Die for preparing lamp trough
By cold-processing and forming the reflective plate at room temperature, the deformation and resetting problem caused by residual stress of the hot-processed forming lamp trough is solved, and a more stable and uniform light source effect is achieved, and the thinness and energy-saving performance of the module are improved.
Patent Information
- Application Number
- CN202323366017.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2023-12-11
- Publication Date
- 2025-07-01
- Estimated Expiration
- 2033-12-11
AI Technical Summary
When used, the hot-processed lamp trough will tend to be deformed and reset due to residual stress, which will cause the lamp trough to deform and affect the light output effect.
The cold processing molding method is adopted to make lamp troughs by punching and bending the reflective plate at room temperature, and the residual stress problems caused by hot processing are avoided.
It reduces the impact of temperature on the deformation of the lamp trough, improves the picture uniformity and stability of the display module, realizes the formation of a block-like light source in a single lamp, improves the color contrast of the picture, and makes the module lighter and thinner, achieving the effect of energy saving and cost reduction.
Smart Images
Figure CN223049942U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the field of lamp slot structures, and more specifically, the utility model relates to a mold for preparing a lamp slot. Background Art
[0002] Currently in the industry, in order to pursue the overall thinness, light quality improvement and energy saving of the module, a "reflective lamp slot" design has been added to the backlight module.
[0003] The production methods of the lamp slot can be generally summarized into two types. One of the production methods is to use white plastic particles to be injection molded into an "ice cube box shape" and a "mesh shape" to form the lamp slot structure. However, since the reflectivity of general white plastic particles is only 80%-85%, the material is prone to embrittlement and yellowing aging phenomena after long-term exposure to a high-temperature cavity, so it still cannot meet the optical requirements, and both the injection production cost and the mold investment cost are relatively high. Another production method is to use thermoforming and vacuum forming to mold the PET material into the lamp slot style. Although the surface of the PET material is coated with a reflective layer or is covered by a material with a reflective effect, its reflectivity can reach 95%-98%, but the production cost of this method is also relatively high, and high temperature will also cause the material to stretch and deform. Therefore, the following non-negligible defects existing in the vacuum forming production method are listed:
[0004] 1. Due to high temperature and mold forming, in order to be stable after forming, an additional cooling treatment must be carried out during the forming process, resulting in a relatively high forming time cost, and the cooling system also causes the mold cost to rise.
[0005] 2. The PET material is softened by high temperature and stretched into shape. This stretching process cannot ensure the uniformity of the material being stretched, and the reflective coating on the material surface may crack and break due to stretching, resulting in uneven optical reflection.
[0006] 3. Due to high temperature and mold forming, but when the lamp beads in the assembled module are lit, the temperature in the cavity of the lamp slot will rise. At this time, the formed lamp slot will be in an open state without the restriction of the mold, and the formed stress will be released and deformed due to the temperature rise in the cavity, seriously affecting the light output effect.
[0007] Therefore, it is necessary to design a lamp slot that is not affected by high temperature to solve the above problems. Summary of the Utility Model
[0008] In order to overcome the above-mentioned defects of the prior art, an embodiment of the utility model provides a mold for preparing a lamp slot. The technical problem to be solved by the utility model is that the lamp slot formed by hot processing and molding will have a tendency of deformation reset due to the influence of residual stress during use, further causing the lamp slot to deform, seriously affecting the light output effect.
[0009] To achieve the above object, the present utility model provides the following technical solutions: A mold for preparing a lamp slot includes: a number of lamp slot monomers arranged in an array form. Each lamp slot monomer includes a mounting plate, side walls, bending edges, and gaps. Side walls corresponding to each side of the mounting plate are fixedly connected obliquely. A gap for introducing glue to solidify the side walls is left between two adjacent side walls within the same lamp slot monomer. A groove for accommodating LED lamp beads is provided on the mounting plate. The four side walls form a horn-shaped structure, with the small end of the horn-shaped structure facing the mounting plate. The corresponding side walls between two adjacent lamp slot monomers are connected by bending edges. A reflective layer is coated on the inner wall of the lamp slot monomer.
[0010] In a preferred embodiment, the reflective layer is a reflector layer.
[0011] In a preferred embodiment, the cross-sectional shape of the side wall is an isosceles trapezoid or a multi-sided pyramid.
[0012] In a preferred embodiment, the shapes and sizes of the four side walls within the same lamp slot monomer are equal.
[0013] A mold for preparing a lamp slot, used to prepare the above-mentioned lamp slot structure, includes a lower forming plate and an upper forming plate. The lower forming plate and the upper forming plate can move relative to each other and close. A core is fixedly connected to the lower forming plate. The upper forming plate includes a plate body and a glue injection port for injecting glue. A cavity corresponding to the core and the lamp slot structure is provided in the plate body. A number of glue injection ports are provided in the plate body, and the positions of the glue injection ports are correspondingly set with the positions of the gaps.
