Multi-pad partitioned under-sink LED holder

Abstract

The utility model discloses a kind of multi-pad separation inner sinking type LED support, including hardware support and plastic seat, hardware support includes two groups of hardware sheet, each group of hardware sheet includes embedding part and welding leg;The inner end of the embedding part of one group of hardware sheet is integrally connected with first solder pad, second solder pad, the inner end of the embedding part of another group of hardware sheet is integrally connected with third solder pad;Plastic seat is concave with bowl-shaped recess, the inner bottom surface of bowl-shaped recess is further concave with first to third inner sinking cavity, first to solder pad is exposed to the bottom surface of first to third inner sinking cavity respectively, to form corresponding first effective solder pad area, second effective solder pad area, third effective solder pad area.Such, the surface of hardware sheet is maximally utilized plastic wrapping, effectively increase the tightness, firmness of hardware and plastic combination, substantially improve the temperature sensitivity of product, reach LED lamp product test standard on car, simultaneously, it is favorable to improve the setting precision of component.

Description

Technical Field

[0001] This utility model relates to the field of LED bracket technology, and in particular to a multi-pad separated recessed LED bracket, which is especially suitable for automobiles, such as automotive turn signals. Background Technology

[0002] As a key component of the LED industry chain, the technological development of LED brackets directly affects the performance, cost, and application scenarios of LED products.

[0003] Currently, a representative LED bracket includes a metal bracket and a plastic base fixed to the metal bracket by injection molding. Typically, a cup-shaped body is formed within the plastic base, and a large, horizontally flush, through-hole solder pad is located on the bottom surface of the cup-shaped body. For example, CN 222706912 discloses a small-pitch white LED strip bracket for mounting LED chips, including a conductive bracket body. The conductive bracket body has a cup-shaped body with a cavity for mounting the chip. The bottom of the cavity has a solder pad for chip conduction. The solder pad has an insulating component for isolating the positive and negative electrodes. Both ends of the conductive bracket body are bent inwards towards the bottom to form solder feet. The solder feet and the lower side of the solder pad form a cavity, and an injection-molded filling portion is provided within the cavity. The solder feet hold the injection-molded filling portion.

[0004] After the LED bracket is encapsulated, it is difficult to meet the testing standards for LED lights in automobiles, especially when it comes to temperature-sensitive testing (constant temperature and humidity testing).

[0005] Therefore, a new technical solution needs to be researched to address the above problems. Utility Model Content

[0006] In view of this, the present invention addresses the deficiencies of the existing technology, and its main purpose is to provide a multi-pad separated recessed LED bracket, which maximizes the use of plastic to wrap the surface of the hardware sheet, effectively increasing the tightness and firmness of the bond between the hardware and the plastic, greatly improving the temperature sensitivity of the product, meeting the testing standards for automotive LED lights, and at the same time, helping to improve the setting accuracy of components.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: A multi-pad-separated recessed LED bracket includes a metal bracket and a plastic base injection-molded and fixed to the metal bracket; The hardware bracket includes two sets of hardware sheets, each set of hardware sheets including an embedded part and a solder foot integrally connected to the outer end of the embedded part; the inner end of the embedded part of one set of hardware sheets is integrally connected to a first solder pad and a second solder pad, and the inner end of the embedded part of the other set of hardware sheets is integrally connected to a third solder pad. The top surface of the plastic base is recessed with a bowl-shaped cavity. The inner bottom surface of the bowl-shaped cavity is further recessed with a first inner cavity, a second inner cavity, and a third inner cavity. The first inner cavity, the second inner cavity, and the third inner cavity are arranged horizontally at intervals. The first pad, the second pad, and the third pad are respectively exposed on the bottom surface of the first inner cavity, the second inner cavity, and the third inner cavity to form a corresponding first effective pad area, a second effective pad area, and a third effective pad area.

[0008] As a preferred embodiment, the first effective pad area, the second effective pad area, and the third effective pad area are arranged in a triangular configuration.

[0009] As a preferred embodiment, the bowl-shaped cavity is a cone shape that is larger at the top and smaller at the bottom. The first effective pad area is located at the center of the bowl-shaped cavity. The first effective pad area is a light source chip placement area, and the first effective pad area is a cone shape that is larger at the top and smaller at the bottom.

