Manufacturing method of attractive lampshade

Abstract

The invention relates to the field of lighting device manufacturing, in particular to an attractive lampshade manufacturing method which comprises the steps that firstly, one of a PC film, a PMMA + PC film, a PET film and a PU film with different thicknesses is selected according to requirements to prepare a film layer of a lampshade blank, and the lampshade blank is obtained after cutting and pattern printing; the blank is placed in a high-pressure gas forming mold and attached to a mold cavity through high-temperature and high-pressure gas subjected to gradient pressurization, and a lampshade primary product is formed; and the primary product is detected, leftover materials are cut, the primary product is put into an injection mold for injection molding after curing treatment, and a lampshade finished product with a preset pattern on the surface is obtained. According to the method, high-pressure gas forming and the injection molding process are combined, precise preparation of the lampshade of the multi-layer membrane structure is achieved, and the product shape and pattern quality are effectively controlled. The problem that in the prior art, even reflection light spots and lampshade quality cannot be considered at the same time during preparation of an energy-saving lampshade is solved, and optimization and unification of lampshade pattern attractiveness and structural strength are achieved.

Description

Technical Field

[0001] This invention relates to the field of lighting device manufacturing technology, and in particular to a method for manufacturing an aesthetically pleasing lampshade. Background Technology

[0002] With the rapid development of lighting technology, aesthetically pleasing lampshades, as key components for improving light source utilization efficiency and reducing energy consumption, have seen their manufacturing process optimization become a focus of industry research. However, traditional lampshade manufacturing methods have significant shortcomings in material forming control, optical performance regulation, and deformation resistance enhancement, specifically manifested in the following ways: Firstly, traditional cutting processes only focus on dimensional accuracy, neglecting the impact of variations in the cut surface texture of PC sheets on internal stress. This leads to dimensional deviations or localized cracking of the initial blank during subsequent high-pressure molding due to uneven internal deformation. Simultaneously, the molding chamber design with a fixed heating rate cannot be adjusted according to the actual deformation of the sheet, easily causing thermal stress concentration in the material and affecting the yield of finished products.

[0003] Secondly, conventional printing processes often use fixed spraying parameters, lacking precise quantitative control over the reflectivity of the bottom surface. Traditional methods judge the printing effect based solely on a single reflectivity value, without considering the impact of localized reflectivity differences on overall optical performance. This leads to problems such as uneven light spots and energy scattering in lampshades under rated power light source illumination, making it difficult to meet the requirements of aesthetically pleasing lampshades for highly uniform light distribution.

[0004] Third, traditional high-pressure gas forming processes lack a reverse adjustment mechanism based on the forming effect. When the initial lampshade exhibits an excessive light spot area ratio, optimization cannot be achieved by adjusting parameters such as gas flow rate, leading to significant quality fluctuations in mass production. Curing processes often employ fixed durations; when the initial lampshade's resistance to deformation fails to meet standards, there is a lack of targeted adjustment strategies. This can easily cause deformation of the lampshade due to thermal or mechanical stress during long-term use, affecting its lifespan and energy-saving performance.

[0005] In summary, there is an urgent need for a method to manufacture aesthetically pleasing lampshades that achieves precise control of material forming, quantitative optimization of optical performance, and enhanced resistance to deformation through multi-parameter dynamic adjustment, in order to solve the problems of low material utilization, unstable optical performance, large quality fluctuations, and short service life in traditional processes. Summary of the Invention

[0006] Therefore, the present invention provides a method for manufacturing an aesthetically pleasing lampshade, which overcomes the problem in the prior art that the preparation of aesthetically pleasing lampshades cannot simultaneously achieve uniform reflective light spots and lampshade quality.

[0007] To achieve the above objectives, the present invention provides a method for manufacturing an aesthetically pleasing lampshade, comprising: Step S1: Select one of the following film layers for preparing the lampshade blank: PC film, PMMA+PC film, PET film, and PU film, according to the pattern of different effects, the specifications of the lampshade, and different shapes. Step S2: The film layer of the lampshade blank is cut into film sheets of a preset size using a cutting machine. The pre-designed pattern is printed onto the printing layer of the film sheet of the lampshade blank using one or more of the following processes: electroplating, color printing, UV transfer printing, color plating, and screen printing. After the printing process is completed, the lampshade blank is obtained. Step S3: Transfer the lampshade blank to the forming mold of the high-pressure gas forming machine; Step S4: Apply high-pressure gas at a preset temperature to the blank in the mold. The gas pressure gradually increases from the initial pressure value to the forming pressure according to a preset gradient. Hold the pressure for a preset time to make the blank fit the mold cavity to form the initial lampshade product. Step S5: Check whether the initial lampshade conforms to the pre-designed shape and requirements, and pre-process the initial lampshade that conforms to the preset standards; Step S6: After cutting the initial lampshade, place it into an injection mold and injection mold it to obtain an aesthetically pleasing finished lampshade. Step S7: After the aesthetically pleasing lampshade is injection molded, the pre-designed pattern appears on the surface of the lampshade product.

