A preparation process of a patch lamp

Abstract

The application provides a preparation process of a patch lamp, and relates to the technical field of lamp manufacturing, and comprises the following steps: S1, preparing required materials; S2, slotting treatment on a soft metal sheet; and S3, stacking the soft metal sheet, a silica gel pad and a driving back plate. According to the application, a long rectangular line is drawn at the 1CM slot on the outer surface of the metal soft sheet, the soft metal sheet is placed on the downside of a laser cutting machine, the laser cutting machine is positioned through the line drawn in advance, the depth of the slot opened on the outer surface of the soft metal sheet is not more than 0.2CM, then the instant gel can be squeezed into the slot opened on the outer surface of the soft metal sheet, the transparent protection plate is inserted into the slot to be fixed, the transparent protection plate is inserted into the slot, the glue is squeezed into the slot, the area of the contact between the transparent protection plate and the body is increased, the connectivity with the patch lamp is improved, and the stability of the transparent protection plate is higher, so that the transparent protection plate is not prone to falling off.

Description

Technical Field

[0001] This invention relates to the field of lighting manufacturing technology, and in particular to a manufacturing process for a surface-mount lamp. Background Technology

[0002] LED chip lights are made of FPC circuit boards, LEDs, and high-quality silicone tubing. They are waterproof, use low-voltage DC power for safety and convenience, and emit a variety of vibrant colors. For outdoor use, they offer advantages such as resistance to UV aging, yellowing, and high temperatures. This product is widely used in building outline lighting, decorative lighting in entertainment venues, and advertising lighting. An LED, or light-emitting diode, is a solid-state semiconductor device that converts electrical energy into visible light. It directly converts electricity into light. The heart of an LED is a semiconductor chip. One end of the chip is attached to a support, serving as the negative electrode, while the other end is connected to the positive electrode of the power supply. The entire chip is encapsulated in epoxy resin. The semiconductor chip consists of two parts: a P-type semiconductor, where holes are dominant, and an N-type semiconductor, where electrons are dominant. When these two semiconductors are connected, they form a PN junction. When current flows through the chip, electrons are pushed into the P-region, where they recombine with holes, releasing energy in the form of photons. This is the principle behind LED light emission. The wavelength of light, which is also the color of light, is determined by the materials that form the PN junction.

[0003] However, in existing technologies, the manufacturing process of surface mount LEDs requires combining the LED with the circuit board. Typically, an outer casing is added to protect the LED. This casing is usually glued directly to the outer surface of the LED, and only the side in contact with the LED makes contact during the bonding process, thus fixing it in a relatively fixed state. After the LED is put into use, if the working environment is too humid, the glue connecting the two can easily oxidize. In this case, the protective casing on the outer surface of the LED is prone to detaching, leaving the LED exposed and more susceptible to damage. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies. When a surface mount LED is put into use, if the working environment is too humid, the adhesive connecting the two components can easily oxidize. In this case, the protective shell on the outer surface of the surface mount LED is prone to falling off, leaving the LED exposed and more susceptible to damage.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a manufacturing process for a surface-mount LED, comprising the following steps:

[0006] S1: Prepare the necessary materials, including: soft metal sheet, silicone pad, drive backplate, plastic side plate, and transparent protective plate;

[0007] S2: Grooving is performed on the soft metal sheet;

[0008] S3: Stack the soft metal sheet, silicone pad, and drive backplate together;

[0009] S4: Attach the plastic side panels between the three stacked pieces;

[0010] S5: Draw a rectangular line 1 cm from the groove on the outer surface of the flexible metal sheet.

[0011] S6: Groove along the rectangular line on the outer surface of the flexible metal sheet;

[0012] S7: Install a transparent protective plate.

[0013] As a preferred implementation method,

[0014] S2.1: Measure the corresponding data, which is the size and specific position of the LED sheet on the driver backplane. After the measurement is completed, slot it.

[0015] S2.2: After the slotting is completed, measure the slot distance to ensure it is accurate, to prevent the LEDs from being unable to be exposed to the outside, which would result in poor lighting effect.

[0016] As a preferred implementation method,

[0017] S3.1: Measure the specific length and width of the drive backplate to determine the actual data;

[0018] S3.2: Cut the soft metal sheet and silicone pad according to the length and width of the drive backplate to make the dimensions of the three more suitable;

[0019] S3.3: After cutting, stack the three together in front and back order, while ensuring that the positional deviation does not exceed 0.3CM. If the error is too large, the slotted holes will not be able to align with the LED light sheet.

[0020] As a preferred implementation method,

[0021] S4.1: Remove the corresponding number of plastic side panels;

[0022] S4.2: Apply glue to the outer surface of the plastic side panel to make the transparent protective panel appear as a transparent panel;

[0023] S4.3: Make contact between the adhesive side and the soft metal sheet, silicone pad, and the side of the drive backplate, and wait 30 minutes to allow it to air dry.