[0010] As a preferred embodiment, each of the embedded portions, and between the first pad and the second pad, is provided with a filler hole.

[0011] As a preferred embodiment, a cutout groove is provided on the second pad corresponding to the center of the second effective pad area.

[0012] As a preferred embodiment, the embedded part of another set of hardware sheets is provided with anti-permeability grooves on both sides corresponding to the glue filling hole. The anti-permeability grooves extend perpendicular to the direction of the weld foot extension, and the inner end of the anti-permeability grooves penetrates the glue filling hole, while the outer end penetrates the outer end of the embedded part, thereby improving the red ink performance of the product.

[0013] As a preferred embodiment, the bottom surfaces of the first pad, the second pad, and the third pad are all provided with a number of densely distributed pits.

[0014] As a preferred embodiment, the bottom of the plastic base is recessed upward to provide a positioning and heat dissipation hole, and the bottom of the plastic base is provided with welding foot receiving grooves on both sides corresponding to the positioning and heat dissipation hole. Thus, a middle protrusion is formed between the welding foot receiving grooves on both sides at the bottom of the plastic base, and the bottom surface of the welding foot is lower than the bottom surface of the middle protrusion.

[0015] As a preferred embodiment, a through hole is provided between the welding foot and the embedded part to facilitate bending operations. The through hole divides the inner end of the welding foot into two parts, left and right. Each part is provided with a pre-bending line at the outer end position of the through hole.

[0016] As a preferred embodiment, the side of the plastic base is provided with a stop portion corresponding to the through hole. The stop portion protrudes from the side of the plastic base. When the welding foot is bent downward, the inner side of the outer end of the through hole flips downward and faces upward to abut against the bottom surface of the stop portion.

[0017] 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 involves setting a first solder pad and a second solder pad in one of two sets of metal sheets, and setting a third solder pad in the other set; at the same time, the inner bottom surface of the bowl-shaped cavity of the plastic seat is further recessed to form a first inner cavity, a second inner cavity, and a third inner cavity. The first solder pad, the second solder pad, and the third solder pad are respectively exposed on the bottom surface of the first inner cavity, the second inner cavity, and the third inner cavity, so as to form a corresponding first effective solder pad area, a second effective solder pad area, and a third effective solder pad area. In this way, the surface of the metal sheet is maximized to utilize plastic wrapping, effectively increasing the tightness and firmness of the bond between the metal and the plastic, greatly improving the temperature sensitivity of the product, meeting the testing standards for LED lights in automobiles, and at the same time, it is beneficial to improve the setting accuracy of components.

[0018] 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

[0019] Figure 1 This is a perspective view of a multi-pad-separated recessed LED bracket according to Embodiment 1 of this utility model; Figure 2 This is another perspective view of the multi-pad partition recessed LED bracket of Embodiment 1 of this utility model; Figure 3 This is a top view of a multi-pad-separated recessed LED bracket according to Embodiment 1 of this utility model; Figure 4 This is a first exploded view of a multi-pad-separated recessed LED bracket according to an embodiment of the present invention; Figure 5 This is a second exploded view of a multi-pad-separated recessed LED bracket according to Embodiment 1 of this utility model; Figure 6 This is the third exploded view of the multi-pad separated recessed LED bracket of Embodiment 1 of this utility model; Figure 7 This is a diagram showing the material strip status of the metal bracket of the multi-pad separated recessed LED bracket according to Embodiment 1 of this utility model. Figure 8 This is an application diagram of the multi-pad separated recessed LED bracket according to Embodiment 1 of this utility model; Figure 9This is a perspective view of the multi-pad-separated recessed LED bracket according to Embodiment 2 of this utility model; Figure 10 This is another perspective view of the multi-pad-separated recessed LED bracket of Embodiment 2 of this utility model; Figure 11 This is a first exploded view of a multi-pad-separated recessed LED bracket according to Embodiment 2 of this utility model; Figure 12 This is a second exploded view of the multi-pad separated recessed LED bracket of Embodiment 2 of this utility model; Figure 13 This is a diagram showing the material strip status of the hardware bracket of the multi-pad separated recessed LED bracket according to Embodiment 2 of this utility model. Figure 14 This is a cross-sectional view of the hardware bracket of the multi-pad separated recessed LED bracket according to Embodiment 2 of this utility model. Detailed Implementation

[0020] Please refer to Figures 1 to 14 As shown, it illustrates the specific structure of an embodiment of the present invention.

