A novel wall washing lens strip module hot pressing device

Abstract

The utility model relates to the technical field of LED lighting technology and outdoor brightening engineering production and manufacturing equipment, concretely to a novel wall washer lens strip module hot pressing device, including base fixed plate, convex electric wood base, lens with positive cross symmetry hot pressing column, long strip PCBA board, copper mould assembly of copper mould with control platform and unloading plate. Electric wood base is equipped with multiple rows of multiple column setting hole and positioning groove, and PCBA board is correspondingly provided with positioning through -hole, and the bottom of copper mould has a circular platform melting cavity. When working, after the lens and PCBA board are positioned in turn, the copper mould assembly is electrified and heated, the hot pressing column is melted and formed to realize the firm connection of the lens and PCBA board, and the unloading plate assists quick material taking. The device solves the problems of traditional process complexity, low efficiency, poor reliability and the like, realizes batch hot pressing, accurate positioning and quick loading and unloading, improves production efficiency and product quality, and is suitable for outdoor brightening engineering wall washer module large-scale production.

Description

Technical Field

[0001] This utility model relates to the technical field of LED lighting technology and outdoor lighting project manufacturing equipment, specifically a novel hot stamping device for wall washer light lens strip modules. Background Technology

[0002] In modern urban construction and landscape design, outdoor lighting projects have become an important component for showcasing the city's appearance and enhancing spatial aesthetics. Wall washer lights, as core lighting equipment, are widely used in building facades, under overpasses, park landscapes, monument complexes, commercial complexes, and entertainment venues due to their ability to evenly project light onto walls, creating a "wall-washing" effect. With the rapid development of LED technology, wall washer lights are gradually shifting from traditional light sources to LED light sources, and are upgrading towards modularity, lightweight design, and high reliability. Modular design not only facilitates on-site installation and maintenance but also allows for adjustments to light efficiency by replacing modules, becoming the mainstream development trend for current wall washer light products. However, the manufacturing and assembly process of the core component of wall washer lights—the light strip module composed of lenses and PCBA boards—has long faced technical bottlenecks, hindering the industry's capacity expansion and product quality optimization.

[0003] The assembly of traditional wall washer lens modules mainly relies on manual assembly processes or simple tooling equipment: operators need to align each lens with the PCBA (Printed Circuit Board Assembly) board one by one, and then fix it with glue or mechanical structures such as screws. This method has significant drawbacks, the core problems being "low precision" and "poor efficiency." Furthermore, the assembly of a single module is time-consuming and affected by operator fatigue, resulting in a low product qualification rate, making it difficult to meet the needs of large-scale production.

[0004] The current production of wall washer lens modules also faces the problem of poor batch consistency. Traditional processes rely heavily on manual operation or simple tooling, making it difficult to process multiple modules simultaneously. Even with tooling fixtures, only 1-2 modules can usually be processed at a time. Furthermore, modules processed by different batches or by different operators vary significantly in terms of connection strength and positioning accuracy, resulting in poor quality of finished wall washer lights and affecting the overall effect of outdoor lighting projects.

[0005] With the expansion of outdoor lighting projects (such as urban landmarks and large theme parks, which often require thousands or even tens of thousands of wall washer lights), the market demand for wall washer lens modules has shifted from "single function" to a comprehensive demand for "high efficiency, reliability, low cost, and easy maintenance." Against this backdrop, the industry urgently needs a new type of wall washer lens module manufacturing equipment to address the pain points of traditional processes. Ideal equipment should possess the following characteristics: firstly, it should enable simultaneous processing of multiple modules, significantly improving production efficiency; secondly, it should employ a glue-free and screw-free connection method, enhancing reliability and lifespan in outdoor environments; thirdly, it should have precise positioning capabilities to ensure consistency in mass production; and fourthly, it should simplify the operation process. This utility model is based on this demand and designs a new type of hot stamping device that achieves efficient and reliable connection between the lens and the PCBA board through hot stamping technology. Utility Model Content

[0006] To address the shortcomings of existing technologies, this utility model provides a novel hot-pressing device for wall washer light lens strip modules, which solves the problems mentioned in the background art.

[0007] Technical solution

[0008] To achieve the above objectives, this utility model is implemented through the following technical solution: a novel hot-pressing device for a wall washer light lens strip module, comprising a base fixing plate, a bakelite base, a lens, a PCBA board, and a copper mold assembly; characterized in that: the bakelite base is convex-shaped and fixed to the upper surface of the base fixing plate; the upper surface of the bakelite base is evenly provided with several mounting holes in multiple rows and columns, arranged in groups of several horizontal rows and several groups vertical rows, and each mounting hole contains a matching lens; the upper surface of the lens is symmetrically provided with four hot-pressing columns to be melted in a symmetrical cross shape; The PCBA board is long and horizontally arranged, with the number of holes matching the number of sets of mounting holes. The PCBA board has four positioning through holes arranged symmetrically in a front-back, left-right, and right-front cross configuration, with the number of sets matching the number of mounting holes in the horizontal direction. These four positioning through holes correspond to the four hot-fix posts of the lens, and the hot-fix posts are inserted into the positioning through holes. The lower part of the copper mold assembly has several copper molds evenly arranged, with the number and arrangement of these copper molds matching the number and arrangement of the mounting holes. The bottom of each copper mold has four melting chambers arranged symmetrically in a front-back, left-right, and right-front cross configuration.

