LED lamp heat sink and manufacturing method thereof

Abstract

An LED lamp heat sink and a manufacturing method thereof, relating to a heat sink and a manufacturing method thereof. An outer cylinder and an inner cylinder are bonded and fixed by an upper sealing ring and a lower sealing plate, mercury is injected between the outer cylinder and the inner cylinder, a plurality of vertical notches 1 are provided at the upper end of the outer cylinder wall, a heat sink fin is inserted into the plurality of vertical notches 1 by the upper end of the outer cylinder, each vertical notch 1 is sealed by a sealant, and the closed ends of the plurality of ∏-shaped pleated bodies located on the inner side of the heat sink fin are bonded and fixed to the corresponding positions of the inner wall of the outer cylinder, a lamp holder is bonded and fixed inside the inner cylinder, a plurality of vertical notches 2 are provided in the middle of the inner cylinder wall, a plurality of high thermal conductivity rectangular metal sheets are respectively inserted into the corresponding vertical notches 2 in the middle, each vertical notch 2 is sealed by a sealant, and the outer end of each high thermal conductivity rectangular metal sheet extends between the outer cylinder and the inner cylinder, and the inner end is tightly attached to the lamp holder. Mercury is used for heat conduction transition, and heat dissipation is stable and efficient.

Description

Technical Field

[0001] The invention relates to a heat sink and a manufacturing method thereof, in particular to a heat sink for an LED lamp and a manufacturing method thereof. Background Art

[0002] In the field of lighting, LED lamps have basically replaced traditional tungsten filament lamps because of their advantages over traditional tungsten filament lamps, such as energy saving and environmental protection and relatively long service life.

[0003] As we all know, LED lamps will generate a lot of heat when in use, especially high-power LED lamps. If the heat generated cannot be discharged in time, it will affect the lighting effect of the LED lamp and even shorten its service life. Therefore, the role of LED lamp heat sinks is particularly important.

[0004] At present, there are two common types of LED lamp heat sinks. One is a one-piece heat sink formed by direct die casting. Due to the production process, the heat sink has thicker heat sink fins and weaker heat dissipation capacity. The other is a heat sink formed by splicing and assembling thin-walled metal parts formed by extrusion. The heat sink has thinner heat sink fins and stronger heat dissipation capacity, but because the thin-walled metal parts are prone to deformation, poor contact is likely to occur during assembly, resulting in failure of heat conduction in some positions.

[0005] Therefore, there is an urgent need for an LED lamp heat sink that is simple and reasonable to manufacture and has stable and effective thermal conduction. Summary of the invention

[0006] In order to solve the deficiencies in the background technology, the present invention provides an LED lamp heat sink and a manufacturing method thereof.

[0007] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: an LED lamp heat sink, comprising a main body mounting shell, a lamp holder, heat dissipation fins and a plurality of highly thermally conductive rectangular metal sheets, the main body mounting shell comprising an outer cylinder and an inner cylinder coaxially spaced and sleeved, the upper and lower ends of the outer cylinder and the inner cylinder being bonded and fixed by an upper sealing ring and a lower sealing plate respectively, mercury is injected between the outer cylinder and the inner cylinder, and the liquid level of the mercury is lower than the upper end surfaces of the outer cylinder and the inner cylinder, a plurality of vertical notches are evenly arranged on the upper end of the outer cylinder wall along the circumferential direction, the heat dissipation fins are made of metal sheets alternately squeezed and wrinkled to enclose a cylindrical shape, the heat dissipation fins are alternately wrinkled along the circumferential direction into a plurality of ∏-shaped wrinkled bodies, and the plurality of ∏-shaped wrinkled bodies are all radially along the heat dissipation fins. The heat dissipation fins are inserted into the plurality of vertical notches 1 by the upper end of the outer cylinder, and each vertical notch 1 is closed by sealant. The closed ends of the plurality of ∏-shaped corrugated bodies on the inner side of the heat dissipation fins are bonded and fixed to the corresponding positions of the inner wall of the outer cylinder. The lamp holder is bonded and fixed to the inside of the inner cylinder, and a plurality of vertical notches 2 are evenly arranged in the middle of the inner cylinder wall along the circumferential direction. The middle of the plurality of high thermal conductivity rectangular metal sheets are respectively inserted into the corresponding vertical notches 2 along the radial direction of the inner cylinder, and each vertical notch 2 is closed by sealant. The outer end of each high thermal conductivity rectangular metal sheet extends between the outer cylinder and the inner cylinder, and the inner end of each high thermal conductivity rectangular metal sheet is tightly attached to the lamp holder.

