LED flexible light bar capable of being bent at will and fully wrapped and integrally extruded and formed and preparation method of LED flexible light bar

Abstract

The invention belongs to the technical field of LED light bars, and particularly relates to an LED flexible light bar capable of being bent at will and formed in a fully-wrapped integrated extrusion mode and a preparation method of the LED flexible light bar. The fully-wrapped integrally-extruded randomly-bent LED flexible light bar comprises a long-strip-shaped flexible circuit board and a plurality of light-emitting assemblies, and the light-emitting assemblies are arranged on the upper surface of the flexible circuit board at intervals in the length direction of the flexible circuit board. The light-emitting assembly comprises light-emitting sources and glass fiber boards, the glass fiber boards are installed on the flexible circuit board, the adjacent glass fiber boards are spaced by a preset interval, the light-emitting sources are arranged on the corresponding glass fiber boards, a plurality of pairs of arc-shaped inner grooves are formed in the flexible circuit board, the inner grooves are located between the two adjacent glass fiber boards, and the light-emitting sources are arranged in the inner grooves. The two inner grooves in the same pair of inner grooves are located on the two sides of the flexible circuit board in the width direction respectively, and the inner grooves are recessed inwards in the direction close to the axis of the flexible circuit board. The LED flexible light bar can be bent at will.

Description

Technical Field

[0001] The present invention belongs to the technical field of LED light bars, and in particular is a fully-integrated, extruded and arbitrarily bendable LED flexible light bar and a preparation method thereof. Background Art

[0002] At present, LED neon light strips have been widely used. The LED neon light strips of the prior art set the light source on a straight flexible circuit board. Although the flexible circuit board has a certain flexibility and can be bent, it is easy to cause poor contact of the light-emitting element during the bending process, especially the lateral bending performance is poor. If forced to bend, it will cause product defects. In actual applications, it is often necessary to bend the LED neon light strip in different directions at different positions to meet the needs of complex light strip modeling effects. Since the bending of LED neon light strips is currently limited, its modeling effect is not ideal. Summary of the invention

[0003] In view of this, the present invention provides a fully-integrated extruded LED flexible light strip that can be bent arbitrarily and a preparation method thereof, which are used to solve the technical problem in the prior art that LED light strips cannot be bent in any direction.

[0004] In the first aspect, the present invention provides a fully-integrated extruded LED flexible light strip that can be bent arbitrarily, including a long flexible circuit board and a plurality of light-emitting components, the plurality of light-emitting components are arranged on the upper surface of the flexible circuit board at intervals along the length direction of the flexible circuit board, the light-emitting component includes a light source and a glass fiber board, the glass fiber board is installed on the flexible circuit board, adjacent glass fiber boards are spaced apart by a preset interval, the light source is arranged on the corresponding glass fiber board, and a plurality of pairs of arc-shaped inner grooves are arranged on the flexible circuit board, the inner grooves are located between two adjacent glass fiber boards, and the two inner grooves in the same pair of inner grooves are respectively located on both sides of the width direction of the flexible circuit board, and the inner grooves are recessed in a direction close to the axis of the flexible circuit board.

[0005] In a second aspect, the present invention provides a method for preparing a fully-inclusive, integrally extruded, and arbitrarily bendable LED flexible light strip, which is used to prepare the fully-inclusive, integrally extruded, and arbitrarily bendable LED flexible light strip described in the first aspect, and the method comprises: The separated fiberglass boards are welded onto the flexible circuit board; Welding each light source onto a corresponding fiberglass board to obtain a first intermediate product; Prepare the diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material; conveying the intermediate product to an extrusion die of an extrusion device; The diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material are respectively fed into corresponding hoppers in the extrusion equipment and subjected to refrigeration treatment; The diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material which have been subjected to refrigeration treatment are respectively transported to the inlet position of the mold by the extrusion equipment to wait for extrusion; The diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material are wrapped around the first intermediate product by an extrusion die and extruded to obtain a second intermediate product; The second intermediate product is transported to a high-temperature tunnel furnace for vulcanization and curing to obtain the LED flexible light strip.

[0006] Beneficial effects: The fully-integrated extrusion-molded LED flexible light strip and preparation method of the present invention that can be bent arbitrarily adopts a combination of soft and hard methods. By setting the light source on a relatively hard glass fiber board, it can be prevented that the light source is squeezed and stressed during the bending process and cannot work normally. The glass fiber board is arranged in an interval manner, and only a flexible circuit board is left in the gap position between two adjacent glass fiber boards, and there are no other hard components. Therefore, when the LED flexible light strip is bent, only the flexible circuit board in the gap position between the two adjacent glass fiber boards can be bent, so that no large destructive force will be generated on the glass fiber board welded with the light source, thereby protecting the light source during the bending process. The arc-shaped inner groove set between the two adjacent glass fiber boards can make the circuit board in the gap position have better flexibility, especially when the LED light strip is bent sideways at the gap position between the two glass fiber boards, it provides sufficient deformation space for the flexible circuit board, so that it has good bending performance while ensuring the overall connection reliability of the LED light strip, and can easily achieve side bending. Due to the use of two symmetrical concave arcs, the LED flexible light strip of this embodiment can be bent forward or sideways in the gap between two adjacent glass fiber boards, or can be bent sideways at the same time, without affecting the glass fiber boards and light sources on both sides. The flexible light strip can be bent in any direction by combining different degrees of forward and side bends. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In order to more clearly illustrate the technical solution of the embodiment of the present invention, the drawings required for use in the embodiment of the present invention will be briefly introduced below. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work, and these are all within the protection scope of the present invention.