[0021] 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.

[0022] A multi-pad-separated recessed LED bracket includes a metal bracket 20 and a plastic base 10 injection-molded and fixed to the metal bracket 20, which is particularly suitable for automobiles, such as automotive turn signals.

[0023] The hardware bracket includes two sets of hardware sheets, usually copper sheets. Each set of hardware sheets includes an embedded part 21 and a weld leg 29 integrally connected to the outer end of the embedded part 21. The weld leg 29 is bent and connected to the embedded part 21 by a bent part 28. The inner end of the embedded part 21 of one set of hardware sheets is integrally connected to a first solder pad 22 and a second solder pad 23, and the inner end of the embedded part 21 of the other set of hardware sheets is integrally connected to a third solder pad 24. The top surface of the plastic base 20 is recessed with a bowl-shaped cavity 11. A foolproof notch 15 is typically provided at one corner of the top surface of the plastic base 20. The inner bottom surface of the bowl-shaped cavity 11 is further recessed with a first inner cavity 12, a second inner cavity 13, and a third inner cavity 14. These three inner cavities are arranged horizontally at intervals. The first solder pad 22, the second solder pad 23, and the third solder pad 24 are respectively exposed on the bottom surfaces of the first inner cavity 12, the second inner cavity 13, and the third inner cavity 14, forming corresponding first effective solder pad areas D1, second effective solder pad areas D2, and third effective solder pad areas D3. This effectively maximizes the use of plastic to cover the surface of the metal sheet, significantly increasing the tightness and firmness of the bond between the metal and the plastic, greatly improving the product's temperature sensitivity, and meeting the testing standards for automotive LED lights. Typically, the spacing between the first effective pad area D1, the second effective pad area D2, and the third effective pad area D3 satisfies sufficient insulation distance requirements. The first effective pad area D1, the second effective pad area D2, and the third effective pad area D3 are arranged in a triangular configuration.

[0024] The bowl-shaped cavity 11 is conical in shape, wider at the top and narrower at the bottom. The first effective pad area D1 is located at the center of the bowl-shaped cavity 11. The first effective pad area D1 is a light source chip placement area, such as a white LED chip placement area. In this embodiment, a white LED chip 100 is placed on the first effective pad area D1, and a Zener diode 200 is placed on the second effective pad area D2. The second effective pad area D2 serves as the positive electrode pad, and the third effective pad area D3 serves as the negative electrode pad. The anode and cathode of the white LED chip 100 are connected to the positive electrode pad and the negative electrode pad, respectively. The Zener diode 200 is soldered to the second effective pad area D2 and then connected to the third effective pad area D3. The Zener diode 200 and the cathode of the white LED chip 100 form a parallel structure. By adopting the form of the first inner cavity 12, the second inner cavity 13, and the third inner cavity 14, it is equivalent to setting a smaller area for the arrangement of components, which is conducive to precise soldering.

[0025] Each of the embedded parts 21, and between the first solder pad 22 and the second solder pad 23, is provided with a filling hole 25, which effectively improves the bonding strength between the metal sheet and the plastic and prevents the product from becoming loose after the foot is bent.

[0026] A hollow groove 231 is provided on the second pad 23 corresponding to the center of the second effective pad area D2. This groove can be used to precisely control the position of the metal sheet, especially the second pad 23, during injection molding. The shape of the hollow groove 231 is not limited, but it is preferably a non-circular groove, such as the cross-shaped groove provided in this embodiment. After the injection molding process is completed, the hollow groove 231 can also be used as a pre-bonding adhesive groove for the light source chip. On the other set of metal sheet embedded portions 21, anti-permeability grooves 26 are provided on both sides corresponding to the adhesive filling hole 25. The anti-permeability grooves 26 extend perpendicularly to the direction of the solder foot extension, and the inner end of the anti-permeability groove 26 penetrates the adhesive filling hole 25, while the outer end penetrates the outer end of the embedded portion 21, improving the red ink performance of the product. One or more anti-permeability grooves 26 can be provided; if multiple grooves are provided, their parallel spacing is set.

