magnetic conductivity material powder 65 in the hot melt adhesive 6, within an electromagnetic field range, a single particle of the high magnetic conductivity material powder 65 still generates heat due to a hysteresis effect, so as to heat the hot melt adhesive 6. As shown in fig. 46, the average particle size of the high magnetic conductivity material powder 65 is 1 to 5 microns, and the high magnetic conductivity material powder 65 is unevenly distributed in the hot melt adhesive 6, when the hot melt adhesive 6 is coated on the inner surface of the lamp holder 3, the high magnetic conductivity material powder 65 particles are connected to each other to form a closed circuit, and within an electromagnetic field range, a single particle of the high magnetic conductivity material powder 65 generates heat due to hysteresis effect, and also generates heat due to the flow of electric charges of the closed circuit. As shown in fig. 47, the average particle size of the high magnetic conductivity material powder 65 is 5 microns to 30 microns, and the high magnetic conductivity material powder 65 is unevenly distributed in the hot melt adhesive 6, when the hot melt adhesive 6 is coated on the inner surface of the lamp holder 3, the high magnetic conductivity material powder 65 particles are connected with each other to form a closed circuit, and within an electromagnetic field range, a single particle of the high magnetic conductivity material powder 65 generates heat due to hysteresis effect, and also generates heat due to the flow of electric charges of the closed circuit. Therefore, by adjusting the particle size, distribution density, distribution morphology of the high magnetic conductivity material powder 65 and the magnetic flux applied to the lamp cap 3, the heating temperature of the hot melt adhesive 6 can be controlled differently. In one embodiment, the hot melt adhesive 6 may have fluidity when heated to a temperature of 200 to 250 degrees celsius, and solidify upon cooling. In another embodiment, the hot melt adhesive 6 is cured when heated to a temperature of 200 to 250 degrees celsius.
Referring to fig. 14 and 39, in another embodiment, a convex pillar 312 is disposed at an end of the lamp cap 3', a hole is disposed at a top end of the convex pillar 312, and a groove 314 having a depth of 0.1 ± 1% mm is disposed at an outer edge of the convex pillar 312 for positioning the conductive pin 53. The conductive pin 53 can be bent over the groove 314 after passing through the hole of the protruding pillar 312 at the end of the lamp cap 3', and then the protruding pillar 312 is covered by a conductive metal cap 311, so that the conductive pin 53 can be fixed between the protruding pillar 312 and the conductive metal cap 311, in this embodiment, the inner diameter of the conductive metal cap 311 is, for example, 7.56 ± 5% mm, the outer diameter of the protruding pillar 312 is, for example, 7.23 ± 5% mm, and the outer diameter of the conductive pin 53 is, for example, 0.5 ± 1% mm, so that the conductive metal cap 311 can directly and tightly cover the protruding pillar 312 without additionally coating adhesive, and thus the electrical connection between the power supply 5 and the conductive metal cap 311 can be completed.
Referring to fig. 2, 3, 12 and 13, in other embodiments, the lamp cap provided by the present invention is provided with a hole 304 for heat dissipation. Therefore, heat generated by the power supply module in the lamp holder can be dissipated without causing the inside of the lamp holder to be in a high-temperature state, so that the reliability of elements in the lamp holder is prevented from being reduced. Further, the hole for heat dissipation on the lamp holder is arc-shaped. Furthermore, the hole for heat dissipation on the lamp holder is three arcs with different sizes. Furthermore, the hole for heat dissipation on the lamp holder is three arcs gradually changing from small to large. Furthermore, the holes for heat dissipation on the lamp cap can be formed by matching the arc shapes and the arc lines at will.
In other embodiments, the light head includes a power socket (not shown) for mounting a power module.
Referring to fig. 17, the lamp tube 1 of the present embodiment includes a diffusion film 13 besides the lamp panel 2 (or flexible circuit board) closely attached to the lamp tube 1, and light generated by the light source 202 passes through the diffusion film 13 and then passes through the lamp tube 1. The diffusion film 13 diffuses the light emitted from the light source 202, so that the diffusion film 13 can be disposed in various forms, for example, as long as the light can pass through the diffusion film 13 and then out of the lamp tube 1: the diffusion film 13 may be coated or covered on the inner peripheral surface of the lamp tube 1, or a diffusion coating (not shown) coated on the surface of the light source 202, or a diffusion film covering (or shielding) the light source 202 as an outer cover.
Referring to fig. 17 again, when the diffusion film 13 is a diffusion film, it can cover the light source 202 without contacting the light source 202. The diffusion film is generally referred to as an optical diffusion sheet or an optical diffusion plate, and generally includes one or more of PS polystyrene, PMMA polymethylmethacrylate, PET (polyethylene terephthalate), and PC (polycarbonate) in combination with diffusion particles to form a composite material, which can diffuse light when the light passes through the composite material, and can modify the light into a uniform surface light source to achieve an optical diffusion effect, thereby uniformly distributing the brightness of the lamp tube.
When the diffusion film 13 is a diffusion coating, the main component thereof may be any one of calcium carbonate, calcium halophosphate, and alumina, or a combination of any two of them, or a combination of three of them. When calcium carbonate is used as a main material and a proper solution is matched to form a diffusion coating, the diffusion coating has excellent diffusion and light transmission effects (the organic rate can reach more than 90 percent). It has also been found that the lamp cap with the strengthened glass sometimes has quality problems, and some proportion of the lamp cap is easy to fall off, and as long as the diffusion coating is also coated on the outer surface of the terminal area 101 of the lamp tube, the friction between the lamp cap and the lamp tube is increased between the diffusion coating and the hot melt adhesive 6, so that the friction between the diffusion coating and the hot melt adhesive 6 is larger than the friction between the end surface of the terminal area 101 of the lamp tube and the hot melt adhesive when the diffusion coating is not coated, and therefore the problem that the lamp cap 3 falls off can be solved greatly by the lamp cap 3 through the friction between the diffusion coating and the hot melt adhesive 6.
In this example, the diffusion coating was formulated to include calcium carbonate, strontium phosphate (e.g., CMS-5000, white powder), a thickener, and ceramic activated carbon (e.g., ceramic activated carbon SW-C, colorless liquid). Specifically, when the diffusion coating is prepared by mixing calcium carbonate as a main material with a thickener, ceramic activated carbon and deionized water and then coating the mixture on the inner circumferential surface of the glass lamp tube, the average coating thickness is between 20 and 30 μm. The diffusion film 13 formed using such a material may have a light transmittance of about 90%, and in general, the light transmittance ranges from about 85% to 96%. In addition, the diffusion film 13 can play a role of electric isolation besides having the effect of diffusing light, so that when the glass lamp tube is broken, the risk of electric shock of a user is reduced; meanwhile, the diffusion film 13 can diffuse light emitted from all sides when the light source 202 emits light, so that the light can illuminate the rear side of the light source 202, namely, the light is close to one side of the flexible circuit soft board, a dark area is prevented from being formed in the lamp tube 1, and the illumination comfort in the space is improved. In addition, when diffusion coatings of different material compositions are selected, there is another possible implementation that a diffusion film thickness in the range of 200 μm to 300 μm and a light transmittance controlled between 92% and 94% can be used, which has another effect.
In other embodiments, the diffusion coating may also be made of calcium carbonate as a main material, mixed with a small amount of reflective material (such as strontium phosphate or barium sulfate), a thickening agent, ceramic activated carbon, and deionized water, and coated on the inner circumferential surface of the glass lamp tube, wherein the average thickness of the coating is between 20 μm and 30 μm. Since the purpose of the diffusion film is to diffuse light, the diffusion phenomenon is microscopically the reflection of light through particles, and the particle size of the reflective material such as strontium phosphate or barium sulfate is much larger than that of calcium carbonate, a small amount of reflective material is added into the diffusion coating to effectively increase the diffusion effect of light.