[0008] Furthermore, the film thickness used to prepare the lampshade blank film layer can be one or thicker than a preset thickness of 0.125mm, 0.3mm, 0.5mm, 0.8mm, 1.0mm, 1.2mm, 1.5mm, 2.0mm, 2.5mm, 3.0mm.

[0009] Furthermore, the high pressure is IR heating, specifically a heating and baking program is set with an IR temperature of 280℃~500℃ and a baking time of 15 seconds~80 seconds, in order to soften the membrane.

[0010] Furthermore, the program parameters in the forming mold of the high-pressure gas forming machine are a baking time of 15 to 50 seconds, and after the film is softened, it is blown with 15 to 80 kg of high-pressure gas to form a semi-finished product.

[0011] Furthermore, the pre-processing of the lampshade prototype that meets the preset standards includes: punching off scraps and taking out the required semi-finished products; placing the semi-finished products into the injection mold for injection molding; and forming the required finished lampshade after injection molding.

[0012] Furthermore, checking whether it conforms to the pre-designed shape and requirements includes: The bonding strength between the film layer and the printed layer and the injection molding layer is detected, and the preparation of the lampshade prototype is determined based on the bonding strength to meet the preset standard. If the interface bonding strength is less than the preset interface bonding strength threshold, it is determined that the preparation of the lampshade prototype does not meet the preset standard, and the pressure holding preset time is increased according to the difference between the preset interface bonding strength threshold and the interface bonding strength. If the interface bonding strength is greater than or equal to a preset interface bonding strength threshold, then the preparation of the lampshade prototype is determined to meet the preset standard.

[0013] Furthermore, the increase in the preset pressure holding time is positively correlated with the difference between the preset interface bonding strength threshold and the interface bonding strength.

[0014] Furthermore, high-pressure gas at a preset temperature is applied to the blank inside the mold. The gas pressure gradually increases from the initial pressure value to the molding pressure according to a preset gradient, and the pressure is held for a preset time, so that the blank fits into the mold cavity to form a preliminary lampshade product, including: Preheat the mold to 60℃~180℃, fix the lampshade blank obtained in step S2 between the upper and lower molds of the forming mold, and ensure that the edge of the blank is sealed and clamped. Place the baking pan over the mold and bake at 280°-500° for 10-80 seconds to soften the membrane. Then close the mold and use high-pressure gas with an initial pressure of 0.5MPa-1.0MPa to maintain this pressure for 5-10 seconds. The gas pressure is gradually increased by 0.3MPa to 0.5MPa every 3 to 5 seconds until a molding pressure of 3.0MPa to 5.0MPa is reached. After reaching the molding pressure, the pressure and temperature are maintained for a holding time of 30 to 60 seconds, so that the lampshade blank can fully adhere to the inner wall of the mold cavity under the action of high pressure gas, thereby forming a lampshade with a preset shape and structure. Different thicknesses of films are baked at different temperatures and for different times.

[0015] Furthermore, the stepwise increase of the preset gradient to the molding pressure also includes: during the gradient pressurization process, simultaneously increasing the gas temperature to 150°C to 180°C at a heating rate of 2°C / second to 3°C / second.

[0016] Furthermore, the curing process includes placing the semi-finished lampshade in a constant temperature curing oven, first heating it to 120℃-140℃ at a rate of 3℃ / min, holding it at that temperature for 20min-30min, then cooling it to 80℃-90℃ at a rate of 2℃ / min, holding it at that temperature for 15min-20min, and finally allowing it to cool naturally to room temperature; wherein, the air flow rate inside the curing oven is controlled at 0.8m / s-1.2m / s, and the relative humidity is maintained at 40%-50%.

[0017] Compared with existing technologies, the beneficial effects of this invention are as follows: This invention determines whether the printing process meets a preset standard based on the reflectivity characteristic value, and reduces the spray flow rate in the printing process based on the difference between the preset reflectivity threshold and the reflectivity characteristic value. The characteristic value comprehensively reflects the overall uniformity of the ceramic coating on the bottom surface, rather than the reflectivity value of a single measuring point. When the reflectivity characteristic value is less than the preset reflectivity threshold, it indicates that the reflectivity difference between different areas of the bottom surface exceeds the allowable range. This directly leads to uneven light spots, excessively bright or dark areas, and affects energy-saving effects and lighting comfort during lampshade use. In this case, by reducing the spray flow rate, local accumulation of the ceramic coating can be reduced, making the coating thickness more uniform, thereby narrowing the reflectivity difference between different areas and improving the consistency of overall reflectivity performance.

