A point light source structure

Abstract

The utility model discloses a point light source structure, aims at solving the problem of the damage of the wire caused by the waterproof structure of the point light source in the prior art, leading to poor contact. The structure includes shell, lens, PCBA, bottom shell and plastic sealing frame covered in the edge of PCBA through injection molding process, the plastic sealing frame is equipped with the threading hole of sealing cooperation with the outer surface of wire, the top surface and bottom surface of plastic sealing frame are equipped with respectively with the first, second sealing protrusion of sealing groove cooperation in the inside of shell and bottom shell, form double physical sealing. The shell and bottom shell are fixed through ultrasonic welding, and are equipped with the first, second wire pressing groove of mutual cooperation at the fitting place, are used for nondestructive clamping wire. The utility model discloses the way that injection molding, physical card joint sealing and mechanical pressure are combined, effectively avoid the damage of wire, improve the waterproof reliability and long -term work stability of product.

Description

Technical Field

[0001] This utility model relates to the field of lighting decoration technology, and more specifically, to a point light source structure. Background Technology

[0002] Currently, commercially available waterproof point light sources primarily employ two technical solutions to address the waterproofing issue at the wire lead-out points. One is the potting compound process, which involves filling the housing with waterproof adhesive to secure internal components and achieve a seal. However, this process has stringent environmental requirements, a long curing time, and the adhesive may age and crack after prolonged use, leading to a decrease in waterproofing performance.

[0003] Another approach is to use in-mold injection molding for waterproofing. However, some products using this method employ screws to secure the wire for electrical connection. This mechanical tightening, especially the screw tip or edge, can easily cut or crush the copper wires inside the wire. Over time, the damaged wire core is prone to breakage under vibration or temperature changes, leading to poor contact of the lamp core, flickering, or even failure to light up, severely impacting product reliability and lifespan.

[0004] Therefore, how to provide a point light source structure that can achieve reliable waterproofing while avoiding damage to the wire is a technical problem that urgently needs to be solved in this field. Utility Model Content

[0005] The purpose of this utility model is to provide a point light source structure, which aims to solve the problem in the background art where fixing wires with screws or other methods can easily damage the wire core, leading to poor contact or flickering after long-term use.

[0006] To solve the above problems, the technical solution adopted by this utility model is as follows:

[0007] A point light source structure includes a housing and a mating lens, a PCBA, a plastic sealing frame, and a bottom shell. The plastic sealing frame is injection molded around the edge of the PCBA. The plastic sealing frame has a wire-passing hole for wires to pass through, and the inner wall of the wire-passing hole forms a sealing fit with the outer surface of the wire. The top surface of the plastic sealing frame has a first sealing protrusion, and the inner wall of the housing has a first sealing groove that mates with the first sealing protrusion. The bottom surface of the plastic sealing frame has a second sealing protrusion, and the bottom shell has a second sealing groove that mates with the second sealing protrusion. The housing and the bottom shell are fixed together by ultrasonic welding, and the housing and the bottom shell respectively have a first wire-pressing groove and a second wire-pressing groove, which cooperate to clamp the wire.

[0008] As a further optimization of this utility model, the lens and the housing are integrally formed.

[0009] In another embodiment of this utility model, the center of the outer shell is provided with a lens mounting hole, and the lens is an independent component and is installed in the lens mounting hole.

[0010] As a further optimization of the above embodiment, the inner wall of the housing is provided with a third sealing groove around the lens mounting hole; the lens includes an optical part and a stepped part, and the stepped part is provided with a third sealing protrusion that cooperates with the third sealing groove.

[0011] As a further optimization of this utility model, the bottom of the plastic sealing frame has a stepped structure, forming an upper stepped surface and a lower stepped surface; the bottom shell is provided with a surrounding frame, the upper stepped surface is attached to the top surface of the surrounding frame, and the lower stepped surface is located inside the surrounding frame.

[0012] As a further optimization of this utility model, the inner side of the plastic sealing frame is provided with a PCBA edge slot for holding the PCBA.

[0013] Compared with the prior art, the beneficial effects of this utility model are:

[0014] (1) This utility model forms a plastic sealing frame on the PCBA through injection molding, and clamps the wire at the wire exit position using the wire clamping grooves on the outer shell and the bottom shell, replacing the traditional screw-based power supply method. This non-destructive fixing method fundamentally avoids damage to the copper wires of the wire, ensures the long-term stability of the electrical connection, and effectively prevents poor contact and flickering caused by damage to the wire core.