[0008] A method for manufacturing a heat sink for an LED lamp according to the present invention comprises the following steps:

[0009] Step 1: Take the outer cylinder and cut a plurality of vertical notches 1 evenly along the circumferential direction at the upper end of its cylinder wall, and take the inner cylinder and cut a plurality of vertical notches 2 evenly along the circumferential direction at the middle of its cylinder wall;

[0010] Step 2: Take a metal sheet and extrude the folds alternately and enclose them to form a heat dissipation fin, the heat dissipation fin is matched with the multiple vertical notches of the outer cylinder, and multiple heat dissipation holes are uniformly melted in the ∏-shaped fold body on the outside of the heat dissipation fin;

[0011] Step 3: Apply adhesive to the closed end of the ∏-shaped pleated body on the inner side of the heat dissipating fin and the side corresponding to the inner wall of the outer cylinder, insert the heat dissipating fin from the upper end of the outer cylinder into the plurality of vertical notches 1, squeeze the closed end of the ∏-shaped pleated body on the inner side of the heat dissipating fin to make it firmly bonded to the inner wall of the outer cylinder, and then seal each vertical notch 1 with sealant;

[0012] Step 4: The lamp holder is fixed inside the inner cylinder by bonding with thermal conductive glue, and it is noted that the positions of the multiple vertical notches 2 of the inner cylinder are avoided. Then, multiple high thermal conductivity rectangular metal sheets are inserted into the corresponding vertical notches 2 from the outside of the inner cylinder in sequence, and the inner end of each high thermal conductivity rectangular metal sheet is tightly attached to the lamp holder. Then, the middle of each high thermal conductivity rectangular metal sheet is sealed and bonded with the corresponding vertical notch 2 by using sealant;

[0013] Step 5: Insert the inner cylinder into the outer cylinder and keep the coaxial position, glue and fix the lower sealing plate to the lower ends of the outer cylinder and the inner cylinder by adhesive, completely seal the lower ends of the outer cylinder and the inner cylinder, then inject mercury between the outer cylinder and the inner cylinder, and finally glue and fix the upper sealing ring to the upper ends of the outer cylinder and the inner cylinder by adhesive, and seal the annular spacing area between the upper ends of the outer cylinder and the inner cylinder.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: the main body mounting shell, the high thermal conductivity rectangular metal sheet and the heat dissipation fins of the present invention are simple in appearance and easy to manufacture, and have a reasonable structure and are easy to install. Mercury is filled in the main body mounting shell, and the mercury is liquid and has a strong heat conduction capacity. The high thermal conductivity rectangular metal sheet is tightly attached to the lamp holder for heat conduction, and at the same time, the high thermal conductivity rectangular metal sheet and the heat dissipation fins are heat-conducted through mercury, which effectively avoids the poor contact between the lamp holder and the heat dissipation fins, which is the most critical part in the heat dissipation process, resulting in heat conduction failure, and the heat dissipation is more stable and efficient. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is an axonometric diagram of the overall structure of the LED lamp heat sink of the present invention;

[0016] Figure 2 It is an axonometric diagram of the split structure of the main body installation shell of the present invention;

[0017] Figure 3 It is an axonometric view of the assembly structure of the main body mounting shell and the heat sink fins of the present invention. For ease of viewing, the upper sealing ring of the main body mounting shell is not shown;

[0018] Figure 4 is an axonometric view of the heat sink fin of the present invention;

[0019] Figure 5 It is an axonometric view of the assembly structure of the main body mounting shell, the lamp holder and the high thermal conductivity rectangular metal sheet of the present invention. For the convenience of viewing, the upper sealing ring of the main body mounting shell is not shown. DETAILED DESCRIPTION

