Die, LED support prefabricated part and LED support
By using a design that combines positioning protrusions with side grooves in the mold, the problems of wear on positioning protrusions and copper chip shedding in LED bracket production are solved, achieving efficient production and low-cost LED bracket manufacturing.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DONGGUAN CHANGTONG PRECISION HARDWARE
- Filing Date
- 2025-01-15
- Publication Date
- 2026-04-21
AI Technical Summary
In the current LED bracket production process, the positioning protrusions are prone to wear and copper shavings, which can lead to short circuits and increased production costs.
The mold design employs positioning bumps that cooperate with side grooves to form a fixing mechanism, reserving flow channels to reduce the contact frequency and contact area between the positioning bumps and the injection fluid, concentrating copper chips in the side grooves, and guiding the copper chips to the outside of the side grooves through the flow channels.
It extends the service life of the mold core, reduces the probability of copper shavings falling off and short circuits, improves production efficiency and yield, and reduces production costs.
Smart Images
Figure CN224145222U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of LED bracket manufacturing, and more particularly to a mold, an LED bracket preform, and an LED bracket. Background Technology
[0002] like Figure 1 As shown, Figure 1 The diagram shows a 3D view of the current LED bracket. The current LED bracket production process is as follows: stamping, injection molding, cutting and bending, and forming.
[0003] The above process can be briefly described as follows: the metal strip is pre-stamped to form a hollow area for injection molding. After the mold core enters or passes through the hollow area, it is used in conjunction with the mold sleeve to inject the metal strip. After injection molding, the metal strip is cut and bent to finally form the LED bracket.
[0004] Specifically, the positioning protrusions of the mold core enter or pass through the aforementioned hollow area. The functions of the positioning protrusions are positioning and restricting the flow of plastic fluid to the outside. Therefore, the positioning protrusions are prone to scraping against the sidewalls of the hollow area of the material strip. In severe cases, they can directly press out a piece of copper shavings. This situation occurs quite frequently. At the same time, after repeated occurrences, the shape of the positioning protrusions is damaged, which leads to the problem of excess plastic during injection molding. If the positioning protrusions have slight contact with the hollow area, fine, hard-to-detect copper wires will remain on the sidewalls of the hollow holes. These wires will fall off onto the LED brackets during subsequent bending processes. These copper shavings are conductive, and their location is random. For example, when they fall into the cup, they will change the internal circuit of a single LED. When they fall onto the pins, the copper shavings will form non-designed conductive lines after the LED is mounted on the circuit board. This can cause short circuits, dead LEDs, or series connections during customer packaging or application mounting.
[0005] Meanwhile, under the impact of high temperature and high pressure, the positioning protrusion will inevitably wear down in the injection molding machine, thus affecting its positioning effect on the metal strip (the positioning protrusion not only acts as an outer enclosure wall in injection molding, but also serves as the positioning of the metal strip); frequent replacement of mold cores will lead to a sharp increase in costs. Utility Model Content
[0006] To solve the above problems, this utility model provides a mold, an LED bracket prefabricated component, and an LED bracket, which primarily solves the problem of short circuits in the circuit.
[0007] This utility model provides a mold, an LED bracket preform, and an LED bracket to mitigate the high wear rate of the positioning protrusion.
[0008] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a mold for preparing an LED bracket, comprising a mold core and a mold sleeve that cooperate with each other, and multiple side grooves extending outward from the hollow area on the strip. The mold core comprises several positioning protrusions located in the side grooves. By combining multiple positioning protrusions and abutting against one side of the side groove, a fixing mechanism for positioning the strip is formed. Furthermore, a flow channel for injection fluid is reserved between the positioning protrusions and the inside of the side groove.
[0009] The beneficial effects of this utility model are:
[0010] 1. The central area of the hollowed-out zone corresponds to the injection port of the injection molding machine. The positioning protrusion is located in the side groove extending outward from the hollowed-out zone, which can reduce the impact of the injection fluid. In other words, this delays the contact time between the injection fluid and the positioning protrusion, and prolongs the collision stroke between the injection fluid and the positioning protrusion. This means that the injection fluid will only contact the positioning protrusion after the flow rate slows down. Therefore, the impact force generated by the injection fluid on the positioning protrusion is greatly reduced, and the damage to the positioning protrusion is less.
