A new connection method of a signal lamp and a lamp cap structure

Abstract

This invention discloses a connection method and structure for automotive signal light heads, belonging to the field of automotive signal light technology. It aims to solve the problems of poor vibration resistance, easy detachment, difficult assembly, and insufficient long-term reliability in existing lamp head connections between metal rings and plastic parts. The method includes: preparing matching positioning protrusions and positioning grooves on the plastic part and the metal ring to achieve pre-positioning and radial fixation; processing a receiving structure on the mating surfaces of the two parts; aligning and pressing the two parts together, and then filling and curing the receiving structure with adhesive, or using ultrasonic welding to solidify the molten plastic filling the receiving structure, thus achieving a fixed connection. This invention significantly improves the vibration resistance, assembly yield, and long-term connection reliability of the lamp head. It is applicable to lamp heads that mate with lamp holders conforming to ECE R37 standards for various automotive signal bulbs, as well as bulbs equipped with such lamp heads.

Description

Technical Field

[0001] This invention relates to the field of automotive lighting technology, and in particular to a novel connection method and lamp head structure for a signal light. Background Technology

[0002] Automotive signal lights are one of the core components for safe vehicle operation, and the connection stability of their lamp head structure directly determines the lifespan and safety of the signal light. Currently, automotive signal bulbs that conform to the ECE R37 standard generally use a mechanical snap-fit ​​combined with thermal fusion fixing method to connect the metal ring and plastic parts of the lamp head.

[0003] In existing technologies, conventional connection schemes are as follows: Figure 1 As shown, four positioning protrusions are integrally formed on the plastic part of the lamp holder, corresponding to four positioning slots on the metal ring. The plastic part and the metal ring are fixedly connected through a tight fit between the positioning protrusions and the positioning slots, combined with a heat fusion process. However, this solution has significant drawbacks in actual production and application: First, it has poor vibration resistance and is prone to loosening and detachment under vibration conditions. In the WBR5.4g vibration durability test specified in the IEC 60810 standard, the existing design sample showed that the metal ring and plastic parts detached after 15 hours of vibration, which cannot meet the usage requirements under high vibration conditions; in the actual vehicle installation and use, the failure of the metal ring and plastic parts detaching also occurs frequently, which poses a serious safety hazard.

[0004] Secondly, the cumulative effect of tolerances at multiple positioning points is significant, making assembly difficult. The dimensional and geometric tolerances at the four positioning points have a cumulative effect, which can easily lead to problems such as jamming or inability to assemble during assembly, or problems such as loose fit or weak connection, significantly reducing the assembly yield and consistency of the product.

[0005] Third, the connection reliability is insufficient, and the long-term stability is poor. The connection method of pure mechanical snap-fit ​​+ thermal fusion relies solely on the mechanical strength of the plastic protrusions and the bonding force of thermal fusion. Under long-term high and low temperature cycles and vibration and impact conditions, the plastic is prone to aging and cracking at the fusion point, ultimately leading to connection failure.

[0006] In view of the many shortcomings of existing technologies, there is an urgent need to develop a new lamp holder connection method to solve the industry pain points of easy detachment of metal rings and plastic parts, high assembly difficulty, and poor vibration resistance. Summary of the Invention

[0007] In view of the shortcomings of the prior art, the purpose of this invention is to provide a novel connection method and lamp head structure for traffic lights, so as to solve the problems of poor vibration resistance, easy detachment, and difficulty in assembly due to tolerance accumulation.

