A light-emitting module based on an enveloping lens cover and a preparation method thereof

Abstract

The application discloses a light-emitting module based on an enclosing lens cover and a preparation method thereof. The light-emitting module comprises a lens cover, a light-emitting plate and a radiator. The radiator adopts a profile. A plurality of slots are arranged on the mounting surface of the radiator. The lens cover comprises a lens main body, an annular flange and a plug-in part. The inner side surface of the annular flange is connected with the outer edge of the lens main body. The annular flange surrounds the mounting surface of the radiator. A sealing structure is arranged between the inner side surface of the annular flange and the edge of the radiator. The application arranges the slots penetrating through the two ends of the mounting surface of the radiator to the side surface of the radiator, and realizes the fixation of the lens cover and the radiator by using the plug-in part on the lens cover. Meanwhile, the application arranges the annular flange at the edge of the lens cover. The annular flange can close the end part of the slot. The first sealing groove filled with sealing glue is formed between the annular flange and the radiator. The profile radiator is used, and the sealing and waterproof performance of the light-emitting module is ensured.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of lighting devices, and particularly relates to a light-emitting module based on an enclosing lens cover and a preparation method thereof. BACKGROUND

[0002] The light-emitting module is a key component widely used in electronic devices such as LED lamps. However, with the increase of module power, the heat dissipation problem is increasingly significant. At present, a cast heat sink is generally used to improve the heat dissipation performance of the light-emitting module. However, due to the draft angle of the fins of the cast heat sink, the length of the fins of the cast heat sink is small, and the fin spacing is large, which cannot effectively increase the heat dissipation area, limiting the improvement of the heat dissipation effect.

[0003] Compared with the cast heat sink commonly used in the light-emitting module, the heat sink prepared from the profile does not have a draft angle, so that the heat sink can have heat dissipation fins with a larger length and a smaller spacing, thereby effectively improving the heat dissipation performance. However, due to the processing reasons, the profile heat sink cannot manufacture a ring-shaped groove structure, which makes it difficult to ensure the sealing effect between the heat sink and the lens. Therefore, how to simultaneously meet the requirements of heat dissipation performance and lens sealing has become a difficult problem to be solved in the field of light-emitting modules. SUMMARY

[0004] The purpose of the present application is to provide a light-emitting module based on an enclosing lens cover and a preparation method thereof.

[0005] In the first aspect, the present application provides a light-emitting module based on an enclosing lens cover, which comprises a lens cover, a light-emitting plate and a heat sink. The heat sink is made of a profile. The two sides of the heat sink are respectively a mounting surface and a heat dissipation surface; the lens cover and the light-emitting plate are arranged on the mounting surface of the heat sink. The light-emitting plate is located between the lens cover and the heat sink.

[0006] The mounting surface of the heat sink is provided with n insertion grooves; n≥2. The lens cover comprises a lens main body, a ring-shaped flange and an insertion piece. The inner side surface of the ring-shaped flange is connected with the outer edge of the lens main body. The ring-shaped flange surrounds the four sides of the mounting surface of the heat sink. The n insertion pieces are arranged on the lens main body and respectively form an interference fit with the n insertion grooves on the heat sink. The inner side surface of the ring-shaped flange and the edge of the heat sink are provided with a sealing structure.

[0007] As a preferred, the insertion grooves are directly formed in the process of extrusion molding of the heat sink. Therefore, the length direction of the insertion grooves is parallel to the extrusion direction of the heat sink during extrusion molding, and the two ends of the insertion grooves are respectively communicated with the two side edges of the heat sink.

[0008] As preferred, two length edges of the bottom edge of the annular flange are provided with groove bodies; the groove bodies are in communication with the inner side of the annular flange. The two groove bodies of the annular flange cooperate with the edges of the heat sink to form two first sealing grooves. The first sealing grooves are filled with sealing glue.

[0009] As preferred, along the arrangement direction of the slots, the mounting surface of the heat sink is divided into two end fastening regions which are staggered with the light-emitting plate, and a light-emitting region which is aligned with the light-emitting plate. There are at least one slot in each of the two end fastening regions.

[0010] As preferred, the top edge of the slot in the end fastening region is higher than the light-emitting region on the heat sink.

[0011] As preferred, the slot in the end fastening region corresponds to an integrated structure of the plug-in part, which extends from one side edge of the inner side of the lens body to the other side edge.

[0012] As preferred, the slot in the end fastening region is filled with sealing glue, thereby forming a sealing structure on the two width edges of the light-emitting module.

[0013] As preferred, two length edges of the bottom edge of the annular flange are provided with groove bodies; the groove bodies are in communication with the inner side of the annular flange. The two groove bodies of the annular flange cooperate with the edges of the heat sink to form two first sealing grooves. The first sealing grooves are filled with sealing glue. The end of the sealing glue in the first sealing groove is integrated with the end of the sealing glue in the two slots in the end fastening region, thereby forming a ring-shaped sealing structure.

[0014] As preferred, along the arrangement direction of the slots, the mounting surface of the heat sink is divided into two end fastening regions which are staggered with the light-emitting plate, and a light-emitting region which is aligned with the light-emitting plate 2. There are at least one slot in the light-emitting region.

[0015] As preferred, the slot in the light-emitting region 3-3 corresponds to an independent structure of the plug-in part, which includes one plug-in block, or includes multiple plug-in blocks which are independent and arranged in sequence. The width of the plug-in block along the length direction of the slot is less than the width of the light-emitting plate along the length direction of the slot; part or all of the plug-in blocks pass through the accommodation through slot on the light-emitting plate as a whole or in part. The number and length of the plug-in blocks on different plug-in parts can be the same or different.