[0027] The bottom surfaces of the first pad 22, the second pad 23, and the third pad 24 are all provided with a number of densely distributed pits, also known as dotting, to further improve the performance of the red ink in the product. Furthermore, the edges of the embedded part 21, the first pad 22, the second pad 23, the third pad 24, and the connecting parts between them are designed in a zigzag shape, forming flanges 27 and concave flanges 271, ensuring a reliable connection between the metal sheet and the plastic base 20. This provides positioning in all directions, including left, right, front, back, and up, preventing loosening and leakage due to pulling.

[0028] The plastic base 10 has a positioning and heat dissipation hole 18 recessed upward at its bottom center. A protruding post 19 is provided on the inner top surface of the positioning and heat dissipation hole 18. Welding foot receiving grooves 16 are respectively provided on both sides of the bottom of the plastic base 10 corresponding to the positioning and heat dissipation hole 18. Thus, a middle protrusion 17 is formed on the bottom of the plastic base 10 between the welding foot receiving grooves 16 on both sides. The positioning and heat dissipation hole 18 is recessed upward on the bottom surface of the middle protrusion 17. The bottom surface of the welding foot 29 serves as the welding surface and is lower than the bottom surface of the middle protrusion 17. The bottom surface of the protruding post 19 is higher than the inner top surface of the welding foot receiving groove 16. The downward extension height of the protruding post 19 is one-third to one-half the height of the positioning and heat dissipation hole 18. The positioning and heat dissipation holes 18 and the protrusions 19 serve as process positioning holes during injection molding, providing a mold positioning reference. The concave holes act as positioning references during injection molding, ensuring mold closing accuracy. They also help to vent gases generated during injection molding, preventing molding defects caused by gas expansion. After injection molding, when the LED bracket is installed, the positioning and heat dissipation holes 18 function as heat dissipation holes. Since the solder pads 19 are mounted in the application environment, the positioning and heat dissipation holes 18 are reserved as empty spaces between the LED bracket and the PCB board. Furthermore, the placement of the positioning and heat dissipation holes 18 takes into account the relatively thick bottom of the plastic base 10, preventing stress concentration during cooling and shrinkage. This also allows for material weight reduction without compromising structural strength.

[0029] A through hole 203 is provided between the welding foot 29 and the embedded part 21 to facilitate bending operation. The through hole 203 divides the inner end of the welding foot 29 into two parts, left and right. Each part is provided with a pre-bending line 202 at the outer end of the through hole 203. This solution can prevent cracking after the product is bent when the width of the left and right welding feet is large.

[0030] The side of the plastic base 10 is provided with a stop part 101 corresponding to the through hole 203. The stop part 101 protrudes from the side of the plastic base 10. When the welding foot 29 is bent downward, the inner side of the outer end of the through hole 203 flips downward and faces upward to abut the bottom surface of the stop part 101. In this way, it plays a positioning role for the bent state of the welding foot 29, which helps to prevent the embedded part 21 of the hardware sheet and the corresponding first welding pad 22, second welding pad 23 and third welding pad 24 from loosening in the vertical direction.

[0031] It should be noted that the applicant conducted several tests on the aforementioned LED bracket products: 1. Red ink test: According to the testing standards of a certain car manufacturer and the packaging standards, after soaking at 95-100℃ for 30 minutes, there was no red ink residue in the bowl-shaped cavity 11, the first inner cavity 12, the second inner cavity 13, and the third inner cavity 14 of the plastic seat 10, and the test was qualified.

[0032] 2. Thermal shock test: According to the testing standards of a certain car manufacturer, the LED bracket sample is 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 test is carried out for one week (168 hours). The performance of the LED bracket under temperature change conditions is analyzed and the test is qualified.

[0033] 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 60RH% 60℃ high temperature and humidity test chamber for 120 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.

[0034] 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.