[0008] A novel connection method for a signal light, applied to the lamp head structure of an automotive signal bulb, the lamp head structure comprising a mating metal ring and a plastic part, comprising the following steps: S1. Preparation of pre-positioning structure: At least one positioning protrusion is processed on one of the plastic part and the metal ring part, and a positioning groove corresponding to the positioning protrusion is processed on the other part. The positioning protrusion and the corresponding positioning groove form a fit to realize the pre-positioning and radial fixation when the metal ring part and the plastic part are assembled. S2. Preparation of adhesive receiving structure: A reserved space for applying adhesive is provided on the mating surface of the plastic part and / or metal ring; S3. Injection and Assembly Curing: Inject adhesive into the adhesive tank, align and press the metal ring and plastic part together through the positioning protrusion and positioning groove, so that the adhesive fills the gap between the adhesive tank and the mating surface. After the adhesive cures, the metal ring and plastic part are axially locked and fixedly connected.

[0009] In this invention, in step S1, the number of positioning protrusions is one or more.

[0010] Furthermore, the number of positioning protrusions is two.

[0011] In this invention, in step S1, the positioning protrusion and the positioning groove are either an interference fit or a clearance fit.

[0012] In this invention, in step S2, the depth of the glue tank is less than 2.0 mm and the width is less than 2.0 mm.

[0013] In this invention, in step S2, the cross-sectional shape of the glue tank is any one of rectangular, dovetail, trapezoidal, or semi-circular, or the glue tank is replaced by densely arranged dotted grooves.

[0014] In this invention, in step S2, the direction of the glue tank is a single-segment continuous annular groove or a 360° annular groove formed by splicing multiple arc-shaped grooves.

[0015] In this invention, in step S3, the adhesive is any one of epoxy resin adhesive, cyanoacrylate instant adhesive, acrylate adhesive, and silicone adhesive.

[0016] In this invention, in step S3, ultrasonic welding is used instead of glue injection bonding. The molten material of the plastic part is filled into the glue tank by ultrasonic welding, and after cooling and solidification, the metal ring and the plastic part are fixedly connected.

[0017] The present invention also provides a car signal light head structure, which is manufactured using the novel connection method of the above-mentioned signal light. The head structure includes a metal ring and a plastic part. A pre-positioning structure that matches each other and an adhesive groove structure filled with adhesive medium are provided between the plastic part and the metal ring. The pre-positioning structure includes at least one set of mutually cooperating positioning protrusions and positioning slots. The positioning protrusions are provided on the plastic part or the metal ring part, and the positioning slots are correspondingly provided on another part. The glue tank structure is formed on the mating surface of the plastic part and / or the metal ring, and the adhesive medium is filled in the glue tank structure.

[0018] The beneficial effects of this invention are: This invention significantly reduces the cumulative effect of dimensional and geometric tolerances caused by multiple positioning points in existing technologies by reducing the number of positioning protrusions and slots. This fundamentally solves the problems of assembly jamming, inability to assemble, or excessively loose fit, significantly improving the assembly yield and consistency of the product. By setting a receiving structure on the mating surface of the plastic part and the metal ring, combined with adhesive filling and curing or ultrasonic welding fusion filling, a composite connection structure of mechanical pre-positioning + full circumferential bonding / fusion is formed. Compared with the existing pure mechanical clamping and heating fusion connection method, this greatly improves the connection strength and vibration resistance of the lamp holder. In the vibration durability test specified by the IEC 60810 standard, the vibration resistance time is increased by more than 2.67 times, effectively avoiding the safety hazard of the metal ring and plastic parts detaching under vibration conditions. At the same time, the composite connection structure can effectively disperse the stress under long-term high and low temperature cycling and vibration impact conditions, alleviating the problems of plastic aging and cracking at the joint, significantly improving the connection reliability and service life of the lamp holder in long-term use, while significantly reducing the glue overflow rate and significantly improving the product appearance quality. Attached Figure Description