[0008] Figure 1 It is a structural schematic diagram of the fully-integrated extrusion-molded and arbitrarily bendable LED flexible light strip of the present invention; Figure 2It is a cross-sectional view of the fully-integrated extruded and arbitrarily bendable LED flexible light strip of the present invention; Figure 3 It is a schematic diagram of the process of the method for preparing the fully-integrated extrusion-molded LED flexible light strip that can be bent arbitrarily according to the present invention; Figure 4 A schematic flow diagram of the method of the integrated extrusion process of the present invention; Figure 5 A schematic structural diagram of the extrusion die used in the present invention; Figure 6 It is a projection diagram of the mold cavity of each module in the extrusion mold; Figure 7 It is a cross-sectional view in the extrusion die; Figure 8 is a schematic diagram of the three-dimensional structure of the second module; Fig. 9 is a schematic diagram of the three-dimensional structure of the first mold cavity from one perspective; Fig.10 It is a schematic diagram of the three-dimensional structure of the first mold cavity from another perspective.

[0009] Parts and their numbers in the picture: Light source 11, glass fiber board 12, flexible circuit board 13, inner groove 131, transparent layer 15, diffusion layer 16, light blocking layer 17, transparent window 18, first module 2, first mold cavity 21, first top plate 211, first bottom plate 212, second top plate 213, third top plate 214, second bottom plate 215, third bottom plate 216, first side plate 217, second side plate 218, third side plate 219, fourth side plate 210, fifth side plate 2111, sixth side plate 2112; second module 3, second mold cavity 31, first partition plate 32, second partition plate 33, guide groove 34, guide block 35, first inclined surface 351, first inlet 36, first outlet 37, second inclined surface 38, first plane 39, third module 4, third mold cavity 41. DETAILED DESCRIPTION

[0010] In order to make the purpose, technical solution and advantages of the embodiment of the present invention clearer, the technical solution in the embodiment of the present invention will be clearly and completely described in combination with the embodiment of the present invention. It should be noted that, in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. In the description of the present invention, it should be understood that the orientation or position relationship indicated by the terms "center", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc. is based on the orientation or position relationship shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. Moreover, the term "include", "comprise" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also includes other elements not explicitly listed, or also includes elements inherent to such a process, method, article or device. In the absence of further restrictions, the elements defined by the phrase "comprising..." do not exclude the existence of other identical elements in the process, method, article or device comprising the elements. If there is no conflict, the embodiments of the present invention and the various features in the embodiments can be combined with each other, all within the protection scope of the present invention.

[0011] Example 1

[0012] like Figure 1 As shown, the present embodiment provides a fully-integrated extruded LED flexible light strip that can be bent arbitrarily, the light strip comprises a long flexible circuit board 13 and a plurality of light-emitting components, the plurality of light-emitting components are arranged on the upper surface of the flexible circuit board 13 at intervals along the length direction of the flexible circuit board 13, the light-emitting component comprises a light source 11 and a glass fiber board 12, the glass fiber board 12 is mounted on the flexible circuit board 13, adjacent glass fiber boards 12 are spaced apart by a preset interval, the light source 11 is arranged on the corresponding glass fiber board 12, the flexible circuit board 13 is provided with a plurality of pairs of arc-shaped inner grooves 131, the inner grooves 131 are located between two adjacent glass fiber boards 12, the two inner grooves 131 in the same pair of inner grooves 131 are respectively located on both sides of the width direction of the flexible circuit board 13, the inner grooves 131 are recessed inwardly in the direction close to the axis of the flexible circuit board 13.

[0013] The LED flexible light strip of this embodiment adopts a combination of soft and hard, wherein the light source 11 is arranged on a relatively hard glass fiber board 12, which can prevent the light source 11 from being squeezed and stressed during the bending process and thus failing to work properly. The glass fiber board 12 is arranged in an interval manner, and only a flexible circuit board 13 is left in the gap between two adjacent glass fiber boards 12, without other hard components. Therefore, when the LED flexible light strip is bent, only the flexible circuit board 13 in the gap between two adjacent glass fiber boards 12 can be bent, so that no large destructive force will be generated on the glass fiber board 12 welded with the light source 11, thereby protecting the light source 11 during the bending process. This embodiment also provides a pair of arc-shaped inner grooves 131 between two adjacent glass fiber boards 12. This design can make the circuit board in the gap position have better flexibility and scalability. In particular, when the LED light strip is bent sideways at the gap between the two glass fiber boards 12, sufficient deformation space is provided for the flexible circuit board 13, so that it has good bending performance while ensuring the overall connection reliability of the LED light strip, and can easily achieve side bending. Due to the arrangement of two symmetrical concave arcs, the LED flexible light strip of this embodiment can be bent straight or sideways in the gap between two adjacent glass fiber boards 12, or can be bent sideways while being straight, without affecting the glass fiber boards 12 and the light source 11 on both sides. The soft light strip of this embodiment can be bent in any direction by combining straight and side bends to different degrees. Since a plurality of spaced light emitting components are arranged on a LED flexible light strip, the LED flexible light strip of this embodiment can be bent at any position, thereby forming a light strip with a complex shape to meet higher requirements for lighting effects.

[0014] In this embodiment, a transparent high temperature resistant anti-pull sheet having the same width as that of the flexible circuit board 13 is further provided on a side of the flexible circuit board 13 facing away from the light source 11 .

[0015] The transparent high temperature resistant anti-pull sheet arranged on the back of the flexible circuit board 13 can further improve the folding resistance of the LED flexible light strip, so that the LED flexible light strip can be bent arbitrarily.

[0016] like Figure 1 and Figure 2As shown, the light-emitting component also includes a transparent layer 15 and a diffusion layer 16, wherein the transparent layer 15 is coated on the top and both sides of the light source 11, and the diffusion layer 16 is located above the transparent layer 15. In this embodiment, the transparent layer 15 is coated on the top and both sides of the light source 11, which can not only protect and support the light source 11 and the fiberglass board 12, but also will not affect the light emission of the light source 11. In this embodiment, the diffusion layer 16 arranged above the transparent layer 15 is used to evenly diffuse the light emitted by the light source 11 to form a light spot. In order to improve the uniformity of diffusion, in this embodiment, the interface between the diffusion layer 16 and the transparent layer 15 is also an arc shape that is concave toward the side of the light source 11. The light-emitting component of this embodiment also includes a light-blocking layer 17, which is coated on both sides of the diffusion layer 16 and the light-blocking layer 17 and both sides of the light source 11. The light blocking layer 17 coated on both sides of the diffusion layer 16 and the light blocking layer 17 and both sides of the light source 11 can block the light on both sides and the bottom of the light source 11, so that the light can only be diffused through the diffusion layer 16 above to form an ideal light spot, thereby providing a lighting effect. In this embodiment, the width of the interface between the light blocking layer 17 and the diffusion layer 16 gradually increases from the end close to the light source 11 to the end away from the light source 11. The above structure is conducive to the light emitted by the light source 11 to be emitted from the diffusion layer 16.

