LED lamp assembling device and LED lamp manufacturing method

Abstract

The present invention provides an LED lamp assembling device, comprising sheet metal parts made of a copper material, a support, light source chips and a lens. The support comprises a support body and a reflection cup, the support is arranged on the sheet metal parts, and the lens is arranged behind the reflection cup and matched with the light source chips; and the support body or the reflection cup is provided with an alignment reference structure used for improving the consistency of light distribution curves; and when the light source chips are assembled, the light source chips take the alignment reference structure as a reference point, and the light source chips are arranged on the support body by means of the alignment reference structure. Compared with the prior art, the present invention provides the alignment reference structure, which can ensure the positions between the light source chips and the support to be relatively consistent, reducing the accumulation of tolerance, so that the positions between the light source chips and the support do not shift, and thus an LED lamp has the advantage of the consistency of light distribution curves. The present invention also provides an LED lamp manufacturing method.

Description

Assembly device for LED lamp and method for manufacturing LED lamp Technical Field

[0001] The present invention belongs to the technical field of LED products, and in particular relates to an assembly device for LED lamps and a method for manufacturing LED lamps. Background Art

[0002] Among the technical products of related LED lamps, there is an assembly device for LED lamps, which includes a sheet metal part made of copper material, a bracket, a light source chip and a lens. The bracket includes a frame and a reflective cup. The bracket is arranged on the sheet metal part, and the lens is arranged behind the reflective cup and cooperates with the light source chip. The aforementioned existing LED lamps do not require secondary light distribution, so the accuracy of the glue pressing during the assembly of the existing LED lamps is not high. However, for the aforementioned LED lamps that require secondary light distribution through lenses, the relative position between the light source chip and the lens has strict regulations; if the bracket is assembled with the circular hole on the sheet metal made of copper material as the reference point as in the prior art, Figure 1 is a sheet metal diagram with circular holes for positioning in the prior art (each rectangle in the figure represents an LED lamp product), and Figure 2 is a product diagram of the error generated when the circular holes on the sheet metal are used as the reference point for glue pressing assembly in the prior art; then the light source chip is assembled with the sheet metal made of copper material as the reference, and then the lens is assembled with the bracket as the reference, which will greatly increase the accumulated tolerance and cause the LED lamp to have inconsistent light distribution curves.

[0003] To this end, the present invention provides an assembly device for an LED lamp and a method for manufacturing the LED lamp.

[0004] Summary of the Invention

[0005] In view of the above problems existing in the prior art, the object of the present invention is to provide an assembly device for LED lamps and a method for manufacturing LED lamps, which have the advantage of making the light distribution curve of the LED lamps consistent.

[0006] The purpose of the present invention can be achieved through the following technical solutions:

[0007] An assembly device for an LED lamp includes a sheet metal part made of copper material, a bracket, a light source chip, and a lens. The bracket includes a frame body and a reflector cup. The bracket is arranged on the sheet metal part. The lens is arranged behind the reflector cup and cooperates with the light source chip.

[0008] The frame or reflective cup is provided with a positioning reference structure for improving the consistency of the light distribution curve; when assembling the light source chip, the light source chip uses the positioning reference structure as a reference point, and the light source chip is set on the frame through the positioning reference structure.

[0009] As a preferred technical solution of the present invention, the alignment reference structure includes two positioning points arranged on the bracket;

[0010] The bracket is provided with a plurality of placement areas spaced apart from each other, each of the placement areas is used to embed the corresponding light source chip, and the two positioning points are spaced apart and arranged at the outer periphery of the placement area.

[0011] Preferably, the placement area is in the shape of a cuboid or a cube;

[0012] One of the positioning points is set at the edge of the top side of the placement area along the length direction, and the other positioning point is set at the edge of the bottom side of the placement area along the length direction. The straight line formed by the two positioning points coincides with the longitudinal center line of the placement area.

[0013] Preferably, the two positioning points are arc portions facing away from the placement area, and the two arc portions are symmetrically arranged along the transverse center line of the placement area.

[0014] As a preferred technical solution of the present invention, the alignment reference structure includes a right-angled edge provided on the reflective cup;

[0015] When the light source chip is assembled, the right-angled side of the light source chip is parallel to the right-angled side of the reflective cup.

[0016] The present invention also provides a method for manufacturing an LED lamp using the assembly device for the LED lamp as claimed in the above claims, comprising the following steps:

[0017] The first step is to form the bracket by injection molding and cover the sheet metal during assembly;

[0018] In the second step, after the light source chip is sucked by a die bonding machine during die bonding, the two positioning points set on the bracket or the right-angled edge set on the reflective cup are used as alignment references, and the robot adjusts the position so that the light source chip is accurately placed in the placement area of ​​the bracket;

[0019] The third step is to place the lens at the front end of the bracket to obtain an LED lamp with consistent light distribution curve.