[0016] As preferred, the number of plug-in blocks in part or all of the plug-in parts with independent structure is m≥3; two plug-in blocks are respectively located at the two side edges of the inner side of the lens body in the m plug-in blocks. At least one plug-in block of the remaining plug-in blocks passes through the accommodation through slot on the light-emitting plate as a whole.

[0017] As preferred, the section shape of the part or all of the displacement channel matches the section shape of the corresponding plug-in block, so that the plug-in block can provide positioning for the light-emitting plate through the displacement channel.

[0018] As preferred, the second sealing grooves are filled with sealing glue.

[0019] As preferred, the static friction between the plug-in block and the plug-in slot exists at the interference position; the static friction makes the extrusion force exist between the lens cover and the light-emitting plate. The extrusion force is generated in the following process: the lens cover is subjected to the pulling force (provided by the static friction) of the plug-in block; the pulling force makes the lens cover elastically deform, and then extrude the light-emitting plate.

[0020] As preferred, the static friction between the plug-in block and the plug-in slot comes from the pre-tightening force applied during the assembly of the lens cover and the heat sink; the pre-tightening force is 5000N-30000N.

[0021] As preferred, the plug-in block is provided with a gap; the depth of the gap is less than the height of the plug-in block; the plug-in block is divided into a deformation part corresponding to the position of the gap and an interference part offset from the position of the gap in the height direction; the interference part forms an interference fit with the plug-in slot, and the interference amount is 0.1mm-0.3mm.

[0022] As preferred, the area of the side wall of the plug-in slot that forms an interference fit with the plug-in block is inclined from the inside to the outside in the depth direction of the plug-in slot.

[0023] As preferred, the two sides of the plug-in block that face the side wall of the plug-in slot are uneven.

[0024] As preferred, the uneven side of the plug-in block has a glue guide groove extending from the root to the tip of the plug-in block.

[0025] As preferred, the position of the part or all of the plug-in slot connected to the corresponding plug-in block is filled with sealing glue.

[0026] As preferred, the bottom edge of the annular flange is provided with grooves on the two length edges and the two width edges; the grooves are in communication with the inner side of the annular flange; the grooves on the two length edges and the two width edges are connected in sequence to form a first sealing groove that surrounds the heat sink; the first sealing groove is filled with sealing glue.

[0027] As preferred, the two sides of the heat sink are mounting surface and heat dissipation surface respectively; the mounting surface of the heat sink is attached to the light-emitting plate; the heat dissipation surface of the heat sink is provided with heat dissipation fins arranged at intervals; the interval of the heat dissipation fins is 8-12 mm; the height of the heat dissipation fins is 30-38 mm.

[0028] As preferred, the light-emitting plate comprises a PCB plate and a plurality of lamp beads distributed on the PCB plate; the lens body is provided with a plurality of lens units; the positions of the lens units correspond to the positions of the lamp beads on the light-emitting plate respectively.

[0029] As preferred, the annular flange forms a convex edge higher than the side of the lens body away from the heat sink at the edge of the lens body.

[0030] As preferred, a plurality of positioning through holes are formed on the light-emitting plate; a plurality of positioning blind holes are formed on the heat sink; a plurality of positioning columns are arranged on the inner side of the lens cover; each positioning column passes through the corresponding positioning through hole on the light-emitting plate and extends into the corresponding positioning blind hole on the heat sink.

[0031] In the second aspect, the application provides a first preparation method of the light-emitting module, which comprises the following steps:

[0032] Step one: the heat sink is processed by extrusion molding process.

[0033] Step two: the light-emitting plate is placed on the heat sink.

[0034] Step three: the lens cover is arranged above the light-emitting plate so that the n plug-in connectors on the lens cover extend into the n insertion slots on the heat sink respectively.

[0035] Step four: the lens cover is subjected to extrusion force towards the heat sink; under the action of the extrusion force, the plug-in connectors in the plug-in fastening structure form interference fit with the insertion slots.

[0036] Step five: the first sealing groove formed between the annular flange and the heat sink is filled with sealing glue; after the sealing glue is solidified, the preparation of the light-emitting module is completed.

[0037] As preferred, before step two, liquid sealing glue is injected into the areas where part or all of the insertion slots are aligned with the plug-in connectors.

[0038] In the third aspect, the application provides a second preparation method of the light-emitting module, which comprises the following steps:

[0039] Step one: the lens cover, the light-emitting plate and the heat sink are obtained.

[0040] On the lens cover, the two length edges of the bottom edge of the annular flange are provided with groove bodies; the two length edges of the side of the lens body facing the heat sink are provided with second sealing grooves.

[0041] On the heat sink, along the arrangement direction of the slots, the mounting surface of the heat sink is divided into two end fastening regions offset from the light-emitting plate and a light-emitting region aligned with the light-emitting plate. At least one slot exists on each of the two end fastening regions. The plug-in fittings corresponding to the slots in the end fastening regions adopt an integrated structure extending from one side edge of the inner side surface of the lens body to the other side edge.

[0042] Step two, inject liquid sealant into the slots in the end fastening regions on the mounting surface of the heat sink.

[0043] Step three, place the light-emitting plate on the heat sink.

[0044] Step four, fill the two second seal grooves in the inner side surface of the lens cover with sealant; then, place the lens cover above the light-emitting plate so that the n plug-in fittings on the lens cover respectively extend into the n slots on the heat sink.

[0045] Step five, apply extrusion force to the lens cover towards the heat sink; under the action of the extrusion force, the plug-in fittings in the plug-in fastening structure form interference fit with the slots. The two grooves on the annular flange form two first seal grooves with the edge of the heat sink.