[0018] Furthermore, the interfacial bonding strength is used to determine whether the preparation of the lampshade prototype meets the preset standard; and the preset holding time is increased based on the difference between the preset interfacial bonding strength threshold and the actual interfacial bonding strength. Interfacial bonding strength is a key indicator for measuring the tightness of the fit between the blank and the mold cavity, directly affecting the molding accuracy and structural stability of the lampshade prototype. Insufficient interfacial bonding strength can lead to uneven stress on the blank within the mold cavity, potentially resulting in irregular edges, surface curvature deviations, or even cracking due to stress concentration during subsequent curing or use. When the interfacial bonding strength is detected to be less than the preset threshold, it indicates that the blank has not adequately adhered to the mold cavity under the current holding time. Increasing the preset holding time provides more time for molecular chain adjustment and stress release, allowing the blank to achieve a tighter contact with the mold cavity under high-pressure gas, thereby improving the interfacial bonding strength to within the standard range. This dynamic adjustment mechanism based on actual test results effectively avoids the problem of unstable molding quality caused by fixed pressure parameters, and ensures the structural integrity and dimensional accuracy of the initial lampshade product.

[0019] Furthermore, the deformation resistance of the initial lampshade sample is used to verify whether its preparation meets a preset standard. The heating rate of the curing process is increased based on the difference between the preset deformation resistance threshold and the actual deformation resistance. Adjusting the heating rate allows for control over the crystallinity and molecular chain arrangement within the material. When the deformation resistance is insufficient, increasing the heating rate enables the material to reach the curing reaction temperature in a shorter time, promoting rapid cross-linking of molecular chains to form a dense structure and enhancing the material's rigidity and resistance to deformation.

[0020] Furthermore, this invention achieves end-to-end quality optimization from initial blank to finished lampshade through a multi-step control mechanism. In the printing stage, quantitative evaluation based on reflectivity characteristic values ​​and precise adjustment of spraying parameters ensure the uniformity of the bottom reflective coating. In the high-pressure gas forming stage, using interface bonding strength as a feedback indicator, the tight fit between the blank and the mold cavity is achieved through adjustment of the preset pressure holding time. In the curing stage, the heating rate is optimized based on the deformation resistance test results, enhancing the structural stability of the lampshade material. The synergistic control of these three key stages forms a closed-loop quality control system, effectively solving problems such as insufficient material forming precision, large fluctuations in optical performance, and weak deformation resistance in traditional processes, significantly improving the yield and reliability of energy-saving lampshades.

[0021] Furthermore, by monitoring and adjusting key parameters in real time, a closed-loop quality control system is formed, which effectively solves the problems of low material utilization, unstable optical performance, large quality fluctuations and short service life in traditional processes. The final energy-saving lampshade not only has excellent uniform light distribution characteristics, which can significantly improve the utilization efficiency of the light source and reduce energy consumption, but also has higher structural strength and deformation resistance, which can meet the needs of long-term stable use. Attached Figure Description

[0022] Figure 1 A flowchart illustrating the manufacturing method of an aesthetically pleasing lampshade according to an embodiment of the present invention; Figure 2 This is a flowchart illustrating whether the preparation of the initial lampshade sample conforms to a preset standard in an embodiment of the present invention. Figure 3 This is a schematic diagram of the structure of the printed layer of the lampshade blank in an embodiment of the present invention; Figure 4 This is a schematic diagram of the heating and baking process of the high-pressure gas forming machine according to an embodiment of the present invention; In the diagram: 1. Initial blank; 11. First target point area; 12. Second target point area; 3. IR heating; 4. Lampshade blank; 5. Molding mold. Detailed Implementation

[0023] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0024] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0025] Please see Figure 1-4 The following are flowcharts respectively: a flowchart of the method for manufacturing an aesthetic lampshade according to an embodiment of the present invention; a flowchart of determining whether the preparation of the initial lampshade conforms to a preset standard according to an embodiment of the present invention; a structural schematic diagram of the initial blank according to an embodiment of the present invention; and a structural schematic diagram of the heating and baking process of the high-pressure gas forming machine according to an embodiment of the present invention.

[0026] The method for manufacturing an aesthetically pleasing lampshade according to an embodiment of the present invention includes: Step S1: Select one of the following film layers for preparing the lampshade blank: PC film, PMMA+PC film, PET film, and PU film, according to the pattern of different effects, the specifications of the lampshade, and different shapes. Step S2: The film layer of the lampshade blank is cut into film sheets of a preset size using a cutting machine. The pre-designed pattern is printed onto the printing layer of the film sheet of the lampshade blank using one or more of the following processes: electroplating, color printing, UV transfer printing, color plating, and screen printing. After the printing process is completed, the lampshade blank is obtained. Step S3: Transfer the lampshade blank to the forming mold of the high-pressure gas forming machine; Step S4: Apply high-pressure gas at a preset temperature to the blank in the mold. The gas pressure gradually increases from the initial pressure value to the forming pressure according to a preset gradient. Hold the pressure for a preset time to make the blank fit the mold cavity to form the initial lampshade product. Step S5: Check whether the initial lampshade conforms to the pre-designed shape and requirements, and pre-process the initial lampshade that conforms to the preset standards; Step S6: After cutting the initial lampshade, place it into an injection mold and injection mold it to obtain an aesthetically pleasing finished lampshade. Step S7: After the aesthetically pleasing lampshade is injection molded, the pre-designed pattern appears on the surface of the lampshade product.

