LED lamp metal heat dissipation bottom shell with injection molding insulation layer

Abstract

The utility model discloses a LED lamps and lanterns metal heat dissipation bottom shell with injection molding insulating layer, include: metal bottom shell and insulating plastic layer, insulating plastic layer is sleeved in the end surface of metal bottom shell, insulating plastic layer adopts injection molding process and forms, be equipped with the cavity of half closed on metal bottom shell, be equipped with the first positioning portion and second positioning portion of convex in the cavity, be equipped with the boss between the first positioning portion and second positioning portion, the first rim has in the outer edge of cavity, the height of boss is equal to the height of first rim, be equipped with the first positioning column and second positioning column on insulating plastic layer, the first positioning column can be sleeved in the upper end of first positioning portion, the second positioning column can be sleeved in the upper end of second positioning portion. The application provides a kind of LED lamps and lanterns insulation structure by injection molding and integrates insulating layer and metal shell, to solve the problem that heat dissipation and insulation are difficult to take into account in the prior art, structure is complex, cost is high, realize the comprehensive effect of efficient heat dissipation, reliable insulation, structure simplification and cost reduction.

Description

Technical Field

[0001] This utility model belongs to the field of LED lighting technology, and specifically relates to a metal heat dissipation base shell for LED lighting fixtures with an injection-molded insulating layer. Background Technology

[0002] With the rapid development of LED (Light Emitting Diode) technology, LED lighting fixtures have been widely used in various fields such as home lighting, commercial lighting, industrial lighting, and outdoor lighting due to their advantages such as energy saving, long lifespan, and environmental friendliness. However, in practical applications, especially in the design of high-power LED lighting fixtures, thermal management has become one of the key factors restricting their performance and lifespan. LEDs generate a large amount of heat during operation. If this heat cannot be dissipated effectively and in a timely manner, it will cause the chip junction temperature to rise, leading to problems such as accelerated light decay, color temperature drift, and even device failure. Therefore, a good heat dissipation design is a prerequisite for ensuring the long-term stable operation of LED lighting fixtures.

[0003] Currently, most LED lights use metal materials, such as aluminum alloy, as their heat dissipation housing due to their excellent thermal conductivity. However, while providing good heat dissipation, the metal housing also presents electrical insulation challenges. The PCB (printed circuit board) and its electronic components need to be installed inside the lamp body; if they are in direct contact with the metal housing, there are safety hazards such as short circuits and leakage, necessitating effective insulation.

[0004] Traditional insulation methods typically involve attaching or embedding independent insulating sheets (such as mica sheets, ceramic sheets, or plastic gaskets) into the inner wall of the metal casing, or isolating the PCB from the metal casing using additional insulating supports. While these methods achieve insulation to some extent, they have several drawbacks: First, the assembly of multiple components leads to complex structures and cumbersome assembly processes, increasing production costs; second, interfacial thermal resistance exists between the insulating material and the metal casing, affecting overall heat dissipation efficiency; third, in compact miniaturized lighting fixtures, the complex internal structure (such as mounting holes, positioning parts, etc.) makes it difficult to precisely match the insulating components, easily resulting in insulation blind spots or assembly deviations, reducing product reliability.

[0005] Furthermore, existing technologies lack an integrated solution that can simultaneously achieve structural simplification, efficient heat conduction, and reliable insulation. Especially with the trend towards miniaturization and integration of lighting fixtures, how to meet multiple requirements such as heat dissipation, insulation, structural support, and ease of assembly within a limited space has become a pressing technical challenge in this field.

[0006] In summary, existing LED lighting fixtures have significant shortcomings in the coordinated design of heat dissipation and insulation, and a new structure is urgently needed to overcome these defects and improve the overall performance and manufacturing efficiency of the products. Utility Model Content

[0007] In order to overcome the shortcomings of the prior art, the purpose of this utility model is to provide an LED lamp insulation structure that integrates the insulation layer and the metal shell through injection molding, so as to solve the problems of heat dissipation and insulation being difficult to balance, complex structure and high cost in the prior art, and achieve the comprehensive effect of efficient heat dissipation, reliable insulation, simplified structure and reduced cost.

