Side emitting LED package with improved air tightness

Abstract

The utility model discloses an improve the side emitting LED support of air tightness, including hardware support and plastic seat, the front of plastic seat is provided with lateral recessed cavity, and the inner end of lateral recessed cavity has insulating partition rib, to divide the inner end of lateral recessed cavity into first embedding space, second embedding space, and, the inner peripheral side extension of lateral recessed cavity has plastic boss, the back of plastic seat extends bottom wall and top wall, and the top of bottom wall forms first scooping chamber to the downward scooping, and first positioning wall located first scooping chamber both sides, hardware support includes first hardware sheet, second hardware sheet, and it includes embedding part, pad and soldering leg of integral connection, and soldering leg is positioned on first positioning wall after bending, and pad is exposed respectively in first embedding space, second embedding space, and its front part surface is positioned by corresponding plastic boss. It improves the plastic seat shrinkage deformation condition, and, improves the wrapping positioning of pad to plastic seat, so, the product air tightness is effectively improved in the combination of double advantage.

Description

Technical Field

[0001] This utility model relates to the field of LED bracket technology, and in particular to a side-emitting LED bracket that improves airtightness, which is mainly applicable to, but not limited to, lighting on automotive dashboards. Background Technology

[0002] There are significant differences between side-emitting and front-emitting LED technologies. For applications requiring high transmittance, high brightness, and customization flexibility, side-emitting LEDs are more advantageous. However, side-emitting LEDs also present challenges such as greater manufacturing difficulty and more complicated installation and positioning.

[0003] Specifically: The LED bracket includes a metal bracket and a plastic base that is injection molded and fixed to the metal bracket. Typically, a cup-shaped body is formed inside the plastic base. For positively emitting LEDs, the cup-shaped body of the plastic base is open and facing upwards. The solder feet are located at the bottom of the plastic base. The bottom of the plastic base has sufficient area and flatness to provide adhesion for the solder feet. The solder feet are bonded to the circuit board in a planar manner, and the four-point planar force is strong, resulting in strong impact resistance. However, for side-emitting LEDs, the periphery of the plastic base (corresponding to the outer periphery of the bowl / cup body) has a certain slope. On the one hand, it is difficult to provide a horizontal attachment surface for the solder feet. On the other hand, the periphery of the plastic base serves as the bottom surface of the side-emitting LED, and its area is small. This significantly weakens the impact resistance of the entire side-emitting LED. In order to increase the impact resistance, the thickness of the plastic base along the depth direction of the bowl / cup body is increased. However, this results in significant shrinkage and deformation of the plastic base, leading to an unsatisfactory connection between the hardware bracket and the plastic base. Gaps are likely to appear, making it difficult to pass the airtightness test (red ink test). Moreover, when bending the solder feet later, it is difficult to accurately control the horizontal welding surface of the solder feet, resulting in poor soldering or increased welding difficulty, which will inevitably affect the installation and application of LED products.

[0004] Therefore, a new technical solution needs to be researched to address the above problems. Utility Model Content

[0005] In view of this, the present invention addresses the deficiencies of the existing technology, and its main purpose is to provide a side-emitting LED bracket that improves airtightness. It improves the shrinkage and deformation of the plastic base, and at the same time, improves the wrapping and positioning of the plastic base on the solder pads. Thus, the combination of these two advantages effectively improves the airtightness of the product.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A side-emitting LED bracket for improving airtightness includes a metal bracket and a plastic base injection-molded and fixed to the metal bracket; The front of the plastic base has a lateral recess, and the inner end of the lateral recess has an insulating rib to divide the inner end of the lateral recess into a first embedding space and a second embedding space located on both sides of the insulating rib. Furthermore, plastic bosses extend from the inner periphery of the lateral recess toward the outer ends of the first embedding space and the second embedding space. The back of the plastic base has a bottom wall and a top wall. The distance between the top walls is located above the bottom wall. The top of the bottom wall has a first material ejection cavity formed by downward material ejection, so that the two sides of the bottom wall form first positioning walls located on both sides of the first material ejection cavity. The hardware bracket includes a first hardware sheet and a second hardware sheet arranged side by side; the first hardware sheet and the second hardware sheet each include an integrally connected embedded part, a solder pad and a solder foot; the solder foot is bent and positioned on the first positioning wall, the solder pad is exposed in the first embedded space and the second embedded space respectively, and its front part surface is wrapped and positioned by the corresponding plastic boss, and the remaining part serves as the effective solder pad usage area.