[0046] Step six, fill the two first seal grooves with sealant. After the sealant solidifies, the light-emitting module is prepared.

[0047] The present application has the beneficial effects that:

[0048] 1. The present application sets slots penetrating through both ends to the side surface of the heat sink on the mounting surface of the heat sink, and realizes the fixation of the lens cover and the heat sink by using the plug-in fittings on the lens cover. Meanwhile, the present application sets an annular flange at the edge of the lens cover; the annular flange can close the end of the slot; and the annular flange and the heat sink form a first seal groove filled with sealant, which guarantees the sealing and waterproof performance of the light-emitting module (specifically, achieves the sealing effect of IP68 level or above) when using profile heat sinks.

[0049] 2. The present application fills sealant in the slots in the end fastening regions of the heat sink, which realizes sufficient sealing on the two width edges of the light-emitting module; the present application sets grooves inside the length edges of the annular flange of the lens cover, so that the two length edges of the lens cover and the heat sink automatically form a first seal groove. Filling sealant in the first seal groove realizes sufficient sealing on the two length edges of the light-emitting module; meanwhile, the sealant on the width edges and the sealant on the length edges can be integrated into a ring-shaped sealing structure, which completely closes all the gaps with the risk of leakage.

[0050] 3、The second sealing groove is arranged on the inner side of the lens cover, and provides a second sealing structure for the two length edges of the light-emitting module, thereby further improving the sealing and waterproof performance of the light-emitting module.

[0051] 4、The lens cover and the slot on the heat sink are in interference fit through the structure of the lens cover and the slot on the heat sink, which can provide tension constraint for the lens cover, so that the lens cover is not easy to deform in the long-term use, and the light distribution accuracy of the lens is improved, so that the light-emitting module maintains high light efficiency in the long-term use.

[0052] 5、The different positions of the light-emitting plate are pressed on the heat sink by the lens cover, avoiding the technical solution of using screws to fix the light-emitting plate and the heat sink, thereby avoiding the problem of warping and deformation of the PCB plate far away from the position of the screw, so that the light-emitting plate in the application can be closely attached to the heat sink at the same time, and the heat dissipation efficiency is improved.

[0053] 6、The PCB plate is pressed between the lens cover and the heat sink, and the overall stress is balanced, so that the thickness of the PCB plate can be further thinned without worrying about the deformation problem, thereby further reducing the production cost of the light-emitting module.

[0054] 7、The plug-in fastening structure is integrally formed on the lens cover, which can form interference fit between the middle position of the lens cover and the heat sink, and will not produce additional independent connecting parts, thereby simplifying the complexity of assembling the light-emitting module. BRIEF DESCRIPTION OF DRAWINGS

[0055] Figure 1 It is a schematic diagram of the overall structure of the embodiment 1 of the application;

[0056] Figure 2 It is an explosion schematic diagram of the embodiment 1 of the application;

[0057] Figure 3 It is a schematic diagram of the cross section of the embodiment 1 of the application along the length edge direction;

[0058] Figure 4 It is a connection schematic diagram between the slot and the corresponding plug-in part in the end fastening area of the embodiment 1 of the application (i.e. Figure 3 the A part of the local enlarged view in the figure);

[0059] Figure 5 This is a schematic diagram of the connection between the slot located in the light-emitting area and the corresponding connector in Embodiment 1 of the present invention (i.e., Figure 3 (Enlarged view of part B in the middle section);

[0060] Figure 6 This is a schematic diagram of the heat sink structure in Embodiment 1 of the present invention;

[0061] Figure 7 This is a schematic diagram of the lens cover structure in Embodiment 1 of the present invention;

[0062] Figure 8 This is a cross-sectional schematic diagram along the width side direction of Embodiment 1 of the present invention;

[0063] Figure 9 This is a schematic diagram of the sealing structure connection on the length side of Embodiment 1 of the present invention (i.e., Figure 8 (Enlarged view of part C in the middle);

[0064] Figure 10 This is a schematic diagram of the connector structure in Embodiment 3 of the present invention. Detailed Implementation

[0065] The present invention will be further described below with reference to the accompanying drawings.

[0066] Example 1

[0067] like Figure 1 , 2 As shown in Figure 3, a light-emitting module based on a surround-type lens cover includes a lens cover 1, a light-emitting plate 2, and a heat sink 3. The heat sink 3 is made of profile and is formed by extrusion of aluminum alloy. The two sides of the heat sink 3 are a mounting surface and a heat-dissipating surface, respectively; the lens cover 1 and the light-emitting plate 2 are disposed on the mounting surface of the heat sink 3. The heat-dissipating surface of the heat sink 3 is provided with spaced-apart heat dissipation fins. The light-emitting plate 2 is located between the lens cover 1 and the heat sink 3. The mounting surface of the heat sink 3 is tightly fitted to the light-emitting plate 2. The light-emitting plate 2 includes a PCB board and several LEDs distributed on the PCB board. Several lens units are integrally formed on the lens cover 1. The position of each lens unit corresponds to the position of each LED on the light-emitting plate 2, and is used to distribute the light emitted by the LEDs. The power supply line of the light-emitting plate 2 is led out through a wire hole in the middle of the heat sink 3. The connection between the heat sink 3 and the power supply line is sealed.

[0068] like Figure 2 and 6As shown, eight slots 3-1 are arranged in sequence along the length direction of the light emitting module on the mounting surface of the heat sink 3. The length direction of the slots 3-1 is parallel to the width direction of the heat sink 3; the arrangement direction of each slot 3-1 is perpendicular to the length direction of the slot 3-1; since the heat sink 3 is a profiled material, the two ends of the slot 3-1 are communicated with the two side edges of the heat sink 3, and the length direction of the slot 3-1 is parallel to the length direction of the heat fins. The slots 3-1 are used to cooperate with the inserting pieces 1-3 on the lens cover 1 to realize the fixation of the lens cover 1 and the heat sink 3.