Of course, in other embodiments, calcium halophosphate or alumina may be used as the main material of the diffusion coating, the particle size of calcium carbonate is between about 2 and 4 μm, and the particle size of calcium halophosphate and alumina is between about 4 and 6 μm and 1 and 2 μm, respectively, in the case of calcium carbonate, when the light transmittance requirement range is 85% to 92%, the average thickness of the calcium halophosphate-based diffusion coating is about 20 to 30 μm, and in the same light transmittance requirement range (85% to 92%), the average thickness of the calcium halophosphate-based diffusion coating is about 25 to 35 μm, and the average thickness of the alumina-based diffusion coating is about 10 to 15 μm. If the transmittance is required to be higher, for example, 92% or more, the thickness of the diffusion coating layer based on calcium carbonate, calcium halophosphate, or alumina is required to be thinner.
That is, the main material to be coated with the diffusion coating, the corresponding forming thickness, etc. can be selected according to the application of the lamp tube 1 and different light transmittance requirements. It should be noted that, the higher the light transmittance of the diffusion film, the more noticeable the graininess of the light source is seen by the user.
With reference to fig. 17, a reflective film 12 is further disposed on the inner circumferential surface of the lamp tube 1, and the reflective film 12 is disposed around the lamp panel 2 having the light source 202 and occupies a part of the inner circumferential surface of the lamp tube 1 along the circumferential direction. As shown in fig. 17, the reflective film 12 extends along the circumferential direction of the lamp tube on both sides of the lamp panel 2, and the lamp panel 2 is substantially located at the middle position of the reflective film 12 along the circumferential direction. The provision of the reflective film 12 has two effects, on one hand, when the lamp 1 is viewed from the side (X direction in the figure), the light source 202 is not directly seen due to the blocking of the reflective film 12, thereby reducing the visual discomfort caused by the granular feeling; on the other hand, the light emitted by the light source 202 is reflected by the reflective film 12, so that the divergence angle of the lamp tube can be controlled, and the light is more irradiated towards the direction not coated with the reflective film, so that the LED straight tube lamp can obtain the same irradiation effect with lower power, and the energy saving performance is improved.
Specifically, the reflective film 12 is attached to the inner peripheral surface of the lamp tube 1, and an opening 12a corresponding to the lamp panel 2 is formed in the reflective film 12, and the size of the opening 12a should be the same as that of the lamp panel 2 or slightly larger than that of the lamp panel 2, so as to accommodate the lamp panel 2 with the light source 202. During assembly, the lamp panel 2 (or flexible circuit board) with the light source 202 is disposed on the inner circumferential surface of the lamp tube 1, and the reflective film 12 is attached to the inner circumferential surface of the lamp tube, wherein the openings 12a of the reflective film 12 correspond to the lamp panel 2 one-to-one, so as to expose the lamp panel 2 outside the reflective film 12.
In one embodiment, the reflectivity of the reflective film 12 is at least greater than 85%, and the reflective effect is preferably greater than 90%, and more preferably greater than 95%, to achieve a more desirable reflective effect. The length of the reflection film 12 extending in the circumferential direction of the lamp tube 1 occupies 30% to 50% of the entire circumference of the lamp tube 1, that is, the ratio between the circumferential length of the reflection film 12 and the circumference of the inner circumferential surface of the lamp tube 1 in the circumferential direction of the lamp tube 1 ranges from 0.3 to 0.5. Note that, in the present invention, only the lamp panel 2 is disposed at the middle position of the reflective film 12 in the circumferential direction, that is, the reflective films 12 on both sides of the lamp panel 2 have substantially the same area, as shown in fig. 17. The material of the reflecting film can be any one of PET, strontium phosphate and barium sulfate, or the combination of any two of the PET, the strontium phosphate and the barium sulfate, or the combination of the three, the reflecting effect is better, the thickness is between 140 and 350 μm, generally between 150 and 220 μm, and the effect is better. As shown in fig. 18, in other embodiments, the reflective film 12 may be disposed on only one side of the lamp panel 2, that is, the reflective film 12 contacts with one side of the lamp panel 2 in the circumferential direction, and the circumferential single side of the reflective film occupies the circumference of the lamp tube 1 in the same ratio of 0.3 to 0.5. Alternatively, as shown in fig. 19 and 20, the reflective film 12 may not be provided with an opening, the reflective film 12 is directly attached to the inner circumferential surface of the lamp 1 during assembly, and then the lamp panel 2 with the light source 202 is fixed to the reflective film 12, where the reflective film 12 may also extend along the circumferential direction of the lamp on one side or both sides of the lamp panel 2.
The reflective films 12 and the diffusing films 13 can be combined to achieve the optical effects of reflection, diffusion, or both. For example, only the reflective film 12 may be provided, and the diffusion film 13 may not be provided, as shown in fig. 19, 20, and 21.
In other embodiments, the width of the flexible circuit board may be widened, and since the surface of the circuit board includes the circuit protection layer made of the ink material, and the ink material has the function of reflecting light, the circuit board itself may perform the function as the reflective film 12 at the widened portion. Preferably, the ratio between the length of the flexible circuit board extending along the circumferential direction of the lamp tube 2 and the circumference of the inner circumferential surface of the lamp tube 2 ranges from 0.3 to 0.5. The flexible circuit soft board can be coated with a circuit protection layer, the circuit protection layer can be made of an ink material and has the function of increasing reflection, the widened flexible circuit soft board extends towards the circumferential direction by taking the light source as a starting point, and the light of the light source can be concentrated by the widened part.
In other embodiments, the glass tube may be coated with a diffusion coating on its entire inner circumference or partially (where the reflective film 12 is present) but in either case, the diffusion coating is preferably applied to the outer surface of the end region of the lamp vessel 1 to provide a stronger adhesion between the burner 3 and the lamp vessel 1.
It should be noted that, in the above embodiments of the present invention, one of the group consisting of the diffusion coating, the diffusion film, the reflective film and the adhesive film can be selected and applied to the optical processing of the light emitted from the light source of the present invention.
Referring to fig. 2, in an embodiment of the present invention, the LED straight lamp further includes an adhesive sheet 4, a lamp panel insulating film 7, and a light source film 8. The lamp panel 2 is adhered to the inner circumferential surface of the lamp tube 1 by an adhesive sheet 4. The adhesive sheet 4 may be a silicone rubber, which is not limited in form, and may be several pieces as shown in the figure, or may be a long piece. The adhesive sheet 4 of various forms, the lamp panel insulating film 7 of various forms and the light source film 8 of various forms can be combined with each other to form different embodiments of the present invention.
The lamp panel insulating film 7 is coated on the surface of the lamp panel 2 facing the light source 202, so that the lamp panel 2 is not exposed, and the lamp panel 2 is isolated from the outside. When gluing, a through hole 71 corresponding to the light source 202 is reserved, and the light source 202 is arranged in the through hole 71. The lamp panel insulating film 7 comprises vinyl polysiloxane, hydrogen polysiloxane and aluminum oxide. The thickness of the lamp panel insulating film 7 ranges from 100 micrometers to 140 micrometers (micrometers). If it is less than 100 μm, it does not function as a sufficient insulation, and if it is more than 140 μm, it causes a waste of materials.