[0009] Preferably, the melting chamber is frustum-shaped inside, with its upper part matching the hot stamping column, which is simultaneously inserted into the melting chamber.

[0010] Preferably, the bakelite base has positioning grooves between two adjacent vertical columns of the mounting holes.

[0011] Preferably, it also includes a discharge plate, which has vertical notches of the same number as the number of rows of mounting holes and matching length and width. A positioning strip is formed between two notches, and the positioning strip matches the positioning groove and is placed therein.

[0012] Preferably, the upper part of the copper mold assembly is provided with a control console, and several copper molds are evenly arranged and fixed in the control console, facing downwards.

[0013] Preferably, the PCBA board coincides with the upper surface of the lens.

[0014] This utility model provides a novel hot-pressing device for wall washer light lens strip modules, which has the following beneficial effects: 1. The device adopts a multi-cavity synchronous processing design, which can connect 21 lens modules at a time. Compared with the traditional process, the processing time per batch is shorter and the production efficiency is improved. At the same time, the "positioning-heating-unloading" process is simple, and operators can be put to work after simple training, which greatly reduces the reliance on skilled workers and is suitable for the batch order requirements of large-scale outdoor lighting projects.

[0015] 2. The lens and PCBA board are integrated by hot-pressing the hot-pressed column, replacing the traditional glue bonding (which is prone to aging and delamination) and screw fastening (which is prone to rust and loosening). The hot-pressed connection structure has strong bonding force, no gaps and no exposed connectors, and is not easily damaged in outdoor high temperature, low temperature and high humidity environments. It solves the problem of poor reliability of traditional connection methods, extends the outdoor service life of the wall washer light lens module and reduces engineering maintenance costs.

[0016] 3. The device uses a multi-positioning structure (positioning lens with mounting hole, positioning PCBA board with positioning through hole, and positioning unloading plate with positioning groove) to minimize the positioning error of each component and avoid the hole offset problem of traditional manual assembly; all modules are heated and pressed down synchronously, and the hot stamping quality is highly consistent, ensuring the quality of the finished product.

[0017] 4. No need for glue, screws or other additional connectors, reducing parts procurement costs; semi-automated processes reduce manual input and lower labor costs.

[0018] 5. The grid-shaped unloading plate is compatible with the positioning slot, enabling single synchronous material handling, shortening the material handling time, and reducing labor and material losses. Attached Figure Description

[0019] Figure 1 This is an exploded three-dimensional structural diagram of the present invention; Figure 2 This is a three-dimensional structural diagram of the present invention; Figure 3 This is the front view of the present invention; Figure 4 for Figure 3 Top view; Figure 5 for Figure 3 The right view; Figure 6 for Figure 3 Sectional view of AA; Figure 7 This is a schematic diagram of the three-dimensional structure of the lens; Figure 8 This is a schematic diagram of the three-dimensional structure of the copper mold; In the diagram: 1. Base fixing plate; 2. Bakelite base; 201. Mounting hole; 202. Positioning groove; 3. Lens; 301. Hot stamping column; 4. PCBA board; 401. Positioning through hole; 5. Copper mold assembly; 501. Copper mold; 502. Melting chamber; 503. Control console; 6. Unloading plate; 601. Positioning strip. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0021] Example 1: Please refer to Figures 1 to 8 A novel hot-heating device for a wall washer light lens strip module includes a base fixing plate (1), a bakelite base (2), a lens (3), a PCBA board (4), and a copper mold assembly (5). The bakelite base (2) is convex in shape and fixed on the upper surface of the base fixing plate (1). The upper surface of the bakelite base (2) is evenly provided with several mounting holes (201) in multiple rows and columns in a horizontal direction and a vertical direction. Each mounting hole is provided with a lens (3) that matches it, ensuring that the lens (3) is placed without shaking, without displacement, and with accurate positioning. The upper surface of the lens (3) is symmetrically provided with four hot-heating columns (301) to be melted in a cross shape. The PCBA board (4) is long and horizontally arranged, with a number of... The number of sets of mounting holes (201) is the same. The PCBA board (4) is uniformly provided with a number of sets of four positioning through holes (401) arranged in a positive cross shape in front, back, left and right. The number of sets is the same as the number of mounting holes (201) in the horizontal direction. The four positioning through holes (401) match the four hot heat pillars (301) of the lens (301) and the hot heat pillars (301) are inserted into the positioning through holes (401). The copper mold assembly (5) is uniformly provided with a number of copper molds (502) at the bottom. The copper molds (502) are made of brass. The number and arrangement of the copper molds (501) are the same as the number and arrangement of the mounting holes (201). The bottom of the copper molds (501) is provided with four melting chambers (502) arranged in a positive cross shape in front, back, left and right.