[0020] As a preferred technical solution of the present invention, the bracket has an open accommodating cavity;

[0021] The alignment reference structure includes a guide slope arranged on the outer wall of the bracket opening. There are multiple guide slopes, and the multiple guide slopes are respectively arranged at the corners between the length side of the outer wall of the bracket opening and the width side of the outer wall of the bracket opening.

[0022] Preferably, it further comprises a bridge plate for limiting the position of placing the sheet metal part;

[0023] The bridge plate has a plurality of inner cavities, and the bracket is embedded in the inner cavity of the corresponding bridge plate.

[0024] Preferably, the top of the bracket is provided with a plurality of rounded corners, and the plurality of rounded corners are respectively arranged at the corners between the length side of the accommodating cavity of the bracket and the width side of the accommodating cavity of the bracket.

[0025] The present invention also provides a method for preparing an assembly device for an LED lamp as claimed in the above claims, comprising the following steps:

[0026] The first step is to place the bracket with the guide slope on the sheet metal part by injection molding during assembly;

[0027] Step 2: After die bonding, the sheet metal is placed on the upper surface of the bridge plate, and the bracket is embedded in the corresponding inner cavity of the bridge plate;

[0028] In the third step, the machine will press the bracket during the gluing process. At this time, the sheet metal part and the bracket are brought as a whole into a glue injection cavity coaxial with the gluing equipment for glue injection and gluing.

[0029] The fourth step is to place the lens at the front end of the bracket with the guide slope, thereby obtaining an LED lamp with a consistent light distribution curve.

[0030] As described above, the LED lamp assembly device and LED lamp manufacturing method provided by the present invention have the following beneficial effects:

[0031] The present invention utilizes the above-mentioned LED lamp assembly device and LED lamp manufacturing method. Compared with the prior art, due to the adoption of such a structure, the frame or reflector cup is provided with a positioning reference structure for improving the consistency of the light distribution curve; it is not necessary to use a circular hole on the sheet metal as a reference for assembling the light source chip as in the prior art. The present invention adopts an alignment reference structure set on the frame or reflector cup, which can ensure that the position between the light source chip and the bracket is relatively consistent, reduce the accumulation of tolerances, and thus prevent the position between the light source chip and the bracket from shifting, thereby giving the LED lamp the advantage of consistent light distribution curve. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG1 is a diagram of a sheet metal part with circular holes for alignment in the prior art;

[0033] FIG2 is a product diagram showing the error caused by gluing and assembling using a circular hole on a sheet metal part as a reference point in the prior art;

[0034] FIG3 is a schematic diagram of a portion of the structure of the first embodiment of the assembly device for an LED lamp of the present invention after the light source chip is assembled;

[0035] FIG4 is a side view from a perspective of FIG3;

[0036] FIG5 is a top view from a perspective of FIG3;

[0037] FIG6 is a partial structural diagram of a second specific embodiment of the assembly device for an LED lamp of the present invention after the light source chip is assembled;

[0038] FIG7 is a partial structural diagram of a third embodiment of an assembly device for an LED lamp according to the present invention after assembling the light source chip (excluding the lens);

[0039] FIG8 is an enlarged view of the AA section of FIG7;

[0040] FIG9 is a perspective view of the third embodiment of the assembly device for an LED lamp of the present invention after the light source chip (excluding the lens) is assembled;

[0041] FIG10 is a cross-sectional view of the assembly process of the third embodiment of the assembly device for the LED lamp of the present invention. DETAILED DESCRIPTION

[0042] The following describes the implementation of the present invention through specific embodiments. People skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.

[0043] It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the limiting conditions for the implementation of the present invention. Therefore, they have no technical substantive significance. Any modification of the structure, change in the proportional relationship, or adjustment of the size should still fall within the scope of the technical content disclosed by the present invention without affecting the efficacy and purpose that can be achieved by the present invention. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" quoted in this specification are only for the convenience of description and are not used to limit the scope of the implementation of the present invention. Changes or adjustments in their relative relationships should also be regarded as the scope of the implementation of the present invention without substantially changing the technical content. The specific structure can be described with reference to the drawings of the patent application.

[0044] The present invention provides an assembly device for an LED lamp, as shown in Figures 3 to 10 , comprising a sheet metal member 1 made of copper, a bracket 2, a light source chip 3, and a lens 4. The bracket 2 comprises a frame 2c and a reflector cup 2d. The bracket 2 is mounted on the sheet metal member 1. The lens 4 is mounted behind the reflector cup 2d and cooperates with the light source chip 3.

