An integrated embossed extrusion lamp shell device and processing method

Abstract

The application discloses a kind of integrated embossing extrusion lamp shell device and processing method, including the die of installation in extruder head, and located in the die one side embossing roller, die includes outer sleeve and inner core, one end of inner core is located in the cavity of outer sleeve, and form extrusion passageway between inner core and outer sleeve for lamp shell extrusion, the other end of inner core extends to the below of embossing roller along the length direction of inner core, and utilize embossing roller to the extruded lamp shell blank is embossed.The inner core of the present application is directly used as embossing support platform by extending the die, cooperate with the embossing roller above, complete the surface embossing simultaneously in the process of lamp shell extrusion molding, without secondary transport and processing, completely avoid the deformation misplacement caused by split type processing, greatly improve product yield;By setting temperature adjusting module and cooling channel in inner core and embossing roller respectively, the temperature of forming area can be controlled constant, effectively prevent the pattern blur and lamp shell stick roll phenomenon caused by temperature fluctuation.

Description

Technical Field

[0001] This invention relates to the field of lampshade manufacturing and processing technology, and more specifically, to an integrated embossing and extrusion lampshade device and processing method. Background Technology

[0002] Currently, most plastic lamp housing embossing processes employ a split production method, where the extrusion molding process and the surface embossing process are separate. In conventional production, the lamp housing substrate is first extruded and shaped using extrusion equipment. Then, the semi-finished product is transferred to specialized embossing equipment for secondary embossing processing, ultimately yielding a finished lamp housing with a pattern.

[0003] However, the aforementioned split-process and its supporting equipment have obvious technical defects: First, the separation of processes makes it impossible to achieve integrated molding of the lamp housing. During the connection between the two processing steps, defects such as lamp housing deformation, pattern misalignment, and dimensional deviation are very likely to occur, resulting in a low product yield. Second, two independent sets of equipment are required, which occupy a large area and have a complicated production process. Material transfer and equipment debugging are time-consuming, resulting in low production efficiency. Third, the secondary processing requires repeated starting and running of equipment, resulting in high power consumption. At the same time, the transfer of semi-finished products, secondary positioning, and embossing operations require specialized personnel, increasing labor costs. Fourth, the two molding processes generate more scrap and waste, resulting in low raw material utilization and thus increasing the overall production cost.

[0004] Therefore, there is an urgent need to propose a new solution that can achieve integrated extrusion and embossing to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an integrated embossing extrusion lamp housing device and processing method.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] An integrated embossing extrusion lamp housing device includes a die installed on the extruder head and an embossing roller located on one side of the die. The die includes an outer die sleeve and an inner core. One end of the inner core is located in the cavity of the outer die sleeve and forms an extrusion channel for extruding the lamp housing between the inner core and the outer die sleeve. The other end of the inner core extends along the length of the inner core to the bottom of the embossing roller, and the embossing roller is used to emboss the extruded lamp housing blank.

[0008] Furthermore, the cavity on the outer mold sleeve is adapted to the shape of the lamp housing, and the inner core is adapted to the shape of the inner cavity of the lamp housing.

[0009] Furthermore, the embossing roller adjusts the distance between itself and the upper surface of the inner core by changing its vertical position.

[0010] Furthermore, the embossing roller is adjusted in vertical position by a lifting mechanism. The lifting mechanism includes a mounting frame, the embossing roller is located inside the mounting frame, and both ends of the embossing roller are rotatably connected to the two side plates of the mounting frame. Guide rods are provided through both side plates of the mounting frame. The two ends of the guide rods are connected to the base and the top plate, respectively. The top plate is threaded with a screw. One end of the screw is connected to a handle, and the other end of the screw is rotatably connected to the mounting frame.

[0011] Furthermore, a limiting block is installed on the guide rod to limit the downward movement of the mounting bracket.

[0012] Furthermore, a temperature sensor and a temperature regulation module for changing the temperature of the core molding area are installed inside the core.

[0013] Furthermore, the embossing roller is provided with a cooling channel, which is arranged along its axial direction.