[0027] Specifically, the film thickness of the four film layers in the lampshade blank can be one of the following preset thicknesses: 0.125mm, 0.3mm, 0.5mm, 0.8mm, 1.0mm, 1.2mm, 1.5mm, 2.0mm, 2.5mm, and 3.0mm.

[0028] Specifically, the high pressure is IR heating 3, which involves setting a heating and baking program with an IR temperature of 280℃~500℃ and a baking time of 15 seconds~80 seconds to soften the membrane.

[0029] Specifically, the program parameters in the forming mold 5 of the high-pressure gas forming machine are a baking time of 15 to 50 seconds, and after the film is softened, it is blown with 15 kg to 80 kg of high-pressure gas to form a semi-finished product.

[0030] Specifically, the pre-processing of the lampshade prototype that meets the preset standards includes: punching off scraps and taking out the required semi-finished products; placing the semi-finished products into the injection mold for injection molding; and forming the required finished lampshade after injection molding.

[0031] Specifically, checking whether it conforms to the pre-designed shape and requirements includes: The bonding strength between the film layer and the printed layer and the injection molding layer is detected, and the preparation of the lampshade prototype is determined based on the bonding strength to meet the preset standard. If the interface bonding strength is less than the preset interface bonding strength threshold, it is determined that the preparation of the lampshade prototype does not meet the preset standard, and the pressure holding preset time is increased according to the difference between the preset interface bonding strength threshold and the interface bonding strength. If the interface bonding strength is greater than or equal to a preset interface bonding strength threshold, then the preparation of the lampshade prototype is determined to meet the preset standard.

[0032] Specifically, the increase in the preset pressure holding time is positively correlated with the difference between the preset interface bonding strength threshold and the interface bonding strength.

[0033] Specifically, high-pressure gas at a preset temperature is applied to the blank inside the mold. The gas pressure gradually increases from the initial pressure value to the forming pressure according to a preset gradient, and the pressure is held for a preset time, so that the blank fits into the mold cavity to form a preliminary lampshade product, including: Preheat the mold to 60℃~180℃, fix the lampshade blank obtained in step S2 between the upper and lower molds of the forming mold, and ensure that the edge of the blank is sealed and clamped. Extend the baking pan over the mold and bake at 280°-500°C for 10-80 seconds to soften the film. Then close the mold and apply high-pressure gas with an initial pressure of 0.5MPa-1.0MPa for 5-10 seconds. Gradually increase the gas pressure by 0.3MPa-0.5MPa every 3-5 seconds until a molding pressure of 3.0MPa-5.0MPa is reached. After reaching the molding pressure, maintain the pressure and temperature for 30-60 seconds to allow the lampshade blank to fully adhere to the inner wall of the mold cavity under the action of high-pressure gas, thus forming a preliminary lampshade with a preset shape and structure. Different thicknesses of film are baked at different temperatures and for different times.

[0034] Specifically, the preset gradient gradually increasing to the molding pressure also includes: during the gradient pressurization process, simultaneously increasing the gas temperature to 150℃~180℃ at a heating rate of 2℃ / second~3℃ / second.

[0035] Specifically, the curing process includes placing the semi-finished lampshade in a constant temperature curing oven, first heating it to 120℃-140℃ at a rate of 3℃ / min, holding it at that temperature for 20min-30min, then cooling it to 80℃-90℃ at a rate of 2℃ / min, holding it at that temperature for 15min-20min, and finally allowing it to cool naturally to room temperature; wherein, the air flow rate inside the curing oven is controlled at 0.8m / s-1.2m / s, and the relative humidity is maintained at 40%-50%.

[0036] Specifically, in this embodiment, a 0.5mm PC film is used to prepare the film layer of the lampshade blank 4. The printing process of the pre-designed pattern of the printing layer is carried out by electroplating. The preferred IR temperature is 280℃~500℃, and the preferred baking time is 15 seconds~80 seconds.

[0037] It will be understood by those skilled in the art that electroplating, color printing, UV transfer printing, color plating, and screen printing are all conventional techniques well known to them. Therefore, the specific processes and parameters of the above processes are not limited here, as long as the pre-designed pattern can be printed onto the printing layer of the color film blank.

[0038] Specifically, checking whether it conforms to the pre-designed shape and requirements includes: The interfacial bonding strength between the film layer and the printed layer is detected, and the preparation of the lampshade prototype is determined based on the interfacial bonding strength to meet the preset standard. If the interface bonding strength is less than the preset interface bonding strength threshold, it is determined that the preparation of the lampshade prototype does not meet the preset standard, and the pressure holding preset time is increased according to the difference between the preset interface bonding strength threshold and the interface bonding strength. If the interface bonding strength is greater than or equal to a preset interface bonding strength threshold, then the preparation of the lampshade prototype is determined to meet the preset standard.