[0069] Along the arrangement direction of each slot 3-1, the mounting surface of the heat sink 3 is offset from the two end fastening areas 3-2 of the light emitting plate 2, and is aligned with the light emitting area 3-3 of the light emitting plate 2.

[0070] The slots 3-1 arranged at the two ends are respectively located in the end fastening areas 3-2; the remaining six slots 3-1 arranged in the middle are located in the light emitting area 3-3. The top edge of the slot 3-1 located in the light emitting area 3-3 is flush with the mounting surface of the heat sink 3.

[0071] The top edge of the slot 3-1 located in the end fastening area 3-2 is higher than the mounting surface of the heat sink 3, that is, the slot 3-1 located in the end fastening area 3-2 is formed by two spaced side plates 3-4 protruding relative to the mounting surface of the heat sink 3.

[0072] As shown in Figs. Figure 3 , 4 , 5, 7, the lens cover 1 includes an integrally formed lens body 1-1, an annular flange 1-2 and an inserting piece 1-3. All the lens units on the lens cover 1 are arranged on the lens body 1-1. The inner side surface of the annular flange 1-2 is connected with the outer edge of the lens body 1-1 and surrounds the four sides of the lens body 1-1. The bottom edge of the annular flange 1-2 surrounds the edge near the mounting surface of the heat sink 3.

[0073] Eight inserting pieces 1-3 are arranged on the inner side surface of the lens cover 1. The eight inserting pieces 1-3 are arranged in sequence along the length direction of the lens cover 1, and correspond to the eight slots 3-1 on the heat sink 3 respectively. The eight inserting pieces 1-3 are respectively inserted into the corresponding slots 3-1 to form an interference fit.

[0074] The inserting piece 1-3 can adopt an integrated structure or an independent structure; among the eight inserting pieces 1-3, the structure of the two inserting pieces 1-3 arranged at the two ends is different from that of the six inserting pieces 1-3 arranged in the middle. The two inserting pieces 1-3 arranged at the two ends correspond to the slots 3-1 on the two end fastening areas 3-2 of the mounting surface of the heat sink 3 respectively; the six inserting pieces 1-3 arranged in the middle correspond to the six slots 3-1 on the light emitting area 3-3 of the mounting surface of the heat sink 3 respectively.

[0075] The two plug-in members 1-3 arranged at the two ends are integrated structures, extending from the length side of the lens body 1-1 to the length side of the other side.

[0076] The six plug-in members 1-3 arranged in the middle are independent structures, including three independent plug-in blocks 1-3-1. Two of the plug-in blocks 1-3-1 are respectively located at the two side edges of the inner side surface of the lens body 1-1. The third plug-in block 1-3-1 is located at the middle position of the inner side surface of the lens body 1-1 in the width direction.

[0077] As shown in Figure 2 The light-emitting plate 2 is provided with six accommodation grooves 2-1. The positions of the accommodation grooves 2-1 correspond to the positions of the middle plug-in blocks 1-3-1 of the six plug-in members 1-3 arranged in the middle. Since the four plug-in members 1-3 arranged in the middle adopt independent structures, the accommodation grooves 2-1 do not need to completely cut off the light-emitting plate. The cross-sectional shape of the accommodation groove 2-1 matches the cross-sectional shape of the corresponding plug-in block 1-3-1, so that the plug-in block 1-3-1 can provide positioning for the light-emitting plate 2 through the accommodation groove 2-1.

[0078] The two insertion grooves 3-1 in the end fastening area 3-2 are filled with sealant, which can seal the gap between the two width edges of the lens cover 1 and the two width edges of the heat sink 3, and provide sealing for the two width edges of the light-emitting module.

[0079] The six insertion grooves 3-1 in the light-emitting area 3-3 are also filled with sealant, which can improve the fastening between the plug-in members 1-3 and the insertion grooves 3-1.

[0080] It should be noted that the insertion grooves 3-1, especially the six insertion grooves 3-1 in the light-emitting area 3-3, are not necessary technical features. In the case that the connection between the plug-in members 1-3 and the insertion grooves 3-1 is stable enough, and the sealing performance of the two width edges of the light-emitting module meets the requirements, the insertion grooves 3-1 can be partially or completely free of sealant.

[0081] After the insertion of the insertion piece 1-3 into the slot 3-1 to the limit position (i.e. the position of the insertion piece 1-3 when the two side faces of the light-emitting plate 2 are in contact with the heat sink 3 and the lens body 1-1 respectively), further pre-tightening pressure is applied to the lens cover 1, so that the light-emitting plate 2 is extruded by the lens cover 1 and the heat sink 3, and the depth of the insertion of the insertion piece 1-3 into the slot 3-1 is further increased (the space required for further insertion is provided by the elastic deformation of the lens cover 1, the light-emitting plate 2 and the heat sink 3); when the pre-tightening pressure applied to the lens cover 1 is removed, the frictional force between the interference-fitted insertion piece 1-3 and the slot 3-1 resists the recovery of the elastic deformation, so that the lens cover 1 maintains the extrusion force on the light-emitting plate 2 and presses the light-emitting plate 2 tightly against the heat sink 3.