[0022] In this utility model, the bakelite base (2) has 21 mounting holes (201) evenly arranged in a 3-row, 7-column configuration on its upper surface, with 7 holes in each row and 3 holes in each column. Each mounting hole obviously contains a matching lens (3), resulting in 21 lenses (3) in 3 rows and 7 columns. The PCBA board (4) consists of three parts, with 7 groups of four positioning through holes (401) evenly arranged in a symmetrical cross shape on the horizontal side. The copper mold assembly (5) has 21 copper molds (502) evenly arranged in 3 rows and 7 columns at its lower part. However, the arrangement and quantity used in this utility model represent only the choice of this utility model and are not the only option. Users can choose the arrangement according to their needs, and all arrangements are within the scope of this patent. Similarly, the arrangement and number of four hot stamping pillars (301) to be melted, which are symmetrically arranged in a cross shape on the upper surface of the lens (3), are only the choice of this utility model. For example, they can be modified to three evenly distributed around the circumference. The positioning through hole (401) on the PCBA board (4) and the melting cavity (502) at the bottom of the copper mold (501) will also change with the arrangement and number of the hot stamping pillars (301). They are not unique. Users can choose to set them according to their own needs, and all of them are within the protection scope of this patent.

[0023] With the bakelite base (2) as the core, the lens (3) is fixed through the mounting hole (201). The positioning through hole (401) and the hot heat column (301) work together to achieve precise alignment between the lens (3) and the PCBA board (4), forming a stable positioning system of "base fixing plate (1) - bakelite base (2) - lens (3) - PCBA board (4)" to ensure that all components have no relative displacement. The melting chamber (502) of each copper mold (501) covers the corresponding hot stamping column (301). When the copper mold (501) is powered on, the melting chamber (502) is heated to the set temperature, causing the hot stamping column (301) to melt. At the same time, the copper mold (501) is pressed down for about 5 seconds and the copper mold assembly (5) is removed. During this period, the melted hot stamping column (301) is hot stamped and extruded under pressure to form a solidified structure that is tightly bonded to the PCBA board (4). The two are connected to form a hot stamping light strip module. The hot stamping columns (301) are distributed in a "symmetrical cross" pattern, so that the connection point between the lens (3) and the PCBA board (4) is evenly stressed, avoiding loosening of the connection due to uneven local stress.

[0024] The melting chamber (502) is truncated cone-shaped inside. The upper part matches the hot stamping column (301), and the lower part has a larger space. After the hot stamping column (301) melts, it gathers in the lower part under pressure, which can not only fully block the positioning through hole (401), but also form a regular solidified structure to prevent the "pull-off" phenomenon when the copper mold (501) is removed.

[0025] The bakelite base (2) has a number of mounting holes (201) with positioning grooves (202) between two adjacent vertical columns.

[0026] It also includes a stripper plate (6), which has vertical notches of the same number as the number of rows of mounting holes (201) and matching length and width. A positioning strip (601) is formed between two notches. The positioning strip (601) matches the positioning groove (202) and is placed inside it. The stripper plate (6) is used to help quickly remove the formed hot-stamped light strip modules after hot stamping, replacing the traditional method of manually picking up materials one by one. The notches and positioning strips (601) form a "grid plate" structure. After hot stamping, the stripper plate (6) can be lifted up with a hand tool to lift up all the hot-stamped light strip modules at the same time. Then the hot-stamped light strip modules can be taken away, realizing quick material picking and unloading. The operator can directly take away the modules to complete one processing cycle. Moreover, the cooperation between the positioning strip (601) and the positioning groove (202) ensures that the stripper plate (6) will not be offset during installation and moves up and down smoothly.

[0027] The copper mold assembly (5) is equipped with a control console (503) on its upper part. Several copper molds (502) are evenly arranged and fixed in the control console (501) with their direction downward. The control console (503) is connected to several copper molds (502) for two reasons: firstly, it is convenient to fix and operate; secondly, it serves as an electrical connection, allowing the copper molds (502) to be powered on and heated through an external power supply device connected to the control console (503).

[0028] The upper surface of the PCBA board (4) overlaps with that of the lens (3). This ensures that the hot-stamped LED strip module is firmly connected without gaps after hot stamping, thus guaranteeing the quality of the finished product.