[0014] In a preferred embodiment, the lower forming plate is fixedly connected to a frame. The upper forming plate is connected to a hydraulic cylinder. The hydraulic cylinder includes a cylinder body and a telescopic rod. The telescopic rod is slidably placed in the cylinder body. A control unit for controlling the telescopic movement of the telescopic rod in the cylinder body is electrically connected to an external controller. The cylinder body is fixedly connected to the frame, and the telescopic rod is fixedly connected to the plate body.
[0015] In a preferred embodiment, the cross-sectional shapes of the core in the lower forming plate and the cavity in the upper forming plate are both frustum of a pyramid shapes.
[0016] In a preferred embodiment, the glue is one of thermosetting glue, quick-drying glue, or UV curable glue.
[0017] In a preferred embodiment, the small mouth of the horn-shaped structure formed by the side walls faces the upper forming plate.
[0018] The technical effects and advantages of the present utility model:
[0019] By using the cold - forming method, the lamp groove is manufactured without changing the nature of the material, greatly reducing the influence of temperature on the deformation of the lamp groove. This can not only improve the uniformity and stability of the display module screen, realize that a single lamp has a dot - shaped light source to form a block - shaped light source, but also improve the color contrast of the screen, making the screen more vivid and saturated. It can also make the module thinner and lighter, reduce the number of LED lamp beads, achieving the effects of energy conservation and cost reduction. Brief Description of the Drawings
[0020] The drawings are used to provide a further understanding of the technical solution of the present utility model, and constitute a part of the present utility model. The embodiments of the present utility model and their descriptions are used to explain the present utility model, and do not constitute an improper limitation to the present utility model.
[0021] Figure 1 It is a structural diagram of a single lamp groove in the present utility model.
[0022] Figure 2 It is a structural diagram of the bent edge in the present utility model.
[0023] Figure 3 It is an array combination diagram of several single lamp grooves in the present utility model.
[0024] Figure 4 It is a schematic diagram of the reflective plate and the cutting edge line on its surface in the present utility model.
[0025] Figure 5 It is a structural schematic diagram of the first bending of the reflective plate in the present utility model.
[0026] Figure 6 It is a structural schematic diagram of the second bending of the reflective plate in the present utility model.
[0027] Figure 7 It is an installation position diagram of the upper forming plate and the lower forming plate in the present utility model.
[0028] Figure 8 It is a cross - sectional view of the mold in the present utility model.
[0029] The reference numerals are: 1, single lamp groove; 11, mounting plate; 12, side wall; 13, bent edge; 14, gap; 2, lower forming plate; 3, upper forming plate; 31, plate body; 32, glue injection port. Detailed Embodiment
[0030] Example embodiments will now be described more fully with reference to the accompanying drawings. However, the example embodiments can be implemented in various forms and should not be construed as limited to the examples set forth herein; rather, these example embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the example embodiments to those skilled in the art. The drawings are merely schematic illustrations of the present disclosure and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and thus their repeated description will be omitted.
[0031] In addition, the described features, structures, or characteristics may be combined in any suitable manner in one or more example embodiments. In the following description, numerous specific details are provided to give a thorough understanding of the example embodiments of the present disclosure. However, those skilled in the art will realize that one or more of the specific details may be omitted, or other methods, components, steps, etc. may be adopted. In other cases, well-known structures, methods, implementations, or operations are not shown or described in detail to avoid obscuring aspects of the present disclosure.
[0032] This application processes the lamp slot by cold working. The so-called cold working refers to punching and bending the reflective sheet at room temperature. However, the existing methods for processing lamp slots, whether injection molding or thermoforming, are all hot working methods. Although hot working methods are common, there is an undeniable impact. That is, after hot working and stretching forming, there is always a certain amount of residual stress in the workpiece. This residual stress always causes the lamp slot to have a tendency of deformation reset. As the service life of the lamp slot increases, the impact of deformation reset caused by this residual stress becomes stronger, resulting in deformation of the lamp slot and affecting the light output effect. In contrast, cold working does not have such residual stress.
[0033] By using the cold working forming method to manufacture the lamp slot without changing the nature of the material, reducing the influence of temperature on the deformation of the lamp slot, not only can the uniformity and stability of the display module image be improved, realizing that a single lamp forms a block-shaped light source from a dot-shaped light source, but also the color contrast of the image can be enhanced, achieving a more vivid and saturated image. Moreover, the module can be made thinner and lighter, reducing the number of LED lamp beads to achieve the effects of energy saving and cost reduction.
[0034] Example 1
[0035] As Figure 1 - Figure 6 shown, a lamp slot structure includes a plurality of lamp slot monomers 1, and the lamp slot monomers 1 are arranged in an array form.
[0036] Here, the production process of the entire lamp slot structure is described.
[0037] S1: Take a PET sheet and coat a layer of reflector material, i.e., reflective material, on the sheet. Define the sheet after spraying as the reflective sheet.
[0038] S2: Place the reflective sheet on a stamping machine and, in accordance with Figure 4 Remove the black part on the reflective sheet to leave space for subsequent folding.
