An IP66 sealed housing and base assembly

Abstract

The application relates to the technical field of light controllers, in particular to an IP66 sealing mode shell and base assembly, which comprises a base and a shell installed on the base; the base is installed at the bottom of the shell through a gasket, the base and the gasket are integrally formed through a secondary injection molding process; the side of the shell is provided with a window; the base is further respectively provided with a connection terminal, a neutral terminal and a signal interface terminal; the connection terminal, the neutral terminal and the signal interface terminal are pressed into the base in a press riveting mode, and glue filling is carried out at the connection positions to reinforce the connection positions. The application can save the labor cost in the process, and the close cooperation between the integrally formed plastic part, the shell and the encapsulation makes the product have better dustproof and waterproof capacity.

Description

Technical Field

[0001] This invention relates to the field of light controller technology, specifically to an IP66 sealed housing and base assembly. Background Technology

[0002] Light controllers are ANSI C136.10 compliant light control products that provide an economical and reliable means of controlling lighting systems from dusk to dawn. These products are specifically designed to improve lighting system performance and energy efficiency. They employ advanced electronic circuitry to control lighting based on changes in natural light intensity, enabling daytime-off and nighttime-on functionality. Some advanced products also include 0-10VDC dimming, DALI, WIFI, Zhaga, and Zigbee communication capabilities.

[0003] To ensure that electronic circuits can function properly even under harsh conditions, XAI offers a UV-resistant, high-impact housing and base assembly that effectively seals and protects enclosed integrated circuitry, helping to protect the product from harsh conditions.

[0004] The base unit provides a power and signal interface solution between network lighting control and luminaire mounting sockets. The enclosed base unit provides IP66-rated dust and water resistance, protecting against harsh outdoor environments, including rain, snow, and salt spray.

[0005] Most photoelectric controllers on the market currently only achieve an IP54 dust and water resistance rating, which is detrimental to product lifespan and makes them unsuitable for long-term use in harsh environments. Photoelectric controllers that achieve an IP66 dust and water resistance rating require the use of O-rings, gaskets, and potting compound for waterproofing, resulting in higher product and labor costs. Summary of the Invention

[0006] The purpose of this invention is to provide an IP66 sealed housing and base assembly to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] An IP-sealed housing and base assembly includes a base and a housing mounted on the base;

[0009] The base is installed on the bottom of the outer shell by a gasket, and the base and the gasket are integrally formed by a secondary injection molding process;

[0010] The outer casing has a viewing window along its side edge; the base is also provided with a connection terminal, a neutral terminal and a signal interface terminal respectively, the connection terminal, the neutral terminal and the signal interface terminal are pressed into the base by riveting, and the connection is reinforced with glue.

[0011] As a further embodiment of the present invention: the outer casing includes an outer barrel, a mounting sleeve disposed at the bottom of the outer barrel, and a side socket opened on the side wall of the outer barrel. The viewing window is installed in the side socket. The base and the washer are assembled in the mounting sleeve. The connecting terminal, the neutral terminal and the signal interface terminal are inserted into the inner cavity of the outer barrel.

[0012] As a further embodiment of the present invention: the base includes an outer fixed section, an assembly section disposed within the outer fixed section, and a loading section disposed within the assembly section. The base is embedded into a washer within the assembly section, and the connecting terminal, neutral terminal, and signal interface terminal are mounted on the loading section.

[0013] As a further aspect of the present invention: the washer includes an upper retaining ring, a lower retaining ring disposed at the bottom of the upper retaining ring, and a positioning sleeve installed at the bottom of the lower retaining ring. The top of the upper retaining ring is provided with an external mounting thread, and the upper retaining ring is assembled to the bottom of the outer shell through the external mounting thread.

[0014] As a further aspect of the present invention: a combination gap is provided between the upper edge retaining ring and the lower edge retaining ring, and a plurality of mating protrusions are provided between the upper edge retaining ring and the lower edge retaining ring. The outer fixing section is embedded in the combination gap, and a plurality of mating holes are provided between the outer fixing section and the assembly section. The mating holes are arranged at equal angles, and the mating protrusions are assembled in the corresponding mating holes.