[0029] Working process: Place the unloading plate (6) on the upper surface of the bakelite base (2), align the positioning strip (601) of the unloading plate (6) with and insert it into the positioning groove (202) of the bakelite base (2), and ensure that the unloading plate (6) is placed stably without swaying left or right. Place the lenses (3) one by one into the mounting holes (201) of the bakelite base (2), with one lens (3) corresponding to each mounting hole (201), and ensure that the hot stamping post (301) on the upper surface of the lens (3) faces upward, and that the lens (3) is in close contact with the inner wall of the mounting hole (201) without any vertical looseness. According to the number of sets of mounting holes (201) on the bakelite base (2) (3 sets in this embodiment), take the corresponding number of PCBA boards (4) and place each PCBA board (4) horizontally above the lens (3), so that the positioning through holes (401) on the PCBA board (4) are aligned and fitted into the hot stamping post (301) of the lens (3) until the lower surface of the PCBA board (4) is completely overlapped with the upper surface of the lens (3). Operate the control console (503) to control the copper mold assembly (5) to move down, so that the copper mold (501) at the bottom of the copper mold assembly (5) is aligned with the lens (3) below, ensuring that the melting cavity (502) at the bottom of each copper mold (501) accurately fits the corresponding hot stamping post (301). When the external power supply of the control panel (503) is turned on, the copper mold (501) is powered on, causing the melting chamber (502) to heat up rapidly. The heat is conducted through the melting chamber (502) to the hot stamping column (301), causing the hot stamping column (301) to melt. At the same time, the copper mold (501) is pressed down for about 5 seconds, and the melted hot stamping column (301) fills and solidifies in the melting chamber (502), forming a structure that blocks the positioning through hole (401) and is tightly bonded to the PCBA board (4). After the hot stamping time is over, the copper mold assembly (5) is removed. The edge of the unloading plate (6) is clamped with a tool (such as a clamp), and the unloading plate (6) is slowly lifted upward along the positioning groove (202). The unloading plate (6) lifts all the hot stamping light strip modules that have been completed through the grid structure. The lifted modules are removed as a whole, completing the processing of one wall washer lens module.

[0030] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A novel hot-pressing device for a wall washer light lens strip module, comprising a base fixing plate (1), a bakelite base (2), a lens (3), a PCBA board (4), and a copper mold assembly (5); characterized in that: The bakelite base (2) is convex in shape and fixed to the upper surface of the base fixing plate (1). The upper surface of the bakelite base (2) is evenly provided with several mounting holes (201) in multiple rows and columns in a horizontal direction and in a vertical direction. Each mounting hole is provided with a lens (3) that matches it. The upper surface of the lens (3) is symmetrically provided with four hot stamping pillars (301) to be melted in a cross shape. The PCBA board (4) is long and horizontally arranged, and its number is the same as the number of groups of mounting holes (201). The PCBA board (4) is evenly provided with several groups of mounting holes in a horizontal direction. Four positioning through holes (401) are arranged in a right cross shape. The number of groups is the same as the number of placement holes (201) in the horizontal direction. The four positioning through holes (401) match the four hot-heating pillars (301) of the lens (301) and the hot-heating pillars (301) are inserted into the positioning through holes (401). Several copper molds (502) are evenly arranged at the bottom of the copper mold assembly (5). The number and arrangement of the several copper molds (501) are the same as the number and arrangement of the several placement holes (201). Four melting chambers (502) are arranged in a right cross shape at the bottom of the copper mold (501).

2. The novel hot stamping device for wall washer light lens strip modules according to claim 1, characterized in that: The melting chamber (502) is truncated cone-shaped inside, and its upper part matches the hot stamping column (301). The hot stamping column (301) is inserted into the melting chamber (502) at the same time.

3. The novel hot-pressing device for wall washer light lens strip modules according to claim 1, characterized in that: The bakelite base (2) has a number of mounting holes (201) with positioning grooves (202) between two adjacent vertical columns.

4. A novel hot-pressing device for wall washer light lens strip modules according to claim 3, characterized in that: It also includes a discharge plate (6), which has vertical notches with the same number as the number of rows of several mounting holes (201) and matching length and width. A positioning strip (601) is formed between two notches, and the positioning strip (601) matches the positioning groove (202) and is placed therein.

5. A novel hot-pressing device for wall washer light lens strip modules according to claim 1, characterized in that: The copper mold assembly (5) is provided with a control console (503) on the upper part, and several copper molds (502) are evenly arranged and fixed in the control console (501) with the direction downward.

6. A novel hot-pressing device for wall washer light lens strip modules according to claim 1, characterized in that: The upper surface of the PCBA board (4) coincides with that of the lens (3).

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