[0019] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a connection diagram of the signal light head structure in Example 1; Figure 2 This is a schematic diagram showing the disassembled structure of the signal light head in Example 1; Figure 3 This is a top view of the plastic part in Example 1; Figure 4 This is a schematic diagram of the cross-sectional structure of the glue tank in Example 1; Figure 5 This is a schematic diagram of the single positioning protrusion on the plastic part in Example 2; Figure 6 This is a schematic diagram of the dovetail groove cross-section structure of the glue tank in Example 2; Figure 7 This is a schematic diagram of the trapezoidal cross-section structure of the glue tank in Example 2; Figure 8 This is a schematic diagram of the three positioning protrusions on the plastic part in Example 3; Figure 9 This is a schematic diagram showing the disassembled structure of the signal light head in Example 4; Figure 10 This is a schematic diagram of the bottom structure of the metal ring in Example 4; Figure 11 This is a schematic diagram of the dotted groove structure on the plastic part in Example 5; The attached diagram is labeled as follows: 1-Plastic part, 2-Metal ring, 3-Positioning protrusion, 4-Positioning groove, 5-Glue groove. Detailed Implementation

[0020] This invention provides a novel connection method for traffic lights. To make the objectives, technical solutions, and effects of this invention clearer and more explicit, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the invention.

[0021] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0022] It should be specifically stated that the scope of protection of this invention covers all solutions that use glue or equivalent adhesive media and glue groove structure to connect the metal ring of the lamp holder to the plastic part. Connection solutions that do not use glue or equivalent adhesive media are not within the scope of protection of this invention.

[0023] Example 1 like Figures 1-4 As shown, this embodiment is the optimal implementation of the present invention, applied to the lamp holders of automotive signal bulbs of models such as PG20-3, PG20-4, PGU20-4, and PG20-7. The maximum power of the bulb is 25W, conforming to the ECE R37 standard. This embodiment discloses a novel connection method for signal lights, including the following steps: S1. Preparation of pre-positioning structure: Two symmetrically arranged positioning protrusions 3 are integrally formed on the plastic part 1 of the lamp holder, and two positioning slots 4 that match the positioning protrusions 3 are opened on the metal ring part 2. The positioning protrusions 3 and the positioning slots 4 are interference fit, and the interference is controlled at 0.08±0.02mm, which ensures the pre-positioning effect and radial fixing force during assembly, and avoids the plastic part from cracking due to excessive interference.

[0024] S2. Preparation of the adhesive receiving structure: On the mating surface where the plastic part 1 and the metal ring part 2 meet, two symmetrically arranged arc-shaped glue grooves 5 are processed. The two arc-shaped glue grooves 5 are spliced ​​together to form a 360° ring structure. The cross-section of the glue groove 5 is rectangular, with a depth of 0.3 mm and a width of 1.0 mm. This parameter ensures the glue holding capacity without weakening the structural strength of the plastic part. At the same time, the glue has the best fluidity and the simplest processing technology.

[0025] S3. Injection and Assembly Curing: Evenly inject epoxy resin into the glue tank 5. Precisely align the metal ring 2 and plastic part 1 with the positioning protrusion 3 and positioning groove 4, and press them together to completely fill the glue tank 5 with epoxy resin and fill the tiny gaps between the mating surfaces. Place the assembled lamp head in a room temperature environment for static curing, or heat it according to the epoxy resin curing process. After curing, the metal ring 2 and plastic part 1 are stably fixedly connected.

[0026] The 20 lamp holder samples prepared in this embodiment were subjected to a WBR5.4g vibration durability test according to the IEC60810 standard. The test results showed that none of the samples showed the phenomenon of metal rings and plastic parts falling off after 40 hours of vibration, while the control samples of the prior art fell off after 15 hours of vibration, indicating that the vibration resistance performance was improved by more than 2.67 times. At the same time, the assembly yield of this embodiment was improved by 32% compared with the prior art, with no assembly jamming or loose fit, and the glue overflow rate was reduced to below 0.5%, resulting in a significant improvement in product appearance quality.

[0027] Example 2 like Figures 5-7 As shown, this embodiment is a single-positioning protrusion implementation, applied to the lamp holders of signal bulbs such as PG20-1, PG20-2, PG18.5d-1, and PG18.5d-3. The specific connection method includes the following steps: S1. Preparation of pre-positioning structure: A positioning protrusion 3 is integrally formed on the plastic part 1 of the lamp head, and a positioning groove 4 matching the positioning protrusion 3 is opened on the metal ring part 2; the positioning protrusion 3 and the positioning groove 4 are fitted with a clearance to achieve basic pre-positioning and radial fixation.