[0082] At the same time, the insertion block 1-3-1 located at the middle position of the inner side face of the lens body 1-1 can avoid the middle part of the lens cover 1 from being deformed by bulging due to heating in use, thereby avoiding the generation of gaps between the lens and the light-emitting plate 2 and avoiding the change of the relative positions between the lamp beads and the corresponding lenses. Therefore, the structure of the insertion piece 1-3 and the slot 3-1 can make the lens light distribution of the light-emitting module remain accurate in long-term use. As can be seen, the insertion piece 1-3 provided in the embodiment can further improve the anti-deformation ability of the lens cover 1, improve the tightness of the bonding of the light-emitting plate and the heat sink, and further limit the light-emitting plate to ensure that the light-emitting plate does not deviate from the position.

[0083] As shown in Figure 8 and 9 , the two length edges of the bottom edge of the annular flange 1-2 are provided with grooves with L-shaped cross sections; the grooves are in communication with the inner side face of the annular flange 1-2. The grooves on the two length edges of the annular flange 1-2 and the two length edges of the heat sink together form two first sealing grooves 4 with U-shaped cross sections. The two first sealing grooves 4 are filled with sealing glue, providing a first layer of sealing structure for the two length edges of the light-emitting module. The two first sealing grooves 4 can close the two ends of the six slots 3-1 in the light-emitting area 3-3, thereby overcoming the hidden danger of the open end of the slot directly formed in the extrusion molding to the sealing performance of the light-emitting module.

[0084] The two length edges of the inner side face of the lens body 1-1 are provided with second sealing grooves 5 with U-shaped cross sections; each insertion piece in the light-emitting area 3-3 is located between the two second sealing grooves 5. The two second sealing grooves 5 are filled with sealing glue, providing a second layer of sealing structure for the two length edges of the light-emitting module.

[0085] The sealing glue in the first sealing groove 4, the second sealing groove 5 and the two slots 3-1 in the end fastening area 3-2 cooperate with each other to completely isolate the light-emitting plate from the external environment, so that the light-emitting module reaches the IP68 waterproof level.

[0086] The embodiment provides a preferred non-essential technical feature that the end of the sealant in the first seal groove 4 is integrated with the end of the sealant in the two insertion grooves 3-1 in the end fastening area 3-2, forming a ring-shaped seal structure with the ends connected.

[0087] The embodiment provides a preferred non-essential technical feature that a gap groove 1-3-2 is arranged along the length direction of the insertion groove 3-1 at the tip position of the insertion piece 1-3, that is, the surface farthest from the lens body 1-1. The gap groove 1-3-2 forms two deformed pieces arranged at a distance on the insertion piece 1-3. The depth of the gap groove 1-3-2 is less than the height of the insertion piece 1-3, so that the end of the insertion piece 1-3 close to the lens cover 1 forms a part not separated by the gap groove 1-3-2. The depth of the gap groove 1-3-2 is greater than or equal to 2 mm (preferably equal to 2 mm), and the width is greater than or equal to 0.7 mm (preferably equal to 0.7 mm).

[0088] The insertion piece 1-3 is divided into a deformed part 1-3-3 corresponding to the position of the gap groove 1-3-2 and an interference part 1-3-4 staggered with the position of the gap groove 1-3-2 in the height direction of the insertion piece 1-3. The deformed part 1-3-3 has small rigidity under the action of the gap groove 1-3-2, is deformed when inserted into the insertion groove 3-1, and facilitates the increase of the depth of the insertion piece 1-3 inserted into the insertion groove 3-1. The interference part 1-3-4 has a solid structure and large rigidity, and forms an interference amount between the side wall of the insertion groove 3-1, so that the lens cover 1 and the heat sink 3 can generate a friction force resisting deformation. The interference amount between the lens cover 1 and the heat sink 3 that can generate a friction force resisting deformation is provided by the interference part 1-3-4 of the insertion piece 1-3.

[0089] The embodiment provides a preferred non-essential technical feature that the two side surfaces of the insertion groove 3-1 in interference fit with the insertion piece 1-3 are arranged in opposite directions and gradually increase in distance in the direction from inside to outside. This shape can facilitate the insertion of the insertion piece 1-3 into the insertion groove 3-1 and gradually form an interference fit structure. The interference amount between the interference part 1-3-4 on the insertion piece 1-3 and the insertion groove 3-1 is greater than or equal to 0.1 mm.

[0090] The embodiment provides a preferred non-essential technical feature that the material of the lens cover 1 is PC, which can withstand the pressure of 5000 N to 30000 N required when the insertion piece 1-3 is inserted into the insertion groove 3-1.

[0091] The embodiment provides a preferred non-essential technical feature that the top edge of the annular flange 1-2 forms a convex edge higher than the outer side surface of the lens body 1-1 at the edge of the lens body 1-1. The convex edge can protect the lens units on the lens body 1-1 from direct impact.

[0092] The embodiment provides a preferred non-essential technical feature: the pitch of the heat dissipation fins is 8mm-12mm (preferably 11mm); the height of the heat dissipation fins is 30mm-38mm (preferably 30mm). In the case that the power of the light-emitting module is small and the heat dissipation requirement is low, the height of the heat dissipation fins can also be set to 10mm, or other heights less than 30mm.

[0093] In the application, the root of the plug 1-3 represents the position where the plug 1-3 is connected to the lens cover; the tip of the plug 1-3 represents the position where the plug 1-3 is farthest away from the lens cover.

[0094] In the application, the bottom edge and the top edge of the annular flange 1-2 do not refer to the up-down concept in the absolute spatial sense; the bottom edge of the annular flange 1-2 represents the edge close to the heat sink 3; and the top edge of the annular flange 1-2 represents the edge close to the heat sink 3.

[0095] In the application, all the length edges and width edges do not refer to the length; the length of the length edge can be greater than or less than the length of the width edge. The width edge represents an edge parallel to the profile extrusion direction of the heat sink 3; and the length edge represents an edge perpendicular to the profile extrusion direction of the heat sink 3.