[0008] To solve the above problems, the technical solution adopted by this utility model is as follows: A metal heat dissipation base shell for LED lamps with an injection-molded insulating layer, comprising: a metal base shell and an insulating plastic layer, wherein the insulating plastic layer is sleeved on the end face of the metal base shell, the insulating plastic layer is formed by injection molding, the metal base shell is provided with a semi-closed cavity, the cavity is provided with a raised first positioning part and a second positioning part, a boss is provided between the first positioning part and the second positioning part, the outer edge of the cavity is provided with a first perimeter, and the height of the boss is equal to the height of the first perimeter; the insulating plastic layer is provided with a first positioning post and a second positioning post, the first positioning post can be sleeved on the upper end of the first positioning part, and the second positioning post can be sleeved on the upper end of the second positioning part.

[0009] Compared to existing technologies, the advantages of this invention are as follows: This invention proposes using an insulating metal base shell as the mounting base shell for a PCB control board, with a heat-conducting metal shell serving as the main structural and heat dissipation body to conduct heat generated by the PCB components. By using injection molding to form a tightly bonded integrated structure with the metal shell, the air gaps and interface thermal resistance present in traditional bonding or assembly methods are eliminated. This allows heat to be transferred more smoothly from the internal components through the contact surface between the plastic layer and the metal to the metal shell, thereby improving overall heat dissipation efficiency. More importantly, it provides excellent insulation for the metal base shell. Especially when the metal base shell has complex structures such as mounting holes and posts, the insulation structure becomes relatively complex. Through injection molding, the molten insulating material can completely fill and wrap all the uneven structures inside the metal base shell, forming an insulating layer that perfectly matches the metal cavity in one step. This not only ensures the integrity and reliability of the insulation and completely eliminates the risk of electrical short circuits caused by improper matching of insulating components, but also greatly simplifies the product structure and assembly process. There is no need to purchase, cut, and install multiple independent insulating components, significantly reducing labor and material costs.

[0010] The aforementioned metal heat dissipation base shell is integrally formed with the first positioning post, the second positioning post, and the insulating plastic layer.

[0011] The aforementioned metal heat dissipation base shell has a groove between the first positioning post and the second positioning post. The groove can be fitted onto the boss so that the outer edge of the boss is insulated.

[0012] In the aforementioned metal heat dissipation base, the outer edge of the insulating plastic layer is provided with a second perimeter. When the insulating plastic layer is fitted onto the metal base, the height of the second perimeter is greater than the height of the first perimeter.

[0013] The aforementioned metal heat dissipation base shell has evenly distributed handles at the upper end of the first perimeter. When the insulating plastic layer is fitted onto the metal base shell, the outer edge of the handles is in contact with the second perimeter.

[0014] The aforementioned metal heat dissipation base shell has a first clearance groove on the first surrounding edge and a second clearance groove on the second surrounding edge. When the insulating plastic layer is fitted onto the metal base shell, the height of the first clearance groove is the same as the groove depth of the second clearance groove.

[0015] The metal heat dissipation base described above can be circular or square in shape.

[0016] In the aforementioned metal heat dissipation base, the outer shape of the insulating plastic layer is the same as the outer shape of the metal base.

[0017] In the aforementioned metal heat dissipation base, the insulating plastic layer undergoes surface treatment before injection molding. The surface treatment includes at least one of sandblasting, chemical oxidation, or plasma cleaning to enhance the bonding force between the metal base and the insulating plastic layer and prevent delamination.

[0018] The aforementioned metal heat dissipation base is used as the mounting base for the PCB board control board. Attached Figure Description

[0019] Figure 1 This is an exploded view of the metal slatted bottom shell structure according to an embodiment of the present invention;

[0020] Figure 2 This is a schematic diagram of the structure of the metal slatted bottom shell according to an embodiment of the present invention;

[0021] Explanation of reference numerals: 100 Metal base shell, 110 Cavity, 120 First positioning part, 130 Second positioning part, 140 Boss, 150 First surrounding edge, 151 Handle, 152 First clearance groove, 200 Insulating plastic layer, 210 First positioning post, 220 Second positioning post, 230 Protrusion, 240 Second surrounding edge, 241 Second clearance groove. Detailed Implementation