The light source film 8 is coated on the surface of the light source 202. The light source film 8 is transparent to ensure light transmittance. The light source film 8 may be in the form of a granule, a strip, or a sheet after being applied to the surface of the light source 202. The parameters of the light source film 8 include refractive index, thickness, and the like. The allowable range of the refractive index of the light source film 8 is 1.22-1.6, and if the refractive index of the light source film 8 is the root of the shell refractive index of the light source 202, or the refractive index of the light source film 8 is plus or minus 15% of the root of the shell refractive index of the light source 202, the light transmittance is better. The light source housing herein refers to a housing that houses an LED die (or chip). In the present embodiment, the refractive index of the light source film 8 ranges from 1.225 to 1.253. The allowable thickness range of the light source film 8 is 1.1mm to 1.3mm, if the allowable thickness is less than 1.1mm, the light source 202 can not be covered, the effect is not good, and if the allowable thickness is more than 1.3mm, the light transmittance can be reduced, and the material cost can be increased.
During assembly, the light source film 8 is coated on the surface of the light source 202; then coating the lamp panel insulating rubber sheet 7 on the surface of one side of the lamp panel 2; then the light source 202 is fixed on the lamp panel 2; then, the surface of one side of the lamp panel 2 opposite to the light source 202 is adhered and fixed on the inner circumferential surface of the lamp tube 1 through an adhesive sheet 4; finally, the lamp head 3 is fixed to the end region of the lamp tube 1, and the light source 202 is electrically connected to the power source 5. Or as shown in fig. 22, the flexible circuit board 2 is used to climb over the transition area 103 and be welded with the power supply 5 (i.e. pass through the transition area 103 and be welded with the power supply 5), or the lamp panel 2 is electrically connected with the power supply 5 by adopting a traditional wire routing manner, and finally the lamp cap 3 is connected with the strengthened transition area 103 by adopting a manner shown in fig. 5 (the structure shown in fig. 3-4) or fig. 7 (the structure shown in fig. 6), so as to form a complete LED straight-tube lamp.
In this embodiment, the lamp panel 2 is fixed at the inner peripheral surface of the lamp tube 1 through the adhesive sheet 4, so that the lamp panel 2 is attached to the inner peripheral surface of the lamp tube 1, thereby increasing the light emitting angle of the whole LED straight lamp, enlarging the visible angle, and generally enabling the visible angle to exceed 330 degrees by setting like this. Through scribbling lamp plate insulating film 7 at lamp plate 2, scribble insulating light source film 8 on light source 202, realize the insulation treatment to whole lamp plate 2, like this, even fluorescent tube 1 breaks, can not take place the electric shock accident yet, improves the security.
Further, the inner or outer circumferential surface of the lamp tube 1 may be covered with an adhesive film (not shown) for isolating the outside and the inside of the lamp tube 1 after the lamp tube 1 is broken. The present embodiment applies an adhesive film on the inner circumferential surface of the lamp tube 1.
The adhesive film comprises the components of vinyl-terminated silicone oil, hydrogen-containing silicone oil, xylene and calcium carbonate. The xylene is an auxiliary material, and when the adhesive film is coated on the inner circumferential surface of the lamp tube 1 and cured, the xylene is volatilized, and the xylene mainly has the function of adjusting the viscosity, so that the thickness of the adhesive film is adjusted.
In one embodiment, the thickness of the adhesive film ranges from 100 μm to 140 μm. If the thickness of the adhesive film is less than 100 μm, the explosion-proof performance is insufficient, the entire lamp tube is cracked when the glass is broken, and if it exceeds 140 μm, the light transmittance is lowered and the material cost is increased. If the requirements for explosion-proof performance and light transmittance are relaxed, the thickness range of the adhesive film can be widened to 10 μm to 800 μm.
In this embodiment, because the inside adhesive film that scribbles of fluorescent tube, after the glass fluorescent tube is broken, the adhesive film can be in the same place the piece adhesion to can not form the through-hole that link up the fluorescent tube inside and outside, thereby prevent that the user from contacting the electrified body of 1 inside of fluorescent tube, in order to avoid taking place the electric shock accident, the adhesive film that adopts above-mentioned ratio simultaneously still has diffusion light, non-light tight effect, improves the luminous degree of consistency and the luminousness of whole LED straight tube lamp. The adhesive film of this embodiment can be used in combination with the adhesive sheet 4, the lamp panel insulating film 7 and the light source film 8 to form various embodiments of the present invention. It should be noted that, when the lamp panel 2 is a flexible circuit board, the adhesive film may not be provided.
Further, the lamp panel 2 may be any one of a strip-shaped aluminum substrate, an FR4 board, or a flexible circuit board. Since the lamp tube 1 of the present embodiment is a glass lamp tube, if the lamp panel 2 is made of a rigid strip-shaped aluminum substrate or FR4 board, when the lamp tube is broken, for example, cut into two sections, the whole lamp tube can still be kept in a straight tube state, and at this time, a user may think that the LED straight tube lamp can also be used and installed by himself, which is likely to cause an electric shock accident. Because the flexible circuit soft board has the characteristics of strong flexibility and easy bending, and the problem that the flexibility and the bending property of the rigid strip aluminum substrate and the FR4 board are insufficient is solved, the lamp panel 2 of the embodiment adopts the flexible circuit soft board, so that after the lamp tube 1 is broken, the broken lamp tube 1 cannot be supported to keep a straight tube state, so as to inform a user that the LED straight tube lamp cannot be used, and avoid the occurrence of electric shock accidents. Therefore, when the flexible circuit soft board is adopted, the problem of electric shock caused by the broken glass tube can be relieved to a certain extent. The following embodiments are described with flexible circuit board as the lamp panel 2.
Referring to fig. 23, the flexible circuit board as the lamp panel 2 includes a circuit layer 2a with a conductive effect, and the light source 202 is disposed on the circuit layer 2a and electrically connected to a power source through the circuit layer 2 a. Referring to fig. 23, in the present embodiment, the flexible circuit board may further include a dielectric layer 2b stacked on the circuit layer 2a, the areas of the dielectric layer 2b and the circuit layer 2a are equal, and the surface of the circuit layer 2a opposite to the dielectric layer 2b is used for disposing the light source 202. The circuit layer 2a is electrically connected to a power source 5 for passing a dc current. The dielectric layer 2b is bonded to the inner circumferential surface of the lamp tube 1 via an adhesive sheet 4 on the surface opposite to the wiring layer 2 a. The wiring layer 2a may be a metal layer or a power layer with wires (e.g., copper wires) disposed thereon.
In other embodiments, the outer surfaces of the circuit layer 2a and the dielectric layer 2b may be covered with a circuit protection layer, which may be an ink material having functions of solder resistance and reflection increase. Or, the flexible circuit board may be a layer structure, that is, only one circuit layer 2a is formed, and then a circuit protection layer made of the above-mentioned ink material is coated on the surface of the circuit layer 2 a. Either a one-layer wiring layer 2a structure or a two-layer structure (a wiring layer 2a and a dielectric layer 2b) can be used with the circuit protection layer. The circuit protection layer may be disposed on one side of the flexible circuit board, for example, only one side having the light source 202. It should be noted that the flexible circuit board is a one-layer circuit layer structure 2a or a two-layer structure (a circuit layer 2a and a dielectric layer 2b), which is significantly more flexible and flexible than a common three-layer flexible substrate (a dielectric layer sandwiched between two circuit layers), and therefore, the flexible circuit board can be matched with a lamp tube 1 having a special shape (e.g., a non-straight tube lamp) to closely attach the flexible circuit board to the wall of the lamp tube 1. In addition, the flexible circuit soft board is closely attached to the tube wall of the lamp tube, so that the better the configuration is, the smaller the number of layers of the flexible circuit soft board is, the better the heat dissipation effect is, the lower the material cost is, the more environment-friendly is, and the flexibility effect is also improved.
