Lamp mask, manufacturing method thereof and lamp

Abstract

The invention provides a lamp mask, a preparation method thereof and a lamp. The lamp mask comprises a mask body and a support which are integrally formed and connected, the mask body is made of light-transmitting polypropylene, and the support is made of reinforced polypropylene. Therefore, by adopting the mask made of the polypropylene material, the material cost of the mask can be reduced, and the compatibility of the mask body and the bracket can be improved by adopting the same material; the polypropylene is not easy to generate stress concentration in the forming process and is good in solvent resistance, so that the problem of mask cracking (stress concentration is easy to induce cracking, and cracking is accelerated after the mask is in contact with alcohol, ketone and benzene solvents) can be reduced; the mask body and the support are integrally formed, the mask integration degree is improved, the continuous extrusion forming process is adopted for batch production, and the comprehensive cost of workpieces is further reduced.

Description

Technical Field

[0001] The invention relates to the technical field of lamps, and in particular to a lamp mask and a preparation method thereof, and a lamp. Background Art

[0002] In recent years, new energy vehicles have ushered in a development boom. At the same time, as the consumer group becomes younger, consumers' demand for car purchases has also risen from the initial means of transportation to a comfortable and intelligent mobile space. As the most direct object of user experience, the car interior has become the focus of the OEM's ingenuity. However, the experience of car interior is multi-dimensional, including shape, material, function, color, lighting, comfort, intelligence, etc. As an important part of the car interior experience, the application of ambient lighting has changed the monotonous and dull cockpit environment in the past, increased the driving experience and fun, and is deeply loved by users. It has also become an indispensable configuration for major OEMs.

[0003] The car interior ambient light is usually arranged in the instrument panel outline, instrument panel and sub-instrument panel, air outlet, cup holder and door guard plate, etc. It is mainly composed of LED light source, lamp head, mask, light guide bar, plug-in terminal, light strip bracket and other parts. Usually, the light guide bar is snapped into the bracket, then the mask is snapped into the bracket, and finally welded or screwed to the environmental part. The mask material is generally made of PC and PMMA transparent materials, but the mask made of this material has problems such as high material cost and easy stress cracking of the finished product. Summary of the invention

[0004] The present invention aims to solve one of the technical problems in the related art at least to a certain extent. To this end, one object of the present invention is to provide a lamp mask, the mask body and the bracket of the lamp mask are made of polypropylene material, which can reduce costs or reduce the occurrence of undesirable problems such as cracking.

[0005] In one aspect of the present invention, the present invention provides a lamp mask. According to an embodiment of the present invention, the lamp mask includes an integrally formed and connected mask body and a bracket, the mask body is made of light-transmitting polypropylene, and the bracket is made of reinforced polypropylene. Therefore, the mask made of polypropylene can reduce its material cost, and the same material is conducive to improving the compatibility between the mask body and the bracket; polypropylene is not easy to produce stress concentration during the molding process, and has good solvent resistance, so the problem of mask cracking can be reduced (stress concentration can easily induce cracking, and cracking will accelerate cracking after contact with alcohol, ketone and benzene solvents); the mask body and the bracket are integrally formed to improve the integration of the mask, and the continuous extrusion molding process is used for batch production, which further reduces the overall cost of the parts.

[0006] According to an embodiment of the present invention, the light-transmitting polypropylene meets the following conditions: light transmittance is 50% to 80%, and haze is 70% to 100%.

[0007] According to an embodiment of the present invention, based on the total weight of the bracket, the bracket includes: 15% to 35% of the reinforcing agent and 65% to 85% of the polypropylene in terms of mass percentage.

[0008] According to an embodiment of the present invention, the reinforcing agent includes talc and / or glass fiber.

