Waterproof lamp and manufacturing process

Abstract

The application discloses a waterproof lamp and a manufacturing process, which comprise a lamp bead and a lamp shell. The lamp bead comprises a light-emitting diode and a light guide cover. The light-emitting diode is arranged in the light guide cover. The positive and negative poles of the light-emitting diode are connected with wires, and the wires protrude from the light guide cover. The lamp shell seals and wraps the lamp bead. Glue is poured into a mold, the light-emitting diode and the light guide cover are arranged in the mold, the light-emitting diode, the light guide cover and part of the wires are immersed in the glue by injecting the glue into the mold, and then the glue is solidified to form the lamp shell by UV irradiation. The lamp shell is an integrally-formed lamp shell. The lamp shell wraps the light-emitting diode, the light guide cover and part of the exposed copper wires in the lamp shell to form a sealed waterproof structure. The application has the advantages of simple structure, excellent waterproof performance, reduced number of spare parts and reduced production cost.

Description

Technical Field

[0001] This invention relates to the field of lighting technology, and in particular to a waterproof lighting fixture and its manufacturing process. Background Technology

[0002] Currently common waterproof lighting fixtures typically involve first soldering wires to the positive and negative terminals of the LED chip, then adding a separator between the wires to separate them. The LED chip with the soldered wires is then inserted into a transparent housing, and finally, adhesive is used to secure the LED chip within the housing, achieving waterproofing through the sealing process. While this method achieves waterproofing, it is relatively complex, has high production costs, and is prone to problems such as sealant aging and peeling during long-term use, leading to water ingress and damage to the lighting fixture, affecting its normal operation and lifespan. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides a waterproof lamp and its manufacturing process, which achieves waterproofing while reducing production costs.

[0004] According to a first aspect of the present invention, a waterproof lamp includes: a lamp bead and a lamp housing; the lamp bead includes a light-emitting diode and a light guide cover, the light-emitting diode is disposed inside the light guide cover, and the positive and negative terminals of the light-emitting diode are connected to wires, the wires protruding from the light guide cover; the lamp housing is a solid structure, the lamp housing is formed by curing with glue, and the lamp housing seals and encapsulates the lamp bead inside.

[0005] In some embodiments of the present invention, an insulating layer is provided on the outer side of the conductor.

[0006] In some embodiments of the present invention, both the positive and negative terminals of the light-emitting diode are provided with pins, and the pins are soldered to the wires.

[0007] In some embodiments of the present invention, one end of the wire connected to the light-emitting diode is wrapped by the lamp housing.

[0008] In some embodiments of the present invention, the lamp housing includes an end and a body, the diameter of the end is smaller than the diameter of the body, the end is integrally formed with the body, and an inclined surface is provided between the end and the body.

[0009] According to the manufacturing process described in the second aspect of the present invention, when applied to the waterproof lamp described in the first aspect of the present invention, the process includes the following steps: S1. Solder the positive and negative terminals of the light-emitting diode to the wires respectively, and install the light-emitting diode into the light guide cover to assemble the lamp bead; S2. Insert the LED beads into the mold, leaving some of the wires exposed; S3. Pour glue into the mold; S4. The adhesive in the injection mold is cured by UV light to form the lamp housing.

[0010] Compared with the prior art, the waterproof lamp and manufacturing process of this invention have the following advantages: by installing the light-emitting diode and light guide into a mold, injecting glue into the mold to immerse the light-emitting diode, light guide, and some wires in the glue, and then curing the glue to form a lamp shell by UV light irradiation, the lamp shell is a one-piece molded lamp shell, and the lamp shell encloses the light-emitting diode, light guide, and some wires inside the lamp shell to form a sealed waterproof structure. The structure is simple, the waterproof performance is excellent, and the number of parts is reduced, thus reducing production costs. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of a waterproof lamp according to a first aspect embodiment of the present invention; Figure 2 This is a flowchart of the manufacturing process of a second aspect embodiment of the present invention.

[0012] Explanation of reference numerals in the attached figures: LED chip 100; light guide cover 110; LED 120; pin 121; wire 122; insulating layer 123; Lamp housing 200; end 210; main body 220; bevel 230. Detailed Implementation

[0013] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0014] like Figure 1 As shown, the waterproof lamp of the first aspect of the present invention includes: a lamp bead 100 and a lamp housing 200; the lamp bead 100 includes a light-emitting diode 120 and a light guide cover 110, the light-emitting diode 120 is disposed inside the light guide cover 110, and the positive and negative terminals of the light-emitting diode 120 are both connected to wires 122, the wires 122 protruding out of the light guide cover 110; the lamp housing 200 is a solid structure, the lamp housing 200 is cured and molded with glue, and the lamp housing 200 seals and encapsulates the lamp bead 100 inside.

[0015] By installing the light-emitting diode 120 and the light guide 110 into a mold, and injecting glue into the mold to immerse the light-emitting diode 120, the light guide 110, and some of the wires 122 in the glue, and then curing the glue by UV light irradiation to form a lamp housing 200, the lamp housing 200 is a one-piece molded lamp housing 200, and the lamp housing 200 encloses the light-emitting diode 120, the light guide 110, and some of the wires 122 inside the lamp housing 200, forming a sealed waterproof structure. The structure is simple, the waterproof performance is excellent, and the number of parts is reduced, thus reducing production costs.