[0096] Embodiment 2

[0097] A preparation method of a light-emitting module is used for preparing the light-emitting module as described in Embodiment 1.

[0098] The preparation method comprises the following steps.

[0099] Step one, the heat sink 3 is processed by an aluminum alloy extrusion forming process; the lens cover 1 is processed by an injection molding process; and the light-emitting plate with completed lamp bead welding is produced.

[0100] Step two, the liquid sealant is injected into the slot 3-1 on the mounting surface of the heat sink 3 and located at the two end fastening areas 3-2. In the slot 3-1 located at the two end fastening areas 3-2, the sealant fills the whole slot 3-1.

[0101] And the liquid sealant is injected into the slot 3-1 on the mounting surface of the heat sink 3 and located at the light-emitting area 3-3. In each slot 3-1 located at the light-emitting area 3-3, the sealant can fill the whole slot 3-1 or can be injected only at the corresponding position of the plug 1-3.

[0102] Step three, the light-emitting plate 2 is placed on the heat sink 3.

[0103] Step four, fill the sealant into the two second sealing grooves 5 on the inner side of the lens cover 1; fill the sealant into all positions of the second sealing grooves 5. Then, place the lens cover 1 on the light-emitting plate 2, so that the eight insertion pieces 1-3 on the lens cover 1 respectively extend into the eight insertion slots 3-1 on the heat sink 3. The insertion pieces 1-3 are in sufficient contact with the sealant in the corresponding insertion slots 3-1.

[0104] Step five, apply the extrusion force to the lens cover 1 towards the heat sink, and the extrusion force is controlled to be 5000N-30000N. Under the action of the extrusion force, the insertion pieces 1-3 are further inserted into the corresponding insertion slots 3-1, so that the interference part 1-3-4 on the insertion piece 1-3 forms the interference fit with the two side walls of the insertion slot 3-1, and the two side surfaces of the light-emitting plate 2 are respectively attached to the lens cover 1 and the heat sink 3, and the light-emitting plate 2 is subjected to the extrusion force applied by the lens cover 1.

[0105] Step six, remove the extrusion force applied to the lens cover 1, and fill the sealant into the two first sealing grooves 4 formed between the two length edges of the annular flange 1-2 on the lens cover 1 and the two length edges of the heat sink 3. Fill the sealant into all positions of the first sealing grooves 4.

[0106] Step seven, wait for the sealant in the insertion slots 3-1, the first sealing grooves 4 and the second sealing grooves 5 to solidify, and the light-emitting module is prepared.

[0107] It should be noted that the sealant can not be injected into the insertion slot 3-1 in the light-emitting area 3-3 under the condition that the connection between the insertion piece 1-3 and the insertion slot 3-1 is stable enough.

[0108] Embodiment 3

[0109] A light-emitting module based on the surrounding lens cover, the difference between this embodiment and embodiment 1 is that the groove structure on the inner side of the annular flange 1-2 of the lens cover 1 is different.

[0110] In this embodiment, the two length edges and the two width edges of the bottom edge of the annular flange 1-2 are provided with grooves with L-shaped cross section; the grooves on the two length edges and the two width edges are connected in sequence and end to end to form a ring; the grooves and the edges of the heat sink jointly form a first sealing groove 4 with U-shaped cross section and surrounding the heat sink. The first sealing groove 4 is filled with sealant.

[0111] The sealant in the first sealing groove 4 forms a sealing ring structure surrounding the heat sink after solidification, which can effectively improve the sealing effect of the light-emitting module; in this embodiment, since the sealant in the first sealing groove 4 can take into account the sealing on the width edges of the light-emitting module, the sealant can not be injected into the insertion slot in the end fastening area.

[0112] The other technical features of this embodiment are the same as those of embodiment 1.

[0113] Embodiment 4

[0114] A light-emitting module based on an encompassing lens cover, the difference between this embodiment and embodiment 1 is that the structure of the plug-in part 1-3 is different.

[0115] In this embodiment, as shown in Figure 10 The two sides of the plug-in part 1-3 are provided with wavy stripe structures 1-3-5. The sealant in the plug-in slot 3-1 enters the gap between the inner recessed area of the stripe structure 1-3-5 on the plug-in part 1-3 and the plug-in slot 3-1, so that the adhesion between the plug-in part 1-3 and the plug-in slot 3-1 is further increased on the basis of friction, improving the stability of the connection between the plug-in part 1-3 and the heat sink 3.

[0116] This embodiment provides a preferred non-essential technical feature: the side of the plug-in part 1-3 provided with the stripe structure 1-3-5 is formed with a glue guide groove extending from the root to the tip of the plug-in part 1-3.

[0117] The other technical features of this embodiment are the same as those of embodiment 1.

[0118] Embodiment 5

[0119] A light-emitting module based on an encompassing lens cover, on the basis of embodiment 1, this embodiment further has the following technical features: two positioning through holes are further provided on the light-emitting plate 2. Two positioning blind holes are provided on the heat sink 3. Two positioning columns are integrally formed on the inner side of the lens cover 1. The two positioning columns respectively pass through the two positioning through holes on the light-emitting plate 2 and respectively extend into the two positioning blind holes on the heat sink 3, thereby realizing the positioning between the lens cover 1, the light-emitting plate 2 and the heat sink 3.

[0120] The other technical features of this embodiment are the same as those of embodiment 1.