Certainly, the flexible circuit board of the present invention is not limited to one or two layers of circuit boards, and in other embodiments, the flexible circuit board includes a plurality of circuit layers 2a and a plurality of dielectric layers 2b, the dielectric layers 2b and the circuit layers 2a are sequentially stacked in a staggered manner and disposed on a side of the circuit layer 2a opposite to the light source 202, and the light source 202 is disposed on the uppermost layer of the plurality of circuit layers 2a and is electrically connected to the power source through the uppermost layer of the circuit layer 2 a. In other embodiments, the flexible circuit board as the lamp panel 2 has a length greater than that of the lamp tube.
Referring to fig. 48, in an embodiment, a flexible circuit board as a lamp panel 2 includes, in order from top to bottom, a first circuit layer 2a, a dielectric layer 2b and a second circuit layer 2c, the thickness of the second circuit layer 2c is greater than that of the first circuit layer 2a, the length of the lamp panel 2 is greater than that of the lamp tube 1, wherein the lamp panel 2 is not provided with a light source 202 and protrudes from an end region of the lamp tube 1, the first circuit layer 2a and the second circuit layer 2c are electrically connected through two through holes 203 and 204, but the through holes 203 and 204 are not connected to each other to avoid short circuit.
In this way, since the second circuit layer 2c has a larger thickness, the first circuit layer 2a and the dielectric layer 2b can be supported, and the lamp panel 2 is not easily deflected or deformed when attached to the inner wall of the lamp tube 1, thereby improving the manufacturing yield. In addition, first circuit layer 2a and second circuit layer 2c are electric to be linked together for circuit layout on first circuit layer 2a can extend to second circuit layer 2c, makes circuit layout on lamp plate 2 more many units. Moreover, the wiring of original circuit layout becomes the bilayer from the individual layer, and the circuit layer individual layer area on lamp plate 2, the ascending size in width direction promptly can further reduce, lets the batch carry out the lamp plate quantity of solid brilliant can increase, promotes productivity ratio.
Furthermore, the first circuit layer 2a and the second circuit layer 2c, which are not provided with the light source 202 and protrude from the end region of the lamp 1, on the lamp panel 2 can also be directly used to implement the circuit layout of the power module, so that the power module can be directly configured on the flexible circuit board.
Referring to fig. 2, the lamp panel 2 is provided with a plurality of light sources 202, the lamp head 3 is provided with a power supply 5 therein, and the light sources 202 and the power supply 5 are electrically connected through the lamp panel 2. In each embodiment of the invention, the power supply 5 can be a single body (i.e. all power supply modules are integrated in one component), and is arranged in the lamp holder 3 at one end of the lamp tube 1; alternatively, the power supply 5 may be divided into two parts, which are called dual bodies (i.e. all power supply modules are respectively disposed in two parts), and the two parts are respectively disposed in the lamp caps 3 at two ends of the lamp tube. If only one end of the lamp tube 1 is processed by the strengthening part, the power supply is preferably selected as a single body and is arranged in the lamp head 3 corresponding to the strengthened tail end region 101.
The power supply can be formed in multiple ways regardless of single or double bodies, for example, the power supply can be a module after encapsulation molding, specifically, a high-thermal-conductivity silica gel (the thermal conductivity coefficient is more than or equal to 0.7w/m · k) is used, and the power supply module is encapsulated and molded through a mold to obtain the power supply. Or, the power supply may be formed without potting adhesive, and the exposed power supply module is directly placed inside the lamp holder, or the exposed power supply module is wrapped by a conventional heat shrink tube and then placed inside the lamp holder 3. In other words, in the embodiments of the present invention, the power supply 5 may be in the form of a single printed circuit board with a power module as shown in fig. 23, or in the form of a single module as shown in fig. 38.
Referring to fig. 2 in combination with fig. 38, in an embodiment, one end of the power supply 5 has a male plug 51, the other end has a metal pin 52, the end of the lamp panel 2 has a female plug 201, and the lamp cap 3 has a hollow conductive pin 301 for connecting an external power supply. The male plug 51 of the power supply 5 is inserted into the female plug 201 of the lamp panel 2, and the metal pin 52 is inserted into the hollow conductive pin 301 of the lamp holder 3. At this time, the male plug 51 and the female plug 201 are equivalent to an adapter and used for electrically connecting the power supply 5 and the lamp panel 2. After the metal pin 52 is inserted into the hollow conductive pin 301, the hollow conductive pin 301 is impacted by an external punching tool, so that the hollow conductive pin 301 is slightly deformed, the metal pin 52 on the power supply 5 is fixed, and the electrical connection is realized. When the lamp is powered on, the current passes through the hollow conductive pin 301, the metal pin 52, the male plug 51 and the female plug 201 in sequence to reach the lamp panel 2, and then reaches the light source 202 through the lamp panel 2. However, the structure of the power supply 5 is not limited to the modularized form shown in fig. 38. The power supply 5 may be a printed circuit board carrying a power module, and is electrically connected to the lamp panel 2 by the male plug 51 and the female plug 201.
In other embodiments, the electrical connection between the power source 5 and the lamp panel 2 may be any type of conventional wire bonding method instead of the male plug 51 and the female plug 201, i.e. a conventional metal wire is used to electrically connect one end of the metal wire to the power source and the other end of the metal wire to the lamp panel 2. Further, the metal wire can be covered with an insulating sleeve to protect the user from electric shock. However, the wire bonding method may have a problem of breakage during transportation, and the quality is slightly poor.
In other embodiments, the power source 5 and the lamp panel 2 may be directly connected by riveting, soldering, or wire bonding. In accordance with the fixing manner of the lamp panel 2, one side surface of the flexible circuit board is fixed to the inner circumferential surface of the lamp tube 1 by an adhesive sheet 4, and both ends of the flexible circuit board may be fixed to the inner circumferential surface of the lamp tube 1 or not.
If both ends of the flexible circuit board are fixed to the inner circumferential surface of the lamp tube 1, it is preferable to provide the female socket 201 on the flexible circuit board and then insert the male socket 51 of the power supply 5 into the female socket 201 to electrically connect.
If the lamp panel 2 is not fixed on the inner circumferential surface of the lamp tube 1 along the two axial ends of the lamp tube 1, if the lamp panel is connected by the wire, the wire may be broken because the two ends are free and the wire is easily shaken in the subsequent moving process. Therefore, the connection mode of the lamp panel 2 and the power supply 5 is preferably welding. Specifically, referring to fig. 22, the lamp panel 2 may be directly soldered to the output terminal of the power supply 5 after climbing over the transition area 103 of the reinforcement structure, so that the use of a wire is eliminated, and the stability of the product quality is improved. At this time, the lamp panel 2 does not need to be provided with the female plug 201, and the output end of the power supply 5 does not need to be provided with the male plug 51.
As shown in fig. 24, a specific implementation may be to leave a power supply pad a at the output end of the power supply 5, and leave tin on the power supply pad a, so that the thickness of tin on the pad is increased, which is convenient for welding, and correspondingly, leave a light source pad b on the end portion of the lamp panel 2, and weld the power supply pad a at the output end of the power supply 5 and the light source pad b of the lamp panel 2 together. The plane on which the bonding pads are located is defined as the front surface, the connection mode of the lamp panel 2 and the power supply 5 is most stable in butt joint of the bonding pads on the front surfaces, but when welding, a welding pressure head needs to be pressed on the back surface of the lamp panel 2, the welding tin is heated through the lamp panel 2, and the problem of reliability is easy to occur. If a hole is formed in the middle of the light source bonding pad b on the front surface of the lamp panel 2 and the light source bonding pad b is overlaid on the power source bonding pad a on the front surface of the power source 5 to be welded with the front surface facing upwards as shown in fig. 30, the welding pressure head can directly heat and melt the soldering tin, and the practical operation is easy to realize.