[0017] Example 2 like Figure 3 As shown, this embodiment provides a method for preparing a fully-inclusive, integrally extruded, and arbitrarily bendable LED flexible light strip, which is used to prepare the fully-inclusive, integrally extruded, and arbitrarily bendable LED flexible light strip described in Example 1, and the method comprises: S1: welding the divided glass fiber board 12 onto the flexible circuit board 13; In this step, the large glass fiber board 12 is divided into small glass fiber boards 12 , which are then welded on the flexible circuit board 13 at a preset spacing.

[0018] S2: welding each light source 11 to the corresponding glass fiber board 12 to obtain a first intermediate product; In this step, the light source 11 is welded to the corresponding glass fiber board 12 according to the product design requirements. One glass fiber board 12 can correspond to one light source 11 or multiple light sources 11, and there is no limitation here. In addition, the pads on the glass fiber board 12 can be combined with the pads on the flexible circuit board 13 to achieve electrical connection between the upper and lower layers of the light bar.

[0019] S3: preparing the diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material; S31: This step includes: adding a diffusing agent and a fluidizing agent to the fumed silica gel to obtain a diffusion layer extrusion raw material; S32: adding a fluidizing agent to the fumed silica gel to obtain a transparent layer extrusion raw material; S33: Adding white masterbatch and fluidizing agent into gas phase silica gel to obtain light blocking layer extrusion raw material.

[0020] Diffusion Layer 16 is responsible for diffusing light and creating a soft luminous effect. The main material is fumed silica gel, with diffusing agent and fluidizing agent added. Transparent Layer 15: Ensures efficient transmission of light and protects it. The main material is fumed silica gel, with fluidizing agent added. White glue blocking layer 17: Limits the direction of light propagation and ensures that the light is concentrated toward the luminous surface. The main material is fumed silica gel, with white masterbatch and fluidizing agent added.

[0021] S4: conveying the intermediate product to an extrusion die of an extrusion device; S5: conveying the diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material to the extrusion die of the extrusion equipment through different raw material channels; During specific implementation, a screw conveyor can be used to transport the raw materials.

[0022] like Figure 4 As shown, in this embodiment, the S5: conveying the diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material to the extrusion die of the extrusion equipment through different raw material channels includes: S51: feeding the diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material into corresponding hoppers in the extrusion equipment for cooling; In this step, the raw materials of each layer are first distributed and transported to their corresponding hoppers, and then the raw materials of each layer are refrigerated.

[0023] S52: The diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material that have been refrigerated are transported to the mold entrance through the extrusion equipment to wait for extrusion.

[0024] S6: using an extrusion die to wrap the diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material around the first intermediate product and extrude them as a whole to obtain a second intermediate product; S7: transporting the second intermediate product to a high-temperature tunnel furnace for vulcanization and curing to obtain the LED flexible light strip, wherein the curing temperature ranges from 179 degrees to 181 degrees.

[0025] In this embodiment, the step S6: using an extrusion die to wrap the diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material around the first intermediate product and extrude the second intermediate product as a whole, comprises: S61: Real-time detection of the thickness of each layer of the second intermediate product obtained by extrusion and obtaining a preset thickness range of each layer of the light bar product; In order to ensure that the thickness of the transparent layer, the diffusion layer and the light-blocking layer of the LED flexible light strip are within the preset range after extrusion molding, thereby meeting the comprehensive requirements of optical performance and mechanical strength, the present invention adds an online thickness detection device at the outlet of the extrusion die or at the outlet of the high-temperature tunnel furnace. The online thickness detection device can use non-contact detection equipment such as a laser thickness gauge, an X-ray thickness gauge or an ultrasonic thickness gauge to detect the actual thickness of each coating layer. The preset thickness range of each layer of the light strip product is determined according to the product design requirements, and products exceeding the preset thickness range are unqualified products. Since the LED flexible light strip in this embodiment includes a transparent layer, a diffusion layer and a light-blocking layer, the transparent layer, the diffusion layer and the light-blocking layer each have their own corresponding preset thickness ranges, and any layer of the transparent layer, the diffusion layer and the light-blocking layer that exceeds the preset thickness range is not an unqualified product.

[0026] S62: Determine whether the thickness of each layer of the second intermediate product is within a preset thickness range of each layer of the corresponding light bar product; S63: if otherwise, adjusting each extrusion process according to the thickness of each layer of the second intermediate product detected in real time and the preset thickness range of each layer of the light bar product, the extrusion process parameters including screw speed, raw material temperature, raw material delivery rate and traction speed; The raw material enters the extrusion die through the flow channel driven by the rotation of the screw, and the speed of the screw affects the extrusion pressure and the flow rate of the raw material during the extrusion process. The raw material delivery rate refers to the speed at which the raw material is delivered to the extrusion die. In order to independently control the extrusion process parameters of each layer of raw material, this embodiment can set an independent delivery device and screw for each layer of raw material. After the light bar is extruded, it can be towed by a traction device at one end of the extrusion die outlet. When the thickness of a certain layer is too large, the screw speed of the extruder corresponding to the layer is reduced to reduce the material supply; vice versa. By changing the speed of the raw material delivery pump of the corresponding layer, the volume flow rate of the raw material injected into the mold is directly controlled, thereby correcting the thickness of the corresponding layer. Appropriately increasing or decreasing the raw material temperature can change the melt viscosity and flow properties of the material, thereby indirectly affecting the thickness distribution of each layer. If the traction speed is too fast, it is equivalent to "thinning" the hot melt; if the traction speed is too slow, it is easy to "extrude thick", so the traction speed will also affect the thickness of each layer. After automatic adjustment, the system will perform thickness detection again to form a closed-loop control until the detection result meets the preset thickness range, thereby realizing real-time dynamic control of the thickness of the transparent layer, diffusion layer and light-blocking layer. This embodiment can effectively improve the qualified rate of finished products of LED flexible light strips, and ensure that the product meets the design requirements in terms of optical uniformity, protective performance and service life. In addition, this method can realize online correction of the thickness of each functional layer of the LED light strip without replacing the mold.