[0011] 2. After changing the mold core, the copper shavings are concentrated in the side groove. The molded part in the side groove is an auxiliary material of the LED bracket. This means that after using this mold core, the copper shavings have been diverted to the outside of the LED bracket. At the same time, the positioning protrusion abuts against one side of the side groove. In other words, the probability of copper shavings being generated during mold closing is very low. Even if copper shavings are generated, there will be no situation where a large amount of copper shavings suddenly rushes to all sides, reducing the amount of copper shavings scattered in the hollow area. In addition, the flow channel formed by the positioning protrusion in the side groove allows the injection fluid to flush away the excess copper shavings in the hollow area when it flows in from the injection port, guiding the copper shavings into the side groove.
[0012] Since the positioning bump only serves a positioning function and does not restrict the flow direction of the plastic, the surface of the positioning bump can be processed into a guide chamfer. In the prior art, the positioning bump is designed with a chamfer to restrict the flow of plastic fluid to the outside, which will cause the injection fluid to overflow. In summary, the LED bracket prepared by the process of this utility model has the effect of high efficiency and better quality, solves the copper shavings problem that plagues the industry, and greatly improves production efficiency.
[0013] In this embodiment, there is at most one positioning bump in each side groove, which reduces the contact area between the positioning bump and the strip, thus reducing the generation of more copper chips.
[0014] There are gaps between the positioning protrusions, which are intended to correspond to the various side grooves.
[0015] Therefore, it is not difficult to conclude that one set of limiting blocks restricts the forward and backward movement of the strip, while the other set restricts the left and right movement of the strip. The following example illustrates this: the first side groove includes a first side, a third side, and the second side groove includes a fourth side, a fifth side, and a sixth side. The first set of positioning protrusions: the first positioning protrusion abuts against the first side, and the second positioning protrusion abuts against the sixth side; the second set of positioning protrusions: the third positioning protrusion abuts against the first side, and the fourth positioning protrusion abuts against the fifth side.
[0016] The above is just one implementation method. Depending on the needs, the number of the first group of positioning protrusions and the second group of positioning protrusions can be increased. For example, there can be a fifth positioning protrusion that abuts against the third side and a sixth positioning protrusion that abuts against the fourth side.
[0017] It should be noted that all of the above methods are for the following purpose: the positioning bump will not come into contact with the part of the strip that serves as the pin (i.e. the bending foot), but only with the frame in the strip. When the bending foot is bent, there is no risk of copper shavings or copper wires falling off that are not easily noticed.
[0018] A preform for an LED bracket includes a preform body, characterized in that the preform body has an auxiliary material to be removed, the auxiliary material extending outward from the preform body; the auxiliary material in the preform is copper shavings or copper wires, etc., and by removing the auxiliary material, the occurrence of new conductive lines can be reduced, and the occurrence of short circuits in the encapsulation can be reduced.
[0019] Furthermore, multiple auxiliary materials are provided and distributed around the preform body. This design aims to increase the space for storing copper shavings. Specifically, since the injection fluid diffuses in all directions, more auxiliary materials mean more flow directions, which can further reduce the accumulation of copper shavings.
[0020] Furthermore, the auxiliary material has multiple positioning holes for positioning. These positioning holes work in conjunction with positioning protrusions to ensure that the precast part does not wobble in the material strip.
[0021] Specifically, there are six auxiliary materials, which are parallel to each other. The parallelism between the auxiliary materials helps to simplify the design of the mold core and reduce the difficulty of the mold core design. In addition, the copper shavings are evenly distributed in each auxiliary material, which optimizes the situation when there are too many copper shavings in some auxiliary materials and overflow into the preform during injection molding.
[0022] An LED bracket, characterized in that the LED bracket is formed by removing the auxiliary material from a pre-formed LED bracket, and the LED bracket has a fracture surface after the auxiliary material has been removed.
[0023] An LED bracket manufacturing process includes the following steps:
[0024] S1, stamping the strip to form a hollow area and a side groove extending from the hollow area;
[0025] S2, adjust the position of the strip so that the positioning protrusion on the side groove and the mold core are corresponding to each other, and ensure that the positioning protrusion can be inserted into the side groove;
[0026] S3, perform mold closing and injection molding, and the injection fluid flows into the hollow area and side groove in an orderly manner;
[0027] S4. Implement mold opening and use adhesive removal equipment to perform adhesive removal process on the material strip to remove the auxiliary material on the LED bracket;
[0028] S5 uses a cutting punch around the LED bracket to form a bent foot;
[0029] S6, perform the bending and shaping of the aforementioned foot.