[0039] S3: Take another mold, which includes a lower forming plate 2 and an upper forming plate 3. Place the reflective sheet obtained in the process of S2 between the lower forming plate 2 and the upper forming plate 3, and use a hydraulic system to drive the lower forming plate 2 and the upper forming plate 3 to close the mold, and press the reflective sheet into a lamp groove shape according to the inner cavity shapes of the lower forming plate 2 and the upper forming plate 3.
[0040] Specifically, each lamp groove unit 1 includes a mounting plate 11, side walls 12, bending edges 13, and gaps 14. The grooves formed in the mounting plate 11 are used to place the LED lamp bead structure. The side walls 12 with the same size and shape are inclined and bent and connected to the four peripheral sides of the mounting plate 11. The four side walls 12 form a horn-shaped structure, and the small opening of the horn is close to the mounting plate 11. There is a gap 14 formed after stamping the reflective sheet between two adjacent side walls 12 in the same lamp groove unit 1.
[0041] The side walls 12 in one lamp groove unit 1 and the side walls 12 in the adjacent lamp groove unit 1 are connected by bending edges 13 formed by bending. A plurality of lamp groove units 1 are arranged in an array and are all connected by bending edges 13.
[0042] It should be noted that the softening critical point temperature of the PET material used in this application is between 70°C and 80°C, which is in a glass state, and the temperature when the LED lamp bead works is about 70°C. Therefore, when the LED lamp bead works, the physical sheet metal processing form belongs to cold processing, without the influence of residual stress, and will not cause secondary changes to the lamp groove made of this PET material, so the light output effect is stabilized.
[0043] Furthermore, the reflector material itself also has a certain heat resistance, and the fixing adhesive is also a high-temperature resistant material. Therefore, the heat resistance of the lamp groove structure described in this embodiment can be further improved, and the probability of the lamp groove structure softening and deforming due to heat is reduced.
[0044] Embodiment 2
[0045] Please refer to Figure 7 and Figure 8, on the basis of the above embodiments, the mold includes a lower forming plate 2 and an upper forming plate 3. The upper forming plate 3 includes a plate body 31 and a glue injection port 32. A plurality of glue injection ports 32 are opened in the plate body 31. A pressing core is fixedly connected inside the lower forming plate 2. A pressing cavity is opened inside the plate body 31. The core, the cavity and the above-mentioned lamp groove structure are matched. When the lower forming plate 2 and the upper forming plate 3 are closed, the position of the plate body 31 corresponds to the gap 14 inside the adjacent lamp groove monomer 1. By dripping glue into the glue injection port 32, the glue can submerge the gap 14. Glue can be dripped at either end of the gap 14 to consolidate a plurality of side walls 12 and further fix the entire lamp groove structure.
[0046] Preferably, the glue can be one of thermosetting glue, quick-drying glue, and UV-curing glue.
[0047] In Embodiment 1 and Embodiment 2, preferably, the lamp groove is designed into a trumpet-shaped structure with a large opening at one end and a small opening at the other end. It can be either a trumpet-shaped structure with multi-edges or an arc-shaped trumpet structure without edges. Through the light collection of the trumpet shape, the lighting effect can be expanded and the number of lamp beads used can be reduced.
[0048] Preferably, the side wall 12 is designed as an isosceles trapezoid, and the trumpet-shaped structure composed of the four side walls 12 is a frustum of a pyramid.
[0049] Finally: The above are only the preferred embodiments of the present utility model and are not used to limit the present utility model. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present utility model shall be included in the protection scope of the present utility model.
Claims
1. A mold for preparing a lamp trough, characterized in that: It includes a lower forming plate (2) and an upper forming plate (3). The lower forming plate (2) and the upper forming plate (3) can move relative to each other and close. A core is fixedly connected to the lower forming plate (2). The upper forming plate (3) includes a plate body (31) and a glue injection port (32) for injecting glue. A cavity corresponding to the core and the lamp groove structure is formed in the plate body (31). A plurality of glue injection ports (32) are formed in the plate body (31). The positions of the glue injection ports (32) are correspondingly arranged with the positions of the gaps (14). A gap (14) for introducing glue to solidify the side walls (12) is left between two adjacent side walls (12) within the same lamp groove unit (1).
2. The mold for preparing a lamp slot according to claim 1, wherein: The lower forming plate (2) is fixedly connected to the frame. The upper forming plate (3) is connected to a hydraulic cylinder. The hydraulic cylinder includes a cylinder body and a telescopic rod. The telescopic rod slides in the cylinder body. The control unit for controlling the telescopic movement of the telescopic rod in the cylinder body is electrically connected to an external controller. The cylinder body is fixedly connected to the frame, and the telescopic rod is fixedly connected to the plate body (31).
3. A mold for preparing a lamp slot according to claim 1, characterized in that: The cross-sectional shapes of the core in the lower forming plate (2) and the cavity in the upper forming plate (3) are both frustum of a pyramid shapes.
4. A mold for preparing a lamp slot according to claim 1, characterized in that: The glue is one of thermosetting glue, quick-drying glue or UV-curing glue.
5. A mold for preparing a lamp slot according to claim 1, characterized in that: The small trumpet-shaped opening formed by the side walls (12) is arranged facing the upper forming plate (3).