[0015] As a further aspect of the present invention: a plurality of clamping blocks are provided on the bottom plane of the assembly section, the clamping blocks are arranged in a ring structure, and a ring-shaped gasket is provided on the inner edge of the positioning sleeve. The loading section is assembled in the positioning sleeve and the ring-shaped clamping blocks and the ring-shaped gasket are tightly fitted together.

[0016] As a further embodiment of the present invention: the signal interface terminal includes an L-shaped terminal piece and assembly cards disposed on both sides of the L-shaped terminal piece. The L-shaped terminal piece is provided with positioning holes, and a strip groove matching the L-shaped terminal piece is provided in the loading area. The two sides of the strip groove are provided with engagement slots for the assembly cards.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] This embodiment's overall design comprises a shell, window, base, gasket, connecting terminals, neutral terminal, and signal interface terminal. The shell and window are combined to form a shell-window assembly, which is integrally molded using a secondary injection molding process. The base and gasket are combined to form a base assembly, which is also integrally molded using a secondary injection molding process. The connecting terminals, neutral terminal, and signal interface terminal are press-fitted into the base assembly. The circuit board has five pre-reserved solder pads, which can be reinforced by soldering the solder pads to the connecting terminals, neutral connecting terminals, and signal interface terminals. During final assembly, the shell-window assembly and the base assembly with the integrated circuit board are connected by press-fitting. Compared to traditional structural designs, this invention saves on labor costs in terms of process; the integrally molded plastic parts and the tight fit between the shell and the overlay give the product superior dust and water resistance.

[0019] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0020] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. Furthermore, these drawings and textual descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concepts of this application to those skilled in the art through reference to specific embodiments.

[0021] Figure 1 A schematic diagram of the structure of the housing and base assembly with IP66 sealing provided for an embodiment of the present invention.

[0022] Figure 2 A schematic diagram of the outer casing provided for an embodiment of the present invention.

[0023] Figure 3 This is a schematic diagram of the base and washer provided for an embodiment of the present invention.

[0024] Figure 4 A schematic diagram of the structure of a signal interface terminal provided for an embodiment of the present invention.

[0025] In the diagram: 1. Outer shell; 2. Viewing window; 3. Base; 4. Washer; 5. Connecting terminal; 6. Neutral terminal; 7. Signal interface terminal; 11. External casing; 12. Mounting sleeve; 13. Side socket; 21. External fixing section; 22. Assembly section; 23. Loading section; 24. Snap-in protrusion; 25. Embedded notch; 26. Clamping block; 27. Interlocking hole; 31. Upper edge retaining ring; 32. Lower edge retaining ring; 33. Positioning sleeve; 34. Mounting external thread; 35. Assembly gap; 36. Interlocking protrusion; 37. Annular gasket; 41. L-shaped terminal piece; 42. Assembly card; 43. Positioning hole; 51. Strip groove; 52. Snap-in opening. Detailed Implementation

[0026] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings, examples of which are illustrated in the drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or identical elements.

[0027] Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0028] The specific implementation of the present invention will be described in detail below with reference to specific embodiments.

[0029] In one embodiment:

[0030] Please see Figure 1 A housing and base assembly with IP66 sealing is provided, including a base 3 and a housing 1 mounted on the base 3;

[0031] The base 3 is installed on the bottom of the outer shell 1 by a washer 4, and the base 3 and the washer 4 are integrally formed by a secondary injection molding process.

[0032] The outer casing 1 has a viewing window 2 along its side edge; the base 3 is also provided with a connection terminal 5, a neutral terminal 6 and a signal interface terminal 7 respectively. The connection terminal 5, the neutral terminal 6 and the signal interface terminal 7 are pressed into the base 3 by riveting and the connection is reinforced with glue.