[0009] In another aspect of the present invention, the present invention provides a method for preparing the aforementioned lamp mask. According to an embodiment of the present invention, the method for preparing the lamp mask comprises: adding a transparent polypropylene raw material to the barrel of a first extruder, and adding a reinforced polypropylene raw material to the barrel of a second extruder; the first extruder and the second extruder continuously extrude and mold the raw materials to obtain a primary product of a mask body and a bracket connected in one piece; the primary product is cooled and shaped to obtain the lamp mask. Thus, in the preparation method, the use of a mask made of polypropylene can reduce its material cost, and the same material is conducive to improving the compatibility of the mask body and the bracket; polypropylene is not easy to produce stress concentration during the extrusion molding process, and has good solvent resistance, so the problem of mask cracking can be reduced (stress concentration is easy to induce cracking, and cracking and accelerating cracking will occur after contact with alcohol, ketone and benzene solvents); the mask body and the bracket are integrally molded to improve the integration of the mask; the continuous extrusion integral molding process is adopted, and batch production is possible without mold opening, and the overall production cost is greatly reduced.

[0010] According to an embodiment of the present invention, the front section temperature of the first extruder and the second extruder is 180-200°C, the middle section temperature is 200-220°C, the rear section temperature is 200-240°C, and the screw speed is 50-100r / min.

[0011] According to an embodiment of the present invention, the processing temperature of the extrusion molding is 235-250°C.

[0012] According to an embodiment of the present invention, the cooling and shaping is performed in an air ring cooling device.

[0013] According to an embodiment of the present invention, the cooling and shaping satisfies at least one of the following conditions: the wind direction is the same as the extrusion direction; the length of the wind cooling field in the extrusion direction is 10 to 20 cm; the wind speed in the wind cooling field is 2 to 10 m / s, and the air outlet temperature is 5 to 20°C.

[0014] In another aspect of the present invention, the present invention provides a lamp. According to an embodiment of the present invention, the lamp includes the lamp cover described above. Therefore, the lamp adopts the lamp cover described above, and the lamp cover is not easy to crack and has high integration, which is conducive to improving the overall performance and service life of the lamp. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The above and / or additional aspects and advantages of the present invention will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0016] Figure 1 is a schematic diagram of the structure of a lamp cover in one embodiment of the present invention;

[0017] Figure 2 is a cross-sectional view of a lamp cover in one embodiment of the present invention;

[0018] Figure 3 is a real photo of a lamp mask in one embodiment of the present invention;

[0019] Figure 4 is a real photo of a lamp mask in another embodiment of the present invention;

[0020] Figure 5 The present invention is a flow chart of a method for preparing a lamp mask in another embodiment of the present invention. DETAILED DESCRIPTION

[0021] The scheme of the present invention will be explained below in conjunction with the embodiments. It will be appreciated by those skilled in the art that the following embodiments are only used to illustrate the present invention and should not be considered as limiting the scope of the present invention. Where specific techniques or conditions are not indicated in the embodiments, the techniques or conditions described in the literature in this area or the product specifications are used. The reagents or instruments used are not indicated by the manufacturer and are all conventional products that can be obtained commercially.

[0022] The present invention is described below with reference to specific embodiments. It should be noted that these embodiments are merely illustrative and do not limit the present invention in any way.

[0023] In one aspect of the present invention, the present invention provides a lamp cover. According to an embodiment of the present invention, referring to Figures 1 to 4 ( Figure 3 and Figure 4 The black part in the middle is the bracket, and the transparent part is the mask body). The lamp mask includes a mask body 10 and a bracket 20 that are integrally formed and connected. The material of the mask body 10 is translucent polypropylene, and the material of the bracket 20 is reinforced polypropylene. Therefore, the use of a mask made of polypropylene can reduce its material cost. The same material is conducive to improving the compatibility between the mask body and the bracket; polypropylene is not easy to produce stress concentration during the molding process, and has good solvent resistance, so the problem of mask cracking can be reduced (stress concentration is easy to induce cracking, and cracking will accelerate cracking after contact with alcohol, ketone and benzene solvents); the mask body and the bracket are integrally formed to improve the integration of the mask, and the continuous extrusion molding process is used for batch production, which further reduces the overall cost of the parts.