[0045] The frame 2c or reflective cup 2d is provided with a positioning reference structure 2a for improving the consistency of the light distribution curve; when assembling the light source chip 3, the light source chip 3 uses the positioning reference structure 2a as a reference point, and the light source chip 3 is set on the frame 2c through the positioning reference structure 2a.

[0046] It should be noted that, since the frame 2c or the reflective cup 2d is provided with a positioning reference structure 2a for improving the consistency of the light distribution curve, it is not necessary to use the circular hole on the sheet metal 1 as a reference for assembling the light source chip 3 as in the prior art. The present invention adopts the positioning reference structure 2a provided on the bracket 2 or the reflective cup 2d, which can ensure that the positions of the light source chip 3 and the bracket 2 are relatively consistent, reduce the accumulation of tolerances, and thus prevent the positions of the light source chip 3 and the bracket 2 from being offset, thereby making the LED lamp lens 4 have the advantage of consistent light distribution curve.

[0047] In this embodiment, the above-mentioned alignment reference structure 2a provides three specific embodiments in the present invention. The specific structure of the alignment reference structure 2a is shown below.

[0048] As shown in FIG3 , a first specific structure of the alignment reference structure 2 a is as follows: the alignment reference structure 2 a includes two positioning points 20 provided on the frame 2 c;

[0049] The frame 2c is provided with a plurality of mutually spaced placement areas (not shown in the figure, but the same below), each of which is used to embed the corresponding light source core 3, and the two positioning points 20 are spaced apart and arranged at the outer periphery of the placement area. When assembling the aforementioned light source chip 3, the light source chip 3 is first sucked up by a crystal bonding machine, and then the circular hole of the sheet metal part 1 in the prior art is no longer used as the assembly reference point. Instead, the positioning point set on the frame 2c of the present invention is used as the assembly reference point, which can accurately and quickly place the light source chip 3 through the fine-tuning position of the manipulator, ensuring that the position of the light source chip 3 and the bracket 2 is relatively consistent, reducing the accumulation of tolerances, so that the position between the light source chip 3 and the bracket 2 will not be offset, thereby making the LED lamp lens 4 have the advantage of consistent light distribution curve.

[0050] In this embodiment, as shown in FIG3 , FIG4 and FIG5 , the placement area is in the shape of a cuboid or a cube;

[0051] One of the positioning points 20 is set at the edge of the top side of the placement area along the length direction, and the other positioning point 20 is set at the edge of the bottom side of the placement area along the length direction. The straight line formed by the two positioning points 20 coincides with the longitudinal center line of the placement area.

[0052] In this embodiment, as shown in FIG3 , the two positioning points 20 are arc portions 200 facing away from the placement area, and the two arc portions 200 are symmetrically arranged along the transverse center line of the placement area. It should be noted that the shapes of the aforementioned positioning points 20 can also be designed to be other shapes.

[0053] As shown in FIG6 , the second specific structure of the alignment reference structure 2 a is as follows: the alignment reference structure 2 a includes a right-angled edge 21 provided on the reflective cup 2 d;

[0054] When assembling the light source chip 3, the right-angled side of the light source chip 3 is parallel to the right-angled side 21 of the reflective cup 2d. When assembling the light source chip 3, the light source chip 3 is first sucked up by a die bonder. The circular hole of the sheet metal part 1 in the prior art is no longer used as the assembly reference point. Instead, the right-angled side 21 of the reflective cup 2d as provided in the present invention is used as the assembly reference point. This allows the light source chip 3 to be accurately and quickly placed through fine-tuning of the position by a manipulator, ensuring that the positions of the light source chip 3 and the bracket 2 are relatively consistent, reducing the accumulation of tolerances, and thus preventing the position of the light source chip 3 and the bracket 2 from shifting, thereby providing the LED lamp lens 4 with the advantage of consistent light distribution curves.

[0055] The present invention also provides an assembly device for the LED lamp as claimed in the above claims and a method for manufacturing the LED lamp, as shown in Figures 3 to 6, comprising the following steps:

[0056] The first step is to assemble the bracket 2 by injection molding and cover the sheet metal part 1;

[0057] In the second step, during die bonding, after the light source chip 3 is sucked up by a die bonding machine, the two positioning points 20 set on the bracket 2 or the right-angled edge 21 set on the reflective cup 2d are used as alignment references, and the robot adjusts the position so that the light source chip 3 is accurately placed in the placement area of ​​the bracket 2;

[0058] In the third step, the lens 4 is arranged at the front end of the bracket 2 to obtain an LED lamp with a consistent light distribution curve.

