Die, LED support prefabricated part, LED support and LED support production process

Abstract

The invention relates to the field of production of LED supports, in particular to a die for preparing an LED support, a plurality of edge grooves extend outwards from a hollow area on a material belt, a die core comprises a plurality of positioning convex blocks, the positioning convex blocks are located in the edge grooves, and a fixing mechanism for positioning the material belt is formed by combining the plurality of positioning convex blocks to abut against one side in the edge grooves. A flow channel for injection molding fluid to pass through is reserved between the positioning convex block and the interior of the edge groove; the central area of the hollow area corresponds to the liquid injection port of the injection molding machine, and the positioning convex block is positioned in the edge groove extending outwards in the hollow area, so that the impact of injection molding fluid can be relieved, the contact time of the injection molding fluid and the positioning convex block is delayed, and the collision stroke of the injection molding fluid and the positioning convex block is prolonged; by means of the structure, injection molding fluid can make contact with the positioning protruding block only after the flowing speed of the injection molding fluid is decreased, impact force generated by the injection molding fluid on the positioning protruding block can greatly slide down, and damage to the positioning protruding block is smaller.

Description

Technical Field

[0001] The invention relates to the field of LED bracket production, and in particular to a mold, an LED bracket prefabricated part, an LED bracket and an LED bracket production process. Background Art

[0002] like Figure 1 As shown, Figure 1 The 3D diagram of the current LED bracket is shown. The current production process of the LED bracket is as follows: stamping, injection molding, leg cutting and bending, and molding;

[0003] The above process is briefly described as follows: the metal strip is pre-stamped to form a hollow area for injection molding on the metal strip. After the mold core enters or passes through the above hollow area, it is used in conjunction with the mold sleeve to perform injection molding on the metal strip. After the injection molding is completed, the metal strip is cut and bent to finally form an LED bracket.

[0004] Specifically, the positioning convex part of the mold core enters or passes through the above hollow area. The functions of the positioning convex part are to position and limit the flow of plastic fluid to the outside. Therefore, the positioning convex part is easy to shovel the side wall of the hollow area of ​​the material strip. In severe cases, a piece of copper chips will be directly pressed out. This situation occurs frequently. At the same time, after repeating the above situation many times, the shape of the positioning convex part is damaged, which leads to the problem of excessive glue in the injection molding process. If the positioning convex part is slightly in contact with the hollow area, the side wall of the hollow hole will have fine and difficult-to-detect copper wires, which will fall off to the LED bracket in the subsequent bending process. These copper chips are conductive, and the falling position is random. For example, when they fall into the cup, they will change the internal circuit of a single lamp bead; when they fall to the pins, after the patch is placed on the circuit board, the copper chips will form a conductive circuit that is not originally designed, which will cause a short circuit, dead light or series connection when the client is encapsulated or the application is patched;

[0005] At the same time, the positioning convex parts will inevitably wear out under the impact of high temperature and high pressure on the injection molding machine's injection molding rubber. Therefore, the positioning convex parts will also be worn out, affecting the positioning effect of the positioning convex parts on the hardware strips (the positioning convex parts not only serve as the outer surrounding walls in injection molding, but also serve as the positioning of the hardware strips); frequent replacement of mold cores will lead to a sharp increase in costs. Summary of the invention

[0006] In order to solve the above problems, the present invention provides a mold, an LED bracket prefabricated part, an LED bracket and an LED bracket production process, which first solve the problem of line short circuit;

[0007] The present invention provides a mold, an LED bracket prefabricated part, an LED bracket and an LED bracket production process, which are used to alleviate the high wear speed of a positioning protrusion.

[0008] To achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a mold for preparing an LED bracket, comprising a mold core and a mold sleeve that are used in conjunction with each other, and a plurality of side grooves extending outward from the hollow area on the material strip, characterized in that the mold core comprises a plurality of positioning protrusions, and the positioning protrusions are located in the above-mentioned side grooves. By combining the plurality of positioning protrusions to abut against one side of the side groove, a fixing mechanism for positioning the material strip is formed, and a flow channel for the injection fluid to pass through is reserved between the above-mentioned positioning protrusions and the inside of the side groove.

[0009] Beneficial effects of the present invention:

[0010] 1. The central area of ​​the hollow area corresponds to the injection port of the injection molding machine. The positioning protrusion is located in the side groove extending outward from the hollow area to reduce the impact of the injection fluid. In other words, this delays the time for the injection fluid to contact the positioning protrusion, and extends the collision stroke of the injection fluid and the positioning protrusion, so that the injection fluid will contact the positioning protrusion only after the flow rate slows down. Therefore, the impact force generated by the injection fluid on the positioning protrusion is greatly reduced, and the damage to the positioning protrusion is also smaller.