[0007] As a preferred embodiment, the embedded part is provided with a filling hole.

[0008] As a preferred embodiment, anti-permeability grooves are provided on both sides of the filling hole. The anti-permeability grooves extend perpendicularly to the direction of the weld foot extension, and the inner end of the anti-permeability grooves penetrates the filling hole, while the outer end penetrates the outer end of the embedded part.

[0009] As a preferred embodiment, the pads of the first hardware sheet and the second hardware sheet are joined together with a spacing, and U-shaped grooves are provided on the pads of both the first hardware sheet and the second hardware sheet. The U-shaped grooves of both form an annular groove, and the effective pad usage area of ​​each is located within the corresponding U-shaped groove enclosure area.

[0010] As a preferred embodiment, the bottom of the top wall forms a second material discharge cavity for material discharge from the top upward and downward, thereby forming second positioning walls on both sides of the second material discharge cavity.

[0011] As a preferred embodiment, the top wall and the bottom wall are arranged symmetrically.

[0012] As a preferred embodiment, the plastic base is provided with a positioning protrusion corresponding to the bottom end of the lateral cavity, and the positioning protrusion is located between the two welding feet.

[0013] As a preferred embodiment, the inner end of the pad is further extended with an elongated portion, which is bent, or a raised strip or groove is provided on its surface to make the surface convex and concave.

[0014] As a preferred embodiment, the welding foot includes a horizontal arm, a vertical arm, and an inclined arm connected in sequence; the top surface of the first positioning wall is an inclined surface extending obliquely upward from the back to the front; the horizontal arm extends and bends along the bottom wall from the bottom of the plastic base toward the back, the vertical arm extends and bends upward along the rear end of the bottom wall, and the inclined arm extends and bends along the top surface of the first positioning wall toward the front.

[0015] As a preferred embodiment, the plastic base is provided with a positioning groove on the back side corresponding to the lateral cavity, and the front end of the positioning groove is a blind end.

[0016] Compared with the prior art, this utility model has significant advantages and beneficial effects. Specifically, as can be seen from the above technical solution, it mainly addresses the problem of unsatisfactory airtightness in side-emitting LED brackets by optimizing the design of the plastic base: plastic bosses extend from the inner periphery of the lateral cavity towards the outer ends of both the first and second embedding spaces; a bottom wall and a top wall extend from the back of the plastic base, with the top wall spaced above the bottom wall; a first material extraction cavity is formed by downward material extraction from the top of the bottom wall, resulting in first positioning walls on both sides of the bottom wall, respectively located on either side of the first material extraction cavity; thus, the hardware bracket combined with the plastic base... Its pads are wrapped and positioned by corresponding plastic bosses, while the remaining part serves as the effective pad usage area, improving the bonding strength. The bottom and top walls are designed, especially the top is scooped downward to form a first scooping cavity and the first positioning walls on both sides of the first scooping cavity. This allows the bottom wall to be designed large enough to provide sufficient adhesion for the solder feet, while avoiding the problem of plastic seat shrinkage and deformation. Therefore, by improving the plastic seat's wrapping and positioning of the pads and improving the plastic seat's shrinkage and deformation, it effectively improves the product's airtightness by combining the dual advantages. Furthermore, this type of side-emitting LED bracket is easy to install and apply, making it suitable for widespread application.