As shown in fig. 24, in the above embodiment, most of the flexible circuit board as the lamp panel 2 is fixed on the inner circumferential surface of the lamp 1, only two ends of the flexible circuit board are not fixed on the inner circumferential surface of the lamp 1, the lamp panel 2 not fixed on the inner circumferential surface of the lamp 1 forms a free portion 21, and the lamp panel 2 is fixed on the inner circumferential surface of the lamp 1. The free portion 21 has the pad b described above. During assembly, the free portion 21 is drawn toward the inside of the lamp tube 1 by the end of the free portion 21 welded to the power source 5. It should be noted that, when the flexible circuit board as the lamp panel 2 has a structure in which two circuit layers 2a and 2c sandwich a dielectric layer 2b as shown in fig. 48, the lamp panel 2 is not provided with the light source 202 and protrudes from the end region of the lamp tube 1 to serve as the free portion 21, so that the free portion 21 realizes the connection of the two circuit layers and the circuit layout of the power module.
In this embodiment, when the lamp panel 2 and the power supply 5 are connected, the pads b and a and the surface of the lamp panel where the light source 202 is located face in the same direction, and the through hole e shown in fig. 30 is formed in the pad b on the lamp panel 2, so that the pad b and the pad a are communicated with each other. When the free portion 21 of the lamp panel 2 contracts and deforms toward the inside of the lamp tube 1, the printed circuit board of the power supply 5 and the welding connection portion between the lamp panel 2 have a lateral pulling force on the power supply 5. Further, the soldering connection between the printed circuit board of the power supply 5 and the lamp panel 2 has a downward pull on the power supply 5, compared to the case where the pad a of the power supply 5 and the pad b of the lamp panel 2 face each other. This downward force is applied from the solder in the through hole e to form a more strengthened and firm electrical connection between the power source 5 and the lamp panel 2.
As shown in fig. 25, the light source pads b of the lamp panel 2 are two unconnected pads, which are electrically connected to the positive and negative electrodes of the light source 202, respectively, the size of the pads is about 3.5 × 2mm2, the printed circuit board of the power supply 5 also has corresponding pads, and tin is reserved above the pads for facilitating automatic welding of the welding machine, the thickness of the tin can be 0.1 to 0.7mm, preferably 0.3 to 0.5mm, and most preferably 0.4 mm. An insulation hole c can be arranged between the two bonding pads, so that the two bonding pads are prevented from being electrically short-circuited due to welding of soldering tin in the welding process, and a positioning hole d can be arranged behind the insulation hole c and used for enabling an automatic welding machine to correctly judge the correct position of the light source bonding pad b.
At least one light source bonding pad b of the lamp panel is electrically connected with the anode and the cathode of the light source 202 respectively. In other embodiments, the number of the light source pads b may be more than one, such as 2, 3, 4 or more than 4, in order to achieve compatibility and expandability for subsequent use. When there are only 1 bonding pad, the two corresponding ends of the lamp panel are electrically connected with the power supply respectively to form a loop, and at the moment, an electronic component replacing mode, such as an inductor replacing a capacitor, is used as a current stabilizing component. As shown in fig. 26 to 28, when there are 3 pads, the 3 rd pad can be used as a ground, and when there are 4 pads, the 4 th pad can be used as a signal input terminal. Accordingly, the number of the power source pads a is the same as that of the light source pads b. When the number of the bonding pads is more than 3, the bonding pads can be arranged in a row or in two rows, and the bonding pads are arranged at proper positions according to the size of the accommodating area in practical use as long as the bonding pads are not electrically connected with each other to cause short circuit. In other embodiments, if part of the circuit is fabricated on the flexible circuit board, the number of the light source bonding pads b can be one, and the fewer the number of the bonding pads, the more the process is saved; the more the number of the bonding pads is, the more the electric connection fixation between the flexible circuit soft board and the power output end is enhanced.
As shown in fig. 30, in other embodiments, the inner portion of the light source pad b may have a structure of a solder through hole e, and the diameter of the solder through hole e may be 1 to 2mm, preferably 1.2 to 1.8mm, and most preferably 1.5mm, and if it is too small, the solder tin is not easy to pass through. When power supply 5's power pad a and the light source pad b of lamp plate 2 weld together, the tin of welding usefulness can pass welding perforation e, then pile up and cool off and condense above welding perforation e, form and have the solder ball structure g that is greater than welding perforation e diameter, this solder ball structure g can play like the function of nail, except that seeing through the tin between power supply pad a and the light source pad b fixed, can strengthen electric connection's firm the deciding because of solder ball structure g's effect even more.
As shown in fig. 31 to 32, in other embodiments, when the distance between the soldering through hole e of the light source pad b and the edge of the lamp panel 2 is less than or equal to 1mm, the soldering tin passes through the hole e and is accumulated at the edge above the hole, and the excessive tin flows back downward from the edge of the lamp panel 2 and then is condensed with the tin on the power source pad a, which is configured like a rivet to firmly pin the lamp panel 2 on the circuit board of the power source 5, thereby having a reliable electrical connection function. As shown in fig. 33 and 34, in other embodiments, the solder gap f replaces the solder through hole e, the solder through hole of the pad is at the edge, the solder tin is used to electrically connect and fix the power pad a and the light source pad b through the solder gap f, the tin is easier to climb onto the light source pad b and accumulate around the solder gap f, after cooling and condensation, more tin forms a solder ball with a diameter larger than the solder gap f, and the solder ball structure enhances the fixing capability of the electrical connection structure. In this embodiment, the solder tin functions like a C-nail because of the design of the solder gap.
The structure of the present embodiment can be achieved whether the bonding through hole of the bonding pad is formed first or is punched directly by a bonding ram or a thermal head as shown in fig. 40 during the bonding process. The surface of the welding pressure head contacted with the soldering tin can be a plane, a concave surface, a convex surface or the combination of the planes, the concave surfaces and the convex surfaces; the welding pressure head is used for limiting the surface of an object to be welded, such as the lamp panel 2, to be in a strip shape or a grid shape, the surface in contact with the soldering tin does not completely cover the through hole, the soldering tin can be ensured to penetrate out of the through hole, and when the soldering tin penetrates out of the welding through hole and is accumulated around the welding through hole, the concave part can provide a containing position for the soldering ball. In other embodiments, the flexible circuit board as the lamp panel 2 has a positioning hole, so that the power pad a and the light source pad b can be accurately positioned through the positioning hole during welding.
Referring to fig. 40, in the above embodiment, the light source pad b of the lamp panel 2 and the power source pad a of the power source 5 can be fixed by welding, and the through hole of the pad is formed first or is punched by the welding pressure head 41 during the welding process. As shown in fig. 40, the welding ram 41 may be generally divided into four regions: a pressure welding surface 411, a flow guide groove 412, a tin forming groove 413 and a pressure welding surface 414, wherein the pressure welding surface 411 is a surface which is actually contacted with soldering tin and provides pressure and a heating source during welding, the shape of the pressing surface can be a plane, a concave surface, a convex surface or a combination thereof, the pressing surface 414 is a surface that is actually contacted with the welding object such as the lamp panel 2, which may be strip-shaped or grid-shaped, the bonding surface 411 will not completely cover the holes on the bonding pads, a plurality of arc-shaped concave diversion grooves 412 are arranged on the lower edge part of the middle pressure welding surface 411 of the welding pressure head 41, the main function of the solder paste is to ensure that the solder melted by heating through the soldering surface 411 can flow into the holes or notches through the solder pads from the recessed guiding space, so that the guiding grooves 412 have the function of guiding and stopping (stopper), when the solder is deposited around the surface of the hole or notch, the solder forming groove 413 located below the guiding groove 412 and recessed below the guiding groove 412 is a location for accommodating the solder to be condensed into a solder ball. In addition, a plane slightly lower than the pressure welding surface 411 at the periphery of the forming groove 413 is a pressing surface 414, and the difference between the height and the thickness of the pressing surface 411 is the thickness of the lamp panel 2, and the main function is to firmly press and fix the lamp panel 2 on the printed circuit board of the power supply 5 in the welding process.
