An integrated dike, potted explosion-proof LED light source module and LED light source device

Abstract

The present invention relates to an integrated dike, potted explosion-proof LED light source module and LED light source device. The LED light source module includes a circuit board, an LED light source, an integrated dike, and a potting glue layer. Among them, the LED light source is installed in the light source cavity of the integrated dike, and the LED light source is electrically connected to the circuit board; the encapsulation glue layer is poured into the light source cavity, so that the LED light source is completely sealed and fully meets the technical requirements of potted explosion-proof. The beneficial effects are: the LED light source module and the LED light source device itself meet the technical requirements of potted explosion-proof, have high explosion-proof performance, and also improve the anti-corrosion performance of the light source itself. When the potted explosion-proof LED light source module and the LED light source device are applied to explosion-proof lamps, the lamp housing only needs to have good protection performance, which not only reduces the cost but also improves the explosion-proof performance, completely subverting the traditional solution that relies on a heavy flameproof housing to ensure explosion-proof performance.

Description

Technical Field

[0001] The present invention relates to the technical field of LEDs, and in particular to an integrated dam, a potted explosion-proof LED light source module, a heat sink, and an LED light source device. Background Art

[0002] In fields such as petrochemical, ships and offshore platforms, grain and oil processing and storage, metal processing and surface treatment, and coal mines, explosive gases or dust may appear and accumulate in the environment. Therefore, the lighting equipment used in the above fields must have explosion-proof performance, that is, what we usually call explosion-proof lamps. Generally speaking, lighting equipment such as lighting lamps and emergency lighting lamps used in the above fields or environments must have explosion-proof performance.

[0003] The explosion-proof of lighting equipment means that through one or more technical means such as structural design, circuit design, device selection, or special processes, it is ensured that when the lighting equipment operates normally or fails, it cannot ignite the combustible gas or dust in the air and will not cause an explosion in the explosive hazardous environment where it is located.

[0004] In recent years, with the development of the industry and the continuous improvement of industry standards, the market demand has become increasingly strong, mainly including explosion-proof lighting products, explosion-proof mobile lighting products, explosion-proof fixed emergency lighting products, etc. National and international explosion-proof industry standards such as GB3836 and IEC60079 not only clearly stipulate how lighting products meet explosion-proof requirements, but also point out the technical direction for practitioners. However, at present, the explosion-proof form of the light source part of the vast majority of LED explosion-proof lighting lamps on the market still continues the scheme of traditional light source explosion-proof lamps, and most of them adopt explosion-proof type technical means for the LED light source part. However, for the explosion-proof type LED light source cavity, in order to ensure that the explosion-proof surface meets the standard requirements and can ensure passing the water pressure test (to prove that it can withstand the pressure generated by the internal cavity explosion, so as to ensure that the explosion does not spread outward), it has the following impacts on the product:

[0005] 1. Seriously affects the freedom of optical distribution design;

[0006] 2. The heavy housing greatly increases the cost of the housing part materials and machining;

[0007] 3. The national and international industry standards strictly prohibit spray painting and anti-corrosion treatment at the position where the explosion-proof surface is located.

[0008] Explosion-proof lamps are applied to ships, offshore platforms, docks or other environments with relatively large corrosion. The unpainted positions often become the first to be corroded, and mild corrosion will lead to the loss of explosion-proof performance; the potted explosion-proof LED light source module can completely avoid the above disadvantages. Summary of the Invention

[0009] The present invention provides an integrated dike, a potted explosion-proof LED light source module, and an LED light source device to solve the problem that the LED light source itself does not have explosion-proof performance in the prior art.

[0010] The technical problem solved by the present invention is achieved by the following technical solutions:

[0011] An integrated dike includes:

[0012] A dike body;

[0013] A plurality of light source dikes distributed on the surface of the dike body, and an inverted conical light source cavity is formed at the center of the light source dike to accommodate one or more LED light sources;

[0014] An annular sealing groove placed on the back of the dike body, close to the outer edge of the dike body; and

[0015] A potting groove placed on the back of the dike body and respectively corresponding to directly above all the copper-clad wires on the circuit board, ensuring that the potted sealant filled after the potting process covers directly above all the copper-clad wires on the corresponding circuit board. Further, the potting groove communicates with two adjacent light source cavities to ensure that when the potting process is implemented, the potting groove and the light source cavities can be quickly filled with the potting sealant.

[0016] As a preferred technical solution, it further includes a plurality of wiring dikes, and a wiring cavity is formed at the center of the wiring dike.

[0017] As a preferred technical solution, the height of the wiring dike is higher than the height of the light source dike.