Claims

1. A light-emitting module based on an enveloping lens cover, comprising a lens cover (1), a light-emitting panel (2) and a heat sink (3); characterized in that: The heat sink (3) is made of profiled material; the lens cover (1) and the light-emitting plate (2) are arranged on the mounting surface of the heat sink (3); the light-emitting plate (2) is located between the lens cover (1) and the heat sink (3). The mounting surface of the heat sink (3) is provided with n slots (3-1); n≥2; the lens cover (1) comprises a lens main body (1-1), an annular flange (1-2) and a plug-in part (1-3); the inner side surface of the annular flange (1-2) is connected with the outer edge of the lens main body (1-1); the annular flange (1-2) surrounds the periphery of the mounting surface of the heat sink (3); n plug-in parts (1-3) are arranged on the lens main body (1-1) and form interference fit with the n slots (3-1) on the heat sink (3) respectively; a sealing structure is arranged between the inner side surface of the annular flange (1-2) and the edge of the heat sink (3). The slots (3-1) are directly formed in the process of extrusion molding of the heat sink (3). Along the arrangement direction of the slots (3-1), the mounting surface of the heat sink (3) is divided into two end fastening areas (3-2) staggered with the light-emitting plate (2) and a light-emitting area (3-3) aligned with the light-emitting plate (2); there are at least one slot (3-1) on each of the two end fastening areas (3-2); the slots (3-1) in the end fastening areas (3-2) are filled with sealing glue. Two length edges of the bottom edge of the annular flange (1-2) are provided with groove bodies; the groove bodies are communicated with the inner side surface of the annular flange (1-2); the two groove bodies on the annular flange (1-2) cooperate with the edge of the heat sink to form two first sealing grooves (4); the first sealing grooves (4) are filled with sealing glue; the end part of the sealing glue in the first sealing groove (4) is integrated with the end part of the sealing glue in the two slots (3-1) in the end fastening area (3-2) to form a ring-shaped sealing structure. 2.The light-emitting module based on the surrounding lens cover according to claim 1, wherein: Two length edges of the bottom edge of the annular flange (1-2) are provided with groove bodies; the two groove bodies on the annular flange (1-2) cooperate with the edge of the heat sink to form two first sealing grooves (4); the first sealing grooves (4) are filled with sealing glue. 3.The light-emitting module based on the surrounding lens cover according to claim 1, wherein: The top edge of the slot (3-1) in the end fastening area (3-2) is higher than the light-emitting area on the heat sink (3).

4. The light emitting module based on the surround lens cover according to claim 1, characterized in that: The plug-in part (1-3) corresponding to the slot (3-1) in the end fastening area (3-2) adopts an integral structure and extends from one side edge of the inner side surface of the lens main body (1-1) to the other side edge.

5. The light emitting module based on the surround lens cover according to claim 1, characterized in that: Along the arrangement direction of the slots (3-1), the mounting surface of the heat sink (3) is divided into two end fastening areas (3-2) staggered with the light-emitting plate (2) and a light-emitting area (3-3) aligned with the light-emitting plate (2); there are at least one slot (3-1) on the light-emitting area (3-3).

6. The light emitting module based on the surround lens cover according to claim 5, characterized in that: The plug-in part (1-3) corresponding to the slot (3-1) in the light-emitting area 3-3 adopts an independent structure, including a plug-in block (1-3-1) or a plurality of plug-in blocks (1-3-1) independently and sequentially arranged at intervals; the width of the plug-in block (1-3-1) along the length direction of the slot (3-1) is less than the width of the light-emitting plate (2) along the length direction of the slot (3-1); part or all of the plug-in blocks (1-3-1) pass through the clearance slot on the light-emitting plate (2) as a whole or partially.

7. The light emitting module based on the surround lens cover according to claim 6, characterized in that: The number m of plug-in blocks in part or all of the plug-in parts (1-3) adopting the independent structure is greater than or equal to 3; two plug-in blocks (1-3-1) in the m plug-in blocks are respectively located at the two side edges of the inner side of the lens body (1-1); at least one plug-in block (1-3-1) in the remaining plug-in blocks (1-3-1) passes through the clearance slot (2-1) provided on the light-emitting plate (2) as a whole. 8.The light-emitting module based on the surrounding lens cover according to claim 6, wherein: The cross-sectional shape of part or all of the clearance slot (2-1) matches the cross-sectional shape of the corresponding plug-in block (1-3-1), so that the plug-in block (1-3-1) can provide positioning for the light-emitting plate (2) through the clearance slot (2-1). 9.The light-emitting module based on the surrounding lens cover according to claim 1, wherein: The two length edges of the side surface of the lens body (1-1) facing the heat sink (3) are each provided with a second sealing groove (5); each plug-in part in the light-emitting area (3-3) is located between the two second sealing grooves (5); the two second sealing grooves (5) are each filled with sealing glue.

10. The light emitting module based on the surround lens cover according to claim 1, characterized in that: The static friction force exists between the plug-in part (1-3) and the slot (3-1) at the interference position; the static friction force causes the extrusion force between the lens cover (1) and the light-emitting plate (2).

11. The light emitting module based on the surround lens cover according to claim 10, characterized in that: The static friction force between the plug-in part (1-3) and the slot (3-1) comes from the pre-tightening force applied during the assembly of the lens cover (1) and the heat sink (3); the pre-tightening force is 5000N-30000N. 12.The light-emitting module based on the surrounding lens cover according to claim 1, wherein: The plug-in part (1-3) is provided with a gap (1-3-2); the depth of the gap (1-3-2) is less than the height of the plug-in part (1-3); the plug-in part (1-3) is divided into a deformation part (5-1-2) corresponding to the position of the gap (1-3-2) and an interference part (5-1-3) offset from the position of the gap (1-3-2) in the height direction; the interference part (5-1-3) forms an interference fit with the slot (3-1), and the interference amount is 0.1mm-0.3mm.