[0024] As a preferred implementation method,

[0025] S6.1: Place the soft metal sheet under the laser cutting machine;

[0026] S6.2: The laser cutting machine is positioned using the lines drawn in step S5;

[0027] S6.3: The laser cutting machine is configured such that the depth of the groove cut on the outer surface of the soft metal sheet does not exceed 0.2 cm to prevent penetration of the soft metal sheet.

[0028] As a preferred implementation method,

[0029] S7.1: Instant gel is extruded into the grooves opened on the outer surface of the soft metal sheet;

[0030] S7.2: Insert the transparent protective plate into the groove within 10 seconds to prevent the glue in the groove from solidifying.

[0031] As a preferred implementation method,

[0032] When drawing lines on the outer surface of a flexible metal sheet, the first line should be drawn one centimeter away from the groove opening. Then, a laser cutter is used to cut the line, ensuring that the depth of the groove does not exceed 0.2 cm. Then, adhesive gel can be injected into the groove. At this point, a transparent protective plate can be inserted into the groove. The transparent protective plate will first contact the inner wall of the groove, and at the same time, the adhesive will also contact the outer surface of the transparent protective plate, which will increase the connection between the transparent protective plate and the LED patch to a certain extent.

[0033] Compared with the prior art, the advantages and positive effects of the present invention are as follows:

[0034] 1. In this invention, a rectangular line is drawn 1 cm from the groove on the outer surface of the flexible metal sheet. The flexible metal sheet is placed under the laser cutting machine, which is positioned using the previously drawn line. The laser cutting machine is then set up, and the depth of the groove on the outer surface of the flexible metal sheet must not exceed 0.2 cm. Then, instant gel is squeezed into the groove on the outer surface of the flexible metal sheet, and the transparent protective plate is inserted into the groove to complete the fixation. The transparent protective plate is inserted into the groove, and the glue squeezed into the groove increases the contact area between the transparent protective plate and the main body, improving the connection with the patch lamp, thereby making the transparent protective plate more stable and less prone to falling off.

[0035] 2. In this invention, the flexible metal sheet is slotted, and then the flexible metal sheet, silicone pad, and drive backplate are taken out. The corresponding data are measured, which are the size and specific position of the LED on the drive backplate. After measurement, slots are made, and the accuracy of the slot distance is measured. Then, the specific length and width of the drive backplate are measured. The flexible metal sheet and silicone pad are cut according to the length and width of the drive backplate. After cutting, the three are stacked together in front and back order, while ensuring that the positional deviation does not exceed 0.3 cm. Then, the three are fixed by applying glue to the outer surface of the plastic side plate, and then contacting the side with glue with the flexible metal sheet, silicone pad, and drive backplate. Wait 30 minutes for it to dry. The LED is quickly assembled and fixed in the above way. At the same time, the flexible metal sheet and silicone pad, as the surface layer and bottom layer, can effectively protect the LED. Detailed Implementation

[0036] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0037] Example 1

[0038] This invention provides a technical solution: a manufacturing process for a surface-mount LED, comprising the following steps:

[0039] S1: Prepare the necessary materials, including: soft metal sheet, silicone pad, drive backplate, plastic side plate, and transparent protective plate;

[0040] S2: Grooving is performed on the soft metal sheet;

[0041] S3: Stack the soft metal sheet, silicone pad, and drive backplate together;

[0042] S4: Attach the plastic side panels between the three stacked pieces;

[0043] S5: Draw a rectangular line 1 cm from the groove on the outer surface of the flexible metal sheet.

[0044] S6: Groove along the rectangular line on the outer surface of the flexible metal sheet;

[0045] S7: Install a transparent protective plate;

[0046] S2.1: Measure the corresponding data, which is the size and specific position of the LED sheet on the driver backplane. After the measurement is completed, slot it.

[0047] S2.2: After the grooving is completed, measure whether the groove spacing is accurate.

[0048] S3.1: Measure the specific length and width of the drive backplate;

[0049] S3.2: Cut the soft metal sheet and silicone pad according to the length and width of the drive backplate;

[0050] S3.3: After cutting, stack the three together in front and back order, while ensuring that the positional deviation does not exceed 0.3CM;

[0051] S4.1: Remove the corresponding number of plastic side panels;

[0052] S4.2: Apply glue to the outer surface of the plastic side panel.