Referring to fig. 41, 25 and 40, the lamp panel 2 and the printed circuit board of the power supply 5 also have corresponding pads, and tin is reserved above the pads for facilitating automatic soldering of the soldering machine, generally speaking, the lamp panel 2 can be firmly soldered on the printed circuit board of the power supply 5 if the thickness of tin is preferably 0.3 to 0.5 mm. If the thickness difference between the reserved tin on the two bonding pads is too large as shown in fig. 41, during the soldering process of the soldering pressure head 41, one bonding pad is already contacted with the reserved tin and is heated to melt, and the other reserved tin is melted to the same height as the reserved tin and is then contacted by the soldering pressure head 41 to melt, so that the bonding pad with the lower reserved tin thickness is often not firmly soldered, and the electrical connection between the lamp panel 2 and the printed circuit board of the power supply 5 is further affected. Therefore, the present embodiment applies the principle of dynamic balance to solve this situation. In this embodiment, a linkage mechanism may be provided on the device for welding the pressing head 41, and the initial welding pressing head 41 is a rotatable mechanism, and when the welding pressing head 41 contacts and detects that the pressure values of the reserved tin on the two pads are the same, the pressing process is applied, so as to solve the above-mentioned situation.
In the above embodiment, the soldering process is achieved by the dynamic balance principle of the lamp panel 2 and the printed circuit board of the power supply 5 being fixed and the soldering ram 41 of the soldering machine being rotated, and in other embodiments, as shown in fig. 42, the soldering process is achieved by the dynamic balance principle of the lamp panel 2 being rotated and the soldering ram 41 being fixed. Firstly, the printed circuit boards of the lamp panel 2 and the power supply 5 are placed in a carrier device (or called a welding carrier) 60, and the carrier device 60 includes a lamp panel carrier (or called a rotating platform) 61 for carrying the printed circuit boards of the lamp panel 2 and the power supply 5, and a carrier bracket 62 for carrying the lamp panel carrier 61. The lamp panel carrier 61 includes a rotation shaft 63 and two elastic components 64 respectively disposed on two sides of the rotation shaft for keeping the lamp panel carrier 61 in a horizontal state when the lamp panel carrier 61 is empty. In the present embodiment, the elastic elements 64 are springs, and one end of each spring is disposed on the carrier support 62 as a pivot, when the lamp panel 2 with two sides of reserved tin with different thicknesses shown in fig. 42 is placed on the lamp panel carrier 61, the lamp panel carrier 61 is driven by the rotating shaft 63 to rotate, until the welding pressure head 41 detects that the pressures of the two sides of reserved tin are equal, the welding process is started, as shown in fig. 43, at this time, a pulling force and a pressure are respectively generated behind the elastic elements 64 on the two sides of the rotating shaft, after the welding process is completed, the driving force of the rotating shaft 63 is removed, and the lamp panel carrier 61 returns to the original horizontal state by the restoring force of the elastic elements 64 on the two sides of the rotating shaft 63.
Of course, the lamp panel carrier 61 of the present embodiment may also be achieved by other mechanisms, instead of requiring the rotating shaft 63 and the elastic component 64, for example, a driving motor, an active rotating mechanism, etc. are built in the lamp panel carrier 61, and at this time, the carrier support 62 (for fixing the elastic component 64) is also not an essential component, and the variation of the welding process achieved by using the principle of dynamic balance to drive the lamp panel 2 to rotate does not depart from the scope of the present invention, and will not be described in detail below.
Referring to fig. 35 and 36, in another embodiment, the lamp panel 2 and the power supply 5 fixed by soldering may be replaced by a circuit board assembly 25 mounted with a power supply module 250. The circuit board assembly 25 has a long circuit board 251 and a short circuit board 253, the long circuit board 251 and the short circuit board 253 are adhered to each other and fixed by adhesion, and the short circuit board 253 is located near the periphery of the long circuit board 251. The short circuit board 253 has a power module 25 integrally forming a power source. The short circuit board 253 is made of a hard material and the longer circuit board 251 is made of a hard material, so as to support the power module 250.
The long circuit board 251 may be the flexible circuit board or the flexible substrate as the lamp panel 2, and has the circuit layer 2a shown in fig. 23. The circuit layer 2a of the lamp panel 2 and the power module 250 may be electrically connected in different manners according to actual use conditions. As shown in fig. 35, the power module 250 and the circuit layer 2a on the long circuit board 251, which is electrically connected to the power module 250, are both located on the same side of the short circuit board 253, and the power module 250 is directly electrically connected to the long circuit board 251. As shown in fig. 36, the power module 250 and the circuit layer 2a on the long circuit board 251, which is electrically connected to the power module 250, are respectively located at two sides of the short circuit board 253, and the power module 250 penetrates through the short circuit board 253 and is electrically connected to the circuit layer 2a of the lamp panel 2.
As shown in fig. 35, in an embodiment, the circuit board assembly 25 omits the case that the lamp panel 2 and the power supply 5 are fixed by soldering in the foregoing embodiments, but first the long circuit board 251 and the short circuit board 253 are fixed by bonding, and then the power supply module 250 is electrically connected to the circuit layer 2a of the lamp panel 2. The lamp panel 2 is not limited to the one-layer or two-layer circuit board, and may further include another circuit layer 2c as shown in fig. 48. The light source 202 is provided on the wiring layer 2a, and is electrically connected to the power source 5 through the wiring layer 2 a. As shown in fig. 36, in another embodiment, the circuit board assembly 25 has a long circuit board 251 and a short circuit board 253, the long circuit board 251 can be a flexible circuit board or a flexible substrate of the lamp panel 2, the lamp panel 2 includes a circuit layer 2a and a dielectric layer 2b, the dielectric layer 2b and the short circuit board 253 are fixedly connected in a splicing manner, and then the circuit layer 2a is attached to the dielectric layer 2b and extends to the short circuit board 253. The above embodiments do not depart from the scope of the application of the circuit board assembly 25 of the present invention.
In the above embodiments, the length of the short circuit board 253 is about 15mm to 40 mm, preferably 19 mm to 36 mm, and the length of the long circuit board 251 may be 800 mm to 2800 mm, preferably 1200 mm to 2400 mm. The ratio of short circuit board 253 to long circuit board 251 may be 1:20 to 1: 200.
In addition, in the above-mentioned embodiment, when the lamp panel 2 and the power supply 5 are fixed by welding, the end of the lamp panel 2 is not fixed on the inner circumferential surface of the lamp 1, and the power supply 5 cannot be safely and fixedly supported, and in other embodiments, if the power supply 5 needs to be separately fixed in the socket at the end region of the lamp 1, the socket is relatively long and the effective light emitting area of the lamp 1 is compressed.
Referring to fig. 39, in an embodiment, the lamp panel is an aluminum hard circuit board 22, and since the end portion of the lamp panel can be fixed to the end region of the lamp tube 1, and the power source 5 is welded and fixed above the end portion of the hard circuit board 22 in a manner of being perpendicular to the hard circuit board 22, the implementation of the welding process is facilitated, and the lamp head 3 does not need to have a space enough to bear the total length of the power source 5, so that the length can be shortened, and the effective light emitting area of the lamp tube can be increased. In addition, in the above embodiment, in addition to the power module, a welding metal wire is required to be additionally installed on the power source 5 to electrically connect with the hollow conductive pin 301 of the lamp cap 3. In this embodiment, the conductive pin 53 can be directly used on the power supply 5 as a power module to electrically connect with the lamp cap 3, and no additional soldering wire is needed, which is more beneficial to the simplification of the manufacturing process.