[0027] In this embodiment, the specific method for adjusting the thickness of each layer includes: S641: Obtain the influence of each extrusion process parameter on the thickness of each layer of the light strip; The influence of process parameters on the thickness of each layer of the light strip refers to the change in thickness of each layer when a certain process parameter changes by a small amount while other process parameters remain unchanged. The greater the change in layer thickness, the higher the corresponding influence, that is, the greater the influence of the process parameter on the layer, and vice versa.

[0028] Since the light strip has a multi-layer structure, the same process parameter may have different influences on each layer. Therefore, this step needs to obtain the influence of each process parameter on each layer.

[0029] S642: Determine the adjustment primacy of each process parameter according to the influence degree corresponding to each extrusion process parameter; the greater the influence degree, the higher the primacy, and the lower the anti-primacy.

[0030] This step sorts the primacy of each layer so that when adjusting a specific layer, the order of adjusting the process parameters can be selected according to the primacy of the layer. Different layers can have different primacy sorting.

[0031] S643: determining a primary adjustment parameter and a secondary adjustment parameter according to the adjustment priority of each extrusion process parameter; In this step, the above four process parameters are divided into two groups according to the order of primacy, namely, the primary adjustment parameters adjusted first and the secondary adjustment parameters adjusted later.

[0032] S645: adjusting the main process parameters according to the adjustment priority of each process parameter, the real-time detected thickness of each layer of the second intermediate product and the preset thickness range of each layer, wherein the main process parameters with the highest priority are adjusted first; Since the main adjustment parameters have a high degree of influence, the gap between the actual thickness of the product and the preset thickness range can be quickly narrowed by adjusting the main adjustment parameters first. In the process of adjusting the main adjustment parameters, the greater the gap between the actual detected thickness and the preset thickness range, the greater the adjustment amount of the main adjustment parameters.

[0033] S646: The secondary process parameters are adjusted according to the adjustment priority of each process parameter, the real-time detection thickness of each layer of the second intermediate product and the preset thickness range of each layer, wherein the secondary process parameters with high priority are adjusted first; after the primary parameter is used to quickly adjust the layer thickness, this step immediately uses the secondary adjustment parameter to make a more accurate adjustment of the layer thickness. In this way, the influence of each process parameter on the layer thickness can be fully utilized to reasonably call each process parameter, and both the speed and accuracy of the adjustment can be taken into account.

[0034] S647: multi-step fine-tuning process: using a gradient descent algorithm to perform multi-step adjustments on each process parameter according to the real-time detected thickness of each layer of the second intermediate product and the preset thickness range of each layer; After two rounds of adjustment of the main adjustment parameters and the secondary adjustment parameters, the remaining adjustment amount is reduced. In this step, the thickness of each layer is fine-tuned. The adjustment process adopts the method of synchronous adjustment of multiple parameters. The gradient descent algorithm is used to assist in setting the adjustment amount of each process parameter during the adjustment process, so that the speed and accuracy of the fine-tuning process can be guaranteed.

[0035] S648: terminating the judgment process: judging whether the real-time detected thickness of each layer of the second intermediate product is within the preset thickness range of the corresponding layer; S649: If yes, stop adjusting; if not, repeat the multi-step fine-tuning process and terminate the judgment process until the real-time detected thickness of each layer of the second intermediate product is within the preset thickness range of the corresponding layer.

[0036] In this embodiment, the step S641: obtaining the influence of each extrusion process parameter on the thickness of each layer of the light bar includes: S6411: target process parameter selection process, wherein the target process parameter selection process includes selecting a target process parameter from various extrusion process parameters; Since the present embodiment has four adjustable process parameters, one process parameter may be selected each time to obtain the influence of the process parameter on the thickness of each layer.

[0037] S6412: Obtain different adjustment benchmarks of target process parameters; The influence of process parameters near different values ​​is not exactly the same, so multiple different adjustment benchmarks can be set, that is, different values ​​are set for the process parameters, and then adjusted near the set values, and the corresponding thickness changes after adjustments near each adjustment benchmark are obtained through experiments.

[0038] S6413: changing the value of the target process parameter based on the adjustment reference while keeping other process parameters unchanged; The value of the target process parameter can be changed by a small amount.

[0039] S6414: Obtain the change in thickness of each layer before and after the target process parameters are changed; S6415: Determine the influence of the target process parameter on the thickness of each layer according to the variation and the variation of the target process parameter; The influence degree may be the ratio of the thickness change to the corresponding target process parameter value change.

[0040] S6416: Determine whether all process parameters have completed the acquisition of influence, if not, jump to the target process selection process until all process parameters have completed the acquisition of influence.

[0041] In this embodiment, the S647: multi-step fine-tuning process: using the gradient descent algorithm to perform multi-step adjustments on each process parameter according to the real-time detected thickness of each layer of the second intermediate product and the preset thickness range of each layer includes: S6471: Obtaining the objective function represented by the sum of squares of thickness deviations of each layer; The thickness deviation of each layer is the minimum difference between the detected thickness of each layer and the corresponding preset thickness range. For example, if the thickness of the transparent layer is a, the thickness deviation of the diffusion layer is b, and the thickness deviation of the light-blocking layer is c, then the objective function C=a represented by the sum of the squares of the thickness deviations of each layer 2 +b 2 +c 2 .

[0042] S6472: Determine the gradient of the objective function with respect to each process parameter according to the objective function; The gradient of the objective function to the process parameters can be obtained by numerical difference. For example, the gradient of the objective function to the screw speed can be obtained by first making the screw speed have a small increment dv, and then obtaining the corresponding increment dC of the objective function. The ratio of dC to dv is the gradient of the objective function to the screw speed.