[0024] In the embodiment of the present invention, since the softening temperature of polypropylene is about 155°C, when the lamp cover is used, the heat generated by the irradiated light is far from enough to soften it, which means that when the polypropylene cover is applied to the lamp, it can meet the heat resistance requirements of the lamp cover.

[0025] According to some embodiments of the present invention, translucent polypropylene (or the mask body) meets the following conditions: the transmittance is 50% to 80%, for example, the transmittance is 50%, 55%, 60%, 65%, 70%, 75%, 80%, etc. The mask body with the above transmittance can ensure that the light can pass through the mask body, thereby ensuring the lighting function of the lamp; the haze of translucent polypropylene is 70% to 100%, and when light is irradiated on the mask body with the above haze, a certain amount of scattering occurs, which weakens the intensity of the transmitted light and improves the mildness of the illumination.

[0026] According to some embodiments of the present invention, based on the total weight of the bracket, the bracket includes, by mass percentage: 15% to 35% (for example, 15%, 18%, 20%, 22%, 25%, 27%, 30%, 32%, 35%, etc.) of a reinforcing agent and 65% to 85% of polypropylene (for example, 65%, 68%, 70%, 72%, 75%, 78%, 80%, 82%, 85%, etc.). The above proportions of reinforced polypropylene can not only achieve good compatibility with the mask body material, but also ensure good properties of polypropylene such as temperature resistance.

[0027] According to some embodiments of the present invention, the reinforcing agent includes talcum powder and / or glass fiber. The reinforcing agent can effectively achieve the reinforcing effect on polypropylene, and the material source is wide, easy to purchase, and low in cost.

[0028] According to an embodiment of the present invention, the bracket can be designed as a snap-on structure, so that it is easy to match and connect with other external structures.

[0029] According to some embodiments of the present invention, there are no special requirements for the specific size and shape of the lamp cover, and those skilled in the art can flexibly design it according to the actual conditions such as the light guide bar, the light source and the installation environment. In some embodiments, the lamp cover is a long strip, such as Figures 1 to 4 In other embodiments, the lamp mask is used as an atmosphere lamp cover for automobile interior decoration, and can be arranged on the instrument panel outline, instrument panel and sub-instrument panel, air outlet, cup holder and door guard plate. The lamp mask is assembled with light guide strip, LED light source lamp head, plug-in terminal and other structures to obtain a lamp.

[0030] In another aspect of the present invention, the present invention provides a method for preparing the above-mentioned lamp mask. Figure 5 , the method for preparing the lamp mask comprises:

[0031] S100: adding a transparent polypropylene raw material into the barrel of the first extruder, and adding a reinforced polypropylene raw material into the barrel of the second extruder.

[0032] In some embodiments of the present invention, the first extruder and the second extruder may both be twin-screw extruders. In a specific production process, the extrusion production line is equipped with two twin-screw extruders, and the light-transmitting polypropylene material and the enhanced polypropylene material are added to the barrels of the two twin-screw extruders respectively.

[0033] Furthermore, in some embodiments, before adding the light-transmitting polypropylene material and the reinforced polypropylene material into the barrel, the light-transmitting polypropylene material and the reinforced polypropylene material may be dried in advance to remove the moisture therein. In some specific embodiments, the drying temperature is 80 to 100° C., and the drying environment is a vacuum environment, specifically, the drying may be performed in a vacuum drying oven for 2 to 4 hours. The above conditions can ensure that the moisture is completely removed without affecting the performance of the polypropylene itself.

[0034] S200: The first extruder and the second extruder continuously extrude the raw materials to obtain a primary product of a mask body and a bracket that are integrally formed and connected.