[0028] S2. Preparation of adhesive receiving structure: A single-segment continuous arc-shaped glue groove 5 is processed on the mating surface of the plastic part 1. The cross-section of the glue groove 5 adopts a dovetail shape or trapezoidal shape, with a depth of 0.5mm and a groove width of 1.0mm.

[0029] S3. Injection and Assembly Curing: Inject cyanoacrylate instant adhesive evenly into the adhesive tank 5, align and press the metal ring 2 and plastic part 1 together, and let stand until the instant adhesive is completely cured to achieve a fixed connection between the metal ring 2 and the plastic part 1.

[0030] The solution in this embodiment can achieve similar connection strength and vibration resistance as in Embodiment 1, and is suitable for rapid production and assembly of small-sized lamp holders.

[0031] Example 3 like Figure 8 As shown, this embodiment is a three-positioning protrusion implementation, applied to the lamp holders of various PG series automotive signal bulbs. The specific connection method includes the following steps: S1. Preparation of pre-positioning structure: Three positioning protrusions 3 are integrally formed on the plastic part 1 of the lamp head, and three positioning slots 4 matching the positioning protrusions 3 are opened on the metal ring part 2; the positioning protrusions 3 and the positioning slots 4 are fitted with a clearance to achieve basic pre-positioning and radial fixation.

[0032] S2. Preparation of adhesive receiving structure: Three continuous arc-shaped glue grooves 5 are processed on the mating surface of plastic part 1. The cross-section of glue groove 5 adopts a dovetail shape or trapezoid, with a depth of 0.5mm and a groove width of 1.0mm.

[0033] S3. Injection and Assembly Curing: Inject cyanoacrylate instant adhesive evenly into the adhesive tank 5, align and press the metal ring 2 and plastic part 1 together, and let stand until the instant adhesive is completely cured to achieve a fixed connection between the metal ring 2 and the plastic part 1.

[0034] The solution in this embodiment can achieve similar connection strength and vibration resistance as in Embodiment 1, and is suitable for rapid production and assembly of small-sized lamp holders.

[0035] Example 4 like Figures 9-10 As shown, this embodiment is a implementation where the positions of the positioning structure and the glue tank are interchanged. The specific connection method includes the following steps: S1. Preparation of pre-positioning structure: Two symmetrically arranged positioning protrusions 3 are integrally formed on the metal ring 2, and two positioning slots 4 that match the positioning protrusions 3 are opened on the plastic part 1; the interference fit between the positioning protrusions 3 and the positioning slots 4 is controlled to be 0.10mm.

[0036] S2. Preparation of adhesive receiving structure: On the mating surface of the metal ring 2, process one or more arc-shaped glue grooves 5. The one or more arc-shaped grooves are spliced ​​to form a 360° ring structure. The cross-sectional shape of the glue groove 5 is rectangular, dovetail, or trapezoidal, with a depth of 0.4 mm and a groove width of 0.8 mm.

[0037] S3. Welding Assembly: Ultrasonic welding is used to replace glue injection bonding. The metal ring 2 and the plastic part 1 are precisely aligned and pressed together by the positioning protrusion 3 and the positioning groove 4. The molten plastic of the plastic part 1 is filled into the glue tank 5 by ultrasonic welding. After cooling and solidification, the metal ring 2 and the plastic part 1 are fixedly connected.

[0038] Example 5 like Figure 11 As shown, this embodiment is an implementation method that uses dotted grooves to replace continuous glue channels. The specific connection method includes the following steps: S1. Preparation of pre-positioning structure: Three evenly arranged positioning protrusions 3 are integrally formed on the plastic part 1 of the lamp head, and three positioning slots 4 that match the positioning protrusions 3 are opened on the metal ring part 2; the interference fit between the positioning protrusions 3 and the positioning slots 4 is controlled to be 0.12mm.