[0017] To more clearly illustrate the structural features and effects of this utility model, the following detailed description of this utility model is provided in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0018] Figure 1 This is a perspective view of a side-emitting LED bracket for improving airtightness according to an embodiment of the present invention; Figure 2 This is another perspective view of the side-emitting LED bracket for improving airtightness according to an embodiment of the present invention; Figure 3 This is a front view of a side-emitting LED bracket with improved airtightness according to an embodiment of the present invention; Figure 4 This is a side view of a side-emitting LED bracket with improved airtightness according to an embodiment of the present invention; Figure 5This is an exploded view of a side-emitting LED bracket for improving airtightness according to an embodiment of the present invention; Figure 6 This is another exploded view of an embodiment of the present invention: a side-emitting LED bracket for improving airtightness; Figure 7 yes Figure 3 Cross-sectional view at point AA; Figure 8 This is an application diagram of the side-emitting LED bracket with improved airtightness according to an embodiment of the present invention; Figure 9 This is a schematic diagram of the material strip of the metal bracket for the side-emitting LED bracket with improved airtightness according to an embodiment of the present invention. Detailed Implementation

[0019] Please refer to Figures 1 to 9 As shown, it illustrates the specific structure of an embodiment of the present invention.

[0020] In the description of this utility model, it should be noted that the terms "upper", "lower", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model 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 limitations on this utility model.

[0021] A side-emitting LED bracket with improved airtightness includes a metal bracket 20 and a plastic base 10 injection-molded and fixed to the metal bracket 20.

[0022] The front of the plastic base 10 is provided with a lateral recess 11, which is conical in shape with a larger outer diameter and a smaller inner diameter. The inner end of the lateral recess 11 has an insulating rib 12 to divide the inner end of the lateral recess 11 into a first embedding space 13 and a second embedding space 14 located on both sides of the insulating rib 12. Furthermore, plastic bosses 15 extend from the inner periphery of the lateral recess 11 toward the outer ends of the first embedding space 13 and the second embedding space 14. The back of the plastic base 10 extends with a bottom wall 16 and a top wall 17. The top wall 17 is positioned above the bottom wall 16. The top of the bottom wall 16 forms a first material extraction cavity 18 by downward material extraction. Typically, the lower end of the first material extraction cavity 18 is a blind end, so that the two sides of the bottom wall 16 form first positioning walls 19 located on both sides of the first material extraction cavity 18. Typically, the top wall 17 and the bottom wall 16 are symmetrically arranged. The bottom of the top wall 17 forms a second ejection cavity by upward and downward material extraction, resulting in second positioning walls on both sides of the top wall 17 located on both sides of the second ejection cavity. This facilitates uniform flow of the adhesive during injection molding and allows for material weight reduction without compromising structural strength. A positioning groove 101 is provided on the plastic base 10 corresponding to the back of the lateral cavity 11. The front end of the positioning groove 101 is a blind end. During injection molding, it functions as a process positioning hole, providing a mold positioning reference. The recessed hole serves as a positioning reference during injection molding, ensuring mold closing accuracy.

[0023] The hardware bracket 20 includes a first hardware sheet 201 and a second hardware sheet 202 arranged side by side. Both the first hardware sheet 201 and the second hardware sheet 202 include an integrally connected embedded portion 21, a solder pad 22, and a solder foot. The solder foot is bent and positioned on the first positioning wall 19. The solder pads 22 are exposed in the first embedded space 13 and the second embedded space 14, respectively, with their front surfaces covered and positioned by corresponding plastic protrusions 15. The remaining portion serves as the effective solder pad usage area. The insulating rib 1 is located between the solder pads 22 of the first hardware sheet 201 and the second hardware sheet 202. The embedded portion 21 is provided with a filling hole 23, effectively improving the bonding strength between the hardware sheet and the plastic, and preventing the product from loosening due to bent feet. Both sides of the filling hole 23 are provided with anti-permeability grooves 24. The anti-permeability grooves 24 extend perpendicularly to the direction of the weld foot, and the inner end of the anti-permeability groove 24 penetrates the filling hole 23, while the outer end penetrates the outer end of the embedded part 21, thereby improving the performance of the red ink in the product. One or more anti-permeability grooves 24 can be provided. If multiple grooves are provided, their parallel spacing is set.