[0043] S6473: Determine the adjustment step of each process parameter according to the influence of each process parameter on the thickness of each layer of the light strip; in this step, the higher the influence, the shorter the adjustment step, so as to achieve accurate coordinated adjustment of each process parameter.

[0044] S6474: an adjustment amount determination process, wherein the adjustment amount determination process includes determining the adjustment amount of each process parameter according to the gradient of each process parameter and the adjustment step length of each parameter of the objective function; The adjustment amount of a certain process parameter is the product of the adjustment step length and the gradient of the process parameter.

[0045] S6475: adjusting each process parameter according to the adjustment amount of each process parameter; S6476: Determine whether the real-time detected thickness of each layer after adjustment is within the preset thickness range of each layer; S6478: If otherwise, obtain the difference between the real-time detected thickness of each layer after adjustment and the preset thickness range of each layer; S6479: adjusting the adjustment step of each parameter according to the difference, and jumping to the adjustment amount determination process until the real-time detected thickness of each layer after adjustment is within the preset thickness range of each layer.

[0046] The larger the difference, the longer the adjustment step. As the adjustment proceeds, the difference will become smaller and smaller, so the adjustment step will also become smaller and smaller, thereby achieving more accurate adjustment. This embodiment uses the influence of process parameters to determine the adjustment step, and can coordinate various process parameters during fine-tuning to balance the influence of different process parameters on thickness.

[0047] The extrusion die used in this embodiment is introduced below. Figure 5 and Figure 6As shown, in this embodiment, the mold includes a first module 2, a second module 3 and a third module 4, the first module 2 and the second module 3 are disc-shaped, the first module 2 is provided with a first mold cavity 21, the second module 3 is provided with a second mold cavity 31, and the third module 4 is provided with a third mold cavity 41, the projection of the third mold cavity 41 on the reference plane is located in the projection of the second mold cavity 31 on the reference plane, the projection of the second mold cavity 31 on the reference plane is located in the projection of the first mold cavity 21 on the reference plane, the second module 3 includes a first partition plate 32 and two second partition plates 33, the opposite ends of the first partition plate 32 are respectively connected to the upper ends of the two second partition plates 33, the diffusion layer 16 is extruded from the upper wall of the first mold cavity 21 and the outer wall of the first partition plate 32, the light blocking layer 17 is extruded from the side wall and bottom wall of the first mold cavity 21 and the outer wall of the second partition plate 33, and the first intermediate product is output from the third mold cavity 41.

[0048] The reference plane is a plane perpendicular to the axial direction of the first module 2. This embodiment adopts a design in which the first module 2, the second module 3 and the third module 4 are nested inside and outside. The diffusion layer 16 extrusion raw material delivered to the mold is extruded and shaped using the upper wall of the first mold cavity 21 and the outer wall of the first partition 32, the light-blocking layer 17 extrusion material is extruded and shaped using the side wall and bottom wall of the first mold cavity 21 and the outer wall of the second partition 33, and the transparent layer 15 material is extruded and shaped using the inner wall of the second mold cavity 31 and the third module 4, so that the transparent layer 15, the diffusion layer 16 and the light-blocking layer 17 can be extruded according to the set shape.

[0049] like Figure 7 and Figure 8 As shown, in this embodiment, a guide groove 34 is provided on a side of the second module 3 facing the first module 2, and a guide block 35 is provided in the guide groove 34. The guide block 35 separates the first inlet 36 and the first outlet 37 from each other up and down. The diameter of the first inlet 36 is smaller than that of the first outlet 37. The surface of the guide block 35 on the side away from the first outlet 37 is an arc, and the surface of the guide block 35 on the side facing the first outlet 37 is a first inclined surface 351 inclined downward; This embodiment utilizes the partitioning effect of the guide block 35, and through the cooperation between the guide block 35 and the guide groove 34, the extruded raw material enters the guide groove 34 from the first inlet 36 below, and detours from the bottom of the first outlet 37 to the position of the first outlet 37 along the arc-shaped lower surface of the guide block 35 and the arc-shaped inner wall of the guide groove 34. The arc-shaped channel surrounded by the arc-shaped lower surface of the guide block 35 and the arc-shaped inner wall of the guide groove 34 detours upward to the position of the first outlet 37, so as to avoid the situation where the raw material directly flows from the first inlet 36 to the first outlet 37 and cannot fully fill the first outlet 37 and enter the mold cavity. Since the caliber of the first inlet is smaller than the caliber of the first outlet 37, the raw material first speeds up and then slows down during the detour from bottom to top, which improves the efficiency of extrusion and enables the raw material to fully fill the extruded first outlet 37 when it flows to the position of the first outlet 37, so that the shape of the extruded light-blocking layer 17 meets the expected requirements. On this basis, this embodiment makes the surface of the guide block 35 on the side facing the first outlet 37 a first inclined surface 351 inclined downward, which is also conducive to the downward flow of the raw material during the extrusion process, allowing the raw material above to fill the first outlet 37.

[0050] A second inclined surface 38 and a first plane 39 are also provided in the guide groove 34. One end of the second inclined surface 38 is connected to the bottom wall of the guide groove 34, and the other end is connected to the first plane 39. In the axial direction of the second module 3, the first plane and the bottom wall of the guide groove 34 are parallel to each other. The first plane is located on the side of the bottom wall of the guide groove 34 close to the discharge direction, and the end of the second partition 33 extends out of the first plane.

[0051] Under the joint action of the second inclined surface 38 and the first mold, the space close to the first outlet 37 gradually decreases, and the raw material is fully squeezed in the process of flowing toward the first outlet 37 and then extruded close to the surface of the second partition 33, so as to ensure that the interface between the light blocking layer 17 and the transparent layer 15 is neat and smooth after extrusion, thereby improving the molding effect.