[0035] According to some embodiments of the present invention, the temperature of the front section of the first extruder is 180-200°C, the temperature of the middle section is 200-220°C, the temperature of the rear section is 200-240°C, and the screw speed is 50-100r / min respectively; the temperature of the front section of the second extruder is 180-200°C, the temperature of the middle section is 200-220°C, the temperature of the rear section is 200-240°C, and the screw speed is 50-100r / min respectively. The temperature of the same section of the two extruders can be the same or different, and those skilled in the art can flexibly set it according to the actual processing requirements of the mask body and the bracket.

[0036] According to some embodiments of the present invention, the processing temperature of extrusion molding is 235-250° C., such as 235° C., 238° C., 240° C., 242° C., 245° C., 248° C., 250° C., etc. The above processing temperature can be well used to continuously extrude a molded molten mask embryo, that is, to obtain a primary product.

[0037] S300: Cooling and shaping the primary product to obtain a lamp cover. The molten embryo is shaped by cooling and shaping to obtain the final product, the lamp cover.

[0038] According to some embodiments of the present invention, the above cooling and shaping is performed in an air ring cooling device. The ring cooling device can perform air cooling on all sides, so that the product is evenly cooled on all sides, thereby improving the overall performance of the lamp cover.

[0039] According to some embodiments of the present invention, during cooling and shaping, the blowing direction of the air ring cooling device is the same as the extrusion direction, so that the wind direction blows along the extrusion direction, that is, the molten primary product is gradually cooled along the extrusion direction, which can prevent the primary product from deforming during the cooling process. In some embodiments, the length of the air cooling field of the air ring cooling device in the extrusion direction is 10 to 20 cm, such as 10 cm, 12 cm, 14 cm, 16 cm, 18 cm, 20 cm, etc., which can effectively ensure the cooling effect and make the molten primary product cool quickly; in some embodiments, the wind speed in the air cooling field is 2 to 10 m / s, and the air outlet temperature is 5 to 20°C, so that the molten primary product cools quickly.

[0040] In some embodiments of the present invention, the cooled and shaped lamp cover can be further cut and trimmed according to the designed size.

[0041] According to an embodiment of the present invention, in the above-mentioned preparation method, a mask made of polypropylene material can be used to reduce its material cost. The same material is conducive to improving the compatibility between the mask body and the bracket; polypropylene is not prone to stress concentration during the extrusion molding process and has good solvent resistance, so the problem of mask cracking can be reduced (stress concentration can easily induce cracking, and contact with alcohol, ketone and benzene solvents will cause cracking and accelerate cracking); the mask body and the bracket are integrally molded to improve the integration of the mask; the continuous extrusion integral molding process is adopted, and batch production is possible without the need for mold opening, and the overall production cost is greatly reduced.

[0042] In another aspect of the present invention, the present invention provides a lamp. According to an embodiment of the present invention, the lamp includes the lamp mask described above. Therefore, the lamp adopts the lamp mask described above, and the lamp mask is not easy to crack and has a high degree of integration, which is conducive to improving the overall performance and service life of the lamp. Those skilled in the art can understand that the lamp has all the features and advantages of the lamp mask described above, and no further elaboration is given here.

[0043] According to the embodiments of the present invention, there are no special requirements for the specific type and application of the lamp, and those skilled in the art can flexibly select according to actual needs. In some embodiments of the present invention, the lamp can be an atmosphere lamp for automobile interior decoration, and can be arranged in the instrument panel outline, instrument panel and sub-instrument panel, air outlet, cup holder and door guard plate, etc. Among them, in addition to the lamp mask mentioned above, the lamp further includes a light guide bar, an LED light source lamp holder, a plug-in terminal and other structures. The lamp mask is assembled with the light guide bar, the LED light source lamp holder, the plug-in terminal and other structures to obtain the above-mentioned lamp.

[0044] Example

[0045] Example 1

[0046] The method of preparing a lamp mask comprises:

[0047] T100: The light-transmitting polypropylene material and the talc-reinforced polypropylene material were dried in a vacuum drying oven at 90°C for 3 hours. The light-transmitting polypropylene material had a light transmittance of 75% and a haze of 83%. The talc-reinforced polypropylene material had a talc content of 20% and a polypropylene content of 80%.