[0022] The embodiments of this utility model are described in detail below, with reference to Figures 1 to 2This utility model provides an LED lamp metal heat dissipation base shell with an injection-molded insulating layer, comprising: a metal base shell 100 and an insulating plastic layer 200. The insulating plastic layer 200 is sleeved on the end face of the metal base shell 100 and is formed by injection molding. The metal base shell 100 has a semi-enclosed cavity 110. The cavity 110 has a raised first positioning part 120 and a second positioning part 130 inside. A boss 140 is provided between the first positioning part 120 and the second positioning part 130. The outer edge of the cavity 110 has a first perimeter 150, and the height of the boss 140 is equal to the height of the first perimeter 150. The insulating plastic layer 200 has a first positioning post 210 and a second positioning post 220. The first positioning post 210 can be sleeved on the upper end of the first positioning part 120, and the second positioning post 220 can be sleeved on the upper end of the second positioning part 130. This invention proposes using an insulating metal base shell as the mounting base shell for a PCB control board. The thermally conductive metal shell serves as both the structural and heat dissipation body, conducting heat generated by the PCB components. By using injection molding to form a tightly integrated structure with the metal shell, the insulating plastic layer 200 is integrated with the metal shell, eliminating air gaps and interfacial thermal resistance present in traditional bonding or assembly methods. This allows heat to be transferred more smoothly from the internal components through the contact surface between the plastic layer and the metal to the metal shell, thereby improving overall heat dissipation efficiency. More importantly, it provides excellent insulation for the metal base shell 100. Especially when the metal base shell 100 has complex structures such as mounting holes and posts, the insulation structure becomes relatively complex. Through injection molding, the molten insulating material completely fills and encapsulates all the uneven structures within the metal base shell 100, creating an insulating layer that perfectly matches the metal cavity in one step. This not only ensures the integrity and reliability of the insulation and completely eliminates the risk of electrical short circuits caused by improper matching of insulating components, but also greatly simplifies the product structure and assembly process. It eliminates the need to purchase, cut, and install multiple independent insulating components, significantly reducing labor and material costs.

[0023] Furthermore, the first positioning post 210 and the second positioning post 220 proposed in this application are integrally formed with the insulating plastic layer 200. Since the positioning posts and the insulating plastic layer 200 are formed simultaneously during injection molding, there is no assembly interface or adhesive interface between them, fundamentally eliminating the risk of positioning posts loosening or falling off due to glue aging, weak adhesion, or mechanical vibration, greatly improving the long-term reliability and mechanical strength of the structure. At the same time, the integral molding process ensures the positional accuracy and dimensional consistency of the positioning posts, avoiding potential positional deviations that may occur when installing positioning posts individually later, and improving the stability between product batches. Furthermore, a groove 230 is provided between the first positioning post 210 and the second positioning post 220, which can fit onto the boss 140, so that the outer edge of the boss 140 is insulated. The interlocking structure of the groove 230 and the boss 140 forms a precise fit during injection molding, effectively restricting the radial movement of the insulating plastic layer 200 within the metal base shell 100. This enhances the mechanical interlocking effect between the two, significantly improving the shear and peel resistance of the mating surface and preventing delamination under temperature cycling or mechanical impact. More importantly, the boss 140 itself is made of metal, and its exposure would pose an electrical safety hazard. By setting the groove 230 to completely cover it with insulating plastic, comprehensive insulation coverage of the outer edge of the boss 140 is achieved, solving the technical problem that such connection points are prone to becoming weak points in insulation in traditional structures, and ensuring the integrity of electrical safety.