[0020] The technical solution of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0021] Specific implementation method 1: Figure 1~Figure 5 As shown, the present invention discloses a heat sink for an LED lamp, comprising a main body mounting shell, a lamp holder 5, heat dissipation fins 6 and a plurality of highly thermally conductive rectangular metal sheets 7, wherein the main body mounting shell comprises an outer cylinder 1 and an inner cylinder 2 which are coaxially spaced and sleeved, wherein the upper and lower ends of the outer cylinder 1 and the inner cylinder 2 are respectively bonded and fixed by an upper sealing ring 3 and a lower sealing plate 4, wherein mercury is injected between the outer cylinder 1 and the inner cylinder 2, and the liquid level of the mercury is lower than the upper end surfaces of the outer cylinder 1 and the inner cylinder 2, and a plurality of vertical notches 1-1 are uniformly arranged at the upper end of the cylinder wall of the outer cylinder 1 along the circumferential direction, wherein the heat dissipation fins 6 are alternately squeezed and wrinkled by metal sheets and enclosed into a cylindrical shape, wherein the heat dissipation fins 6 are alternately wrinkled along the circumferential direction into a plurality of ∏-shaped wrinkled bodies 6-1, wherein the plurality of ∏-shaped wrinkled bodies 6-1 are radially arranged along the heat dissipation fins 6, and each adjacent two ∏ ∏-shaped pleated bodies 6-1 have opening directions opposite to each other, and the heat dissipation fins 6 are inserted into the multiple vertical notches 1-1 by the upper end of the outer cylinder 1, and each vertical notch 1-1 is closed by a sealant, and the closed ends of the multiple ∏-shaped pleated bodies 6-1 on the inner side of the heat dissipation fins 6 are bonded and fixed to the corresponding positions of the inner wall of the outer cylinder 1, and the lamp holder 5 is bonded and fixed inside the inner cylinder 2, and a plurality of vertical notches 2-1 are evenly arranged in the middle of the wall of the inner cylinder 2 along the circumferential direction, and the middle of the multiple high thermal conductivity rectangular metal sheets 7 are respectively inserted into the corresponding vertical notches 2-1 along the radial direction of the inner cylinder 2, and each vertical notch 2-1 is closed by a sealant, and the outer end of each high thermal conductivity rectangular metal sheet 7 extends between the outer cylinder 1 and the inner cylinder 2, and the inner end of each high thermal conductivity rectangular metal sheet 7 is tightly attached to the lamp holder 5.

[0022] Specific implementation method 2: Figure 4 As shown, this embodiment is a further description of the specific embodiment 1, and the heat dissipation fins 6 are located on the outer side of the multiple ∏-shaped folded bodies 6-1 and are evenly provided with multiple heat dissipation holes 8.

[0023] Specific implementation method three: Figure 3 , 5 As shown, this embodiment is a further explanation of the specific embodiment one or the specific embodiment two, and the lamp holder 5 and the inner cylinder 2 and the closed ends of the multiple ∏-shaped folds 6-1 on the inner side of the heat dissipation fins 6 are bonded and fixed to the corresponding positions of the inner wall of the outer cylinder 1 by using thermal conductive adhesive.

[0024] Specific implementation method four: Figure 4 , 5 As shown, this embodiment is a further explanation of the specific embodiment three, and the heat sink fins 6 and multiple high thermal conductivity rectangular metal sheets 7 are all made of aluminum or aluminum-copper alloy materials, wherein the high thermal conductivity rectangular metal sheets 7 have a thickness of 2~4mm, and the heat sink fins 6 have a thickness of 0.5~1mm.

[0025] Specific implementation method five: Figure 2 As shown, this embodiment is a further description of the specific embodiment 1, and the liquid level of mercury is 1-2 cm lower than the upper end surfaces of the outer cylinder 1 and the inner cylinder 2.