[0016] Understandably, referring to Figure 1 An insulating layer 123 is provided on the outside of the conductor 122. When the power is on, the current is transmitted inside the conductor 122, and the insulating layer 123 wraps around the conductor 122, physically isolating the live conductor from the external environment. During the manufacturing process, the insulating layer 123 is placed into the mold along with the conductor 122. It can withstand the wetting and curing process of glue, effectively preventing the two conductors 122 from short-circuiting due to pressure or accidental contact in the narrow space of the lamp holder, thus improving the electrical safety and operational stability of the lamp.

[0017] Understandably, referring to Figure 1 The LED 120 has pins 121 on both its positive and negative terminals, and these pins 121 are soldered to wires 122. During assembly, soldering, such as tin soldering, forms a strong bond between the pins 121 and the wires 122. Soldering provides superior mechanical strength and conductivity, can withstand the impact of glue flow during subsequent encapsulation, and prevents the wires 122 from detaching or making poor contact before encapsulation, thus ensuring the stability of the finished lamp's light emission.

[0018] Understandably, referring to Figure 1 One end of the wire 122 connected to the light-emitting diode 120 is wrapped by the lamp housing 200. During the mold injection process, the liquid glue flows and completely covers the connection part between the wire 122 and the light-emitting diode 120. After curing by UV light, the solid lamp housing 200 material tightly covers the connection part, permanently fixing it inside the lamp housing 200, preventing it from contacting the outside air or moisture, and reducing the risk of corrosion of the solder joint.

[0019] Understandably, referring to Figure 1The lamp housing 200 includes an end portion 210 and a main body 220. The diameter of the end portion 210 is smaller than the diameter of the main body 220. The end portion 210 and the main body 220 are integrally molded. After the adhesive cures, the lamp housing 200 forms an integral structure with a stepped shape. The end portion 210 and the main body 220 are transitioned by a bevel 230. The diameter difference between the end portion 210 and the main body 220 facilitates the assembly and positioning of the lamp in specific mounting holes. The bevel 230 transition avoids the risk of stress cracking that may occur with right-angle designs and also facilitates the demolding process. The integrally molded structure eliminates the seam between the end portion 210 and the main body 220, prevents water leakage, and enhances the mechanical strength of the overall structure.

[0020] Reference Figure 2 The manufacturing process of the second aspect of the present invention, applied to the waterproof lamp of the first aspect of the present invention, includes the following steps: S1. Solder wires 122 to the positive and negative terminals of LED 120 respectively, and put LED 120 into light guide cover 110 to form LED bead 100. S2. Insert the LED bead 100 into the mold and expose part of the wire 122; S3. Pour glue into the mold. Glue of any transparency and color can be used. S4. By irradiating with a UV lamp, the glue in the injection mold is cured quickly, shortening the production time, improving production efficiency, forming a seamless lamp housing 200, improving waterproof performance, and completely sealing and wrapping the lamp beads 100, achieving waterproofing without affecting the light emission.

[0021] By installing the light-emitting diode 120 and the light guide 110 into a mold, and injecting glue into the mold to immerse the light-emitting diode 120, the light guide 110, and some of the wires 122 in the glue, and then curing the glue by UV light irradiation to form a lamp housing 200, the lamp housing 200 is a one-piece molded lamp housing 200, and the lamp housing 200 encloses the light-emitting diode 120, the light guide 110, and some of the wires 122 inside the lamp housing 200, forming a sealed waterproof structure. The structure is simple, the waterproof performance is excellent, and the number of parts is reduced, thus reducing production costs.

[0022] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and substitutions can be made without departing from the technical principles of the present invention, and these improvements and substitutions should also be considered within the protection scope of the present invention.

Claims

1. A waterproof lighting fixture, characterized in that, Including: The LED bead includes a light-emitting diode and a light guide cover. The light-emitting diode is disposed inside the light guide cover, and both the positive and negative terminals of the light-emitting diode are connected to wires, which protrude from the light guide cover. The lamp housing is a solid structure, formed by curing with glue, and seals and encapsulates the lamp beads inside.

2. The waterproof lighting fixture according to claim 1, characterized in that, An insulating layer is provided on the outside of the conductor.

3. The waterproof lighting fixture according to claim 1, characterized in that, The light-emitting diode has pins on both its positive and negative terminals, and these pins are soldered to the wires.

4. The waterproof lighting fixture according to claim 1, characterized in that, One end of the wire connected to the light-emitting diode is wrapped by the lamp housing.

5. The waterproof lighting fixture according to claim 1, characterized in that, The lamp housing includes an end and a main body. The diameter of the end is smaller than the diameter of the main body. The end and the main body are integrally formed. An inclined surface is provided between the end and the main body.

6. A manufacturing process, applied to the waterproof lighting fixture according to any one of claims 1 to 5, comprising the following steps: S1. Solder the positive and negative leads of the light-emitting diode to the wires respectively, and put the light-emitting diode into the light guide cover to assemble the lamp bead; S2. Insert the LED beads into the mold, leaving some of the wires exposed; S3. Pour glue into the mold; S4. The adhesive in the injection mold is cured by UV light to form the lamp housing.

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