[0024] Furthermore, referring to Figure 1The insulating plastic layer 200 has a second perimeter 240 on its outer edge. When the insulating plastic layer 200 is fitted onto the metal base shell 100, the height of the second perimeter 240 is greater than the height of the first perimeter 150. When the height of the second perimeter 240 of the insulating plastic layer 200 exceeds the first perimeter 150 of the metal base shell 100, after injection molding, the entire top edge of the metal base shell 100 (i.e., the first perimeter 150) will be completely covered and wrapped by the insulating plastic. This effectively avoids direct exposure of the metal edge, fundamentally eliminating the safety hazard of electric shock that may occur when users come into contact with live metal parts during installation, maintenance, or accidental damage to the lamp. Of course, this application does not limit the specific structure of the first perimeter 150 and the second perimeter 240. Preferably, both the first perimeter 150 and the second perimeter 240 are cylindrical. Furthermore, the upper end of the first perimeter 150 has evenly distributed handles 151. When the insulating plastic layer 200 is fitted onto the metal base shell 100, the outer edge of the handles 151 is in contact with the second perimeter 240. The handles 151 not only facilitate manual handling and installation of the lamps, improving usability, but more importantly, they act as structural reinforcing ribs, enhancing the rigidity and deformation resistance of the outer edge of the metal base shell 100, preventing shell twisting due to uneven stress during handling or installation. The evenly distributed handles 151 ensure uniform stress distribution, avoiding localized stress concentration. After the insulating plastic layer 200 is injection molded, the outer edge of the handles 151 fits against the second perimeter 240, forming an additional contact surface and bonding area, significantly increasing the bonding area between the metal and plastic, thereby improving the bonding strength and sealing of the interface, further preventing delamination and water seepage. Of course, this application does not limit the specific structure of the carrying part 151. Preferably, the carrying part 151 is provided with a handle for operation.

[0025] Furthermore, referring to Figure 2The first perimeter 150 has a first clearance groove 152, and the second perimeter 240 has a second clearance groove 241. When the insulating plastic layer 200 is fitted onto the metal base shell 100, the height of the first clearance groove 152 is the same as the depth of the second clearance groove 241. The clearance grooves are mainly used to avoid wires, connectors, or other protruding parts inside the lamp, preventing interference during assembly and ensuring that the PCB board or other components can be installed smoothly. The first clearance groove 152 is located on the first metal perimeter 150, and the second clearance groove 241 is located on the insulating plastic second perimeter 240. After injection molding, the two are positioned and matched in size, forming a continuous clearance channel, ensuring the integrity of the clearance function. Furthermore, the shape of the metal base shell 100 can be circular, square, or polygonal. By allowing the base shell to adopt different shapes, the insulation structure of this application can be widely used in various types of LED lamps, such as round downlights, square panel lights, spotlights, etc., greatly expanding the application range of the technical solution. Furthermore, the external shape of the insulating plastic layer 200 proposed in this application is the same as the external shape of the metal base shell 100. When the two have the same shape, the edges of the composite structure after injection molding are neat, without obvious misalignment or steps, which not only improves the aesthetic appearance of the product, but more importantly, ensures the compatibility of subsequent assembly. Moreover, this design simplifies mold design, allowing the cavity of the injection mold to match the shape of the inner cavity of the metal base shell 100, without the need to consider shape differences, thus reducing mold complexity and manufacturing costs. At the same time, the consistent shape means that the insulating layer completely covers the top edge of the metal base shell 100, avoiding the risk of scratches or electric shocks that may be caused by exposed metal edges, thus improving safety in use.

[0026] Furthermore, the insulating plastic layer 200 undergoes surface treatment before injection molding. This surface treatment includes at least one of sandblasting, chemical oxidation, or plasma cleaning to enhance the bonding force between the metal base shell 100 and the insulating plastic layer 200, preventing delamination. Surface treatment processes such as sandblasting, chemical oxidation, or plasma cleaning effectively remove oil, oxides, and impurities from the metal surface, while increasing its surface roughness or activity, significantly improving the wettability and chemical bonding force between the metal and the molten plastic. This results in a stronger bond between the injection-molded insulating layer and the metal base shell 100, significantly improving the interfacial bonding strength and effectively preventing delamination, blistering, or peeling under the thermal expansion and contraction cycles generated during long-term operation of the lamp. Especially in high-temperature and high-humidity environments, good interfacial bonding prevents moisture penetration along the interface, avoiding degradation of electrical performance or corrosion. Furthermore, the metal base shell 100 proposed in this application is used as a mounting base for a PCB board control board. As a PCB mounting base, this structure directly supports the LED driver circuit and light source components. Its integrated design combines heat dissipation, insulation, and support, solving the complex problem of requiring separate heat sinks, insulating pads, and mounting brackets in traditional lighting fixtures. The excellent thermal conductivity of the metal base ensures that heat generated on the PCB can be quickly conducted to the outer casing and dissipated, effectively controlling the chip junction temperature; while the injection-molded insulating layer safely and reliably isolates the charged PCB from the metal casing, meeting safety regulations.