[0018] As a preferred technical solution, the dike body is also provided with mounting holes and mounting hole sealing grooves located outside the mounting holes, and the mounting hole sealing grooves are located on the back of the dike body.

[0019] As a preferred technical solution, the width of the potting groove is greater than the width of the copper-clad wire.

[0020] As a preferred technical solution, the dike body is also provided with hooks for installation and fixation.

[0021] As a preferred technical solution, exhaust holes penetrating the dike body are provided on the potting groove to ensure that the potting groove can be filled with the potting sealant when the potting process is implemented.

[0022] A potted explosion-proof LED light source module includes a circuit board, an LED light source, the aforementioned integrated dike, and a potted sealant layer. Among them, the LED light source is installed in the light source cavity of the integrated dike, and the LED light source is electrically connected to the circuit board;

[0023] The potting glue layer is potted in the light source cavity, the potting groove of the integrated dam, and the wiring dam of the integrated dam, so that the LED light source, the copper-clad wire, and the wire pad in the wiring cavity are completely sealed, and fully meet the technical requirements of potting type explosion protection.

[0024] As a preferred technical solution, the LED light source arrays are arranged on the circuit board.

[0025] As a preferred technical solution, the array mode of the LED light source arrays is a rectangular array, a circular array, a staggered array or an irregular array.

[0026] As a preferred technical solution, the wire pads of the circuit board are located in the wiring cavity of the integrated dam.

[0027] As a preferred technical solution, a wire hole is provided in the wiring cavity, and a wire-passing rubber plug is installed in the wire hole. After the wire is welded and fixed to the wire pad, it passes through the wire-passing rubber plug and enters through the wire hole.

[0028] As a preferred technical solution, a potting glue layer is potted in the wiring cavity, and the wire and the wire-passing rubber plug are completely sealed.

[0029] As a preferred technical solution, the circuit board is provided with circuit board card holes that cooperate with the hooks of the integrated dam for fixing.

[0030] As a preferred technical solution, the connection mode between the LED light sources is series or parallel.

[0031] As a preferred technical solution, the connection mode between the LED light sources is a mixed connection network.

[0032] As a preferred technical solution, the LED light sources include but are not limited to light sources of types such as SMD, CSP, and COB.

[0033] The present invention also proposes a potting type explosion-proof LED light source device, which includes the aforementioned potting type explosion-proof LED light source module and a heat sink. The LED light source module is fixed on the heat sink, and a thermally conductive insulating gasket is provided between the LED light source module and the heat sink.

[0034] As a preferred technical solution, the heat sink is provided with heat sink card holes that cooperate with the hooks of the LED light source module for fixing.

[0035] The beneficial effects of the present invention are: enabling the LED light source module to have explosion-proof performance and meet the explosion-proof standards, and also being able to effectively prevent the occurrence of corrosion phenomena. Description of the Drawings

[0036] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0037] Figure 1 For the invention: Structural schematic diagram of an integrated dike

[0038] Figure 2 For the invention: Front structural schematic diagram of an integrated dike

[0039] Figure 3 For Figure 2 Cross-sectional schematic diagram in the A-A direction in

[0040] Figure 4 For the invention: Rear structural schematic diagram of an integrated dike

[0041] Figure 5 For the invention: Structural schematic diagram of a potted explosion-proof LED light source module

[0042] Figure 6 For the invention: Cross-sectional structural schematic diagram before potting of a potted explosion-proof LED light source module

[0043] Figure 7 For the invention: Cross-sectional structural schematic diagram after potting of a potted explosion-proof LED light source module

[0044] Figure 8 For the invention: Structural schematic diagram of the circuit board of a potted explosion-proof LED light source module

[0045] Figure 9 For the invention: Structural schematic diagram of a potted explosion-proof LED light source device

[0046] Figure 10 For the invention: Cross-sectional structural schematic diagram of a potted explosion-proof LED light source device

[0047] Wherein: 10 - circuit board, 20 - LED light source, 30 - integrated dam, 40 - potting glue layer, 100 - LED light source module, 200 - heat sink, 300 - thermally conductive insulating gasket, 101 - circuit board card hole, 102 - circuit board mounting hole, 206 - heat sink card hole, 301 - dam body, 302 - light source dam, 303 - annular sealing groove, 304 - potting groove, 305 - light source cavity, 306 - wiring dam, 307 - wiring cavity, 308 - mounting hole, 309 - mounting hole sealing groove, 310 - hook, 311 - wire hole, 312 - wire passing rubber plug, 399 - vent hole. Specific embodiments

[0048] In order to make the technical means, creative features, achieved purposes and functions of the present invention easy to understand, the present invention will be further described below with reference to specific drawings.