[0033] The overall design of this embodiment consists of a housing 1, a viewing window 2, a base 3, a gasket 4, a connecting terminal 5, a neutral terminal 6, and a signal interface terminal 7; the specific connection method is as follows:

[0034] The outer shell 1 and the window 2 are combined to form an outer shell and window assembly. The outer shell 1 and the window 2 are integrally formed by a secondary injection molding process. The base 3 and the gasket 4 are combined to form a base assembly. The base 3 and the gasket 4 are integrally formed by a secondary injection molding process.

[0035] This embodiment includes two connection terminals 5, one neutral connection terminal 6, and four signal interface terminals 7. The connection terminals 5, neutral terminal 6, and signal interface terminals 7 are combined with the base assembly to form a terminal base assembly. The connection terminals 5, neutral terminal 6, and signal interface terminals 7 are pressed into the base assembly by riveting, and glue is applied to the connection points for reinforcement to ensure that rainwater does not enter the product from there.

[0036] Assembly of circuit board and base assembly: The circuit board has five pre-reserved pads, which can be reinforced by soldering the pads to the connection terminals, neutral connection terminals and signal interface terminals.

[0037] Finished product assembly: The outer shell window assembly and the base assembly with integrated circuit board are connected by press-fitting.

[0038] Compared to traditional structural designs, this embodiment saves on labor costs in terms of manufacturing process; the one-piece molded plastic parts and the tight fit between the shell and the rubber coating give the product superior dust and water resistance; two connection terminals and one neutral connection terminal can provide power to the integrated circuit board; four signal interfaces enable the integrated circuit board to communicate with public networks, such as 0-10VDC dimming, DALI, WIFI, Zhaga, Zigbee, etc., depending on the product design.

[0039] In one embodiment:

[0040] Please see Figure 2 The outer casing 1 includes an outer barrel 11, a mounting sleeve 12 disposed at the bottom of the outer barrel 11, and a side inlet 13 opened on the side wall of the outer barrel 11. The viewing window 2 is installed in the side inlet 13. The base 3 and the gasket 4 are assembled in the mounting sleeve 12. The connecting terminal 5, the neutral terminal 6, and the signal interface terminal 7 are inserted into the inner cavity of the outer barrel 11. The outer casing 1 is an integral outer shell structure. The viewing window 2 is integrally installed in the side inlet 13 through a secondary injection molding process. The connecting terminal 5, the neutral terminal 6, and the signal interface terminal 7 are assembled on the base 3. The base 3 and the gasket 4 are assembled and then installed in the mounting sleeve 12, and the connection is reinforced with glue.

[0041] In one embodiment:

[0042] Please see Figure 2The base 3 includes an outer fixed section 21, an assembly section 22 disposed within the outer fixed section 21, and a loading section 23 disposed within the assembly section 22. The base 3 is embedded into the washer 4 through the assembly section 22. The connecting terminal 5, the neutral terminal 6, and the signal interface terminal 7 are mounted on the loading section 23.

[0043] The washer 4 includes an upper edge retaining ring 31, a lower edge retaining ring 32 disposed at the bottom of the upper edge retaining ring 31, and a positioning sleeve 33 installed at the bottom of the lower edge retaining ring 32. The top of the upper edge retaining ring 31 is provided with an external thread 34, and the upper edge retaining ring 31 is assembled to the bottom of the outer shell 1 by the external thread 34.

[0044] A combination gap 35 is provided between the upper edge retaining ring 31 and the lower edge retaining ring 32, and a plurality of mating protrusions 36 are provided between the upper edge retaining ring 31 and the lower edge retaining ring 32. The outer fixing section 21 is embedded in the combination gap 35. A plurality of mating holes 27 are provided between the outer fixing section 21 and the assembly section 22. The mating holes 27 are arranged at equal angles, and the mating protrusions 36 are assembled in the corresponding mating holes 27.

[0045] The gasket 4, including an upper retaining ring 31 and a lower retaining ring 32, clamps the base 3 from both sides to maintain an overall airtight seal. Several mating holes 27 are provided between the outer fixing section 21 and the assembly section 22 to securely assemble the upper retaining ring 31, the lower retaining ring 32, and the base 3 into the assembly section 22. The outer fixing section 21 is embedded within the assembly gap 35. The top of the upper retaining ring 31 is then assembled to the bottom of the outer casing 1 via an external thread 34, and the connection between the outer casing and the base assembly can be potted for protection.