[0027] It should be noted that in the description of this utility model, any descriptions of orientation, such as up, down, front, back, left, right, etc., indicating orientation or positional relationships, are based on the orientation or positional relationships 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, be constructed or operated in a specific orientation, and should not be construed as a limitation of this utility model.

[0028] In the description of this utility model, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. If "first" or "second" is mentioned, it is only for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0029] In the description of this utility model, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in conjunction with the specific content of the technical solution.

[0030] The above embodiments are merely preferred embodiments of this utility model and should not be construed as limiting the scope of protection of this utility model. Any non-substantial changes and substitutions made by those skilled in the art based on this utility model shall fall within the scope of protection claimed by this utility model.

Claims

1. A metal heat dissipation base shell for LED lamps with an injection-molded insulating layer, characterized in that, include: A metal base shell (100) and an insulating plastic layer (200) are provided. The insulating plastic layer (200) is sleeved on the end face of the metal base shell (100). The insulating plastic layer (200) is formed by injection molding. The metal base shell (100) is provided with a semi-closed cavity (110). The cavity (110) is provided with a first positioning part (120) and a second positioning part (130). A space is provided between the first positioning part (120) and the second positioning part (130). The cavity (110) has a first perimeter (150) on its outer edge, and the height of the boss (140) is equal to the height of the first perimeter (150). The insulating plastic layer (200) is provided with a first positioning post (210) and a second positioning post (220). The first positioning post (210) can be sleeved on the upper end of the first positioning part (120), and the second positioning post (220) can be sleeved on the upper end of the second positioning part (130).

2. The metal heat dissipation base shell according to claim 1, characterized in that, The first positioning post (210), the second positioning post (220), and the insulating plastic layer (200) are integrally formed.

3. The metal heat dissipation base shell according to claim 1, characterized in that, A groove (230) is provided between the first positioning post (210) and the second positioning post (220). The groove (230) can be fitted onto the boss (140) so that the outer edge of the boss (140) is insulated.

4. The metal heat dissipation base shell according to claim 1, characterized in that, The outer edge of the insulating plastic layer (200) is provided with a second perimeter (240). When the insulating plastic layer (200) is sleeved on the metal bottom shell (100), the height of the second perimeter (240) is greater than the height of the first perimeter (150).

5. The metal heat dissipation base shell according to claim 4, characterized in that, The upper end of the first rim (150) has evenly distributed handles (151). When the insulating plastic layer (200) is fitted onto the metal bottom shell (100), the outer edge of the handle (151) is in contact with the second rim (240).

6. The metal heat dissipation base shell according to claim 4, characterized in that, The first perimeter (150) is provided with a first clearance groove (152), and the second perimeter (240) is provided with a second clearance groove (241). When the insulating plastic layer (200) is sleeved on the metal bottom shell (100), the height of the first clearance groove (152) is the same as the groove depth of the second clearance groove (241).

7. The metal heat dissipation base shell according to claim 1, characterized in that, The metal base shell (100) is circular or square in shape.

8. The metal heat dissipation base according to claim 7, characterized in that, The external shape of the insulating plastic layer (200) is the same as the external shape of the metal base shell (100).

9. The metal heat dissipation base according to claim 1, characterized in that, The insulating plastic layer (200) undergoes surface treatment before injection molding. The surface treatment includes at least one of sandblasting, chemical oxidation, or plasma cleaning to enhance the bonding force between the metal base shell (100) and the insulating plastic layer (200) and prevent delamination.

10. The metal heat dissipation base shell according to claim 1, characterized in that, The metal base (100) is used as the mounting base for the PCB board control board.

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