[0052] like Fig. 9 and Fig.10 As shown, in this embodiment, the first mold cavity 21 is surrounded by a first top plate 211, a first bottom plate 212, a second top plate 213, a third top plate 214, a second bottom plate 215, a third bottom plate 216 arranged horizontally, and a first side plate 217, a second side plate 218, a third side plate 219, a fourth side plate 210, a fifth side plate 2111, and a sixth side plate 2112 arranged vertically; The first top plate 211 is located above the first bottom plate 212, and the length of the first top plate 211 is the same as the length of the first bottom plate 212. The first side plate 217 and the second side plate 218 are located at opposite sides of the first top plate 211, respectively. The first side plate 217 and the second side plate 218 are formed by extending from the bottom of the first top plate 211 toward the first bottom plate 212. The length of the first side plate 217 and the length of the second side plate 218 are equal and equal to the length of the first top plate 211. The third side plate 219 is located at the lower part of the first side plate 217, and the fourth side plate 210 is located at the lower part of the second side plate 218. The third side plate 219 is formed by extending the first side plate 217 toward the first bottom plate 212, and the fourth side plate 210 is formed by extending the second side plate 218 toward the first bottom plate 212. The lengths of the third side plate 219 and the fourth side plate 210 are equal and smaller than the lengths of the first side plate 217 and the second side plate 218. The second top plate 213 is located on a side of the third side plate 219 facing away from the fourth side plate 210, and the third top plate 214 is located on a side of the fourth side plate 210 facing away from the third side plate 219. The heights of the second top plate 213 and the third top plate 214 are lower than the height of the first top plate 211. The length of the second top plate 213 is equal to the length of the third top plate 214 and is smaller than the lengths of the third side plate 219 and the fourth side plate 210. The bottoms of the second top plate 213 and the third top plate 214 are flush with the bottoms of the third side plate 219 and the fourth side plate 210. The fifth side plate 2111 is located on a side of the second top plate 213 facing away from the sixth side plate 2112, and the sixth side plate 2112 is located on a side of the third top plate 214 facing away from the fifth side plate 2111. The fifth side plate 2111 extends from an end of the second top plate 213 toward the second bottom plate 215 to a position intersecting with the second bottom plate 215, and the sixth side plate 2112 extends from an end of the third top plate 214 toward the third bottom plate 216 to a position intersecting with the third top plate 214. The second bottom plate 215 and the third bottom plate 216 are respectively located on two equal sides of the first bottom plate 212, the lengths of the second bottom plate 215 and the third bottom plate 216 are equal and equal to the lengths of the third side plate 219 and the fourth side plate 210, and the lengths of the second bottom plate 215 and the third bottom plate 216 are less than the length of the first bottom plate 212.

[0053] Since the second top plate 213, the third top plate 214, the fifth side plate 2111 and the sixth side plate 2112 at the outermost sides are the shortest, when the transparent layer 15 extrude the raw materials into the area controlled by the second top plate 213, the third top plate 214, the fifth side plate 2111 and the sixth side plate 2112, the flow rate is faster and the pressure is higher, which is conducive to the rapid molding of the material to form the boundary of the transparent layer 15. After passing through the area controlled by the second top plate 213, the third top plate 214, the fifth side plate 2111 and the sixth side plate 2112, the restriction of the local area at the junction of the outermost horizontal direction and the vertical direction of the material is released, and the flow rate of the transparent layer 15 extruded raw material slows down, so that the transparent layer 15 extruded raw material can fully flow to fill the local voids generated by the rapid flow in the previous stage. In this process, the third side plate 219 and the fourth side plate 210 in the first mold cavity 21 are used to guide the upper transparent layer 15 extruded raw material to control its movement toward the center, so that the local voids can be filled during the flow of the transparent layer 15 extruded raw material, and slight deformation of the transparent layer 15 can be avoided. When the transparent layer 15 extruded raw material continues to flow into the area not restricted by the third side plate 219 and the fourth side plate 210, the flow rate of the extruded material above the first top plate 211 is further slowed down, so that it can fully flow to fill the void area above the first top plate 211. The above structure allows the outer boundary area of ​​the transparent layer 15 to be quickly formed, and the large area on the top plate is formed after sufficient flow, so that the edge of the junction is clear, avoiding mixing with the diffusion layer 16 material, and eliminating local stress caused by uneven flow.

[0054] After adopting the above structure, the fifth side plate 2111 and the sixth side plate 2112 located at the outermost side of the first mold cavity 21 can cooperate with the second partition plate 33 in the second mold cavity 31 to perform the glue injection and edge pressing process on the extruded material of the transparent layer 15 entering the first mold cavity 21, so that the extruded material of the transparent layer 15 is continuously squeezed by the fifth side plate 2111, the sixth side plate 2112 and the second partition plate 33 during the extrusion process to form a neat side edge and gradually maintain the stability of the side edge during the extrusion process, thereby forming a transparent layer 15 with neat edges. Since the length of the fifth side plate 2111 and the sixth side plate 2112 is less than the length of the second partition plate 33, it can be ensured that the material of the transparent layer 15 will not contact the light-blocking layer 17 before the glue injection and edge pressing are completed. Since the length of the second partition plate 33 exceeds the position of the first plane 39, the transparent layer 15 will not contact the light-blocking layer 17 before extrusion and shaping. Therefore, after adopting the above structure, the transparent layer 15 and the light-blocking layer 17 can be contacted after being fully formed and stabilized, thereby forming a clear interface.

[0055] It should be clear that the present invention is not limited to the specific configuration and processing described above and shown in the figure. For the sake of simplicity, a detailed description of the known method is omitted here. In the above embodiment, several specific steps are described and shown as examples. However, the method process of the present invention is not limited to the specific steps described and shown, and those skilled in the art can make various changes, modifications and additions, or change the order between the steps after understanding the spirit of the present invention. The functional blocks shown in the structural block diagram described above can be implemented as hardware, software, firmware or a combination thereof. When implemented in hardware, it can be, for example, an electronic circuit, an application-specific integrated circuit (ASIC), appropriate firmware, plug-in, function card, etc. When implemented in software, the elements of the present invention are programs or code segments used to perform the required tasks. The program or code segment can be stored in a machine-readable medium or transmitted on a transmission medium or communication link via a data signal carried in a carrier. "Machine-readable medium" can include any medium that can store or transmit information. Examples of machine-readable media include electronic circuits, semiconductor memory devices, ROMs, flash memories, erasable ROMs (EROMs), floppy disks, CD-ROMs, optical disks, hard disks, optical fiber media, radio frequency (RF) links, and the like. The code segments can be downloaded via a computer network such as the Internet, an intranet, etc. It should also be noted that the exemplary embodiments mentioned in the present invention describe some methods or systems based on a series of steps or devices. However, the present invention is not limited to the order of the above steps, that is, the steps can be performed in the order mentioned in the embodiment, or in a different order from the embodiment, or several steps can be performed simultaneously.