[0015] (2) This utility model adopts a multi-layer waterproof design. First, the wire hole forms a preliminary seal with the wire during injection molding; second, the top and bottom surfaces of the plastic sealing frame form a double physical seal with the outer shell and bottom shell through the cooperation of sealing protrusions and sealing grooves; finally, the first and second wire clamping grooves further seal the wire outlet while clamping the wire. This combined waterproof structure has a strong barrier effect and reliable and stable waterproof performance, which is superior to the traditional potting compound process.

[0016] (3) The present invention has an ingenious structural design and precise fit between components. The entire assembly and sealing can be completed in one go through ultrasonic welding process, without waiting for the glue to cure, which simplifies the production process and improves production efficiency and product consistency.

[0017] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, embodiments of this utility model are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is an external view of the point light source structure described in Example 1;

[0020] Figure 2 This is a cross-sectional view of the point light source structure described in Embodiment 1;

[0021] Figure 3 This is a structural diagram of the integrally formed lens and housing in Example 1;

[0022] Figure 4 This is a structural diagram of the bottom shell described in Example 1;

[0023] Figure 5 This is a top-view structural diagram of the plastic sealing frame described in Example 1;

[0024] Figure 6 This is a lower-view structural diagram of the plastic sealing frame described in Example 1;

[0025] Figure 7 This is a cross-sectional view of the point light source structure described in Embodiment 2, wherein, unlike Embodiment 1, the outer shell and lens are designed separately before being welded and assembled into the point light source structure;

[0026] Figure 8 This is a top-view structural diagram of the outer shell described in Embodiment 2;

[0027] Figure 9 This is a lower-view structural diagram of the outer shell described in Embodiment 2;

[0028] Figure 10 This is a structural diagram of the lens described in Example 2;

[0029] In the diagram: 1. Outer shell; 11. First sealing groove; 12. First wire pressing groove; 13. Lens mounting hole; 14. Third sealing groove; 2. Lens; 21. Third sealing protrusion; 22. Optical part; 23. Stepped part; 3. PCBA; 4. Plastic sealing frame; 41. First sealing protrusion; 42. Wire through hole; 43. PCBA edge slot; 44. Upper stepped surface; 45. Lower stepped surface; 46. Second sealing protrusion; 5. Bottom shell; 51. Second wire pressing groove; 52. Second sealing groove; 53. Enclosure; 6. Wire. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments.

[0031] Example 1

[0032] Please refer to Figures 1 to 6 This embodiment provides a point light source structure, the core components of which include an integrally molded shell and lens assembly (hereinafter referred to as the top cover assembly), PCBA 3, plastic sealing frame 4, bottom shell 5, and wires 6.

[0033] First, the structure of each key component will be explained:

[0034] Top cover components: such as Figure 3 As shown, the outer shell 1 and the lens 2 are integrally injection molded. The inner wall of the outer shell 1 is provided with an annular first sealing groove 11, and the side wall is provided with a first wire pressing groove 12 for accommodating the wire 6.

[0035] Plastic sealing frame 4: such as Figure 5 and Figure 6 As shown, this component is the core of achieving multiple seals. Its top surface has a first sealing protrusion 41 that mates with the first sealing groove 11; its bottom surface has a stepped structure, with a second sealing protrusion 46 on the outer periphery of the lower stepped surface 45. A wire through hole 42 is provided in the middle, and a PCBA edge slot 43 is formed on the inner side.

[0036] Bottom shell 5: as Figure 4 As shown, it has a frame 53 inside, a second sealing groove 52 that cooperates with the second sealing protrusion 46 on the inner side of the frame 53, and a second pressure groove 51 on the corresponding edge.

[0037] The assembly and manufacturing process of the point light source structure described in this embodiment requires secondary ultrasonic fusion (i.e., ultrasonic plastic sealing welding), and includes at least the following steps:

[0038] (1) Preparation of core components—injection molding edge banding process

[0039] The PCBA 3, with the pre-soldered wires 6, is placed in a dedicated injection mold. Through injection molding, molten plastic is wrapped around the edges of the PCBA 3, thus forming a single unit. Figure 5 and Figure 6The plastic sealing frame 4 is shown. During this process, the injection-molded PCBA edge groove 43 wraps around and holds the edge of the PCBA 3, thus firmly fixing it in place. Simultaneously, the plastic cures around the wire 6, creating a tight seal between the inner wall of the wire hole 42 and the outer surface of the wire 6, completing the first layer of waterproofing at the wire exit point. After this step, a semi-finished product integrating the PCBA, wire, and sealing structure is obtained, referred to as the core component.

[0040] (2) First ultrasonic fusion - upper sealing

[0041] The core component obtained in step (1) is installed into the top cover assembly, so that the first sealing protrusion 41 of the plastic sealing frame 4 is aligned and embedded into the first sealing groove 11 of the outer shell 1. Subsequently, ultrasonic energy and pressure are applied to make the contact surface melt instantly and re-solidify, thereby firmly welding the plastic sealing frame 4 to the top cover assembly to form the first reliable annular waterproof seal.