[0039] Specifically, the increase in the preset pressure holding time is positively correlated with the difference between the preset interface bonding strength threshold and the interface bonding strength.

[0040] Specifically, high-pressure gas at a preset temperature is applied to the blank inside the mold. The gas pressure gradually increases from the initial pressure value to the molding pressure according to a preset gradient, and the pressure is held for a preset time to allow the blank to conform to the mold cavity and form a preliminary lampshade product. This includes: first, preheating the mold to 120℃~150℃, fixing the lampshade blank obtained in step S2 between the upper and lower molds of the molding mold 5, ensuring that the edges of the blank are sealed and clamped. Next, high-pressure gas with an initial temperature of 80℃~100℃ and an initial pressure value of 0.3MPa~0.5MPa is introduced into the mold and maintained at this pressure for 5 seconds~10 seconds to allow the blank to soften initially and come into contact with the surface of the mold cavity. Subsequently, the gas pressure is gradually increased according to a preset gradient of 0.2MPa every 3 seconds~5 seconds until a molding pressure of 1.2MPa~1.8MPa is reached. After reaching the molding pressure, the pressure and temperature are maintained for a holding time of 30 to 60 seconds, so that the lampshade blank can fully fit the inner wall of the mold cavity under the action of high pressure gas, thereby forming a lampshade initial product with a preset shape and structure.

[0041] Specifically, step S4 is performed in a high-pressure gas forming chamber. The initial pressure of the high-pressure gas forming chamber is set to 0.3MPa-0.5MPa (0.4MPa is used in this embodiment), and the forming pressure is controlled between 1.2MPa-1.8MPa (1.5MPa is used in this embodiment). The pressure gradient is preset to 0.2MPa per level, meaning it starts from an initial pressure of 0.4MPa and gradually increases to a forming pressure of 1.5MPa in increments of 0.6MPa, 0.8MPa, 1.0MPa, 1.2MPa, and 1.4MPa. The pressure increase rate for each level is controlled at 0.2MPa / s to ensure that the billet deforms slowly and uniformly under pressure, avoiding excessive local stretching or cracking of the billet due to a sudden increase in pressure. The pressure holding time is set to 45 seconds; the preset temperature is set to 80℃-120℃, and 100℃ is selected in this embodiment. At this temperature, the molecular chain activity of the 4 film material of the lampshade blank is enhanced, the plasticity is improved, and it is easier to fit the complex curved surface of the mold cavity under the action of high pressure gas. The heating rate is set to 5℃ / min-8℃ / min according to the material characteristics of the blank, and 7℃ / min is selected in this embodiment.

[0042] Specifically, the printing process further includes applying a ceramic coating to the side of the printed layer away from the film layer to enhance reflectivity, thereby obtaining a reflectivity characteristic value of the bottom surface of the initial blank 11, and determining whether the printing process meets a preset standard based on the reflectivity characteristic value. If the reflectivity characteristic value is less than the preset reflectivity threshold, it is determined that the printing process does not meet the preset standard, and the spraying flow rate of the ceramic coating is reduced according to the difference between the preset reflectivity threshold and the reflectivity characteristic value. If the reflectance characteristic value is greater than or equal to the preset reflectance threshold, then the printing process is determined to meet the preset standard. The reflectance characteristic value is the ratio of the reflectance difference between the first target point area 11 and the second target point area 12 after the printing process is completed to the preset reflectance deviation threshold; the first target point area 11 and the second target point area 12 are the two preset areas with the largest reflectance difference selected in the initial blank 1.

[0043] Specifically, the reflectivity characteristic value comprehensively reflects the overall uniformity of the ceramic coating on the bottom surface, rather than the reflectivity value of a single measuring point. When the reflectivity characteristic value is less than a preset reflectivity threshold, it indicates that the reflectivity difference between different areas of the bottom surface exceeds the allowable range. This directly leads to uneven light spots, excessively bright or dark areas, and other problems during lampshade use, affecting energy-saving performance and lighting comfort. In this case, reducing the spray flow rate can reduce local accumulation of the ceramic coating, making the coating thickness more uniform, thereby reducing the reflectivity difference between different areas and improving the consistency of overall reflectivity performance. The preset reflectivity threshold is set to 85%.

[0044] Specifically, the reduction in the spray flow rate is positively correlated with the difference between the preset reflectivity threshold and the reflectivity characteristic value. It is understood that this positive correlation can be linear or nonlinear, and is not specifically limited. Similarly, the slope of a linear positive correlation is not specifically limited and can be set according to the actual preparation conditions, as long as the difference between the preset reflectivity threshold and the reflectivity characteristic value is larger, the reduction in the spray flow rate is larger. For example, if the reduction in the spray flow rate is set to ΔM, and the difference between the preset reflectivity threshold and the reflectivity characteristic value is set to Δμ, then ΔM = γ × (Δμ + μ0), where γ is the spray volume adjustment coefficient, set to 1.06, and μ0 is a constant.