[0026] Specific implementation method six: Figure 1~Figure 5 As shown, this embodiment discloses a method for manufacturing a heat sink for an LED lamp as described in a fourth specific embodiment, and the manufacturing method comprises the following steps:

[0027] Step 1: Take the outer cylinder 1 and cut a plurality of vertical notches 1-1 evenly along the circumferential direction at the upper end of its cylinder wall; take the inner cylinder 2 and cut a plurality of vertical notches 2-1 evenly along the circumferential direction in the middle of its cylinder wall;

[0028] Step 2: Take a metal sheet and extrude the folds alternately and enclose them to form a heat dissipation fin 6, the heat dissipation fin 6 is matched with the multiple vertical notches 1-1 of the outer cylinder 1, and multiple heat dissipation holes 8 are uniformly melted in the ∏-shaped fold body 6-1 on the outside of the heat dissipation fin 6;

[0029] Step 3: Apply adhesive to the closed end of the ∏-shaped pleated body 6-1 on the inner side of the heat dissipating fin 6 and the side corresponding to the inner wall of the outer cylinder 1, insert the heat dissipating fin 6 from the upper end of the outer cylinder 1 into the plurality of vertical notches 1-1, squeeze the closed end of the ∏-shaped pleated body 6-1 on the inner side of the heat dissipating fin 6 to make it firmly bonded to the inner wall of the outer cylinder 1, and then seal each vertical notch 1-1 with sealant;

[0030] Step 4: The lamp holder 5 is fixed inside the inner cylinder 2 by bonding with thermal conductive adhesive, and it is noted that the positions of the multiple vertical notches 2-1 of the inner cylinder 2 are avoided. Then, multiple high thermal conductivity rectangular metal sheets 7 are sequentially inserted from the outside of the inner cylinder 2 into the corresponding vertical notches 2-1, and the inner end of each high thermal conductivity rectangular metal sheet 7 is tightly attached to the lamp holder 5. Then, the middle of each high thermal conductivity rectangular metal sheet 7 is sealed and bonded to the corresponding vertical notch 2-1 by using sealant;

[0031] Step 5: Insert the inner cylinder 2 into the outer cylinder 1 and keep the coaxial position, glue and fix the lower sealing plate 4 to the lower ends of the outer cylinder 1 and the inner cylinder 2 by adhesive, and completely seal the lower ends of the outer cylinder 1 and the inner cylinder 2, then inject mercury between the outer cylinder 1 and the inner cylinder 2, and finally glue and fix the upper sealing ring 3 to the upper ends of the outer cylinder 1 and the inner cylinder 2 by adhesive, and seal the annular spacing area between the upper ends of the outer cylinder 1 and the inner cylinder 2.

[0032] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other forms of assembly without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-restrictive, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations within the meaning and range of equivalents of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

[0033] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A heat sink for an LED lamp, characterized in that: The invention comprises a main body mounting shell, a lamp holder (5), a heat dissipation fin (6) and a plurality of highly thermally conductive rectangular metal sheets (7), wherein the main body mounting shell comprises an outer cylinder (1) and an inner cylinder (2) which are coaxially spaced and sleeved, the upper and lower ends of the outer cylinder (1) and the inner cylinder (2) being bonded and fixed by an upper sealing ring (3) and a lower sealing plate (4) respectively, and mercury is injected between the outer cylinder (1) and the inner cylinder (2), and the liquid level of the mercury is 1 to 2 cm lower than the upper end surfaces of the outer cylinder (1) and the inner cylinder (2), and the outer cylinder ( 1) A plurality of vertical notches (1-1) are evenly arranged at the upper end of the cylinder wall along the circumferential direction; the heat dissipation fins (6) are made of metal sheets that are alternately squeezed and wrinkled to form a cylindrical shape; the heat dissipation fins (6) are alternately wrinkled along the circumferential direction to form a plurality of ∏-shaped wrinkled bodies (6-1); the plurality of ∏-shaped wrinkled bodies (6-1) are all arranged along the radial direction of the heat dissipation fins (6); and the opening directions of each two adjacent ∏-shaped wrinkled bodies (6-1) are opposite; the heat dissipation fins (6) are inserted into the plurality of vertical notches (1-1) from the upper end of the outer cylinder (1) (1-1), each vertical notch one (1-1) is sealed by a sealant, and the closed ends of the multiple ∏-shaped folded bodies (6-1) located on the inner side of the heat dissipation fins (6) are bonded and fixed to the corresponding positions of the inner wall of the outer cylinder (1), the lamp holder (5) is bonded and fixed inside the inner cylinder (2), and the middle of the inner cylinder (2) wall is evenly provided with multiple vertical notches two (2-1) along the circumferential direction, and the middle of the multiple high thermal conductivity rectangular metal sheets (7) are respectively inserted in the corresponding vertical notches along the radial direction of the inner cylinder (2). In the second notch (2-1), each vertical notch (2-1) is sealed by a sealant, the outer end of each high thermal conductivity rectangular metal sheet (7) extends between the outer cylinder (1) and the inner cylinder (2), the inner end of each high thermal conductivity rectangular metal sheet (7) is tightly attached to the lamp holder (5), the heat dissipation fin (6) and the plurality of high thermal conductivity rectangular metal sheets (7) are made of aluminum or aluminum-copper alloy material, wherein the thickness of the high thermal conductivity rectangular metal sheet (7) is 2-4 mm, and the thickness of the heat dissipation fin (6) is 0.5-1 mm.