[0024] Further, the pads 22 (the other pad 22') of the first metal piece 201 and the second metal piece 202 are joined in a spaced manner. U-shaped grooves 25 are provided on the pads 22 of the first metal piece 201 and the second metal piece 202, and the U-shaped grooves 25 of both enclose an annular groove. The effective pad use area of each is located within the area enclosed by the corresponding U-shaped groove 25. Thus, on the basis of the plastic boss 15, the bonding firmness between the pad 22 and the plastic base 10 is further improved, and the airtight performance of the product is greatly improved. The inner end of the pad 22 further extends with an extended portion, and the extended portion is bent, or convex strips or grooves are provided on its surface to make the surface a convex-concave surface. In this embodiment, one of the pads 22 and the other pad 22' of the first metal piece 201 and the second metal piece 202 is in the shape of a raised character, and the other is in the shape of a recessed character. The insulating partition rib 12 is in the corresponding shape of a capital letter C. The light source chip 200 is provided on one pad 22, and the zener diode 100 is provided on the other pad 22'. The plastic boss 15 extends radially from the inner peripheral side of the cone towards the center, and the inner end edge of its extension is designed with multiple smooth arc connections, taking into account various aspects such as injection molding, installation, and light efficiency.

[0025] In other embodiments, a number of densely arranged pitted points 251, also known as pitting, can be provided on both sides of the U-shaped groove 25 to further improve the red ink performance of the product.

[0026] Moreover, the solder feet include a horizontal arm 26, a vertical arm 27, and an inclined arm 28 connected in sequence. The top surface of the first positioning wall 19 is an inclined surface that extends obliquely upwards from the back towards the front. The horizontal arm 26 extends along the bottom wall 16 from the bottom of the plastic base 10 towards the back in a bent manner. The vertical arm 27 extends upwards along the rear end of the bottom wall 16 in a bent manner. The inclined arm 28 extends towards the front along the top surface of the first positioning wall 19 in a bent manner. A positioning convex portion 102 is provided on the plastic base 10 corresponding to the bottom end of the lateral concave cavity 11. The positioning convex portion 102 is located between the two solder feet. The positioning convex portion 102 can be used for pre-positioning during installation and also serves to isolate the two solder feet.

[0027] It should be noted that the applicant has conducted a number of tests on the above LED bracket products: 1. Red ink test: According to the test standard of a certain automobile enterprise, the empty bracket is placed horizontally in a container (with the lateral concave cavity 11 facing upwards), and pure red ink is poured from the edge of the container. The amount of ink should not cover the surface of the lateral concave cavity 11 of the bracket. After standing for 24 hours like this, observe whether there is ink penetration into the lateral concave cavity 11 of the bracket. The maximum width of red ink penetration around the silver-plated layer in the functional area is 0.06 mm, and it is qualified after testing.

[0028] 2. Thermal shock test: According to the testing standards of a certain car manufacturer, the LED bracket sample was placed in the test chamber and subjected to a low temperature of -40℃ for 30 minutes and a high temperature of 150℃ for 30 minutes as one cycle. The cycle was repeated 150 times. The performance of the LED bracket under temperature change conditions was analyzed and the test was qualified.

[0029] 3. Temperature and humidity test (constant temperature and humidity test): According to the testing standards of a certain car manufacturer, after the bracket is packaged, it is subjected to moisture absorption in a dual 85%RH85℃ high temperature and humidity test chamber for 96 hours, and after three reflow soldering tests (260℃), there is no delamination between the plastic base and the hardware bracket, and the test is qualified.

[0030] In addition, based on the testing standards of a certain car manufacturer, a number of other tests were also conducted, including vulcanization test, bracket mechanical strength test, salt spray test, silver layer adhesion test, tinning test, high temperature test, solder joint breakage test, drop test, glue application test, and bending test. Since these tests are not strongly related to the main technical solution of this patent, they will not be described in detail.

[0031] The key design feature of this invention is to address the issue of unsatisfactory airtightness in side-emitting LED brackets by optimizing the design of the plastic base: plastic bosses extend from the inner periphery of the lateral cavity towards the outer ends of both the first and second embedding spaces; a bottom wall and a top wall extend from the back of the plastic base, with the top wall spaced above the bottom wall; a first material extraction cavity is formed by downward material extraction from the top of the bottom wall, resulting in first positioning walls on both sides of the bottom wall, located on either side of the first material extraction cavity; thus, the solder pads of the hardware bracket, after being combined with the plastic base, are covered by the corresponding plastic bosses. The outer portion serves as the effective pad area, enhancing bonding strength. The design of the bottom and top walls, particularly the downward-facing top forming a first ejection cavity and the first positioning walls on either side of the first ejection cavity, allows for a sufficiently large bottom wall to provide adequate adhesion for the solder pads. This also prevents shrinkage and deformation of the plastic base. Therefore, by improving the plastic base's positioning and wrapping around the pads, and mitigating shrinkage and deformation, this dual advantage effectively improves product airtightness. Furthermore, this side-emitting LED bracket structure is easy to install and apply, making it suitable for widespread use.