[0030] The LED brackets produced by this manufacturing process have a very high yield rate. This is mainly achieved by using positioning bumps to contact one side of the side groove, creating space for copper shavings to accumulate in the side groove. This removes a large amount of copper shavings or wires remaining in the bracket, thus greatly reducing the possibility of short circuits during encapsulation and lowering production costs. In addition, by prioritizing the injection port from the hollow area, the copper shavings remaining in the hollow area can also flow smoothly into the side groove.
[0031] This method uses a smaller contact area to position the strip, resulting in less copper shavings generated during mold closing and more effectively controlling the defect rate of LED light fixtures.
[0032] In addition, this method of producing LED brackets results in less wear on the mold core. The stroke between the positioning protrusions in the mold core and the injection port is extended. As the flow rate of the injection fluid decreases, the impact force on the positioning protrusions also decreases. Therefore, the service life of the mold core is extended and the frequency of mold core replacement is reduced.
[0033] Furthermore, in the new process, the positioning bosses are only used for positioning. Since there is no need to restrict the flow of plastic, the surface of the positioning bosses can be processed with guide chamfers (if the positioning bosses in the old process are processed with guide chamfers, there will be excess plastic). Copper shavings will hardly be pressed out. In addition, the positioning bosses will not come into contact with the part of the strip that serves as the lead (i.e. the bending foot), but only with the frame in the strip. When the bending foot is bent, there is no risk of copper shavings or copper wires falling off that are not easily detected. Attached Figure Description
[0034] Figure 1 This is a 3D view of the LED bracket.
[0035] Figure 2 It is a 3D diagram of the mold core.
[0036] Figure 3 This is a top-down view showing the assembly of the material strip and the positioning bump bracket.
[0037] Figure 4 is Figure 3 Enlarged diagram of point A.
[0038] Figure 5 This is a structural diagram of part of the material strip.
[0039] Figure 6 It is a 3D view of the parts after separation during the mold-closing process.
[0040] Figure 7 yes Figure 6 Enlarged diagram of point B.
[0041] Figure 8 This is a structural diagram of the LED bracket after it has been molded and formed on the material strip.
[0042] Figure 9 This is a diagram showing the usage status of the adhesive removal equipment.
[0043] Figure 10 This is a schematic diagram of using a cutting punch.
[0044] Figure 11 This is a 3D view of the LED bracket prefabricated component. Detailed Implementation
[0045] like Figure 1-11 As shown, a mold for manufacturing an LED bracket includes a mold core and a mold sleeve that cooperate with each other. In this embodiment, the mold core is set on the moving mold 1, and the mold sleeve is located on the fixed mold 2. Multiple side grooves 3 extend outward from the hollow area 4 on the strip 5. The mold core includes several positioning protrusions 1a, which are located in the side grooves 3. By combining multiple positioning protrusions 1a with one side of the side groove 3, a fixing mechanism for positioning the strip 5 is formed. A flow channel 1b for injection fluid is reserved between the positioning protrusions 1a and the inside of the side groove 3.
[0046] The beneficial effects of this utility model are:
[0047] 1. The central area of the hollow area 4 corresponds to the injection port of the injection molding machine. The positioning protrusion 1a is located in the side groove 3 extending outward from the hollow area 4, which can reduce the impact of the injection fluid. In other words, this delays the contact time between the injection fluid and the positioning protrusion 1a, and prolongs the collision stroke between the injection fluid and the positioning protrusion 1a. This means that the injection fluid will only contact the positioning protrusion 1a after the flow rate slows down. Therefore, the impact force generated by the injection fluid on the positioning protrusion 1a is greatly reduced, and the damage to the positioning protrusion 1a is also smaller.