[0011] 2. After replacing the mold core, copper chips are concentrated in the side groove, and the molded part in the side groove belongs to the auxiliary material of the LED bracket, which means that after using this mold core, the copper chips have been drained out of the LED bracket; at the same time, the positioning protrusion is against one side of the side groove, that is, when the mold is closed, the probability of copper chips being generated is very low, and even if copper chips appear, there will not be a large amount of copper chips suddenly rushing around, reducing the amount of copper chips scattered in the hollow area; in addition, through the flow channel formed by the positioning protrusion in the side groove, when the injection fluid flows in from the injection port, the excess copper chips in the hollow area will be washed away and the copper chips will be guided into the side groove.

[0012] Since the positioning protrusion only plays a positioning role and there is no need to restrict the flow direction of the plastic flow, the surface of the positioning protrusion can be processed into a guide chamfer. The positioning protrusion in the prior art is designed as a chamfer to restrict the flow of plastic fluid to the outside, which will cause the problem of injection fluid overflow. In summary, the LED bracket prepared by the process of the present invention has high efficiency and better quality, solves the copper chips problem that plagues the industry and greatly improves production efficiency.

[0013] In this embodiment, there is at most one positioning protrusion in each side groove, which also reduces the contact area between the positioning protrusion and the material strip, and reduces the generation of more copper scraps;

[0014] Gaps are reserved between the positioning protrusions in order to correspond to the side grooves.

[0015] Therefore, it is not difficult to conclude that one group limits the forward and backward movement of the material belt, and the other group limits the left and right movement of the material belt; the following is an example, the first side groove includes a first side, a first side, and a third side, the second side groove includes a fourth side, a fifth side, and a sixth side, the first group of positioning protrusions: the first positioning protrusion abuts against the first side, and the second positioning protrusion abuts against the sixth side; the second group of positioning protrusions: the third positioning protrusion abuts against the first side, and the fourth positioning protrusion abuts against the fifth side;

[0016] The above is only one implementation mode. According to the requirements, the number of the first group of positioning protrusions and the second group of positioning protrusions can also be increased, for example, a fifth positioning protrusion is abutted against the third side, and a sixth positioning protrusion is abutted against the fourth side.

[0017] It should be noted that the above methods are all for the purpose of achieving the following purpose: the positioning bump will not come into contact with the part of the material strip that serves as the pin (i.e., the bending foot), but only with the frame in the material strip. When the bending foot is bent, there is no risk of copper chips or copper wire falling off that is not easily noticeable.

[0018] A preform of an LED bracket includes a preform body, characterized in that the preform body is provided with an accessory material to be removed, and the accessory material extends outside the preform body; the accessory material in the preform is used to store copper scraps or copper wires, etc., and by removing the accessory material, the occurrence of new conductive circuits can be reduced, and the occurrence of circuit short circuits in the package can be reduced.

[0019] Furthermore, there are multiple auxiliary materials distributed around the preform body. The purpose of this design is to increase the space for storing copper chips. Specifically, the injection fluid diffuses around, and more auxiliary materials mean more flow directions, which can further reduce the accumulation of copper chips.

[0020] Furthermore, a plurality of positioning holes are reserved on the auxiliary material for positioning. The positioning holes are used in conjunction with the positioning protrusions to ensure that the preform does not shake in the material strip.

[0021] Specifically, there are six auxiliary materials, which are parallel to each other. The parallelism between the auxiliary materials is conducive to simplifying the design of the mold core and reducing the difficulty of the mold core design. In addition, the copper chips are evenly distributed in each auxiliary material, which optimizes the situation when there are too many copper chips in some auxiliary materials and overflow into the preform during injection molding.

[0022] An LED bracket, characterized in that the LED bracket is formed by removing auxiliary materials from a prefabricated part of the LED bracket, and the LED bracket has a fracture surface after the auxiliary materials are removed.

[0023] A production process for an LED bracket includes the following steps:

[0024] S1, punching the material strip to form a hollow area and a side groove extending from the hollow area on the material strip;

[0025] S2, adjust the position of the material strip so that the side groove and the positioning protrusion on the mold core correspond to each other, ensuring that the positioning protrusion can penetrate into the side groove;

[0026] S3, performing mold closing and injection molding, and the injection fluid flows into the hollow area and the side groove in an orderly manner;

[0027] S4, performing mold opening, and using a degumming device to perform a degumming process on the material strip to remove the auxiliary materials on the LED bracket;

[0028] S5, using a foot cutting punch on the periphery of the LED bracket to form a bent foot;

[0029] S6, performing bending forming on the above-mentioned legs.

