Eave lamp and production method thereof

Abstract

The invention discloses an eave lamp and a production method thereof.The eave lamp comprises a waterproof rubber coating body, a lens and a light-emitting device, a device space used for containing the light-emitting device is formed in the lens, a mounting opening is formed in the bottom of the lens, and the light-emitting device is arranged in the device space through the mounting opening; and the waterproof rubber coating body coats the mounting port through injection molding of a mold so as to seal the device space. The lens comprises a lens body and a base shell used for being connected with the waterproof rubber coating body, the lens body is arranged on the top of the base shell, and the installation opening is formed in the bottom face of the base shell. The outer contour of the bottom of the lens body is located within the range of the outer contour of the base shell so that the top face of the base shell can form a combination step face relative to the side wall of the lens body, and the base shell is wrapped in the waterproof rubber coating body. The LED lamp is simple in structure, easy to produce in batches and good in waterproof effect.

Description

Technical Field

[0001] The present invention relates to the technical field of outdoor lighting for houses, and in particular to an eaves lamp and a production method thereof. Background Art

[0002] The conventional structure of existing eaves lights typically consists of a housing, base cover, lens, and light source board. After assembly, glue is poured between the housing and base cover to achieve a waterproof seal. However, due to the small size of eaves lights, pouring glue between the housing and base cover is difficult, making the glue pouring process complex and highly unstable during production, thus affecting the quality of the glue pouring. Furthermore, waiting for the glue to dry completely wastes significant production time, hindering mass production. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide an eaves lamp which has a simple structure, is easy to mass produce and has a good waterproof effect.

[0004] The technical problem to be solved by the present invention is to provide a production method of an eaves lamp, which simplifies the assembly process and has strong waterproof performance and high production efficiency.

[0005] In order to solve the above technical problems, the present invention provides an eave lamp, including a waterproof encapsulated body, a lens and a light-emitting device, wherein a device space for accommodating the light-emitting device is provided in the lens, and a mounting port is provided at the bottom of the lens, and the light-emitting device is placed in the device space through the mounting port; the waterproof encapsulated body is covered with the mounting port by mold injection molding to seal the device space.

[0006] The lens includes a lens body and a base shell for connecting with the waterproof encapsulated body. The lens body is arranged on the top of the base shell, and the installation port is opened at the bottom surface of the base shell.

[0007] The bottom outer contour of the lens body is located within the range of the outer contour of the base shell, so that the top surface of the base shell forms a bonding step surface relative to the side wall of the lens body, and the base shell is enclosed in the waterproof encapsulation.

[0008] As an improvement of the above solution, the light-emitting device includes a light-emitting element and a control board for control and power supply, the control board is provided with a light-emitting area for installing the light-emitting element, the light-emitting element is provided on the control board, and the light-emitting area is correspondingly provided below the lens body.

[0009] As an improvement to the above solution, the shape of the mounting opening is adapted to the control board so as to define the relative position between the light-emitting area and the lens body after the control board is placed in the device space.

[0010] As an improvement to the above solution, the lens further includes a rubber-coated spacer ring of a preset thickness, and the rubber-coated spacer ring is provided between the lens body and the base shell;

[0011] The thickness of the rubber-coated spacer ring is 1 / 3 to 1 / 2 of the minimum width of the bonding step surface.

[0012] As an improvement to the above solution, both sides of the control board are electrically connected with wiring harnesses for electrical connection, and both side walls of the base shell are provided with circuit openings for the wiring harnesses to pass through.

[0013] As an improvement to the above solution, the side wall of the waterproof encapsulated body is provided with a connecting ear, and the connecting ear is provided with a connecting hole for connecting with an external component.

[0014] As an improvement to the above solution, the side wall of the waterproof encapsulated body is provided with a wiring harness protection portion corresponding to the line opening, and the wiring harness protection portion protrudes by a preset length relative to the side wall of the waterproof encapsulated body to wrap the wiring harness passing through the waterproof encapsulated body.

[0015] As an improvement of the above solution, the light-emitting element includes a main lamp bead and multiple auxiliary lamp beads, and the auxiliary lamp beads are evenly distributed around the main lamp bead.

[0016] As an improvement to the above solution, the waterproof encapsulated body and the harness protection portion are an integrated structure, and are both formed in one step by injection molding.