[0049] Embodiment 1

[0050] Referring to Figures 1-4 As shown, an integrated dam 30 includes: a dam body 301, a light source dam 302, an annular sealing groove 303, and a potting groove 304. Among them, there are multiple light source dams 302, which are distributed on the surface of the dam body 301. A conical light source cavity 305 is formed at the center of the light source dam 302 for accommodating one or more LED light sources (not shown in this example). The light source dams 302 in the present invention are arrayed on the surface of the dam body 301. Among them, the array method is a rectangular array, a circular array, an interleaved array or an irregular array, specifically depending on actual needs. In this embodiment, the distribution of the light source dams 302 is in a regular matrix array distribution.

[0051] The annular sealing groove 303 in the present invention is placed on the back of the dam body 301, close to the outer edge of the dam body 301. The function of the annular sealing groove 303 is to facilitate the fixation of the dam. For example, before potting, a circle of silicone is dotted in the annular sealing groove 303 by a device, and then the LED light source board is buckled on the dam body 301 to bond the two together, making the structure more stable.

[0052] The potting groove 304 in the present invention is located between two adjacent light source dams 302, communicates with two adjacent light source cavities 305, and ensures that the potting compound filled after the potting process covers directly above all the copper-clad wires 903 on the corresponding circuit board 10. Through the application of the potting groove 304, when potting, the compound will flow into the surrounding grooves, finally filling the entire potting groove 304 and covering directly above all the copper-clad wires 903 on the corresponding circuit board 10. In order to achieve better explosion-proof performance, the width of the potting groove 304 is greater than the width of the copper-clad wire 903. In order to further achieve the highest explosion-proof performance, it is necessary to ensure that the potting groove 304 is filled with potting compound during the potting process. Therefore, an exhaust hole 399 penetrating the dam body 301 is provided on the potting groove 304 to ensure that the potting groove 304 is filled with potting compound when the potting process is implemented.

[0053] On the dam body 301 of the present invention, a plurality of wiring dams 306 are further provided. A wiring cavity 307 is formed at the center of the wiring dam 306. The function of the wiring cavity 307 is to fix the wire and the wire pad 902. Therefore, the height of the wiring dam 306 should be higher than the height of the light source dam 302. After being filled with potting compound, it can ensure that the wiring cavity 307 meets the explosion-proof standard.

[0054] On the dam body 301 of the present invention, a mounting hole 308 and a mounting hole sealing groove 309 located outside the mounting hole 308 are further provided. The mounting hole sealing groove 309 is located on the back of the dam body 301. Through the application of the mounting hole 308, it is convenient to realize the fixation and positioning of the dam body 301. In the specific use process, a circle of silica gel is dotted into the mounting hole sealing groove 309, and then the LED light source board is buckled on the dam body 301 to bond the two together, making the structure more stable.

[0055] In order to achieve a more stable structure, a hook 310 for installation and fixation is further provided on the dam body 301. When bonding and integrating the dam 30 with the LED light source board, the hooks 310 on the integrated dam 30 are tightly clamped with the card slots on the LED light source board one by one.

[0056] The integrated dam 30 in the present invention has the following advantages:

[0057] By adding the potting groove 304 connecting the light source cavities 305, the smoothness of the potting process is ensured. At the same time, the position of the potting groove 304 is consistent with the position of the copper-clad wire 903, ensuring the sealing performance to the greatest extent and fully meeting the technical requirements of potting type explosion-proof.

[0058] Through the application of structures such as the annular sealing groove 303, the mounting hole 308, and the hook 310, the cooperation structure between the integrated dam 30 and the LED light source board is ensured to be stable and safe.

[0059] Example 2

[0060] Refer to Figures 5-8 As shown, an encapsulated explosion-proof LED light source module 100 includes a circuit board 10, an LED light source 20, an integrated dam 30 as in Example 1, and a potting glue layer 40. Among them, the integrated dam 30 is fixedly attached to the circuit board 10, and the LED light source 20 is installed in the light source cavity 305 of the integrated dam 30. Among them, one or more LED light sources 20 are installed in the light source cavity 305, and the LED light source 20 is electrically connected to the circuit board 10; the potting glue layer 40 is poured into the light source cavity 305, the potting groove 304 of the integrated dam 30, and the wiring dam 306 of the integrated dam 30, and makes the LED light source 20, the copper-clad wire and the wire pad 902 in the wiring cavity 307 completely sealed, and fully meets the technical requirements of encapsulated explosion-proof. Since the light source cavity 305 in the present invention adopts an inverted conical structure, it can play a role in reliable reinforcement and achieve better durability and explosion-proof performance.