13. The light emitting module based on the surround lens cover according to claim 1, characterized in that: The regions of the side wall of the slot (3-1) forming the interference fit with the plug-in part (1-3) are all inclined from the inside to the outside in the depth direction of the slot (3-1). 14.The light emitting module based on the surrounding lens cover according to claim 1, wherein: The two side surfaces of the plug-in part (1-3) facing the side wall of the slot (3-1) are both uneven.

15. The light emitting module based on the surround lens cover according to claim 14, characterized in that: The uneven side surface of the plug-in part (1-3) has a glue guide groove extending from the root of the plug-in part (1-3) to the tip.

16. The light emitting module based on the surround lens cover according to claim 1, characterized in that: The position of part or all of the slot (3-1) connected to the corresponding plug-in part (1-3) is filled with sealing glue.

17. The light emitting module based on the surround lens cover according to claim 1, characterized in that: The two length edges and the two width edges of the bottom edge of the annular flange (1-2) are provided with groove bodies; the groove bodies are in communication with the inner side of the annular flange (1-2); the groove bodies on the two length edges and the two width edges are sequentially connected in a ring shape; the groove bodies and the edge of the heat sink jointly enclose a first sealing groove (4) surrounding the heat sink; the first sealing groove (4) is filled with sealing glue.

18. The light emitting module based on the surround lens cover according to claim 1, characterized in that: The two sides of the heat sink (3) are respectively a mounting surface and a heat dissipation surface; the mounting surface of the heat sink (3) is attached to the light-emitting plate (2); the heat dissipation surface of the heat sink (3) is provided with heat dissipation fins arranged at intervals; the interval of the heat dissipation fins is 8mm-12mm; the height of the heat dissipation fins is 30mm-38mm.

19. The light emitting module based on the surround lens cover according to claim 1, characterized in that: The light-emitting plate (2) comprises a PCB board and a plurality of lamp beads distributed on the PCB board; the lens main body (1-1) is provided with a plurality of lens units; the positions of the lens units respectively correspond to the positions of the lamp beads on the light-emitting plate (2).

20. The light emitting module based on the surround lens cover according to claim 1, characterized in that: The annular flange (1-2) forms a ring of convex edges higher than the side of the lens main body (1-1) away from the heat sink (3) at the edge of the lens main body (1-1).

21. The light emitting module based on the surround lens cover according to claim 1, characterized in that: A plurality of positioning through holes are formed on the light-emitting plate (2); a plurality of positioning blind holes are formed on the heat sink (3); a plurality of positioning columns are provided on the inner side of the lens cover (1); each positioning column passes through the corresponding positioning through hole on the light-emitting plate (2) and extends into the corresponding positioning blind hole on the heat sink (3).

22. A method for preparing a light-emitting module, characterized in that: A light-emitting module based on an enclosing lens cover is prepared according to any one of claims 1-21; The preparation method comprises the following steps: Step one, the heat sink (3) is processed by an extrusion molding process; Step two, the light-emitting plate (2) is placed on the heat sink (3); Step three, the lens cover (1) is placed above the light-emitting plate (2), so that the n insertion pieces (1-3) on the lens cover (1) respectively extend into the n insertion slots (3-1) on the heat sink (3); Step four, an extrusion force is applied to the lens cover (1) towards the heat sink; under the action of the extrusion force, each insertion piece (1-3) and the insertion slot (3-1) form an interference fit; Step five, the first sealing groove (4) formed between the annular flange (1-2) and the heat sink (3) is filled with sealing glue; after the sealing glue is cured, the light-emitting module is prepared.

23. The method of claim 22, wherein: Before step two is performed, liquid sealing glue is also injected into the areas where part or all of the insertion slots (3-1) and the insertion pieces are aligned.

24. A method for preparing a light-emitting module, characterized in that: A light-emitting module based on an enclosing lens cover is prepared according to claim 1; The preparation method comprises the following steps: Step one, the lens cover (1), the light-emitting plate (2) and the heat sink (3) are obtained; On the lens cover (1), groove bodies are provided on the two length edges of the bottom edge of the annular flange (1-2); second sealing grooves (5) are provided on the two length edges of the side of the lens main body (1-1) facing the heat sink (3); On the heat sink (3), along the arrangement direction of each slot (3-1), the mounting surface of the heat sink (3) is divided into two end fastening areas (3-2) staggered with the light-emitting plate (2) and a light-emitting area (3-3) aligned with the light-emitting plate (2); there is at least one slot (3-1) on each of the two end fastening areas (3-2); the plug-in part (1-3) corresponding to the slot (3-1) in the end fastening area (3-2) adopts an integrated structure extending from one side edge of the inner side surface of the lens main body (1-1) to the other side edge; Step two, inject liquid sealant into the slots (3-1) on the mounting surface of the heat sink (3) located in the two end fastening areas (3-2); Step three, place the light-emitting plate (2) on the heat sink (3); Step four, fill sealant into the two second sealing grooves (5) on the inner side surface of the lens cover (1); then, place the lens cover (1) above the light-emitting plate (2), so that the n plug-in parts (1-3) on the lens cover (1) respectively extend into the n slots (3-1) on the heat sink (3); Step five, apply a pressing force to the lens cover (1) towards the heat sink; under the action of the pressing force, each plug-in part (1-3) forms an interference fit with the slot (3-1); two first sealing grooves (4) are formed between the two grooves on the annular flange (1-2) and the edge of the heat sink; Step six, fill sealant into the two first sealing grooves (4); after the sealant solidifies, the light-emitting module is completed.

Images