[0017] A method for producing an eaves lamp comprises the following steps:

[0018] Prepare a lens and a light-emitting device. The lens includes a lens body and a base housing for connecting to the waterproof encapsulated body. The light-emitting device includes a control board for control and power supply and a light-emitting element electrically connected to the control board. The base housing has a mounting port for embedding the control board.

[0019] Weld the wiring harness to the control board of the light-emitting device, and then embed the control board into the mounting port of the lens to complete the assembly between the light-emitting device and the lens, obtaining a semi-finished product for use;

[0020] The injection mold is provided with a plurality of mold cavities for forming waterproof encapsulated bodies, so as to respectively accommodate the semi-finished products;

[0021] After all the semi-finished products are placed in the corresponding mold cavities, the injection mold is injection molded to form a waterproof encapsulated body;

[0022] After the waterproof colloid is cooled, the waterproof colloid is combined with the semi-finished product to obtain an eaves lamp with the installation opening wrapped and sealed by the waterproof colloid.

[0023] As an improvement to the above solution, the injection mold includes a bottom mold and a top mold, the bottom mold is provided with a lens groove adapted to the lens body, the lens further includes a rubber-coated spacer ring of a preset thickness, the rubber-coated spacer ring is provided between the lens body and the base shell, and after the lens body is placed in the lens groove, the rubber-coated spacer ring is supported on the mold-matching end surface of the bottom mold to maintain a gap of the preset thickness between the base shell and the mold-matching end surface of the bottom mold;

[0024] The top mold is provided with a sealing groove for forming a waterproof colloid. When the bottom mold and the top mold are closed, a preset distance is left between the surface of the base shell and the inner wall of the sealing groove to form a colloid space for injecting the colloid.

[0025] After the colloid space is filled with colloid and cooled, a waterproof colloid body is formed to wrap the base shell.

[0026] The implementation of the present invention has the following beneficial effects:

[0027] The present invention discloses an eaves lamp, comprising a waterproof encapsulated body, a lens, and a light-emitting device. A device space for accommodating the light-emitting device is provided in the lens, and a mounting port is provided at the bottom of the lens, through which the light-emitting device is placed in the device space; the waterproof encapsulated body is covered with the mounting port by mold injection molding to seal the device space. Therefore, the eaves lamp of the present invention is assembled with only two parts, and the waterproof encapsulated body can be formed by mold injection molding while achieving a stable connection between the lens and the light-emitting device and a fully enclosed waterproof sealing process. Therefore, the present invention eliminates the need for the existing mosaic assembly of the waterproof outer shell and the bottom shell, and can complete the sealing assembly and achieve a waterproof effect only by injection molding.

[0028] Furthermore, the lens includes a lens body and a base shell for connecting to the waterproof encapsulation. The lens body is disposed on the top of the base shell, and the mounting opening is formed on the bottom surface of the base shell. The bottom outer contour of the lens body is located within the outer contour of the base shell, so that the top surface of the base shell forms a bonding step relative to the side wall of the lens body, and the base shell is enclosed in the waterproof encapsulation. With this arrangement, after the waterproof encapsulation is formed, the waterproof encapsulation is enclosed at the bonding step, which prevents separation between the lens and the waterproof encapsulation, thereby ensuring assembly stability and waterproofness between the lens and the light-emitting device.

[0029] Correspondingly, the present invention also discloses a production method for the above-mentioned eaves lamp, which simplifies the assembly process, and the product has strong waterproof performance and high production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1It is a schematic diagram of the three-dimensional structure of the eaves lamp of the present invention;

[0031] Figure 2 It is a schematic diagram of the structural decomposition of the lens and the light-emitting device of the present invention;

[0032] Figure 3 is a schematic cross-sectional view of the lens and light-emitting device of the present invention;

[0033] Figure 4 It is a structural schematic diagram of the injection mold of the present invention. DETAILED DESCRIPTION

[0034] In order to make the objectives, technical solutions and advantages of the present invention more clear, the present invention will be described in further detail below with reference to the accompanying drawings.

[0035] See also Figure 1 、 2 And 3, the present invention provides an eaves lamp, including a waterproof encapsulated body 1, a lens and a light-emitting device, wherein a device space 2a for accommodating the light-emitting device is provided in the lens, and a mounting port 2b is provided at the bottom of the lens, and the light-emitting device is placed in the device space 2a through the mounting port 2b; the waterproof encapsulated body 1 is covered with the mounting port 2b by mold injection molding to seal the device space 2a.