[0048] T200: The extrusion production line is equipped with two twin-screw extruders. The barrel of the first twin-screw extruder is filled with light-transmitting polypropylene material, and the barrel of the second twin-screw extruder is filled with talcum powder-reinforced polypropylene material;

[0049] T300: The first twin-screw extruder and the second twin-screw extruder continuously extrude the raw materials to obtain a primary product of a molten mask body and a bracket that are integrally formed and connected, wherein the front section temperature of the first twin-screw extruder and the second twin-screw extruder are both 190°C, the middle section temperature is both 210°C, the rear section temperature is both 220°C, the screw speed is both 100r / min, and the extrusion production line processing temperature is 240°C;

[0050] T400: The extruded molten primary product is cooled and shaped in an air ring cooling device to obtain an atmosphere lampshade, wherein the air ring cooling device provides a 10 cm long air cooling field in the extrusion direction, the wind speed in the air cooling field is 5 m / s, and the air outlet temperature is 18°C.

[0051] Example 2

[0052] The method of preparing a lamp mask comprises:

[0053] T100: The light-transmitting polypropylene material and the talc-reinforced polypropylene material were dried in a vacuum drying oven at 100°C for 2 hours. The light-transmitting polypropylene material had a light transmittance of 55% and a haze of 95%. The talc-reinforced polypropylene material had a talc content of 30% and a polypropylene content of 70%.

[0054] T200: The extrusion production line is equipped with two twin-screw extruders. The barrel of the first twin-screw extruder is filled with light-transmitting polypropylene material, and the barrel of the second twin-screw extruder is filled with talcum powder-reinforced polypropylene material;

[0055] T300: The first twin-screw extruder and the second twin-screw extruder continuously extrude the raw materials to obtain a primary product of a molten mask body and a bracket that are integrally formed and connected, wherein the temperature of the front section of the first twin-screw extruder is set to 190°C, the temperature of the middle section is 210°C, the temperature of the rear section is 220°C, and the screw speed is 100r / min; the temperature of the front section of the second twin-screw extruder is 195°C, the temperature of the middle section is 215°C, the temperature of the rear section is 230°C, the screw speed is 70r / min, and the processing temperature of the extrusion production line is 245°C;

[0056] T400: The extruded molten primary product is cooled and shaped in an air ring cooling device to obtain an atmosphere lampshade, wherein the air ring cooling device provides a 15 cm long air cooling field in the extrusion direction, the wind speed in the air cooling field is 2 m / s, and the air outlet temperature is 12°C.

[0057] Example 3

[0058] The method of preparing a lamp mask comprises:

[0059] T100: The light-transmitting polypropylene material and the glass fiber reinforced polypropylene material were dried in a vacuum drying oven at 85°C for 4 hours. The light-transmitting polypropylene material had a light transmittance of 80% and a haze of 70%. The glass fiber reinforced polypropylene material had a glass fiber content of 15% and a polypropylene content of 85%.

[0060] T200: The extrusion production line is equipped with two twin-screw extruders. The barrel of the first twin-screw extruder is filled with light-transmitting polypropylene material, and the barrel of the second twin-screw extruder is filled with glass fiber-reinforced polypropylene material;

[0061] T300: The first twin-screw extruder and the second twin-screw extruder continuously extrude the raw materials to obtain the primary product of the molten mask body and the bracket which are integrally formed and connected, wherein the temperature of the front section of the first twin-screw extruder is set to 195°C, the temperature of the middle section is set to 210°C, and the temperature of the rear section is set to 225°C; the temperature of the front section of the second twin-screw extruder is set to 200°C, the temperature of the middle section is set to 220°C, the temperature of the rear section is set to 235°C, the screw speed is set to 80r / min, and the processing temperature of the extrusion production line is set to 250°C;

[0062] T400: The extruded molten primary product is cooled and shaped in an air ring cooling device to obtain an atmosphere lampshade, wherein the air ring cooling device provides a 20 cm long air cooling field in the extrusion direction, the wind speed in the air cooling field is 4 m / s, and the air outlet temperature is 20°C.