[0045] Specifically, if the interface bonding strength is less than a preset interface bonding strength threshold, it is determined that the preparation of the lampshade prototype does not meet the preset standard, and the preset time is increased according to the difference between the preset interface bonding strength threshold and the interface bonding strength. If the interface bonding strength is greater than or equal to a preset interface bonding strength threshold, then the preparation of the lampshade prototype is determined to meet the preset standard.

[0046] Specifically, interfacial bonding strength is a key indicator for measuring the tightness of the fit between the blank and the mold cavity, directly affecting the molding accuracy and structural stability of the initial lampshade. Insufficient interfacial bonding strength leads to uneven stress on the blank within the mold cavity, potentially resulting in irregular edges, surface curvature deviations, and even cracking due to stress concentration during subsequent curing or use. When the detected interfacial bonding strength is less than a preset threshold, it indicates that the blank has not adequately adhered to the mold cavity under the current holding pressure duration. In this case, increasing the preset holding pressure duration allows the material more time for molecular chain adjustment and stress release, enabling a tighter contact between the blank and the mold cavity under high-pressure gas, thereby improving the interfacial bonding strength to within the standard range. This dynamic adjustment mechanism based on actual test results effectively avoids the molding quality instability caused by fixed holding pressure parameters, ensuring the structural integrity and dimensional accuracy of the initial lampshade. In this embodiment, the preset interfacial bonding strength threshold is set to 2.5 MPa. The interfacial bonding strength was determined using a tensile test. The specific procedure was as follows: a 10mm × 50mm rectangular sample was cut from the edge area of ​​the initial lampshade sample. A universal testing machine was used to apply a tensile force along the interface between the film layer and the printed layer at a loading rate of 5mm / min. The maximum tensile force at which the sample broke was recorded. The maximum tensile force was divided by the overlap area of ​​the sample to calculate the measured value of the interfacial bonding strength. During the test, it was ensured that there was no slippage at the sample clamping point and that the direction of the tensile force remained parallel to the interface to guarantee the accuracy and reliability of the test results.

[0047] Specifically, the increase in the preset holding time is positively correlated with the difference between the preset interface bonding strength threshold and the interface bonding strength. It is understood that the positive correlation can be linear or nonlinear, and there is no specific limitation. Similarly, the slope of the linear positive correlation is not limited and can be set according to the actual preparation conditions, as long as the increase in the preset holding time is greater than the difference between the preset interface bonding strength threshold and the interface bonding strength. For example, if the increase in the preset holding time is set to ΔT, and the difference between the preset interface bonding strength threshold and the interface bonding strength is set to Δλ, then ΔT = α × (Δλ + λ0), where α is the time adjustment coefficient, set to 1.02, and λ0 is a constant.

[0048] Specifically, if the deformation resistance of the lampshade semi-finished product is less than the preset deformation resistance threshold, then the preparation of the lampshade semi-finished product is found to be non-compliant with the preset standard, and the heating rate of the curing process is increased according to the difference between the preset deformation resistance threshold and the deformation resistance. If the deformation resistance of the lampshade semi-finished product is greater than or equal to the preset deformation resistance threshold, then the preparation of the lampshade semi-finished product is verified to meet the preset standard.

[0049] Specifically, the crystallinity and molecular chain arrangement of the material can be controlled by adjusting the heating rate. When the deformation resistance is insufficient, increasing the heating rate can bring the material to the curing reaction temperature in a shorter time, promoting rapid cross-linking of molecular chains to form a dense structure and enhancing the material's rigidity and resistance to deformation. In this embodiment, the preset deformation resistance threshold is set at 300 MPa. In actual operation, the deformation resistance is tested through a three-point bending test. The cured lampshade sample is cut into standard specimens, which are rectangular specimens of 10 mm × 50 mm with a span of 50 mm. The loading rate is controlled at 2 mm / min, and the maximum bending stress at the fracture point is recorded as a quantitative indicator of the deformation resistance. When the deformation resistance is found to be less than 300 MPa, it indicates that the internal structure of the material is loose and the degree of cross-linking of molecular chains is insufficient. In this case, the heating rate of the curing process needs to be increased. For example, if the original heating rate is 5℃ / min and the difference in deformation resistance is 20MPa, the heating rate can be increased to 6℃ / min. By accelerating the molecular motion speed, the cross-linking reaction can be fully carried out, allowing the material to form a more stable three-dimensional network structure, thereby achieving the preset deformation resistance requirements.