[0030] The LED bracket prepared by this production process has a very high yield rate, mainly because the positioning bump is in contact with one side of the side groove, so that there is space for accumulating copper chips in the side groove, and a large amount of copper chips or copper wires remaining in the bracket can be removed, so the short circuit during packaging is greatly reduced, and the production cost is reduced; in addition, combined with the injection port, the copper chips remaining in the hollow area can be injected first, and the copper chips remaining in the hollow area can also flow smoothly into the side groove;

[0031] This method uses a smaller contact area to position the material strip, so there are fewer copper chips generated by the mold closing, and the defective rate of the LED lamp holder is more effectively controlled.

[0032] In addition, this method of producing LED brackets causes relatively little loss to the mold core. The travel between the positioning protrusion in the mold core and the injection port is extended. After the flow rate of the injection fluid decreases, the impact force on the positioning protrusion also becomes smaller. Therefore, the service life of the mold core is extended and the frequency of replacing the mold core is reduced.

[0033] In addition, in the new process, the positioning boss is only used for positioning, because there is no need to restrict the flow direction of the plastic, and the surface of the positioning boss can be processed into a guide chamfer (if the positioning boss of the old process is processed into a guide chamfer, there will be more plastic), and almost no copper chips will be pressed out. In addition, the positioning bump will not come into contact with the part of the material strip that serves as the pin (i.e. the bending foot), but only with the frame in the material strip. When the bending foot is bent, there is no risk of copper chips or copper wire falling off that are not easy to detect. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a three-dimensional diagram of the LED bracket.

[0035] Figure 2 It is a three-dimensional diagram of the mold core.

[0036] Figure 3 It is a schematic diagram of the material strip and the positioning bump bracket after being assembled in a top view.

[0037] Figure 4 is Figure 3 An enlarged schematic diagram of point A.

[0038] Figure 5 This is a structural diagram of part of the material strip.

[0039] Figure 6 It is a three-dimensional diagram after separation during the mold closing process.

[0040] Figure 7 yes Figure 6 An enlarged schematic diagram of point B.

[0041] Figure 8 This is the structural diagram of the LED bracket after the mold is opened and formed on the material strip.

[0042] Fig. 9 This is a usage status diagram of the glue removal equipment.

[0043] Fig.10 This is a schematic diagram of using a cutting punch.

[0044] Fig.11 This is a three-dimensional picture of the LED bracket prefabricated parts DETAILED DESCRIPTION

[0045] like Figure 1-11 As shown, a mold for preparing an LED bracket includes a mold core and a mold sleeve that cooperate with each other. In this embodiment, the mold core is arranged on a movable mold 1, and the mold sleeve is located on a fixed mold 2. A plurality of side grooves 3 extend outward from a hollow area 4 on a material strip 5. It is characterized in that the mold core includes a plurality of positioning protrusions 1a, and the positioning protrusions 1a are located in the above-mentioned side grooves 3. By combining the plurality of positioning protrusions 1a to abut against one side of the side groove 3, a fixing mechanism for positioning the material strip 5 is formed, and a flow channel 1b for the injection fluid to pass is reserved between the above-mentioned positioning protrusions 1a and the inside of the side groove 3.

[0046] Beneficial effects of the present invention:

[0047] 1. The central area of ​​the hollow area 4 corresponds to the injection port of the injection molding machine. The positioning protrusion 1a is located in the side groove 3 extending outward from the hollow area 4 to reduce the impact of the injection fluid. In other words, this delays the time for the injection fluid to contact the positioning protrusion 1a, and extends the collision stroke of the injection fluid and the positioning protrusion 1a, so that the injection fluid will contact the positioning protrusion 1a only after the flow rate slows down. Therefore, the impact force generated by the injection fluid on the positioning protrusion 1a is greatly reduced, and the damage to the positioning protrusion 1a is also smaller.

[0048] 2. After replacing the mold core, the copper chips are concentrated in the side groove 3, and the molded part in the side groove 3 belongs to the auxiliary material 6 of the LED bracket 7, which means that after using this mold core, the copper chips have been drained to the outside of the LED bracket 7; at the same time, the positioning protrusion 1a is against one side of the side groove 3, that is, when the mold is closed, the amount of copper chips generated is relatively small, and there will not be a large amount of copper chips suddenly rushing around, reducing the amount of copper chips scattered in the hollow area 4; in addition, through the flow channel 1b formed by the positioning protrusion 1a in the side groove 3, when the injection fluid flows in from the injection port, the excess copper chips in the hollow area 4 will be washed away, and the copper chips will be guided into the side groove 3.