[0046] In one embodiment, the outer edge of the outer fixed section 21 is provided with a snap-in protrusion 24 and an embedded notch 25, and the inner edge of the outer fixed section 21 is provided with a corresponding mating area and is installed with the upper edge retaining ring 31.

[0047] In one embodiment, a plurality of clamping blocks 26 are provided on the bottom plane of the assembly section 22. The clamping blocks 26 are arranged in a ring structure. An annular gasket 37 is provided on the inner edge of the positioning sleeve 33. The loading section 23 is assembled in the positioning sleeve 33 and the annularly arranged clamping blocks 26 are in close contact with the annular gasket 37.

[0048] In one embodiment:

[0049] Please see Figure 3The signal interface terminal 7 includes an L-shaped terminal piece 41 and assembly cards 42 disposed on both sides of the L-shaped terminal piece 41. The L-shaped terminal piece 41 is provided with positioning holes 43. The loading section 23 is provided with corresponding strip grooves 51 that match the L-shaped terminal piece 41. The two sides of the strip grooves 51 are provided with engagement slots 52 that are adapted to the assembly cards 42. The degree of fitting of the signal interface terminal 7 into the assembly is ensured from bottom to top. The assembly gap between the loading section 23 and the L-shaped terminal piece 41 can be reinforced by potting glue.

[0050] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0051] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A housing and base assembly with IP66 sealing, comprising a base and a housing mounted on the base; characterized in that, The base is installed on the bottom of the outer shell by a gasket, and the base and the gasket are integrally formed by a secondary injection molding process; The side edge of the housing is equipped with a viewing window; the base is also provided with a connection terminal, a neutral terminal and a signal interface terminal respectively, the connection terminal, the neutral terminal and the signal interface terminal are pressed into the base by riveting, and the connection is reinforced with glue; The base includes an outer fixing section, an assembly section disposed within the outer fixing section, and a loading section disposed within the assembly section. The base is embedded into a gasket within the assembly section, and the connection terminal, neutral terminal, and signal interface terminal are mounted on the loading section. The gasket includes an upper retaining ring, a lower retaining ring disposed at the bottom of the upper retaining ring, and a positioning sleeve installed at the bottom of the lower retaining ring. The top of the upper retaining ring is provided with an external mounting thread, and the upper retaining ring is assembled to the bottom of the outer shell through the external mounting thread. A combination gap is provided between the upper edge retaining ring and the lower edge retaining ring, and several mating protrusions are provided between the upper edge retaining ring and the lower edge retaining ring. The outer fixing section is embedded in the combination gap. Several mating holes are provided between the outer fixing section and the assembly section. The mating holes are arranged at equal angles. The mating protrusions are assembled in the corresponding mating holes.

2. The housing and base assembly with IP66 sealing according to claim 1, characterized in that, The housing includes an external barrel, a mounting sleeve disposed at the bottom of the external barrel, and a side socket opened on the side wall of the external barrel. The viewing window is installed in the side socket. The base and the gasket are assembled in the mounting sleeve. The connecting terminal, the neutral terminal and the signal interface terminal are inserted into the inner cavity of the external barrel.

3. The housing and base assembly with IP66 sealing according to claim 1, characterized in that, Several clamping blocks are provided on the bottom plane of the assembly section. The clamping blocks are arranged in a ring structure. An annular gasket is provided on the inner edge of the positioning sleeve. The loading section is assembled in the positioning sleeve and the annularly arranged clamping blocks and the annular gasket are tightly fitted together.

4. The housing and base assembly with IP66 sealing according to claim 3, characterized in that, The signal interface terminal includes an L-shaped terminal piece and assembly cards disposed on both sides of the L-shaped terminal piece. The L-shaped terminal piece is provided with positioning holes, and the loading area is provided with corresponding strip grooves that match the L-shaped terminal piece. The two sides of the strip grooves are provided with engagement slots for the assembly cards.

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