[0014] The present invention also provides a processing method for an integrated embossing extrusion lamp housing device, comprising the following steps:

[0015] Step S1: The plastic granule raw material is fed into the extruder, and the plastic is completely melted and plasticized by heating the extruder barrel to form a melt;

[0016] Step S2: The melt enters the die through the extruder head. The die includes an outer die sleeve and an inner core. An extrusion channel is formed between the outer die sleeve and the inner core. The melt is extruded through the extrusion channel to form a continuous long strip lamp housing blank.

[0017] Step S3: Under the action of traction, the extruded lamp housing blank passes between the embossing roller and the inner core. The embossing roller applies pressure to the upper surface of the lamp housing blank to roll out the textured structure, while the inner core supports and maintains the shape.

[0018] Step S4: The embossed continuous lamp housing blank immediately enters the vacuum forming sleeve for cooling and shaping.

[0019] In step S5, the continuous lamp housing after cooling and shaping is pulled forward and cut by a cutting machine when it reaches the preset length, resulting in a single integrated lamp housing product.

[0020] The beneficial effects of this invention are:

[0021] 1. This invention directly utilizes the inner core extension of the die as an embossing support platform, in conjunction with the embossing roller above, to simultaneously complete surface embossing during the lamp housing extrusion molding process, eliminating the need for secondary transfer and processing, completely avoiding deformation and misalignment caused by split processing, and significantly improving the product yield.

[0022] 2. This invention adjusts the distance between the embossing roller and the upper surface of the inner core through a lifting mechanism and a top handle, which can flexibly adapt to embossing operations of lamp housings with different wall thicknesses and materials, and the equipment has high versatility.

[0023] 3. The present invention has a temperature regulation module and a cooling channel respectively set inside the inner core and the embossing roller, which can control the temperature of the forming area to be constant and effectively prevent the blurring of the pattern and the sticking of the lamp shell to the roller caused by temperature fluctuation.

[0024] 4. This invention eliminates the need for personnel and power consumption in the secondary embossing process, and the equipment is highly integrated, effectively reducing the overall cost of mass production of lamp housings. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of one structure of the integrated embossing extrusion lamp housing device in this embodiment;

[0026] Figure 2 This is a schematic diagram of one structure of the die in this embodiment.

[0027] Reference numerals: 1. Outer mold sleeve, 101. Cavity, 2. Inner core, 3. Extrusion channel, 4. Embossing roller, 5. Lifting mechanism, 501. Mounting frame, 502. Guide rod, 503. Base, 504. Top plate, 505. Screw, 506. Handle, 507. Limiting block, 6. Vacuum shaping sleeve. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Example: An integrated embossing extrusion lamp housing device, such as Figure 1 and Figure 2 As shown, the device includes a die installed on the extruder head and an embossing roller 4 located on one side of the die. This device adds a detachable die and embossing roller between the extruder head and the vacuum forming sleeve 6, seamlessly connecting the extrusion molding and embossing processes, thus shortening the production flow. The die is used to extrude molten plastic into a lamp housing blank (this lamp housing blank is an integrated structure of the base shell and lampshade). The embossing roller 4 is used to emboss the upper surface of the lamp housing blank (corresponding to the lampshade). After embossing, the lamp housing blank enters the vacuum forming sleeve 6 for cooling and shaping.

[0030] Specifically, the die includes an outer die sleeve 1 and an inner core 2. The outer die sleeve 1 is detachably fixed to the extruder head by bolts, and a cavity 101 adapted to the shape of the lamp housing is formed on the outer die sleeve 1. One end of the inner core 2 is located inside the cavity 101 of the outer die sleeve 1, and the other end of the inner core 2 extends along its length to below the embossing roller 4. The inner core 2 is adapted to the inner cavity shape of the lamp housing. The inner core 2 is also detachably fixed to the extruder head by bolts.

[0031] When the inner core 2 is located within the cavity 101 of the outer mold sleeve 1, an extrusion channel 3 for extruding the lamp housing is formed between the outer surface of one end of the inner core 2 and the inner wall of the cavity 101 of the outer mold sleeve 1. When the molten plastic passes through the extrusion channel 3, a preliminary lamp housing blank is formed. The extrusion channel 3 can be configured into different shapes (such as a U-shape or a ring shape) according to product requirements. When the extrusion channel 3 is U-shaped, the gaps at the four corner positions can be slightly larger than the side gaps, which promotes a consistent flow pressure of the molten plastic, thereby obtaining a uniform wall thickness.