[0049] Gaps are reserved between the positioning protrusions 1 a so as to correspond to the side grooves 3 .

[0050] In this embodiment, there is at most one positioning protrusion 1a in each side groove 3, which also reduces the contact area between the positioning protrusion 1a and the material strip 5 and reduces the generation of more copper scraps;

[0051] Therefore, it is not difficult to conclude that one group limits the forward and backward movement of the material belt 5, and the other group limits the left and right movement of the material belt 5; the following is an example, the plurality of first side grooves 3 include a first side 31, a first side 32, and a third side 33, the plurality of second side grooves 3 include a fourth side 34, a fifth side 35, and a sixth side 36, the first group of positioning protrusions 1a: the first positioning protrusion 1a-1 abuts against the first side 31, and the second positioning protrusion 1a-2 abuts against the sixth side 36; the second group of positioning protrusions 1a: the third positioning protrusion 1a-3 abuts against the first side 32, and the fourth positioning protrusion 1a-4 abuts against the fifth side 35;

[0052] The above is only one embodiment. According to the needs, the number of the first group of positioning protrusions 1a and the second group of positioning protrusions 1a can also be increased, for example, the fifth positioning protrusion 1a-5 is abutted against the third side 33, and the sixth positioning protrusion 1a-6 is abutted against the fourth side 34; or, only the first side groove 5 is used, the first positioning protrusion 1a-1 is abutted against the first side 31, and the fifth positioning protrusion 1a-5 is abutted against the third side 33, so as to realize the positioning of the material strip 5;

[0053] It should be noted that the above methods are all for the following purpose (such as Fig.10 As shown): the positioning protrusion 1a will not come into contact with the portion of the material strip 5 that serves as the pin (i.e., the bending leg 10), but will only come into contact with the frame in the material strip 5. When the bending leg 10 is bent, there is no risk of copper chips or copper wires that are not easily noticeable falling off.

[0054] The existing mold has several thousand holes. For example, if there are 3,000 holes, one hole has 6 positioning convex parts, so there are 18,000 positioning convex parts. In the existing production process, as long as one positioning convex part is damaged, a defective product will be produced. However, even if the positioning convex block 1a of the present invention has a large number of damages, a defective product will not be produced.

[0055] A production process of an LED bracket 7 comprises the following steps:

[0056] S1, stamping the material strip 5 to form a hollow area 4 and a side groove 3 extending from the hollow area 4 on the material strip 5;

[0057] S2, adjust the position of the material strip 5 so that the side groove 3 and the positioning protrusion 1a on the mold core correspond to each other, ensuring that the positioning protrusion 1a can penetrate into the side groove 3;

[0058] S3, performing mold closing and injection molding, and the injection fluid flows into the hollow area 4 and the side groove 3 in an orderly manner;

[0059] S4, performing mold opening, and using a degumming device 8 to perform a degumming process on the material strip 5 to remove the accessory material 6 on the LED bracket 7;

[0060] S5, using a foot cutting punch 9 on the periphery of the LED bracket 7 to form a bent foot 10;

[0061] S6, bending the bending legs to complete the forming of the LED bracket.

[0062] The LED bracket 7 prepared by this production process has a very high yield rate, mainly because the positioning protrusion 1a is in contact with one side of the side groove 3, so that there is space for accumulating copper chips in the side groove 3, and a large amount of copper chips or copper wires remaining in the bracket can be removed, so the short circuit during packaging is greatly reduced, and the production cost is reduced; in addition, combined with the injection port, the copper chips remaining in the hollow area 4 can be injected preferentially, and the copper chips remaining in the hollow area 4 can also flow smoothly into the side groove 3;

[0063] This method uses a smaller contact area to position the material strip 5, so that less copper chips are generated by the mold closing, and the defective rate of the LED lamp holder is more effectively controlled.

[0064] In addition, this method of producing the LED bracket 1 causes relatively little loss to the mold core, and the travel between the positioning protrusion 1a in the mold core and the injection port is extended. After the flow rate of the injection fluid decreases, the impact force on the positioning protrusion 1a also becomes smaller, thereby extending the service life of the mold core and reducing the frequency of replacing the mold core.

[0065] A preform of an LED bracket 7 includes a preform body 11, characterized in that an accessory material 6 to be removed is provided on the preform body 11, and the accessory material 6 extends out of the preform body 11; the accessory material 6 in the preform is used to store copper scraps or copper wires, etc. By removing the accessory material 6, the occurrence of new conductive circuits can be reduced, and the occurrence of circuit short circuits in the package can be reduced.