[0036] The lens includes a lens body 2 and a base shell 3 for connecting with the waterproof encapsulated body 1 . The lens body 2 is arranged on the top of the base shell 3 , and the mounting port 2 b is opened at the bottom surface of the base shell 3 .

[0037] The bottom outer contour of the lens body 2 is located within the range of the outer contour of the base shell 3, so that the top surface of the base shell 3 forms a bonding step surface 3a relative to the side wall of the lens body 2, and the base shell 3 is enclosed in the waterproof encapsulation body 1.

[0038] Specifically, the light emitting device includes a light emitting element 4 and a control board 5 for control and power supply, wherein the light emitting element 4 is provided on the control board 5. The control board 5 can be a conventional PCB circuit board, and its structural principle is not described in detail here.

[0039] In order to ensure the lighting effect of the light emitting element 4, the control board 5 is provided with a light emitting area for mounting the light emitting element 4, and the light emitting area is correspondingly provided below the lens body 2. The light emitting element 4 is electrically connected to the light emitting area of ​​the control board 5.

[0040] The light-emitting element 4 includes a main lamp bead 41 and a plurality of auxiliary lamp beads 4, which are evenly distributed around the main lamp bead 41. Preferably, both the main lamp bead 41 and the auxiliary lamp beads 4 are LED lamp beads, and the power of the main lamp bead 41 is greater than that of the auxiliary lamp beads 4. This matches the hemispherical lens shape of the lens body 2 to achieve the optical effect of spherical refraction.

[0041] Furthermore, in order to facilitate the relative position between the light-emitting area and the lens body 2, the shape of the mounting opening is adapted to the control board, so that after the control board 5 is placed in the device space 31, the light-emitting area is correspondingly located below the lens body 2. Preferably, the control board 5 is in the shape of a regular polygon.

[0042] In order to facilitate the outdoor installation of the eaves lamp, the side wall of the waterproof colloid body 1 is provided with a connecting ear 11, and the connecting ear 11 is provided with a connecting hole 12 for connecting with an external component.

[0043] For powering the control board 5, the side walls of the base housing 3 are provided with line ports 32 for inserting the wiring harness 6. To facilitate the series connection of the eaves lights, the control board 5 is electrically connected to the wiring harness 6 on both sides, and the side walls of the base housing 3 are provided with line ports 32 for inserting the wiring harness.

[0044] The sidewall of the waterproof coating 1 is provided with a wire harness protector 13 corresponding to the wiring opening 32. This protector 13 protrudes from the sidewall of the waterproof coating 1 by a predetermined length to enclose the wire harness exiting the coating 1. The provision of this protector 13 not only significantly reduces the risk of wires being damaged by bending but also further reduces the distance for external water to penetrate between the wires and the waterproof coating 1, thereby enhancing waterproofing.

[0045] Preferably, the waterproof encapsulated body 1 and the harness protection portion 13 are an integrated structure and are made of soft rubber. Preferably, the lens is an integrated structure, the lens is made of a hard base material PC material, and the waterproof encapsulated body 1 and the harness protection portion 13 are made of a soft rubber PVC material.

[0046] Accordingly, the waterproof encapsulated body 1 and the harness protection portion 13 can be molded in one step by injection molding. Preferably, the waterproof encapsulated body 1 and the harness protection portion 13 can be connected to the lens body 2 by mold injection molding, thereby enabling rapid mass production and strong sealing.

[0047] Furthermore, to facilitate the injection molding of the waterproof encapsulated body 1 and the harness protection portion 13, the lens also includes an encapsulated spacer ring 9 of a preset thickness, which is positioned between the lens body 2 and the base shell 3. The design of the encapsulated spacer ring 9 allows the integrated lens to be placed upside down in the injection mold. This allows the encapsulated spacer ring 9 to be supported on the mold end face, thereby forming an injection space 8a between the base shell 3 and the mold end face, thereby allowing the base shell 3 to be enclosed within the waterproof encapsulated body 1. This design greatly simplifies the structural design of the corresponding injection mold and also standardizes the placement of the lens.