[0032] Driven by a traction machine, the lamp housing blank moves forward and enters the vacuum forming sleeve 6 for cooling and shaping. During the forward movement of the lamp housing blank, since its upper surface (corresponding to the lampshade) is located between the inner core 2 and the embossing roller 4, the friction between the blank and the embossing roller 4 drives the roller 4 to rotate synchronously. The outer surface of the embossing roller 4 is textured, and the embossing process applies a pattern to the lamp housing blank during its rotation.

[0033] Furthermore, the embossing roller 4 is adjusted in vertical position via the lifting mechanism 5, thereby adjusting the distance between the embossing roller 4 and the upper surface of the inner core 2. By changing this distance, lamp housings of different wall thicknesses can be adapted, and the friction between the embossing roller 4 and the lamp housing blank can be adjusted, ensuring that clear patterns are embossed without causing excessive stretching or uneven wall thickness of the lamp housing.

[0034] The lifting mechanism 5 includes an inverted U-shaped mounting frame 501. The embossing roller 4 is located within the inner cavity of the mounting frame 501, and both ends of the embossing roller 4 are rotatably connected to the two side plates of the mounting frame 501. Guide rods 502 are provided through both side plates of the mounting frame 501, and four sets of guide rods 502 are provided (i.e., each side plate of the mounting frame 501 is equipped with two sets of guide rods 502) to improve the stability of the side plate movement. The bottom ends of the four sets of guide rods 502 are connected to the base 503, and the top ends of the four sets of guide rods 502 are connected to the top plate 504. The top plate 504 is threadedly connected to a screw 505, which is vertically positioned. One end of the screw 505 is connected to a handle 506, and the other end is rotatably connected to the mounting frame 501 via a thrust bearing or a double-row angular contact ball bearing. When the operator rotates the handle 506, the screw 505 rotates, changing the vertical position of the mounting frame 501 through threaded transmission, thereby adjusting the vertical position of the embossing roller 4. The guide rod 502 is also provided with a limit block 507, which is used to limit the downward stroke of the mounting frame 501 to prevent the embossing roller 4 from moving downward too much and causing a hard collision with the inner core 2 below or damaging the lamp housing.

[0035] Furthermore, the device also includes a temperature regulation component, which comprises a temperature sensor, a temperature regulation module, and a controller. The controller is electrically connected to both the temperature sensor and the temperature regulation module. The temperature sensor is located within the inner core 2 and is used to collect the temperature of the molding area of ​​the inner core 2 in real time and feed it back to the controller. The temperature regulation module is embedded within the inner core 2 and is used to change the temperature of the molding area of ​​the inner core 2 (e.g., by embedding an electric heating wire). The controller is used to adjust the heating temperature of the temperature regulation module and to display the current temperature value, the set temperature value, and the monitored temperature value. By setting up the temperature regulation component, real-time monitoring and control of the molding temperature can be achieved, ensuring a constant embossing molding temperature and avoiding problems such as blurred patterns and lamp housing deformation caused by temperature deviations. It should be noted that the inner core 2 is preferably made of a high thermal conductivity metal material.

[0036] Furthermore, an axial cooling channel is provided inside the embossing roller 4. During operation, circulating cooling water can be introduced to regulate the surface temperature of the embossing roller 4, effectively preventing overheating and material sticking to the embossing roller due to prolonged embossing operations.

[0037] This embodiment also provides a method for processing an integrated embossed extrusion lamp housing, including the following steps:

[0038] Step S1: According to the material of the lamp housing (such as PC, PVC, acrylic, etc.), the plastic granules are fed into the extruder, and the plastic is completely melted and plasticized by heating the extruder barrel to form a melt.