[0066] Furthermore, there are multiple auxiliary materials 6 distributed around the preform body 11. The purpose of this design is to increase the space for storing copper chips. Specifically, the injection fluid diffuses around, and more auxiliary materials 6 represent more flow directions, which can further reduce the accumulation of copper chips.

[0067] Furthermore, a plurality of positioning holes 61 for positioning are reserved on the auxiliary material 6 . The positioning holes 61 are used in conjunction with 1 a to ensure that the preform body 11 does not shake in the material strip 5 .

[0068] Specifically, six auxiliary materials 6 are provided and are parallel to each other. The parallelism between the auxiliary materials 6 is conducive to simplifying the design of the mold core and reducing the difficulty of the mold core design. In addition, the copper chips are evenly distributed in each auxiliary material 6, which optimizes the situation when there are too many copper chips in some auxiliary materials 6 and overflow into the preform during injection molding.

[0069] An LED bracket 7, characterized in that the LED bracket 7 is formed by removing the auxiliary material 6 from the prefabricated part of the LED bracket 7, and the LED bracket has a fracture surface after the auxiliary material 6 is removed.

[0070] The above implementation modes are merely descriptions of the preferred implementation modes of the present invention, and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary engineering and technical personnel in the field shall fall within the protection scope determined by the claims of the present invention.

Claims

1. A LED bracket production process, characterized in that: A mold for preparing an LED bracket according to any one of claims 1 to 5 is included, and the mold has the following steps: S1, punching the material strip to form a hollow area and a side groove extending from the hollow area on the material strip; S2, adjust the position of the material strip so that the side groove and the positioning protrusion on the mold core correspond to each other, ensuring that the positioning protrusion can penetrate into the side groove; S3, performing mold closing and injection molding, and the injection fluid flows into the hollow area and the side groove in an orderly manner; S4, performing mold opening, and using a degumming device to perform a degumming process on the material strip to remove the auxiliary materials on the LED bracket; S5, using a foot cutting punch on the periphery of the LED bracket to form a bent foot; S6, performing bending forming on the above-mentioned legs.

2. A mold for implementing injection molding in the LED bracket production process as claimed in claim 1, characterized in that: It comprises a mold core and a mold sleeve which cooperate with each other, and a plurality of side grooves extend outward from the hollow area on the material strip. It is characterized in that the mold core comprises a plurality of positioning protrusions, and the positioning protrusions are located in the above-mentioned side grooves. A fixing mechanism for positioning the material strip is formed by combining the plurality of positioning protrusions to abut against one side of the side groove, and a flow channel for the injection fluid to pass is reserved between the above-mentioned positioning protrusions and the inside of the side groove.

3. A mold according to claim 2, characterized in that: Each side groove has at most one positioning protrusion.

4. A mold according to claim 2, characterized in that: Gaps are reserved between the positioning protrusions.

5. A mold according to claim 2, characterized in that: The positioning protrusions include a first positioning protrusion, a second positioning protrusion, a third positioning protrusion, and a fourth positioning protrusion. The side grooves have at least two groups, namely the first side groove and the second side groove. One group limits the forward and backward movement of the material belt, and the other group limits the left and right movement of the material belt. The first side groove includes a first side, a first side, and a third side. The second side groove includes a fourth side, a fifth side, and a sixth side. The first positioning protrusion abuts against the first side, and the second positioning protrusion abuts against the sixth side; the third positioning protrusion abuts against the first side, and the fourth positioning protrusion abuts against the fifth side.

6. A mold according to claim 5, characterized in that: It also includes a fifth positioning protrusion and a sixth positioning protrusion. The fifth positioning protrusion abuts against the third side, and the sixth positioning protrusion abuts against the fourth side.

7. An LED bracket prefabricated part manufactured according to the LED bracket production process as claimed in claim 1, characterized in that: The invention comprises a preform body, characterized in that an accessory material to be removed is provided on the preform body, and the accessory material extends out of the preform body; the accessory material in the preform is used to store copper scraps or copper wires, etc. After removing the accessory material, the occurrence of new conductive circuits can be reduced, and the occurrence of circuit short circuits in the package can be reduced.

8. The LED bracket prefabricated part according to claim 7, characterized in that: A plurality of auxiliary materials are provided and distributed around the prefabricated component body.

9. The LED bracket prefabricated part according to claim 7, characterized in that: A plurality of positioning holes for positioning are reserved on the auxiliary material; six auxiliary materials are provided and are parallel to each other.

10. An LED bracket, characterized in that: The LED bracket is formed by removing the auxiliary materials from the LED bracket preform according to any one of claims 7 to 9, and the LED bracket has a fracture surface after the auxiliary materials are removed.

Images