[0050] Specifically, the curing process includes placing the semi-finished lampshade in a constant-temperature curing oven, first heating it to 120℃-140℃ at a rate of 3℃ / min and holding it at that temperature for 20-30 minutes, then cooling it to 80℃-90℃ at a rate of 2℃ / min and holding it at that temperature for 15-20 minutes, and finally allowing it to cool naturally to room temperature. The airflow velocity inside the curing oven is controlled at 0.8m / s-1.2m / s, and the relative humidity is maintained at 40%-50%. In this embodiment, the temperature is first raised to 130℃ at a rate of 3℃ / min and held for 25 minutes, then cooled to 85℃ at a rate of 2℃ / min and held for 18 minutes, and finally allowed to cool naturally to room temperature. The airflow velocity inside the curing oven is controlled at 1.0m / s, and the relative humidity is maintained at 45%. These curing process parameters ensure that the initial lampshade is heated uniformly during curing, internal stress is effectively released, and the material's molecular chains are fully cross-linked, resulting in good mechanical properties and dimensional stability. During the heating phase, a rate of 3℃ / min prevents cracking caused by excessive temperature differences between the inside and outside of the material due to rapid heating. A holding temperature of 130℃ and a holding time of 25 minutes provide sufficient energy and time for molecular chain movement and cross-linking reactions. The cooling phase uses a slower rate of 2℃ / min and a holding time of 85℃ for 18 minutes, which helps reduce internal stress generated during cooling. Finally, natural cooling to room temperature further ensures the dimensional accuracy and structural stability of the initial lampshade product. Controlling airflow velocity and relative humidity is also crucial. An airflow velocity of 1.0 m / s ensures uniform temperature distribution within the furnace, preventing localized overheating or undercooling, while a relative humidity of 45% prevents the material from absorbing too much moisture or becoming too dry during curing, thus affecting the curing effect and the final product quality.

[0051] Specifically, the increase in the heating rate is positively correlated with the difference between the preset anti-deformation performance threshold and the anti-deformation performance. It is understood that the positive correlation can be linear or nonlinear, and is not specifically limited. The slope of the linear positive correlation is also not specifically limited and can be set according to the actual preparation conditions, as long as the larger the difference between the preset anti-deformation performance threshold and the anti-deformation performance, the larger the increase in the heating rate. For example, if the increase in the heating rate is set to ΔF, and the difference between the preset anti-deformation performance threshold and the anti-deformation performance is set to Δσ, then ΔF = β × (Δσ + σ0), where β is the heating rate adjustment coefficient, set to 0.96, and σ0 is a constant.

[0052] Specifically, this setup significantly improves the overall performance and production efficiency of the lampshade. Firstly, in terms of material selection, choosing PC film, PMMA+PC film, PET film, and PU film fully leverages the advantages of each material. PC film provides the lampshade with excellent impact resistance and heat resistance, PMMA+PC film enhances light transmittance and surface gloss, PET film offers excellent chemical resistance and dimensional stability, and PU film strengthens the lampshade's abrasion resistance and flexibility, resulting in a balanced and optimized lampshade in terms of strength, light transmittance, and durability. Secondly, the hot-pressing bonding process between the printed layer and the film layer ensures the clarity and adhesion of the pattern, avoiding the fading and peeling problems common in traditional printing. Simultaneously, the pre-defined size cutting process lays a precise foundation for subsequent molding. Furthermore, during high-pressure gas molding, the gas pressure gradually increases according to a preset gradient, ensuring that the blank is evenly stressed and slowly deformed within the mold cavity. This effectively reduces the risk of defects such as bubbles, wrinkles, or cracks during molding. The preset pressure holding time further guarantees the stability and precision of the initial lampshade shape. Strict inspection and trimming of the initial lampshade blanks promptly remove defective products, ensuring the quality of blanks entering subsequent processes. Injection molding after curing not only makes the lampshade structure more stable but also perfectly fixes the preset pattern to the product surface, achieving a unity of aesthetics and functionality. This step-by-step, refined manufacturing method offers strong overall process controllability and close integration of each stage, which helps improve the production qualification rate and reduce production costs. Simultaneously, the resulting energy-saving lampshades meet the usage requirements of different scenarios in terms of optical performance, mechanical strength, and appearance.

[0053] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

[0054] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for manufacturing an aesthetically pleasing lampshade, characterized in that, include: Step S1: Select one of the following film layers for preparing the lampshade blank: PC film, PMMA+PC film, PET film, and PU film, according to the pattern of different effects, the specifications of the lampshade, and different shapes. Step S2: The film layer of the lampshade blank is cut into film sheets of a preset size using a cutting machine. The pre-designed pattern is printed onto the printing layer of the film sheet of the lampshade blank using one or more of the following processes: electroplating, color printing, UV transfer printing, color plating, and screen printing. After the printing process is completed, the lampshade blank is obtained. Step S3: Transfer the lampshade blank to the forming mold of the high-pressure gas forming machine; Step S4: Apply high-pressure gas at a preset temperature to the blank in the mold. The gas pressure gradually increases from the initial pressure value to the forming pressure according to a preset gradient. Hold the pressure for a preset time to make the blank fit the mold cavity to form the initial lampshade product. Step S5: Check whether the initial lampshade conforms to the pre-designed shape and requirements, and pre-process the initial lampshade that conforms to the preset standards; Step S6: After cutting the initial lampshade, place it into an injection mold and injection mold it to obtain an aesthetically pleasing finished lampshade. Step S7: After the aesthetically pleasing lampshade is injection molded, the pre-designed pattern appears on the surface of the lampshade product.