[0039] Preparation of S2 adhesive receiving structure: On the mating surface of plastic part 1, densely arranged dot-shaped grooves are processed to replace the continuous glue groove. The dot-shaped grooves are evenly distributed on the mating surface, and the depth of a single dot-shaped groove is 0.3mm and the diameter is 1.0mm.

[0040] S3 Injection and Assembly Curing: Inject acrylic adhesive into each dotted groove, align and press the metal ring 2 and plastic part 1 together, and after the adhesive cures, the metal ring 2 and plastic part 1 are fixedly connected.

[0041] The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention, and these equivalent modifications or substitutions are all included within the scope defined by the claims of the present invention.

Claims

1. A novel connection method for a signal light, applied to the lamp head structure of an automotive signal bulb, the lamp head structure comprising a mating metal ring and a plastic part, characterized in that, Includes the following steps: S1. Preparation of pre-positioning structure: At least one positioning protrusion is processed on one of the plastic part and the metal ring part, and a positioning groove corresponding to the positioning protrusion is processed on the other part. The positioning protrusion and the corresponding positioning groove form a fit to realize the pre-positioning and radial fixation when the metal ring part and the plastic part are assembled. S2. Preparation of adhesive receiving structure: A reserved space for applying adhesive is provided on the mating surface of the plastic part and / or metal ring; S3. Injection and Assembly Curing: Inject adhesive into the adhesive tank, align and press the metal ring and plastic part together through the positioning protrusion and positioning groove, so that the adhesive fills the gap between the adhesive tank and the mating surface. After the adhesive cures, the metal ring and plastic part are axially locked and fixedly connected.

2. The novel connection method for traffic lights according to claim 1, characterized in that, In step S1, the number of positioning protrusions is one or more.

3. The novel connection method for traffic lights according to claim 2, characterized in that, The number of positioning protrusions is two.

4. The novel connection method for traffic lights according to claim 1, characterized in that, In step S1, the positioning protrusion and the positioning groove are either an interference fit or a clearance fit.

5. The novel connection method for traffic lights according to claim 1, characterized in that, In step S2, the depth of the glue tank is less than 2.0 mm and the width is less than 2.0 mm.

6. The novel connection method for traffic lights according to claim 1, characterized in that, In step S2, the cross-sectional shape of the glue tank is any one of rectangular, dovetail, trapezoidal, or semi-circular, or the glue tank can be replaced by densely arranged dotted grooves.

7. The novel connection method for traffic lights according to claim 1, characterized in that, In step S2, the direction of the glue tank is a single-segment continuous annular groove or a 360° annular groove formed by splicing multiple arc-shaped grooves.

8. The novel connection method for traffic lights according to claim 1, characterized in that, In step S3, the adhesive is any one of epoxy resin adhesive, cyanoacrylate instant adhesive, acrylate adhesive, and silicone adhesive.

9. The novel connection method for traffic lights according to claim 1, characterized in that, In step S3, ultrasonic welding is used instead of glue injection bonding. The molten plastic part is filled into the glue tank by ultrasonic welding, and after cooling and solidification, the metal ring and the plastic part are fixedly connected.

10. A structure for a car signal light head, characterized in that, The signal light is manufactured using the novel connection method of any one of claims 1-9. The lamp head structure includes a metal ring and a plastic part. A pre-positioning structure that matches each other and an adhesive groove structure filled with adhesive medium are provided between the plastic part and the metal ring. The pre-positioning structure includes at least one set of mutually cooperating positioning protrusions and positioning slots. The positioning protrusions are provided on the plastic part or the metal ring part, and the positioning slots are correspondingly provided on another part. The glue tank structure is formed on the mating surface of the plastic part and / or the metal ring, and the adhesive medium is filled in the glue tank structure.

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