[0048] 2. After the mold core is replaced, the copper shavings are concentrated in the side groove 3. The part formed in the side groove 3 belongs to the auxiliary material 6 of the LED bracket 7. This means that after using this mold core, the copper shavings have been diverted to the outside of the LED bracket 7. At the same time, the positioning protrusion 1a abuts against one side of the side groove 3. That is to say, when the mold is closed, the amount of copper shavings generated is relatively small, and there will be no situation where a large amount of copper shavings suddenly rush to all sides, reducing the amount of copper shavings scattered in the hollow area 4. In addition, the flow channel 1b formed by the positioning protrusion 1a in the side groove 3 allows the injection fluid to flow in from the injection port, which will flush away the excess copper shavings in the hollow area 4 and guide the copper shavings into the side groove 3.
[0049] There is a gap between the positioning protrusions 1a, which is intended to correspond with each side groove 3.
[0050] In this embodiment, each side groove 3 has at most one positioning bump 1a, which reduces the contact area between the positioning bump 1a and the strip 5 and reduces the generation of more copper shavings.
[0051] Therefore, it is not difficult to conclude that one set limits the forward and backward movement of the material strip 5, and the other set limits the left and right movement of the material strip 5. The following example illustrates this: multiple first side grooves 3 include a first side 31, a first side 32, and a third side 33; multiple second side grooves 3 include a fourth side 34, a fifth side 35, and a sixth side 36; the first set of positioning protrusions 1a: the first positioning protrusion 1a-1 abuts against the first side 31, and the second positioning protrusion 1a-2 abuts against the sixth side 36; the second set of positioning protrusions 1a: the third positioning protrusion 1a-3 abuts against the first side 32, and the fourth positioning protrusion 1a-4 abuts against the fifth side 35.
[0052] The above is just one implementation method. Depending on the needs, the number of the first group of positioning protrusions 1a and the second group of positioning protrusions 1a can be increased. For example, there is a fifth positioning protrusion 1a-5 that abuts against the third side 33 and a sixth positioning protrusion 1a-6 that abuts against the fourth side 34; or, simply using the first side groove 5, with the first positioning protrusion 1a-1 abutting against the first side 31 and the fifth positioning protrusion 1a-5 abutting against the third side 33, can achieve the positioning of the material strip 5.
[0053] It should be noted that all of the above methods are for the purpose of achieving the following (e.g.) Figure 10 As shown): The positioning bump 1a will not contact the part of the strip 5 that serves as the pin (i.e. the bending foot 10), but will only contact the frame in the strip 5. When the bending foot 10 is bent, there is no risk of copper shavings or copper wires falling off that are not easily noticed.
[0054] Existing molds have thousands of cavities. Taking a 3000-cavity mold as an example, with 6 positioning protrusions per cavity, there are 18000 positioning protrusions. In existing production processes, damage to even one positioning protrusion will result in a defective product. However, the positioning protrusion 1a of this invention will not produce defective products even if it suffers extensive damage.
[0055] A manufacturing process for an LED bracket 7 includes the following steps:
[0056] S1, stamping is performed on the strip 5 to form a hollow area 4 and a side groove 3 extending from the hollow area 4 on the strip 5;
[0057] S2, adjust the position of the strip 5 so that the side groove 3 and the positioning protrusion 1a on the mold core are corresponding to each other, ensuring that the positioning protrusion 1a can be inserted into the side groove 3;
[0058] S3, perform mold closing and injection molding, and the injection fluid flows into the hollow area 4 and the side groove 3 in an orderly manner;
[0059] S4, Implement mold opening, and use the glue removal equipment 8 to carry out the glue removal process on the material strip 5 to remove the auxiliary material 6 on the LED bracket 7;
[0060] S5, a cutting punch 9 is used around the LED bracket 7 to form a bent foot 10;
[0061] S6, perform the bending of the aforementioned bending feet to form the complete LED bracket.
[0062] The LED bracket 7 produced by this manufacturing process has a very high yield rate. This is mainly because the positioning bump 1a contacts one side of the side groove 3, which creates space for copper shavings to accumulate in the side groove 3. This removes a large amount of copper shavings or copper wires that remain in the bracket, thus greatly reducing the possibility of short circuits during encapsulation and reducing production costs. In addition, the liquid injection port is preferentially injected from the hollow area 4, so the copper shavings remaining in the hollow area 4 can also flow smoothly into the side groove 3.