[0053] S4.3: Make contact with the side with glue to the soft metal sheet, silicone pad, and the side of the drive backplate, and wait 30 minutes to allow it to air dry;

[0054] S6.1: Place the soft metal sheet under the laser cutting machine;

[0055] S6.2: The laser cutting machine is positioned using the lines drawn in step S5;

[0056] S6.3: The laser cutting machine shall be configured such that the depth of the groove cut on the outer surface of the soft metal sheet shall not exceed 0.2 cm;

[0057] S7.1: Instant gel is extruded into the grooves opened on the outer surface of the soft metal sheet;

[0058] S7.2: Insert the transparent protective plate into the slot.

[0059] When drawing lines on the outer surface of a flexible metal sheet, the first line should be drawn one centimeter away from the groove opening. Then, use a laser cutter to cut the line. During the cutting process, the depth of the groove opening should not exceed 0.2 cm. Then, inject adhesive into the groove. At this time, insert the transparent protective plate into the groove. First, the transparent protective plate will contact the inner wall of the groove, and at the same time, the adhesive will also contact the outer surface of the transparent protective plate.

[0060] The working principle of this embodiment:

[0061] First, the flexible metal sheet needs to be slotted. Then, remove the flexible metal sheet, silicone pad, and driver backplate, and measure the corresponding data. These data represent the size and specific position of the LED on the driver backplate. After measurement, slots are cut, and the accuracy of the slot spacing is checked. Then, the specific length and width of the driver backplate are measured. The flexible metal sheet and silicone pad are cut according to the length and width of the driver backplate. After cutting, the three are stacked together in front-to-back order, ensuring that the positional deviation does not exceed 0.3 cm. Finally, the three are fixed by attaching them to the outer surface of the plastic side panel. Apply glue to the surface of the flexible metal sheet, then place the glued side against the flexible metal sheet, silicone pad, and the side of the drive backplate. Allow it to air dry for 30 minutes. Draw a rectangular line 1 cm from the groove on the outer surface of the flexible metal sheet. Place the flexible metal sheet under the laser cutter. Position the laser cutter using the previously drawn line. Set the laser cutter so that the groove on the outer surface of the flexible metal sheet is no deeper than 0.2 cm. Then, squeeze instant gel into the groove on the outer surface of the flexible metal sheet. Insert the transparent protective plate into the groove to complete the fixation.

[0062] Comparative Example 1

[0063] This embodiment is largely the same as the method of Embodiment 1 provided, the main difference being that: instead of slotting the soft metal sheet, glue is used directly for adhesion;

[0064] Comparative Example 2

[0065] This embodiment is largely the same as the method in Embodiment 1 provided, the main difference being that: the transparent side plate is not used to connect the soft metal sheet, silicone pad, and drive back plate.

[0066] Comparative Example 3

[0067] This embodiment is largely the same as the method in Embodiment 1, except that a transparent protective plate is used for protection.

[0068] Performance testing

[0069] According to GB 7000.1-2015 General Requirements and Tests for Luminaires:

[0070] Results of light transmittance, stability, and durability of the patch lamp products provided in equal amounts from Examples 1 and Comparative Examples 1-3:

[0071] Example 1 98％ 99％ 99.9％ Comparative Example 1 98％ 96％ 85％ Comparative Example 2 98％ 87％ 80％ Comparative Example 3 99％ 89％ 72％

[0072] Analysis of the relevant data in the tables above shows that the manufacturing process of a patch lamp according to the present invention includes the following steps:

[0073] S1: Prepare the necessary materials, including: soft metal sheet, silicone pad, drive backplate, plastic side plate, and transparent protective plate;

[0074] S2: Grooving is performed on the soft metal sheet;

[0075] S3: Stack the soft metal sheet, silicone pad, and drive backplate together;

[0076] S4: Attach the plastic side panels between the three stacked pieces;

[0077] S5: Draw a rectangular line 1 cm from the groove on the outer surface of the flexible metal sheet.

[0078] S6: Groove along the rectangular line on the outer surface of the flexible metal sheet;

[0079] S7: Install a transparent protective plate;

[0080] S2.1: Measure the corresponding data, which is the size and specific position of the LED sheet on the driver backplane. After the measurement is completed, slot it.

[0081] S2.2: After the grooving is completed, measure whether the groove spacing is accurate.

[0082] S3.1: Measure the specific length and width of the drive backplate;

[0083] S3.2: Cut the soft metal sheet and silicone pad according to the length and width of the drive backplate;

[0084] S3.3: After cutting, stack the three together in front and back order, while ensuring that the positional deviation does not exceed 0.3CM;

[0085] S4.1: Remove the corresponding number of plastic side panels;

[0086] S4.2: Apply glue to the outer surface of the plastic side panel.