[0039] In step S2, the melt enters the die through the extruder head. The die includes an outer die sleeve 1 and an inner core 2. An extrusion channel 3 is formed between the outer die sleeve 1 and the inner core 2. The melt is extruded through the extrusion channel 3 to form a continuous long strip lamp housing blank.

[0040] In step S3, the extruded lamp housing blank passes between the embossing roller 4 and the inner core 2 under the action of traction. The embossing roller 4 applies pressure to the upper surface of the lamp housing blank to roll out the textured structure, while the inner core 2 supports and maintains the shape.

[0041] Step S4: The embossed continuous lamp housing blank immediately enters the vacuum shaping sleeve 6 for cooling and shaping.

[0042] In step S5, the continuous lamp housing after cooling and shaping is pulled forward by a tracked traction machine. When it reaches the preset length, it is automatically cut by a cutting machine to obtain a single integrated lamp housing finished product.

[0043] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An integrated embossing extrusion lamp housing device, characterized in that, The device includes a die installed on the extruder head and an embossing roller (4) located on one side of the die. The die includes an outer die sleeve (1) and an inner core (2). One end of the inner core (2) is located in the cavity (101) of the outer die sleeve (1) and forms an extrusion channel (3) for extruding the lamp housing between the inner core (2) and the outer die sleeve (1). The other end of the inner core (2) extends along the length of the inner core (2) to the bottom of the embossing roller (4) and the embossing roller (4) is used to emboss the extruded lamp housing blank.

2. The integrated embossing extrusion lamp housing device according to claim 1, characterized in that, The cavity (101) on the outer mold sleeve (1) is adapted to the shape of the lamp housing, and the inner core (2) is adapted to the shape of the inner cavity of the lamp housing.

3. The integrated embossing extrusion lamp housing device according to claim 1, characterized in that, The embossing roller (4) adjusts the distance between itself and the upper surface of the inner core (2) by changing its vertical position.

4. The integrated embossing extrusion lamp housing device according to claim 3, characterized in that, The embossing roller (4) is adjusted up and down by a lifting mechanism (5). The lifting mechanism (5) includes a mounting frame (501). The embossing roller (4) is located inside the mounting frame (501). Both ends of the embossing roller (4) are rotatably connected to the two side plates of the mounting frame (501). Guide rods (502) are provided through both side plates of the mounting frame (501). Both ends of the guide rods (502) are connected to the base (503) and the top plate (504) respectively. The top plate (504) is threadedly connected to a screw (505). One end of the screw (505) is connected to a handle (506), and the other end of the screw (505) is rotatably connected to the mounting frame (501).

5. The integrated embossing extrusion lamp housing device according to claim 4, characterized in that, The guide rod (502) is equipped with a limiting block (507) for limiting the downward movement of the mounting bracket (501).

6. The integrated embossing extrusion lamp housing device according to claim 1, characterized in that, A temperature sensor and a temperature adjustment module for changing the temperature of the molding area of ​​the inner core (2) are installed inside the inner core (2).

7. The integrated embossing extrusion lamp housing device according to claim 1, characterized in that, The embossing roller (4) is provided with a cooling channel, which is arranged along its axial direction.

8. A method for processing the integrated embossing extrusion lamp housing device as described in any one of claims 1-7, characterized in that, Includes the following steps: Step S1: The plastic granule raw material is fed into the extruder, and the plastic is completely melted and plasticized by heating the extruder barrel to form a melt; Step S2, the melt enters the die through the extruder head. The die includes an outer die sleeve (1) and an inner core (2). An extrusion channel (3) is formed between the outer die sleeve (1) and the inner core (2). The melt is extruded through the extrusion channel (3) to form a continuous long strip lamp shell blank. In step S3, the extruded lamp housing blank passes between the embossing roller (4) and the inner core (2) under the action of traction. The embossing roller (4) applies pressure to the upper surface of the lamp housing blank to roll out the textured structure, while the inner core (2) supports and maintains the shape. Step S4: The embossed continuous lamp housing blank immediately enters the vacuum shaping sleeve (6) for cooling and shaping; In step S5, the continuous lamp housing after cooling and shaping is pulled forward and cut by a cutting machine when it reaches the preset length, resulting in a single integrated lamp housing product.

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