[0063] The lamp covers prepared in Examples 1 to 3 were respectively assembled with light guide strips, LED light source lamp holders, plug-in terminals and other structures to obtain lamps. The lamp covers prepared in Examples 1 to 3 were respectively tested for lighting thermal cycle, lighting heat resistance, cold resistance and chemical reagent corrosion resistance. The test results are shown in Table 1. The test method includes:

[0064] Lighting Thermal Cycle

[0065] Test method: Light up the lamp at a voltage of 13.5V±0.2V, and perform an aging test in a test chamber at 80℃ / 2h→20℃ / 0.5h→30℃ / 2h→20℃ / 0.5h for 5 cycles;

[0066] Technical requirements: no softening, cracking, gloss change, etc.

[0067] Lighting heat resistance

[0068] Test method: Light the lamp at a voltage of 13.5V±0.2V and place it in a test chamber at 80℃ for 8h;

[0069] Technical requirements: no softening, cracking, gloss change, etc.

[0070] cold resistance

[0071] Test method: Place the lamp in a test chamber at -40℃ for 72h;

[0072] Technical requirements: no softening, cracking, gloss change, etc.

[0073] Resistant to chemical corrosion

[0074] Test method: Apply artificial sweat, detergent and defogging agent to the surface of the lamp mask, wipe it eight times in both horizontal and vertical directions at a speed of 100 mm / s, and observe it for 1 hour;

[0075] Technical requirements: no abnormal phenomena such as cracks, breaks, whitening, peeling, expansion, gloss changes, fading, surface stickiness, softening and hardening.

[0076] Table 1

[0077]

[0078] It can be seen from Table 1 that the lamp cover of the present invention meets its use requirements and has good use performance.

[0079] The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0080] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, unless they are contradictory.

[0081] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present invention.

Claims

1. A lamp cover, characterized in that: It comprises a mask body and a bracket which are integrally formed and connected, the mask body is made of light-transmitting polypropylene, and the bracket is made of reinforced polypropylene.

2. The lamp cover according to claim 1, characterized in that: The light-transmitting polypropylene meets the following conditions: Light transmittance is 50% to 80%; The haze is 70% to 100%.

3. The lamp cover according to claim 1, characterized in that: Based on the total weight of the bracket, the bracket includes: 15% to 35% of the reinforcing agent and 65% to 85% of the polypropylene in terms of mass percentage.

4. The lamp cover according to claim 3, characterized in that: The reinforcing agent includes talc and / or glass fiber.

5. A method for preparing the lamp cover according to any one of claims 1 to 4, characterized in that: include: Adding transparent polypropylene raw material into the barrel of the first extruder, and adding reinforced polypropylene raw material into the barrel of the second extruder; The first extruder and the second extruder continuously extrude the raw materials to obtain a primary product of a mask body and a bracket that are integrally formed and connected; The primary product is cooled and shaped to obtain the lamp cover.

6. The method according to claim 5, characterized in that The temperatures of the front sections of the first extruder and the second extruder are 180-200° C., the temperatures of the middle sections are 200-220° C., the temperatures of the rear sections are 200-240° C., and the screw speeds are 50-100 r / min.

7. The method according to claim 5 or 6, characterized in that: The processing temperature of the extrusion molding is 235-250°C.

8. The method according to claim 5 or 6, characterized in that: The cooling and shaping is carried out in an air ring cooling device.

9. The method according to claim 8, characterized in that The cooling and shaping meets at least one of the following conditions: The wind direction is the same as the extrusion direction; The length of the air cooling field in the extrusion direction is 10 to 20 cm; The wind speed in the air cooling field is 2-10 m / s, and the air outlet temperature is 5-20°C.

10. A lamp, characterized in that: The invention comprises the lamp cover according to any one of claims 1 to 4.

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