[0048] Preferably, the thickness of the rubber-encapsulated spacer ring 9 is 1 / 3 to 1 / 2 of the minimum width of the bonding step. This design prevents the height of the rubber-encapsulated spacer ring 8a from being too large, which could cause peeling between the sidewall of the rubber-encapsulated spacer ring 9 and the waterproof overmolding body 1 due to plastic shrinkage after injection molding. Similarly, the height of the rubber-encapsulated spacer ring 9 is prevented from being too small, which could make it difficult to fully fill the injection molding space 8a and affect the complete molding of the waterproof overmolding body 1.

[0049] See also Figure 4 The present invention also provides a method for producing an eaves lamp, comprising the following steps:

[0050] 1. Prepare a lens and a light-emitting device. The lens includes a lens body 2 and a base shell 3 for connecting to a waterproof encapsulated body 1. The light-emitting device includes a control board 5 for control and power supply and a light-emitting element 4 electrically connected to the control board. The base shell 3 is provided with an installation port 2b for inserting the control board 5. The structure of the lens and the light-emitting device is similar to that of the embodiment of FIG. Figure 1-3 The corresponding structures shown are the same and will not be described in detail here.

[0051] 2. Solder the wiring harness 6 to the control board 5 of the light emitting device to complete the electrical connection between the wiring harness 6 and the control board 5;

[0052] Then the control board 5 is embedded in the mounting port 2b of the lens to complete the assembly between the light-emitting device and the lens, and a semi-finished product is obtained for use; since the mounting port 2b will be sealed by the subsequent waterproof encapsulated body, the chimeric assembly method of the control board 5 and the lens does not require the installation of additional connecting accessories, and the assembly method is simple, and it only needs to ensure that the assembly relationship is maintained during the subsequent transfer to the injection mold.

[0053] 3. The injection mold is provided with a plurality of mold cavities for forming a waterproof encapsulated body, so as to respectively accommodate the semi-finished products;

[0054] After all the semi-finished products are placed in the corresponding mold cavities, the injection mold is used for injection molding to form a waterproof encapsulated body; therefore, the production method of the present invention can complete the injection molding of multiple eaves lamps at one time, with high production efficiency.

[0055] 4. After the waterproof colloid is cooled, the waterproof colloid is combined with the semi-finished product to obtain an eaves lamp with the installation opening 2b wrapped and sealed by the waterproof colloid 1.

[0056] Furthermore, the injection mold includes a bottom mold 7 and a top mold 8, the bottom mold 7 is provided with a lens groove 71 adapted to the lens body 2, and the lens also includes a rubber-coated spacer ring 9 of a preset thickness, the rubber-coated spacer ring 9 is arranged between the lens body 2 and the base shell 3, and after the lens body 2 is placed in the lens groove 71, the rubber-coated spacer ring 9 is supported on the clamping end face 7a of the bottom mold 7 to maintain a gap of the preset thickness between the base shell 3 and the clamping end face 7a of the bottom mold; the design of the gap allows the colloid to flow into the gap during the injection molding process.

[0057] The top mold 8 is provided with a sealing groove 81 for forming a waterproof encapsulated body, and the bottom mold 7 is also provided with a sealing bottom mold groove 72 corresponding to the sealing groove. When the bottom mold 7 and the top mold 8 are closed, a preset distance is left between the surface of the base shell 3 and the inner wall of the sealing groove 81 and the sealing bottom mold groove 72 to form a colloid space 8a for injecting colloid; after the colloid space 8a is filled with colloid and cooled, a waterproof encapsulated body 1 is formed to wrap the base shell 3.

[0058] Therefore, for the design of the rubber-coated spacer ring, since the lens body is generally in the shape of a semi-spherical shell, when placing the lens, the rubber-coated spacer ring is supported on the mold end face 7a of the bottom mold 7 to prevent the lens from being placed tilted, thereby causing the injection molding of the waterproof rubber-coated body 1 to have uneven thickness on the left and right sides.

[0059] Furthermore, the design of the rubber-encapsulated spacer ring maintains a gap of a predetermined thickness between the base housing 3 and the mold-clamping end surface 7a of the bottom mold 7. This gap allows the colloid to flow into the gap during the injection molding process. Consequently, the colloid flowing into the gap and the colloid space 8a are integrally molded during the injection molding process, thereby more comprehensively encapsulating the base housing 3. In particular, the colloid can be encapsulated up to the mating step 3a of the base housing 3, significantly improving the waterproof performance and preventing separation between the lens and the waterproof encapsulated body 1.