[0056] The above is only a specific implementation of the present invention. Those skilled in the art can clearly understand that for the convenience and simplicity of description, the specific working process of the system, module and unit described above can refer to the corresponding process in the aforementioned method embodiment, and will not be repeated here. It should be understood that the protection scope of the present invention is not limited to this. Any technician familiar with the technical field can easily think of various equivalent modifications or replacements within the technical scope disclosed by the present invention, and these modifications or replacements should be covered within the protection scope of the present invention.

Claims

1. The fully-integrated extruded LED flexible light strip can be bent arbitrarily, characterized by: It includes a long strip of flexible circuit board and a plurality of light-emitting components, wherein the plurality of light-emitting components are arranged on the upper surface of the flexible circuit board at intervals along the length direction of the flexible circuit board, the light-emitting component includes a light source and a glass fiber board, the glass fiber board is installed on the flexible circuit board, adjacent glass fiber boards are spaced apart by a preset interval, the light source is arranged on the corresponding glass fiber board, and a plurality of pairs of arc-shaped inner grooves are arranged on the flexible circuit board, wherein the inner grooves are located between two adjacent glass fiber boards, and two inner grooves in the same pair of inner grooves are respectively located on both sides in the width direction of the flexible circuit board, and the inner grooves are recessed in a direction close to the axis of the flexible circuit board.

2. The all-in-one extruded LED flexible light strip that can be bent arbitrarily according to claim 1 is characterized in that: The light-emitting component also includes a transparent layer and a diffusion layer, wherein the transparent layer is coated on the top and both sides of the light source, and the diffusion layer is located above the transparent layer. The light-emitting component also includes a light-blocking layer, which is coated on the diffusion layer, the light-blocking layer, the transparent layer and both sides of the light source.

3. The all-in-one extruded and arbitrarily bendable LED flexible light strip according to claim 2, characterized in that: A transparent window is provided on the side of the flexible circuit board facing away from the light source, and a transparent high-temperature resistant anti-pull sheet with the same width as the flexible circuit board is also provided on the side of the flexible circuit board facing away from the light source. The interface between the diffusion layer and the transparent layer is an arc-shaped indented toward the light source, and the width of the interface between the light-blocking layer and the diffusion layer gradually expands from the end close to the light source to the end away from the light source.

4. A method for preparing an all-in-one extrusion-molded LED flexible light strip that can be bent arbitrarily, characterized in that: The method for preparing the fully-integrated extrusion-molded LED flexible light strip that can be bent arbitrarily according to any one of claims 1 to 3 comprises: The separated fiberglass boards are welded onto the flexible circuit board; Welding each light source onto a corresponding fiberglass board to obtain a first intermediate product; Prepare the diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material; conveying the intermediate product to an extrusion die of an extrusion device; The diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material are respectively fed into corresponding hoppers in the extrusion equipment and subjected to refrigeration treatment; The diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material which have been subjected to refrigeration treatment are respectively transported to the inlet position of the mold by the extrusion equipment to wait for extrusion; The diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material are wrapped around the first intermediate product by an extrusion die and extruded to obtain a second intermediate product; The second intermediate product is transported to a high-temperature tunnel furnace for vulcanization and curing to obtain the LED flexible light strip.

5. The method for preparing the fully-integrated extrusion-molded LED flexible light strip that can be bent arbitrarily according to claim 4, characterized in that: The method of using an extrusion die to wrap the diffusion layer extrusion raw material, the transparent layer extrusion raw material and the light blocking layer extrusion raw material around the first intermediate product and extrude the raw material into a single piece to obtain the second intermediate product comprises: Perform real-time detection on the thickness of each layer of the second intermediate product obtained by extrusion and obtain the preset thickness range of each layer of the light bar product; Determine whether the thickness of each layer of the second intermediate product is within a preset thickness range of each layer of the corresponding light bar product; If otherwise, various extrusion process parameters are adjusted according to the thickness of each layer of the second intermediate product detected in real time and the preset thickness range of each layer of the light bar product, wherein the extrusion process parameters include screw speed, raw material temperature, raw material conveying rate and traction speed, including: Get the influence of each extrusion process parameter on the thickness of each layer of the light strip; Determine the adjustment priority of each process parameter according to the corresponding influence of each extrusion process parameter; Determine the primary adjustment parameters and the secondary adjustment parameters according to the adjustment priority of each extrusion process parameter; The main adjustment parameters are adjusted according to the adjustment priority of each extrusion process parameter, the real-time detected thickness of each layer of the second intermediate product and the preset thickness range of each layer, wherein the main adjustment parameters with high adjustment priority are adjusted first; The secondary adjustment parameters are adjusted according to the adjustment priority of each extrusion process parameter, the real-time detected thickness of each layer of the second intermediate product and the preset thickness range of each layer, wherein the secondary adjustment parameters with the highest priority are adjusted first; Multi-step fine-tuning process: the multi-step fine-tuning process includes using a gradient descent algorithm to perform multi-step adjustments on each extrusion process parameter according to the real-time detected thickness of each layer of the second intermediate product and the preset thickness range of each layer; Termination judgment process: The termination judgment process includes judging whether the real-time detected thickness of each layer of the second intermediate product is within the preset thickness range of each layer; If yes, stop adjusting, if not, repeat the multi-step fine-tuning process and terminate the judgment process until the real-time detected thickness of each layer of the second intermediate product is within the preset thickness range of the corresponding layer.