Referring to fig. 37, in the embodiments of the present invention, the light source 202 may be further modified to include a bracket 202b having a groove 202a, and an LED die (or chip) 18 disposed in the groove 202 a. The groove 202a may be one or more. The groove 202a is filled with phosphor powder, and the phosphor powder covers the LED die (or chip) 18 to perform a light color conversion function. Specifically, compared to the square shape with the ratio of the length to the width of the conventional LED die (or chip) being about 1:1, the ratio of the length to the width of the LED die (or chip) 18 used in the embodiments of the present invention may be in the range of 2:1 to 10:1, and the ratio of the length to the width of the LED die (or chip) 18 used in the embodiments of the present invention is preferably in the range of 2.5:1 to 5:1, and more preferably in the range of 3:1 to 4.5:1, so that the length direction of the LED die (or chip) 18 is arranged along the length direction of the lamp tube 1, thereby improving the problems of the average current density of the LED die (or chip) 18 and the light emitting shape of the whole lamp tube 1.
Referring to fig. 37 again, the bracket 202b of at least one light source 202 has a first sidewall 15 arranged along the length direction of the lamp and extending along the width direction of the lamp, and a second sidewall 16 arranged along the width direction of the lamp and extending along the length direction of the lamp, wherein the first sidewall 15 is lower than the second sidewall 16, and the two first sidewalls 15 and the two second sidewalls surround the groove 202 a. The first sidewall 15 "extends along the width direction of the lamp tube 1", and it is only required that the extending trend is substantially the same as the width direction of the lamp tube 1, and it is not required to be strictly parallel to the width direction of the lamp tube 1, for example, the first sidewall 15 may have a slight angle difference with the width direction of the lamp tube 1, or the first sidewall 15 may also have various shapes such as a zigzag shape, an arc shape, and a wave shape; the second sidewall 16 "extends along the length direction of the lamp tube 1", and is not required to be strictly parallel to the length direction of the lamp tube 1 as long as the extending trend is substantially the same as the length direction of the lamp tube 1, for example, the second sidewall 16 may have a slight angle difference with the length direction of the lamp tube 1, or the second sidewall 16 may have various shapes such as a zigzag shape, an arc shape, and a wave shape. In various embodiments of the present invention, other arrangements or extensions of the sidewalls of the rack with one or more light sources in the row of light sources are also possible.
In the embodiments of the present invention, the first sidewall 15 is lower than the second sidewall 16, so that the light can easily spread out over the bracket 202b, and through the design of the space with proper density, the uncomfortable feeling of the particles can not be generated in the Y direction. On the other hand, when the user views the tube from the side of the tube, for example, in the X direction, the second sidewall 16 can block the user's line of sight from directly seeing the light source 202 to reduce discomfort from particles.
Referring again to fig. 37, in various embodiments of the present invention, the inner surface 15a of the first sidewall 15 may be sloped such that light rays are more easily emitted through the slope than if the inner surface 15a were perpendicular to the bottom wall. The slope may comprise a plane or a curved surface, or the slope may be a combination of a plane and a curved surface. When a flat surface is used, the slope of the flat surface is between about 30 degrees and about 60 degrees. That is, the angle between the slope of the planar form and the bottom wall of the groove 202a ranges from 120 degrees to 150 degrees. Preferably, the slope of the flat surface is between about 15 degrees and about 75 degrees, that is, the angle between the slope of the flat surface and the bottom wall of the recess 202a is in the range of 105 degrees to 165 degrees.
In the embodiments of the present invention, there are a plurality of light sources 202 in one lamp tube 1, and the plurality of light sources 202 may be arranged in one or more rows, and each row of light sources 202 is arranged along the axial direction (Y direction) of the lamp tube 1. When the plurality of light sources 202 are arranged in a row along the length direction of the lamp tube, all the second sidewalls 16 of the brackets 202b of the plurality of light sources 202 located on the same side along the width direction of the lamp tube are on the same straight line, i.e. the second sidewalls 16 on the same side form a wall-like structure, so as to block the user from directly seeing the light sources 202 from the sight. When the plurality of light sources 202 are arranged in a plurality of rows along the length direction of the lamp tube and arranged along the axial direction (Y direction) of the lamp tube 1, only the support 202b of the outermost two rows of light sources 202 (i.e. two rows of light sources 202 adjacent to the wall of the lamp tube) has two first side walls 15 arranged along the length direction (Y direction) of the lamp tube 1 and two second side walls 16 arranged along the width direction (X direction) of the lamp tube 1, that is, the support 202b of the outermost two rows of light sources 202 has the first side wall 15 extending along the width direction (X direction) of the lamp tube 1 and the second side wall 16 extending along the length direction (Y direction) of the lamp tube 1, and the arrangement direction of the support 202b of the other rows of light sources 202 between the two rows of light sources 202 is not limited, for example, the support 202b of the middle row (third row) of light sources 202, and each support 202b may have two first side walls 15 arranged along the length direction (Y direction) of the lamp tube 1 and the width direction (X direction) of the lamp tube 1 ) The two second sidewalls 16 arranged, or each of the brackets 202b, may have two first sidewalls 15 arranged along the width direction (X direction) of the lamp 1 and two second sidewalls 16 arranged along the length direction (Y direction) of the lamp 1, or may be staggered, etc., as long as the second sidewalls 16 of the brackets 202b in the outermost two columns of light sources 202 may block the user's view from directly seeing the light sources 202 when the user views the lamp from the side of the lamp, for example, along the X direction, thereby reducing the discomfort of the particles. For the two outermost rows of light sources, other arrangements or extensions of the side walls of the holder with one or more light sources therein are also permissible.
In summary, when the plurality of light sources 202 are arranged in a row along the length direction of the tube, the second sidewalls 16 of the brackets 202b of all the light sources 202 need to be respectively located on the same straight line, i.e. the second sidewalls 16 on the same side form a structure similar to a wall, so as to block the user from directly seeing the light sources 202. When the plurality of light sources 202 are arranged in a plurality of rows along the length direction of the lamp tube, the outermost second sidewalls 16 of the brackets 202b of all the light sources 202 in the two rows at the outermost side along the width direction of the lamp tube need to be respectively located on two straight lines to form a structure similar to a double-faced wall so as to block the sight of a user from directly seeing the light sources 202; the arrangement and extension of the side walls of the middle row or rows of light sources 202 are not required, and may be the same as the outermost two rows of light sources 202, or may adopt other different arrangements.
The LED straight tube lamp of the present invention is realized as described above in the embodiments. It should be noted that, in each embodiment, for the same LED straight lamp, among the features of "the lamp tube has a reinforcing portion structure", "the lamp panel adopts a flexible circuit soft board", "the inner circumferential surface of the lamp tube is coated with an adhesive film", "the inner circumferential surface of the lamp tube is coated with a diffusion film", "the light source is covered with a diffusion film", "the inner wall of the lamp tube is coated with a reflective film", "the lamp cap is a lamp cap including a heat conducting portion", "the lamp cap is a lamp cap including a magnetic conductive metal sheet", "the light source has a support", "the power supply has an assembly of long and short circuit boards", and the like, one or more technical features may be included.