2. The LED lamp heat sink according to claim 1, characterized in that: The plurality of ∏-shaped folded bodies (6-1) located on the outside of the heat dissipation fins (6) are evenly provided with a plurality of heat dissipation holes (8).

3. The LED lamp heat sink according to claim 1 or 2, characterized in that: The lamp holder (5) and the inner cylinder (2) are bonded and fixed together, as are the closed ends of the multiple ∏-shaped folded bodies (6-1) located on the inner side of the heat dissipation fins (6) and the corresponding positions on the inner wall of the outer cylinder (1) using heat-conducting adhesive.

4. The method for manufacturing a heat sink for an LED lamp according to claim 1, characterized in that: The manufacturing method comprises the following steps: Step 1: Take the outer cylinder (1) and cut a plurality of vertical notches 1 (1-1) evenly along the circumferential direction at the upper end of the cylinder wall; take the inner cylinder (2) and cut a plurality of vertical notches 2 (2-1) evenly along the circumferential direction at the middle of the cylinder wall; Step 2: Take a metal sheet and extrude it alternately to form folds and enclose it to form a heat dissipation fin (6); the heat dissipation fin (6) cooperates with the plurality of vertical notches (1-1) of the outer cylinder (1); and a plurality of heat dissipation holes (8) are uniformly formed by hot melting on the ∏-shaped folded body (6-1) located on the outside of the heat dissipation fin (6); Step 3: Apply adhesive to the closed end of the ∏-shaped folded body (6-1) located on the inner side of the heat dissipation fin (6) and the side corresponding to the inner wall of the outer cylinder (1), insert the heat dissipation fin (6) from the upper end of the outer cylinder (1) into the plurality of vertical notches (1-1), squeeze the closed end of the ∏-shaped folded body (6-1) located on the inner side of the heat dissipation fin (6) so that it is firmly bonded to the inner wall of the outer cylinder (1), and then seal each vertical notch (1-1) with a sealant; Step 4: The lamp holder (5) is fixed inside the inner cylinder (2) by bonding with heat-conducting adhesive, and the positions of the plurality of vertical notches (2-1) of the inner cylinder (2) are avoided. Then, a plurality of highly thermally conductive rectangular metal sheets (7) are sequentially inserted from the outside of the inner cylinder (2) into the corresponding vertical notches (2-1), and the inner end of each highly thermally conductive rectangular metal sheet (7) is tightly attached to the lamp holder (5). Then, the middle of each highly thermally conductive rectangular metal sheet (7) is sealed and bonded to the corresponding vertical notch (2-1) by using sealant; Step 5: Insert the inner cylinder (2) into the outer cylinder (1) and keep the coaxial position, and glue the lower sealing plate (4) to the lower ends of the outer cylinder (1) and the inner cylinder (2) by adhesive, and completely seal the lower ends of the outer cylinder (1) and the inner cylinder (2). Then, inject mercury between the outer cylinder (1) and the inner cylinder (2), and finally glue the upper sealing ring (3) to the upper ends of the outer cylinder (1) and the inner cylinder (2) by adhesive, and seal the annular space between the upper ends of the outer cylinder (1) and the inner cylinder (2).

Images