[0087] S4.3: Make contact with the side with glue to the soft metal sheet, silicone pad, and the side of the drive backplate, and wait 30 minutes to allow it to air dry;

[0088] S6.1: Place the soft metal sheet under the laser cutting machine;

[0089] S6.2: The laser cutting machine is positioned using the lines drawn in step S5;

[0090] S6.3: The laser cutting machine shall be configured such that the depth of the groove cut on the outer surface of the soft metal sheet shall not exceed 0.2 cm;

[0091] S7.1: Instant gel is extruded into the grooves opened on the outer surface of the soft metal sheet;

[0092] S7.2: Insert the transparent protective plate into the slot.

[0093] The working principle of this embodiment:

[0094] First, the flexible metal sheet needs to be slotted. Then, remove the flexible metal sheet, silicone pad, and driver backplate, and measure the corresponding data. These data represent the size and specific position of the LED on the driver backplate. After measurement, slots are cut, and the accuracy of the slot spacing is checked. Then, the specific length and width of the driver backplate are measured. The flexible metal sheet and silicone pad are cut according to the length and width of the driver backplate. After cutting, the three are stacked together in front-to-back order, ensuring that the positional deviation does not exceed 0.3 cm. Finally, the three are fixed by attaching them to the outer surface of the plastic side panel. Apply glue to the surface of the flexible metal sheet, then place the glued side against the flexible metal sheet, silicone pad, and the side of the drive backplate. Allow it to air dry for 30 minutes. Draw a rectangular line 1 cm from the groove on the outer surface of the flexible metal sheet. Place the flexible metal sheet under the laser cutter. Position the laser cutter using the previously drawn line. Set the laser cutter so that the groove on the outer surface of the flexible metal sheet is no deeper than 0.2 cm. Then, squeeze instant gel into the groove on the outer surface of the flexible metal sheet. Insert the transparent protective plate into the groove to complete the fixation.

[0095] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments for application in other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A fabrication process for a surface-mount lamp, characterized in that: Includes the following steps: S1: Prepare the necessary materials, including: soft metal sheet, silicone pad, drive backplate, plastic side plate, and transparent protective plate; S2: Grooving is performed on the soft metal sheet; S3: Stack the soft metal sheet, silicone pad, and drive backplate together; S4: Attach the plastic side panels between the three stacked pieces; S5: Draw a rectangular line 1 cm from the groove on the outer surface of the soft metal sheet. S6: Cut grooves along the rectangular lines on the outer surface of the soft metal sheet. Set the laser cutting machine so that the depth of the grooves cut on the outer surface of the soft metal sheet does not exceed 0.2 cm. S7: Install a transparent protective plate; When drawing lines on the outer surface of a soft metal sheet, the first line should be drawn one centimeter away from the groove. Then, a laser cutter is used to cut the line. During the cutting process, the depth of the groove should not exceed 0.2 cm. Then, instant gel is injected into the groove. At this time, a transparent protective plate is inserted into the groove. First, the transparent protective plate will contact the inner wall of the groove, and at the same time, the glue will also contact the outer surface of the transparent protective plate.

2. The fabrication process of a patch lamp according to claim 1, characterized in that: Step S2 includes the following steps: S2.1: Measure the corresponding data, which is the size and specific position of the LED sheet on the driver backplane. After the measurement is completed, slot it. S2.2: After the grooving is completed, measure whether the groove spacing is accurate.

3. The fabrication process of a patch lamp according to claim 1, characterized in that: Step S3 includes the following steps: S3.1: Measure the specific length and width of the drive backplate; S3.2: Cut the soft metal sheet and silicone pad according to the length and width of the drive backplate; S3.3: After cutting, stack the three together in front and back order, while ensuring that the positional deviation does not exceed 0.3CM.

4. The fabrication process of a patch lamp according to claim 1, characterized in that: Step S4 includes the following steps: S4.1: Remove the corresponding number of plastic side panels; S4.2: Apply glue to the outer surface of the plastic side panel. S4.3: Make contact between the adhesive side and the soft metal sheet, silicone pad, and the side of the drive backplate, and wait 30 minutes to allow it to air dry.

5. The fabrication process of a patch lamp according to claim 1, characterized in that: Step S6 includes the following steps: S6.1: Place the soft metal sheet under the laser cutting machine; S6.2: The laser cutting machine is positioned using the lines drawn in step S5; S6.3: The laser cutting machine is configured such that the depth of the groove cut on the outer surface of the soft metal sheet shall not exceed 0.2 cm.

6. The fabrication process of a patch lamp according to claim 1, characterized in that: Step S7 includes the following steps: S7.1: Instant gel is extruded into the grooves opened on the outer surface of the soft metal sheet; S7.2: Insert the transparent protective plate into the slot.

7. A surface mount lamp, wherein the manufacturing process of a surface mount lamp according to any one of claims 1-6 is characterized in that: Including the surface mount LED body.