6. The method for preparing the fully-integrated extrusion-molded LED flexible light strip that can be bent arbitrarily according to claim 5, characterized in that: The method of obtaining the influence of each extrusion process parameter on the thickness of each layer of the light bar includes: A target process parameter selection process, wherein the target process parameter selection process comprises selecting a target process parameter from various extrusion process parameters; Obtaining different adjustment benchmarks of target process parameters; While keeping other process parameters unchanged, change the value of the target process parameter on the basis of adjusting the benchmark; Obtain the thickness variation of each layer before and after the target process parameters are changed; Determining the influence of the target process parameter on the thickness of each layer according to the variation and the variation of the target process parameter; Determine whether all process parameters have completed the influence acquisition. If not, jump to the target process selection process until all process parameters have completed the influence acquisition.

7. The method for preparing the fully-integrated extrusion-molded LED flexible light strip that can be bent arbitrarily according to claim 5, characterized in that: The multi-step fine-tuning process: The multi-step fine-tuning process includes using a gradient descent algorithm to perform multi-step adjustments on each extrusion process parameter according to the real-time detected thickness of each layer of the second intermediate product and the preset thickness range of each layer, including: Obtaining the objective function represented by the sum of squares of thickness deviations of each layer; Determining the gradient of the objective function with respect to each process parameter according to the objective function; Determine the adjustment step of each process parameter according to the influence of each process parameter on the thickness of each layer of the light bar; The adjustment amount determination process includes determining the adjustment amount of each process parameter according to the gradient of each process parameter and the adjustment step length of each parameter of the objective function; Adjust each process parameter according to the adjustment amount of each process parameter; Determine whether the real-time detected thickness of each layer after adjustment is within the preset thickness range of each layer; If otherwise, the difference between the real-time detected thickness of each layer after adjustment and the preset thickness range of each layer is obtained; The adjustment step of each parameter is adjusted according to the difference, and the process of determining the adjustment amount is jumped to until the real-time detected thickness of each layer after adjustment is within the preset thickness range of each layer.

8. The method for preparing the fully-integrated extrusion-molded LED flexible light strip that can be bent arbitrarily according to claim 4, characterized in that: The extrusion die includes a first module, a second module and a third module, the first module and the second module are disc-shaped, a first mold cavity is arranged in the first module, a second mold cavity is arranged in the second module, and a third mold cavity is arranged in the third module, the projection of the third mold cavity on the reference plane is located in the projection of the second mold cavity on the reference plane, and the projection of the second mold cavity on the reference plane is located in the projection of the first mold cavity on the reference plane, the second module includes a first partition plate and two second partition plates, the opposite ends of the first partition plate are respectively connected to the upper ends of the two second partition plates, the diffusion layer is extruded from the upper wall of the first mold cavity and the outer wall of the first partition plate, the light blocking layer is extruded from the side wall and bottom wall of the first mold cavity and the outer wall of the second partition plate, and the first intermediate product is output from the third mold cavity.

9. The method for preparing the fully-integrated extrusion-molded LED flexible light strip that can be bent arbitrarily according to claim 8, characterized in that: A guide groove is provided on a side of the second module facing the first module, a guide block is provided in the guide groove, the guide block separates the first inlet and the first outlet of the second cavity up and down, the caliber of the first inlet is smaller than the caliber of the first outlet, the surface of the guide block on the side away from the first outlet is arc-shaped, and the surface of the guide block on the side facing the first outlet is a first inclined surface inclined downward; A second inclined surface and a first plane are also provided in the guide groove, one end of the second inclined surface is connected to the bottom wall of the guide groove, and the other end is connected to the first plane; in the axial direction of the second module, the first plane and the bottom wall of the guide groove are parallel to each other, the first plane is located on the side of the bottom wall of the guide groove close to the discharge direction, and the end of the second partition extends out of the first plane.

10. The method for preparing the fully-integrated extrusion-molded LED flexible light strip that can be bent arbitrarily according to claim 9, characterized in that: The first mold cavity is surrounded by a first top plate, a first bottom plate, a second top plate, a third top plate, a second bottom plate, a third bottom plate arranged horizontally, and a first side plate, a second side plate, a third side plate, a fourth side plate, a fifth side plate, and a sixth side plate arranged vertically; The first top plate is located above the first bottom plate, and the length of the first top plate is the same as the length of the first bottom plate. The first side plate and the second side plate are located on opposite sides of the first top plate, respectively. The first side plate and the second side plate are formed by extending from the bottom of the first top plate toward the first bottom plate. The length of the first side plate and the length of the second side plate are equal and equal to the length of the first top plate. The third side plate is located at the lower part of the first side plate, the fourth side plate is located at the lower part of the second side plate, the third side plate is formed by extending the first side plate toward the first bottom plate, the fourth side plate is formed by extending the second side plate toward the first bottom plate, and the lengths of the third side plate and the fourth side plate are equal and smaller than the lengths of the first side plate and the second side plate; The second top plate is located on a side of the third side plate facing away from the fourth side plate, the third top plate is located on a side of the fourth side plate facing away from the third side plate, the heights of the second top plate and the third top plate are lower than the height of the first top plate, the lengths of the second top plate and the third top plate are equal and lower than the lengths of the third side plate and the fourth side plate, and the bottoms of the second top plate and the third top plate are flush with the bottoms of the third side plate and the fourth side plate; The fifth side plate is located on a side of the second top plate facing away from the sixth side plate, the sixth side plate is located on a side of the third top plate facing away from the fifth side plate, the fifth side plate extends from an end of the second top plate toward the second bottom plate to a position intersecting with the second bottom plate, the sixth side plate extends from an end of the third top plate toward the third bottom plate to a position intersecting with the third bottom plate, and the length of the fifth side plate is less than the length of the second partition plate; The second bottom plate and the third bottom plate are respectively located on two equal sides of the first bottom plate, the lengths of the second bottom plate and the third bottom plate are equal and equal to the lengths of the third side plate and the fourth side plate, and the lengths of the second bottom plate and the third bottom plate are less than the length of the first bottom plate.

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