[0032] The above description is merely a preferred embodiment of the present utility model and does not constitute any limitation on the technical scope of the present utility model. Therefore, any minor modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model shall still fall within the scope of the technical solution of the present utility model.

Claims

1. A side-emitting LED bracket for improving airtightness, comprising a metal bracket and a plastic base injection-molded and fixed to the metal bracket, characterized in that: The front of the plastic base has a lateral recess, and the inner end of the lateral recess has an insulating rib to divide the inner end of the lateral recess into a first embedding space and a second embedding space located on both sides of the insulating rib. Furthermore, plastic bosses extend from the inner periphery of the lateral recess toward the outer ends of the first embedding space and the second embedding space. The back of the plastic base has a bottom wall and a top wall. The distance between the top walls is located above the bottom wall. The top of the bottom wall has a first material ejection cavity formed by downward material ejection, so that the two sides of the bottom wall form first positioning walls located on both sides of the first material ejection cavity. The hardware bracket includes a first hardware sheet and a second hardware sheet arranged side by side; the first hardware sheet and the second hardware sheet each include an integrally connected embedded part, a solder pad and a solder foot; the solder foot is bent and positioned on the first positioning wall, the solder pad is exposed in the first embedded space and the second embedded space respectively, and its front part surface is wrapped and positioned by the corresponding plastic boss, and the remaining part serves as the effective solder pad usage area.

2. The side-emitting LED bracket for improving airtightness according to claim 1, characterized in that: The embedded part is provided with glue filling holes.

3. The side-emitting LED bracket for improving airtightness according to claim 2, characterized in that: Both sides of the filling hole are provided with anti-permeability grooves. The anti-permeability grooves extend perpendicularly to the direction of the weld foot extension, and the inner end of the anti-permeability grooves passes through the filling hole and the outer end passes through the outer end of the embedded part.

4. The side-emitting LED bracket for improving airtightness according to claim 1, characterized in that: The pads of the first and second metal sheets are joined together at a spacing. Both the first and second metal sheets have U-shaped grooves on their pads, and the U-shaped grooves of both sheets form an annular groove. The effective pad usage area of ​​each sheet is located within the corresponding U-shaped groove enclosure area.

5. The side-emitting LED bracket for improving airtightness according to claim 1, characterized in that: The bottom of the top wall forms a second material-discharging cavity by discharging material upwards and downwards, thereby forming second positioning walls on both sides of the top wall, which are respectively located on both sides of the second material-discharging cavity.

6. The side-emitting LED bracket for improving airtightness according to claim 5, characterized in that: The top wall and the bottom wall are arranged symmetrically.

7. The side-emitting LED bracket for improving airtightness according to claim 1, characterized in that: The plastic base is provided with a positioning protrusion at the bottom end corresponding to the lateral cavity, and the positioning protrusion is located between the two welding feet.

8. The side-emitting LED bracket for improving airtightness according to claim 1, characterized in that: The inner end of the pad is further extended with an elongated portion, which is bent or has a raised strip or groove on its surface to make the surface convex and concave.

9. The side-emitting LED bracket for improving airtightness according to claim 1, characterized in that: The welding foot includes a horizontal arm, a vertical arm, and an inclined arm connected in sequence; the top surface of the first positioning wall is an inclined surface extending obliquely upward from the back to the front; the horizontal arm extends from the bottom of the plastic base toward the back along the bottom wall, the vertical arm extends upward along the rear end of the bottom wall, and the inclined arm extends toward the front along the top surface of the first positioning wall.

10. The side-emitting LED bracket for improving airtightness according to claim 1, characterized in that: The plastic base has a positioning groove on the back side corresponding to the lateral cavity, and the front end of the positioning groove is a blind end.

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