In addition, the content related to the "lamp tube has the reinforcement structure" may be selected from one or a combination of related technical features in the embodiments, wherein the content related to the "lamp panel adopts the flexible circuit board" may be selected from one or a combination of related technical features in the embodiments, wherein the content related to the "lamp tube inner circumferential surface coated with the adhesive film" may be selected from one or a combination of related technical features in the embodiments, wherein the content related to the "lamp tube inner circumferential surface coated with the diffusion film" may be selected from one or a combination of related technical features in the embodiments, wherein the content related to the "light source housing covered with the diffusion film" may be selected from one or a combination of related technical features in the embodiments, wherein the content related to the "lamp tube inner wall coated with the reflective film" may be selected from one or a combination of related technical features in the embodiments, the content of "the base is a base including a heat conducting portion" may be selected from one or a combination of related technical features in the embodiments, the content of "the base is a base including a magnetic conductive metal sheet" may be selected from one or a combination of related technical features in the embodiments, and the content of "the light source has a bracket" may be selected from one or a combination of related technical features in the embodiments.
For example, in the structure of the reinforced portion of the lamp tube, the lamp tube includes a body region and end regions respectively located at two ends of the body region, a transition region is arranged between the end regions and the body region, two ends of the transition region are both arc-shaped, the end regions are respectively sleeved with a lamp cap, the outer diameter of at least one of the end regions is smaller than the outer diameter of the body region, and the outer diameter of the lamp cap corresponding to the lamp cap whose outer diameter is smaller than the outer diameter of the body region is equal to the outer diameter of the body region.
For example, in the case that the lamp panel is a flexible circuit flexible board, the flexible circuit flexible board is connected to the output terminal of the power supply by wire bonding or the flexible circuit flexible board is welded to the output terminal of the power supply. In addition, the flexible circuit soft board comprises a dielectric layer and a circuit layer which are stacked; the flexible circuit soft board can be coated with a circuit protection layer made of an ink material on the surface, and the function of the reflecting film is realized by increasing the width along the circumferential direction.
For example, in the case where the diffusion film is coated on the inner peripheral surface of the lamp tube, the diffusion coating is composed of at least one of calcium carbonate, calcium halophosphate, and alumina, a thickener, and ceramic activated carbon. In addition, the diffusion film can also be a diffusion film and covers the light source.
For example, in the case where the inner wall of the lamp tube is coated with a reflective film, the light source may be disposed on the reflective film, in the opening of the reflective film, or at the side of the reflective film.
For example, in a lamp cap design, the lamp cap may include an insulating tube and a heat conducting portion, wherein the hot melt adhesive may fill a portion of the accommodating space or fill the accommodating space. Or the lamp cap comprises an insulating tube and a magnetic conductive metal part, wherein the magnetic conductive metal part can be circular or non-circular, and the contact area with the insulating tube can be reduced by arranging a hole or an indentation. In addition, the support part and the protruding part are arranged in the insulating tube to strengthen the support of the magnetic conduction metal part and reduce the contact area between the magnetic conduction metal part and the insulating tube.
For example, in a light source design, the light source includes a support having a recess, and an LED die disposed in the recess; the bracket is provided with a first side wall arranged along the length direction of the lamp tube and a second side wall arranged along the width direction of the lamp tube, and the first side wall is lower than the second side wall.
For example, in the power supply design, the assembly of the long and short circuit boards has a long circuit board and a short circuit board, the long circuit board and the short circuit board are attached to each other and fixed by means of adhesion, and the short circuit board is located near the periphery of the long circuit board. The short circuit board is provided with a power module which integrally forms a power supply.
That is, the above features can be arbitrarily arranged and combined, and used for the improvement of the LED straight tube lamp. Although the present invention is disclosed above, the present invention is not limited thereto. Various changes and modifications may be effected therein by one skilled in the art without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (8)
1. A method for connecting a lamp tube and a lamp cap of an LED straight tube lamp is characterized by comprising the following steps: coating a hot melt adhesive on the inner surface of the lamp cap; sleeving the lamp holder at the end part of the lamp tube, wherein the lamp tube comprises a lamp panel provided with an LED light source; heating the hot melt adhesive to enable the hot melt adhesive to be filled between the inner surface of the lamp holder and the outer surface of the end part of the lamp tube after being heated and expanded; the lamp holder includes an insulating tube and a heat conduction portion fixedly arranged on the outer peripheral surface of the insulating tube, the lamp tube includes a body region and end regions respectively arranged at two ends of the body region, the axial length of the end region inserted into the lamp holder accounts for between one third and two thirds of the axial length of the heat conduction portion, the heat conduction portion includes a protruding part extending out of the insulating tube, and the step of coating the hot melt adhesive on the inner surface of the lamp holder further includes the following steps: coating the hot melt adhesive on the inner surface of the protruding portion of the heat conducting portion; the step of heating and expanding the hot melt adhesive by external heating equipment further comprises the following steps: the heat conducting part is heated through external heating equipment and conducts heat to the hot melt adhesive, and the hot melt adhesive absorbs the heat and then expands; the lamp tube comprises a body area and tail end areas which are respectively positioned at two ends of the body area, a transition area is arranged between the tail end areas and the body area, the outer diameter of the tail end areas is smaller than that of the body area, and the lamp cap is sleeved outside the tail end areas through the hot melt adhesive.
2. The method of claim 1, wherein the hot melt adhesive is heated to a temperature of 200 to 250 degrees celsius.
3. The method of claim 1, wherein the insulating tube is a plastic tube.
4. The method of claim 1 or 2, wherein the hot melt adhesive is cured immediately after expanding upon heating.
5. A method according to claim 1 or 2, characterized in that an external heating device is fixed in a default position, and the lamp head is moved together with the lamp tube and into the external heating device.
6. The method of claim 1 or 2, wherein the lamp head is fixed in a default position with the lamp tube, and an external heating device is moved to cover the lamp head.
7. The method of claim 1 or 2, wherein said hot melt adhesive comprises, as essential components: phenolic resin 2127#, shellac, rosin, calcite powder, zinc oxide, high magnetic conductivity material powder and ethanol, wherein the high magnetic conductivity material powder accounts for 10-50% of the weight of the hot melt adhesive, and the high magnetic conductivity material powder is one of mixtures composed of iron, nickel, cobalt or alloys thereof.
8. The method as recited in claim 2, wherein when said hot melt adhesive is heated to a temperature of 200 ℃ and 250 ℃, the volume of said hot melt adhesive expands 1 to 1.3 times compared to that at room temperature.
Applications Claiming Priority (19)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2014105088998 | 2014-09-28 | ||
| CN2014105076609 | 2014-09-28 | ||
| CN201410508899 | 2014-09-28 | ||
| CN201410507660 | 2014-09-28 | ||
| CN201410623355 | 2014-11-06 | ||
| CN2014106233556 | 2014-11-06 | ||
| CN201410734425 | 2014-12-05 | ||
| CN2014107344255 | 2014-12-05 | ||
| CN201510136796 | 2015-03-27 | ||
| CN2015101367968 | 2015-03-27 | ||
| CN2015102591513 | 2015-05-19 | ||
| CN201510259151 | 2015-05-19 | ||
| CN2015104829441 | 2015-08-07 | ||
| CN201510482944 | 2015-08-07 | ||
| CN2015104834755 | 2015-08-08 | ||
| CN201510483475 | 2015-08-08 | ||
| CN2015105555434 | 2015-09-02 | ||
| CN201510555543 | 2015-09-02 | ||
| CN201510624523.8A CN105465644B (en) | 2014-09-28 | 2015-09-28 | Lamp tube of LED straight lamp and lamp cap connecting method |
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| CN201510624523.8A Division CN105465644B (en) | 2014-09-28 | 2015-09-28 | Lamp tube of LED straight lamp and lamp cap connecting method |
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| CN107339300A CN107339300A (en) | 2017-11-10 |
| CN107339300B true CN107339300B (en) | 2022-02-08 |
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