[0061] The connection method between the LED light sources 20 in the present invention is series or parallel, or can also be a mixed network connection. Compared with the series or parallel scheme, the association between the LEDs is minimized, and the phenomenon of the entire string of dead lights caused by the failure of a single LED can be avoided to the greatest extent.

[0062] The LED light sources 20 in the present invention are arrayed on the circuit board 10, and the array method of the LED light sources 20 is a rectangular array, a circular array, a staggered array or an irregular array. Specifically, it depends on the actual application. In this embodiment, it is a rectangular array.

[0063] In order to realize the explosion-proof function of the wire pad 902 on the circuit board 10, the wire pad 902 is located in the wiring cavity 307 of the integrated dam 30. Since there is a wiring dam 306 outside the wiring cavity 307, and the height of the wiring dam 306 is higher than the height of the integrated dam 30, after filling with potting glue, it fully meets the technical requirements of encapsulated explosion-proof. In the wiring cavity 307 of the present invention, there is a wire hole 311, and a wire-passing rubber plug 312 is installed in the wire hole 311. After the wire is welded and fixed to the wire pad 902, it passes through the wire-passing rubber plug 312 and penetrates into the wire hole 311.

[0064] The wire-passing rubber plug 312 in the present invention is made of high-temperature resistant silicone rubber, and its functions are: preventing the edge of the circuit board 10 from cutting the wire; preventing the wire hole 311 from leaking glue when potting the positive and negative wire pads 902, which affects the appearance and explosion-proof performance. In order to achieve a better explosion-proof effect, a potting glue layer 40 is poured into the wiring cavity 307, and the wire and the wire-passing rubber plug 312 are completely sealed, and fully meet the technical requirements of encapsulated explosion-proof.

[0065] The potting glue layer 40 in the present invention generally uses silicone rubber at the LED packaging level, which does not contain any toxic or corrosive substances. After curing, its high light transmittance, high dielectric strength, and high volume resistance can ensure that the product has excellent optical and electrical properties. The relatively wide temperature application range can adapt to various extreme temperature environments, and its good adhesiveness and low hardness can effectively ensure the lifespan of the LED light source 20 and the durability of the entire light source cavity 305 structure.

[0066] Furthermore, the packaging form or device type of the LED light source 20 in the present invention includes but is not limited to light sources of types such as SMD, CSP, and COB. The LED light source 20 is bonded or soldered to the corresponding pads on the circuit board 10 through conductive silver glue or solder to establish a reliable electrical connection.

[0067] Furthermore, in order to ensure the tight fit between the integrated dam 30 and the circuit board 10, the circuit board 10 is provided with circuit board card holes 101 that cooperate with the hooks 310 for fixation, or circuit board mounting holes 102 that cooperate with fasteners for fixation.

[0068] Embodiment 3

[0069] Refer to Figures 9-10 As shown, the present invention also proposes a potted explosion-proof LED light source device, which includes a potted explosion-proof LED light source module 100 of Embodiment 2 and a heat sink 200. The LED light source module 100 is fixed on the heat sink 200, and a thermally conductive insulating gasket 300 is provided between the LED light source module 100 and the heat sink 200.

[0070] In order to achieve the stability of the entire light source device, the heat sink 200 is provided with heat sink card holes 206 that cooperate with the hooks 310 of the LED light source module 100 for fixation.

[0071] In the specific assembly process, first, use equipment to apply a circle of silicone rubber to the annular sealing groove 303 and the mounting hole sealing groove 309 on the back of the integrated dam 30, and then invert the circuit board 10 containing the LED light source 20 onto the integrated dam 30 to bond the two together to make the structure more stable. Then, fill the light source cavity 305 and the wiring cavity 307 with sealant to form the potting glue layer 40, which fully meets the technical requirements of potted explosion-proof. Finally, fix the circuit board 10 on the heat sink 200 through fasteners 901. Since the side of the integrated dam 30 in this example has hooks 310, through holes are provided on both the circuit board 10 and the heat sink 200 to allow the hooks 310 to pass through and achieve fixation with the heat sink 200. The LED light source device with the above structural combination has good stability and meets the technical requirements of potted explosion-proof.