[0063] This method uses a smaller contact area to position the material strip 5, thus producing less copper shavings during mold closing and more effectively controlling the defect rate of LED light fixtures.
[0064] In addition, this method of producing LED bracket 1 results in less wear on the mold core. The stroke between the positioning protrusion 1a in the mold core and the injection port is extended. After the flow rate of the injection fluid decreases, the impact force on the positioning protrusion 1a is also reduced. Therefore, the service life of the mold core is extended and the frequency of mold core replacement is reduced.
[0065] A preform for an LED bracket 7 includes a preform body 11, characterized in that the preform body 11 is provided with an accessory material 6 to be removed, the accessory material 6 extending outward from the preform body 11; the accessory material 6 in the preform stores copper shavings or copper wires, etc., and by removing the accessory material 6, the occurrence of new conductive lines can be reduced, and the occurrence of short circuits in the encapsulation can be reduced.
[0066] Furthermore, there are multiple auxiliary materials 6, which are distributed around the preform body 11. This design aims to increase the space for storing copper shavings. Specifically, the injection fluid diffuses in all directions, and more auxiliary materials 6 represent more flow directions, which can further reduce the accumulation of copper shavings.
[0067] Furthermore, the auxiliary material 6 has multiple positioning holes 61 for positioning. The function of these positioning holes 61 is to work in conjunction with 1a to ensure that the precast body 11 does not shake in the material strip 5.
[0068] Specifically, there are six auxiliary materials 6, which are parallel to each other. The parallelism between the auxiliary materials 6 helps to simplify the design of the mold core and reduce the difficulty of the mold core design. In addition, the copper shavings are evenly distributed in each auxiliary material 6, which optimizes the situation when there are too many copper shavings in some auxiliary materials 6 and they overflow into the preform during injection molding.
[0069] An LED bracket 7 is formed by removing an accessory material 6 from a preform of an LED bracket 7, and the LED bracket has a fracture surface after removing the accessory material 6.
[0070] The above embodiments are merely preferred embodiments of the present utility model and are not intended to limit the scope of the present utility model. Various modifications and improvements made by those skilled in the art to the technical solutions of the present utility model without departing from the spirit of the present utility model should fall within the protection scope defined by the claims of the present utility model.
Claims
1. A mold comprising a mold core and a mold jacket used in cooperation with each other, a plurality of edge grooves being formed on a hollowed-out area on a material strip and extending outward therefrom, characterized in that, The mold core contains several positioning protrusions located in the aforementioned side groove. By combining multiple positioning protrusions and abutting against one side of the side groove, a fixing mechanism for positioning the material strip is formed. Furthermore, a flow channel for injection fluid is reserved between the positioning protrusions and the inside of the side groove.
2. A mold according to claim 1, wherein Each side slot can have at most one positioning bump.
3. A mold according to claim 1, wherein There is a gap between the positioning bumps.
4. A mold according to claim 1, wherein The positioning protrusion includes a first positioning protrusion, a second positioning protrusion, a third positioning protrusion, and a fourth positioning protrusion. The side groove has at least two sets, namely a first side groove and a second side groove. One set limits the forward and backward movement of the material strip, and the other set limits the left and right movement of the material strip. The first side groove includes a first side, a third side, and a fourth side, a fifth side, and a sixth side. The first positioning protrusion abuts against the first side, the second positioning protrusion abuts against the sixth side, the third positioning protrusion abuts against the first side, and the fourth positioning protrusion abuts against the fifth side.
5. A mold according to claim 4, wherein It also includes a fifth positioning protrusion and a sixth positioning protrusion, with the fifth positioning protrusion abutting against the third side and the sixth positioning protrusion abutting against the fourth side.
6. A LED holder preform made using the mold according to any one of claims 1 to 5, characterized by, It includes a preform body, on which there is an attachment to be removed, the attachment extending outward from the preform body.
7. An LED support preform according to claim 6, wherein, Multiple auxiliary materials are provided and distributed around the precast component body.
8. An LED support preform according to claim 7, wherein, The accessory material has multiple positioning holes for positioning; there are six accessories, and they are parallel to each other.
9. An LED holder, characterized by The LED bracket is formed by removing the auxiliary material from the LED bracket preform of any one of claims 6-8, and the LED bracket has a fracture surface after the auxiliary material is removed.