[0042] (3) Second ultrasonic fusion - overall sealing and fixation

[0043] The bottom shell 5 is placed over the bottom of the semi-finished product obtained in step (2), so that the second sealing protrusion 46 of the plastic sealing frame 4 is embedded in the second sealing groove 52 of the bottom shell 5. At the same time, the wire 6 is placed in the channel formed by the first wire pressing groove 12 and the second wire pressing groove 51. Ultrasonic energy and pressure are applied again to weld the corresponding contact surfaces of the bottom shell 5, the outer shell 1, and the plastic sealing frame 4. This step not only forms a second annular waterproof seal, but also firmly clamps the wire 6 through the wire pressing groove, completing the final sealing and assembly of the entire point light source structure.

[0044] Example 2

[0045] Please refer to Figures 7 to 10 The main difference between this embodiment and embodiment 1 is that the outer shell 1 and the lens 2 adopt a split design, so its assembly process is more complicated.

[0046] The structural differences of the key components are as follows:

[0047] Outer shell 1: such as Figure 8 and Figure 9 As shown, a lens mounting hole 13 is provided in the center, and a third sealing groove 14 is provided around the hole on the inner wall.

[0048] Lens 2: such as Figure 10 As shown, it is an independent component, and its stepped portion 23 is provided with a third sealing protrusion 21 that cooperates with the third sealing groove 14.

[0049] The assembly and manufacturing process of the point light source structure described in this embodiment requires three ultrasonic fusion operations and includes at least the following steps:

[0050] (1) First ultrasonic fusion - fabrication of the top cover assembly

[0051] The independent lens 2 is placed in the lens mounting hole 13 of the housing 1, aligning its third sealing protrusion 21 with the third sealing groove 14. Ultrasonic energy is applied to weld the two together, forming a sealed and waterproof top cover assembly.

[0052] (2) Preparation of core components—injection molding edge banding process

[0053] This step is exactly the same as step (1) in Example 1. The core component integrating PCBA 3, wire 6 and plastic sealing frame 4 is prepared by injection molding.

[0054] (3) Second ultrasonic fusion - upper sealing

[0055] Assemble the core component obtained in step (2) with the top cover component obtained in step (1) so that the first sealing protrusion 41 of the plastic sealing frame 4 is embedded in the first sealing groove 11 of the outer shell 1. Weld the two together by applying ultrasonic energy to complete the upper seal.

[0056] (4) Third ultrasonic fusion - overall sealing and fixation

[0057] The bottom shell 5 is placed over the semi-finished product obtained in step (3), so that the second sealing protrusion 46 is embedded in the second sealing groove 52, and the wire 6 is positioned. Finally, the bottom shell 5 is welded to the entire upper component into a sealed whole by a third ultrasonic fusion, while clamping and fixing the wire 6.

[0058] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A point light source structure, characterized in that, include: The outer casing and the lens that mates with it; PCBA; A plastic sealing frame covers the edge of the PCBA, wherein the plastic sealing frame has a wire-passing hole for wires to pass through, and the inner wall of the wire-passing hole forms a sealing fit with the outer surface of the wire. Bottom shell; The plastic sealing frame has a first sealing protrusion on its top surface and a first sealing groove that mates with the first sealing protrusion on its inner wall. The plastic sealing frame has a second sealing protrusion on its bottom surface and a second sealing groove that mates with the second sealing protrusion on its bottom shell. The outer shell and the bottom shell are fixed by ultrasonic welding, and the outer shell and the bottom shell are respectively provided with a first pressure groove and a second pressure groove, which cooperate to clamp the wire.

2. The point light source structure according to claim 1, characterized in that, The lens and the housing are integrally formed.

3. The point light source structure according to claim 1, characterized in that, The outer casing has a lens mounting hole at its center, and the lens is an independent component that is welded and fixed in the lens mounting hole.

4. The point light source structure according to claim 3, characterized in that, The inner wall of the housing is provided with a third sealing groove around the lens mounting hole; the lens includes an optical part and a stepped part, and the stepped part is provided with a third sealing protrusion that cooperates with the third sealing groove.

5. The point light source structure according to claim 1, characterized in that, The bottom of the plastic sealing frame has a stepped structure, forming an upper stepped surface and a lower stepped surface; the bottom shell is provided with a surrounding frame, the upper stepped surface is attached to the top surface of the surrounding frame, and the lower stepped surface is located inside the surrounding frame.

6. The point light source structure according to claim 1, characterized in that, The inner side of the plastic sealing frame is provided with a PCBA edge slot for holding the PCBA.

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