[0035] The key design feature of this invention lies in the fact that one of the two sets of metal sheets is provided with a first solder pad and a second solder pad, while the other set is provided with a third solder pad. Simultaneously, the inner bottom surface of the bowl-shaped cavity of the plastic base is further recessed to form a first inner cavity, a second inner cavity, and a third inner cavity. The first, second, and third solder pads are correspondingly exposed on the bottom surfaces of the first, second, and third inner cavity, forming corresponding first, second, and third effective solder pad areas. This maximizes the use of plastic to cover the surface of the metal sheets, effectively increasing the tightness and firmness of the bond between the metal and plastic, significantly improving the product's temperature sensitivity, meeting the testing standards for automotive LED lights, and also improving the accuracy of component placement.

[0036] 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 multi-pad recessed LED bracket, comprising a metal bracket and a plastic base injection-molded and fixed to the metal bracket, characterized in that: The hardware bracket includes two sets of hardware sheets, each set of hardware sheets including an embedded part and a solder foot integrally connected to the outer end of the embedded part; the inner end of the embedded part of one set of hardware sheets is integrally connected to a first solder pad and a second solder pad, and the inner end of the embedded part of the other set of hardware sheets is integrally connected to a third solder pad. The top surface of the plastic base is recessed with a bowl-shaped cavity. The inner bottom surface of the bowl-shaped cavity is further recessed with a first inner cavity, a second inner cavity, and a third inner cavity. The first inner cavity, the second inner cavity, and the third inner cavity are arranged horizontally at intervals. The first pad, the second pad, and the third pad are respectively exposed on the bottom surface of the first inner cavity, the second inner cavity, and the third inner cavity to form a corresponding first effective pad area, a second effective pad area, and a third effective pad area.

2. The multi-pad separated recessed LED bracket according to claim 1, characterized in that: The first effective pad area, the second effective pad area, and the third effective pad area are arranged in a triangular pattern.

3. The multi-pad separated recessed LED bracket according to claim 2, characterized in that: The bowl-shaped cavity is a cone shape that is larger at the top and smaller at the bottom. The first effective pad area is located at the center of the bowl-shaped cavity. The first effective pad area is the light source chip placement area. The first effective pad area is a cone shape that is larger at the top and smaller at the bottom.

4. The multi-pad separated recessed LED bracket according to claim 1, 2, or 3, characterized in that: Each of the aforementioned embedded portions, and between the first pad and the second pad, is provided with a filler hole.

5. The multi-pad separated recessed LED bracket according to claim 1, characterized in that: A cutout groove is provided on the second pad corresponding to the center of the second effective pad area.

6. The multi-pad separated recessed LED bracket according to claim 4, characterized in that: On the other set of hardware sheets, anti-permeability grooves are provided on both sides of the glue filling hole. The anti-permeability grooves extend perpendicular to the direction of the weld foot extension, and the inner end of the anti-permeability grooves passes through the glue filling hole and the outer end passes through the outer end of the embedded part.

7. The multi-pad separated recessed LED bracket according to claim 6, characterized in that: The bottom surfaces of the first pad, the second pad, and the third pad are all provided with a number of densely distributed pits.

8. The multi-pad separated recessed LED bracket according to claim 1, characterized in that: The bottom of the plastic base is recessed upward to provide a positioning and heat dissipation hole, and the bottom of the plastic base is provided with welding foot receiving grooves on both sides corresponding to the positioning and heat dissipation hole. Thus, a middle convex part is formed between the welding foot receiving grooves on both sides at the bottom of the plastic base, and the bottom surface of the welding foot is lower than the bottom surface of the middle convex part.

9. The multi-pad separated recessed LED bracket according to claim 1, characterized in that: A through hole is provided between the welding foot and the embedded part to facilitate bending operations. The through hole divides the inner end of the welding foot into two parts, left and right. Each part is provided with a pre-bending line at the outer end position of the through hole.

10. The multi-pad separated recessed LED bracket according to claim 9, characterized in that: The side of the plastic base is provided with a stop part corresponding to the through hole. The stop part protrudes from the side of the plastic base. When the welding foot is bent downward, the inner side of the outer end of the through hole flips downward and faces upward to abut the bottom surface of the stop part.

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