2. The method for manufacturing an aesthetically pleasing lampshade according to claim 1, characterized in that, The film thickness used to prepare the lampshade blank film layer can be one or thicker than one of the preset thicknesses of 0.125mm, 0.3mm, 0.5mm, 0.8mm, 1.0mm, 1.2mm, 1.5mm, 2.0mm, 2.5mm, and 3.0mm.

3. The method for manufacturing an aesthetically pleasing lampshade according to claim 2, characterized in that, The high pressure is IR heating, specifically a heating and baking program is set with an IR temperature of 280℃~500℃ and a baking time of 15 seconds~80 seconds, to soften the membrane.

4. The method for manufacturing an aesthetically pleasing lampshade according to claim 3, characterized in that, The program parameters in the forming mold of the high-pressure gas forming machine are a baking time of 15 to 80 seconds, and after the film is softened, it is blown with 15 kg to 80 kg of high-pressure gas to form a semi-finished product.

5. The method for manufacturing an aesthetically pleasing lampshade according to claim 4, characterized in that, The pre-processing of the lampshade prototype that meets the preset standards includes: punching off scraps and taking out the required semi-finished products; placing the semi-finished products into the injection mold for injection molding; and forming the required finished lampshade after injection molding.

6. The method for manufacturing an aesthetically pleasing lampshade according to claim 5, characterized in that, Checking whether it conforms to the pre-designed shape and requirements includes: The bonding strength between the film layer and the printed layer and the injection molding layer is detected, and the preparation of the lampshade prototype is determined based on the bonding strength to meet the preset standard. If the interface bonding strength is less than the preset interface bonding strength threshold, it is determined that the preparation of the lampshade prototype does not meet the preset standard, and the pressure holding preset time is increased according to the difference between the preset interface bonding strength threshold and the interface bonding strength. If the interface bonding strength is greater than or equal to a preset interface bonding strength threshold, then the preparation of the lampshade prototype is determined to meet the preset standard.

7. The method for manufacturing an aesthetically pleasing lampshade according to claim 6, characterized in that, The increase in the preset pressure holding time is positively correlated with the difference between the preset interface bonding strength threshold and the interface bonding strength.

8. The method for manufacturing an aesthetically pleasing lampshade according to claim 7, characterized in that, High-pressure gas at a preset temperature is applied to the blank inside the mold. The gas pressure gradually increases from the initial pressure value to the forming pressure according to a preset gradient, and the pressure is held for a preset time to allow the blank to conform to the mold cavity and form a preliminary lampshade product, including: Preheat the mold to 60℃~180℃, fix the lampshade blank obtained in step S2 between the upper and lower molds of the forming mold, and ensure that the edge of the blank is sealed and clamped. Place the baking pan over the mold and bake at 280°-500° for 10-80 seconds to soften the membrane. Then close the mold and use high-pressure gas with an initial pressure of 0.5MPa-1.0MPa to maintain this pressure for 5-10 seconds. The gas pressure is gradually increased by 0.3MPa to 0.5MPa every 3 to 5 seconds until a molding pressure of 3.0MPa to 5.0MPa is reached. After reaching the molding pressure, the pressure and temperature are maintained for a holding time of 30 to 60 seconds, so that the lampshade blank can fully adhere to the inner wall of the mold cavity under the action of high pressure gas, thereby forming a lampshade with a preset shape and structure. Different thicknesses of films are baked at different temperatures and for different times.

9. The method for manufacturing an aesthetically pleasing lampshade according to claim 8, characterized in that, The preset gradient gradually increases to the molding pressure, which also includes: during the gradient pressurization process, the gas temperature is simultaneously increased to 150℃~180℃ at a heating rate of 2℃ / second~3℃ / second.

10. The method for manufacturing an aesthetically pleasing lampshade according to claim 9, characterized in that, The curing process includes placing the semi-finished lampshade in a constant temperature curing oven, first heating it to 120℃-140℃ at a rate of 3℃ / min, holding it at that temperature for 20min-30min, then cooling it to 80℃-90℃ at a rate of 2℃ / min, holding it at that temperature for 15min-20min, and finally allowing it to cool naturally to room temperature; wherein, the air flow rate in the curing oven is controlled at 0.8m / s-1.2m / s, and the relative humidity is maintained at 40%-50%.

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