[0060] The above is a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. A roof lamp, characterized in that: The invention comprises a waterproof encapsulated body, a lens, and a light-emitting device. The lens is provided with a device space for accommodating the light-emitting device. The bottom of the lens is provided with a mounting opening, and the light-emitting device is placed in the device space through the mounting opening. The waterproof encapsulated body is molded by injection molding to cover the mounting opening to seal the device space. The lens comprises a lens body and a base shell for connecting to the waterproof encapsulated body, the lens body is arranged on the top of the base shell, and the mounting port is opened on the bottom surface of the base shell; The bottom outer contour of the lens body is located within the range of the outer contour of the base shell, so that the top surface of the base shell forms a bonding step surface relative to the side wall of the lens body, and the base shell is enclosed in the waterproof encapsulation.

2. The eaves lamp according to claim 1, characterized in that: The light emitting device includes a light emitting element and a control board for control and power supply. The control board is provided with a light emitting area for mounting the light emitting element. The light emitting element is provided on the control board, and the light emitting area is correspondingly provided below the lens body.

3. The eaves lamp according to claim 2, characterized in that: The shape of the mounting opening is adapted to the control board so as to define the relative position between the light-emitting area and the lens body after the control board is placed in the device space.

4. The eaves lamp according to claim 3, characterized in that: The lens further includes a rubber-coated spacer ring of a preset thickness, and the rubber-coated spacer ring is arranged between the lens body and the base shell; The thickness of the rubber-coated spacer ring is 1 / 3 to 1 / 2 of the minimum width of the bonding step surface.

5. The eaves lamp according to claim 2, characterized in that: Both sides of the control board are electrically connected with wiring harnesses for electrical connection, and both side walls of the base shell are provided with circuit openings for the wiring harnesses to pass through; The side wall of the waterproof colloid body is provided with a connecting ear, and the connecting ear is provided with a connecting hole for connecting with an external component.

6. The eaves lamp according to claim 5, characterized in that: The side wall of the waterproof lagging body is provided with a wire harness protection portion corresponding to the line opening, and the wire harness protection portion protrudes relative to the side wall of the waterproof lagging body by a preset length to wrap the wire harness passing through the waterproof lagging body.

7. The eaves lamp according to claim 2, characterized in that: The light-emitting element includes a main lamp bead and a plurality of auxiliary lamp beads, and the auxiliary lamp beads are evenly distributed around the main lamp bead.

8. The eaves lamp according to claim 6, characterized in that: The waterproof colloid body and the harness protection part are an integrated structure and are both formed in one step by injection molding.

9. A method for producing an eaves lamp, characterized in that: The following steps are involved: Prepare a lens and a light-emitting device. The lens includes a lens body and a base housing for connecting to the waterproof encapsulated body. The light-emitting device includes a control board for control and power supply and a light-emitting element electrically connected to the control board. The base housing has a mounting port for embedding the control board. Weld the wiring harness to the control board of the light-emitting device, and then embed the control board into the mounting port of the lens to complete the assembly between the light-emitting device and the lens, obtaining a semi-finished product for use; The injection mold is provided with a plurality of mold cavities for forming waterproof encapsulated bodies, so as to respectively accommodate the semi-finished products; After all the semi-finished products are placed in the corresponding mold cavities, the injection mold is injection molded to form a waterproof encapsulated body; After the waterproof colloid is cooled, the waterproof colloid is combined with the semi-finished product to obtain an eaves lamp with the installation opening wrapped and sealed by the waterproof colloid.

10. The eaves lamp according to claim 9, characterized in that: The injection mold includes a bottom mold and a top mold. The bottom mold is provided with a lens groove adapted to the lens body. The lens further includes a rubber-coated spacer ring of a preset thickness, which is provided between the lens body and the base shell. After the lens body is placed in the lens groove, the rubber-coated spacer ring is supported on the mold-matching end surface of the bottom mold to maintain a gap of the preset thickness between the base shell and the mold-matching end surface of the bottom mold. The top mold is provided with a sealing groove for forming a waterproof colloid. When the bottom mold and the top mold are closed, a preset distance is left between the surface of the base shell and the inner wall of the sealing groove to form a colloid space for injecting the colloid. After the colloid space is filled with colloid and cooled, a waterproof colloid body is formed to wrap the base shell.

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