[0072] The potted explosion-proof LED light source module meets the following technical parameters or material characteristics, which comply with the requirements of the potted explosion-proof standard (the latest versions of GB3836.9 and IEC60079.18):

[0073] ① The insulation characteristics of the insulating material of the printed circuit board (PCB) and the thermally conductive insulating gasket;

[0074] ② The electrical clearance and creepage distance between different pads and copper-clad circuits on the printed circuit board (PCB);

[0075] ③ After the printed circuit board (PCB) is bonded or welded to the LED light source 20 and the positive and negative wires are welded, the electrical clearance and creepage distance between different energized points;

[0076] ④ The minimum distance between the side wall of the LED light source 20 and the integrated dike 30; within each light source cavity 31, the minimum distance between the upper surface of the LED light source 20 and the upper surface of the cured transparent composite;

[0077] ⑤ The minimum distance between the wire pad 11 and the wiring dike 40;

[0078] ⑥ The minimum distance between the top (highest point) of the wire pad 11 and the upper surface of the cured transparent composite;

[0079] ⑦ The continuous operating temperature (COT), water absorption, and other physical and chemical characteristics of the transparent composite.

[0080] The beneficial effects of the present invention are as follows: Through various technical means such as structural design, material selection, and process design, the LED light source module and the LED light source device itself meet the technical requirements of potted explosion-proof, have high explosion-proof performance, and also improve the anti-corrosion performance of the light source itself. When the potted explosion-proof LED light source module and the LED light source device are applied to explosion-proof lamps, the lamp housing only needs to have good protection performance, which not only reduces costs but also improves explosion-proof performance, completely subverting the traditional solution that relies on a heavy flameproof housing to ensure explosion-proof performance.

[0081] The above shows and describes the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. What is described in the above embodiments and the specification only illustrates the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements all fall within the scope of the present invention claimed. The scope of protection claimed by the present invention is defined by the appended claims and their equivalents.

Claims

1. An integrated dike, characterized in that, Comprising: A dike body; A plurality of light source dikes distributed on the surface of the dike body, and an inverted conical light source cavity is formed at the center of the light source dike for accommodating one or more LED light sources; An annular sealing groove disposed on the back of the dike body, close to the outer edge of the dike body; And A potting groove disposed on the back of the dike body and respectively corresponding to directly above all copper-clad wires on the circuit board, or Connecting two adjacent light source cavities; A plurality of wiring dikes, and a wiring cavity is formed at the center of the wiring dike; An exhaust hole penetrating the dike body is provided on the potting groove; Mounting holes and mounting hole sealing grooves located outside the mounting holes are further provided on the dike body, and the mounting hole sealing grooves are located on the back of the dike body.

2. The integrated cofferdam according to claim 1, wherein The height of the wiring dike is higher than the height of the light source dike.

3. An integrated cofferdam according to claim 1, characterized in that, The width of the potting groove is greater than the width of the copper-clad wire.

4. An integrated dike according to claim 1, characterized in that, Hook for installation and fixation is further provided on the dike body.

5. An encapsulated explosion-proof LED light source module, characterized in that, Comprising a circuit board, an LED light source, an integrated dike as described in any one of claims 1-4, and a potting glue layer, wherein the LED light source is installed in the light source cavity of the integrated dike, and the LED light source is electrically connected to the circuit board; The potting glue layer is poured into the light source cavity, the potting groove of the integrated dike, and the wiring dike of the integrated dike, and the LED light source, the copper-clad wire, and the wire pads in the wiring cavity are completely sealed, and fully meet the technical requirements of potting type explosion protection; The wire pads of the circuit board are located in the wiring cavity of the integrated dike; A wire hole is provided in the wiring cavity, and a wire-passing rubber plug is installed in the wire hole. After the wire is welded and fixed to the wire pad, it passes through the wire-passing rubber plug and penetrates into the wire hole; A potting glue layer is poured into the wiring cavity to completely seal the wire and the wire-passing rubber plug.

6. The potted explosion-proof LED light source module according to claim 5, characterized in that, The LED light sources are arrayed on the circuit board.

7. The potted explosion-proof LED light source module according to claim 6, characterized in that, The array mode of the LED light sources is a rectangular array, a circular array, a staggered array or an irregular array.

8. The potted explosion-proof LED light source module according to claim 5, characterized in that, Circuit board card holes for cooperating with the hooks for fixation are provided on the circuit board.

9. The potted explosion-proof LED light source module according to claim 5, characterized in that The connection mode between the LED light sources is series or parallel; or The connection mode between the LED light sources is a mixed connection network.

10. The potted explosion-proof LED light source module according to claim 9, characterized in that, The LED light sources include SMD, CSP, and COB type light sources.

11. A potted explosion-proof LED light source device, characterized in that, Comprising a potting type explosion-proof LED light source module as described in any one of claims 5-10 and a heat sink, the LED light source module is fixed on the heat sink, and a heat-conducting insulating gasket is provided between the LED light source module and the heat sink; Heat sink card holes for cooperating with the hooks of the LED light source module are provided on the heat sink.

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