[0059] 7 , 8 and 9 , a third specific structure of the alignment reference structure 2 a is as follows: the bracket 2 has an open accommodating cavity 201 ;

[0060] The alignment reference structure 2a includes a guide slope 22 provided on the outer wall of the opening of the bracket 2. There are multiple guide slopes 22, and the multiple guide slopes 22 are respectively arranged at the corners between the length side of the outer wall of the opening of the bracket 2 and the width side of the outer wall of the opening of the bracket 2. When assembling the aforementioned light source chip 3, the light source chip 3 is first sucked by the crystal bonding machine. The circular hole of the sheet metal part 1 in the prior art is no longer used as the assembly reference point. Instead, the guide slope 22 of the present invention is used as the assembly reference point. The light source chip 3 can be accurately and quickly placed by the fine-tuning position of the manipulator, ensuring that the positions of the light source chip 3 and the bracket 2 are relatively consistent, reducing the accumulation of tolerances, so that the position between the light source chip 3 and the bracket 2 will not be offset, thereby achieving the advantage of consistency in the light distribution curve between the light source chip 3 and the lens 4. It should be noted that the number of the aforementioned guide slopes 22 can be 1, 2, 3 or even more.

[0061] In this embodiment, as shown in FIG7, FIG8 and FIG10, a bridge plate 5 for limiting the position of the sheet metal part 1 is further included; wherein the upper die 6 and the lower die 7 in FIG10 are coordinated;

[0062] The bridge plate 5 has multiple inner cavities (not shown in the figure, but shown below), and the brackets 2c are embedded in the corresponding inner cavities of the bridge plate 5. The bridge plate 5 is provided to limit the placement of the sheet metal component 1 and ensure the relative position of the lens 4 and the bracket 2 is consistent after injection molding. Specifically, the bridge plate 5 is processed according to the position of each bracket 2. The multiple inner cavities on the bridge plate 5 are respectively transitionally matched with the corresponding brackets 2, that is, the brackets 2 are embedded in the corresponding inner cavities of the bridge plate 5. Since the brackets 2 are provided with guide ramps 22, they can play a guiding and centering role, making the bridge plate 5 easier to place during assembly.

[0063] In this embodiment, as shown in Figures 7 and 8 , the top of the bracket 2 is provided with a plurality of rounded corners 23, which are arranged at the corners between the length side edges and the width side edges of the accommodating cavity 201 of the bracket 2. The provision of the aforementioned rounded corners 23 has an avoidance effect, which can reduce the collision between the bracket 2 and the glue press used in the assembly glue process, thereby improving the reliability of the assembly.

[0064] It should be noted that when manufacturing and assembling the LED lamp of the present invention, epoxy resin needs to be filled on the surface of the reflective cup 2d and the light source chip 3, and epoxy resin also needs to be filled on the surface of the frame 2c of the bracket 2.

[0065] The present invention also provides an assembly device for the LED lamp as claimed in the above claims and a method for manufacturing the LED lamp, as shown in FIG7, FIG8 and FIG9, comprising the following steps:

[0066] The first step is to place the bracket 2 with the guide slope 22 on the sheet metal part 1 by injection molding during assembly;

[0067] Step 2: After die bonding, the sheet metal part 1 is placed on the upper surface of the bridge plate 5, and the bracket 2 is embedded in the corresponding inner cavity of the bridge plate 5;

[0068] In the third step, the machine will press the bracket 2 during the gluing process. At this time, the sheet metal part 1 and the bracket 2 are brought as a whole into a place coaxial with the injection cavity of the gluing equipment for gluing and gluing.

[0069] In the fourth step, the lens 4 is arranged at the front end of the bracket 2 with the guide slope 22, so that an LED lamp with a consistent light distribution curve can be obtained. When the LED lamp of the present invention is made using the above method, first, a plurality of the brackets 2 are set on the sheet metal 1 made of copper material. Since the bracket 2 is provided with a guide slope 22, the glue press can press the bracket 2 during glue pressing. At this time, the automatic centering effect of the guide slope 22 is utilized to bring the plurality of brackets 2 as a whole to a position concentric with the cavity of the glue injection machine; the thickness of the sheet metal 1 is very thin, and the sheet metal 1 is connected to the top and bottom edges of the bracket 2 along the length direction, which helps to achieve relative consistency in the position between the light source chip 3 and the bracket 2; due to the setting of the bridge plate 5, the bridge plate 5 limits the position of the sheet metal 1, reducing the deformation of the sheet metal 1; since the bracket 2 is embedded in the inner cavity of the corresponding bridge plate 5, it is ensured that the relative position of the bracket 2 will not be offset, which helps to ensure that the position between the lens 4 and the bracket 2 is relatively consistent after injection molding.

[0070] As described above, the LED lamp assembly device and LED lamp manufacturing method provided by the present invention have the following beneficial effects:

[0071] The present invention utilizes the above-mentioned LED lamp assembly device and LED lamp manufacturing method. Compared with the prior art, due to the adoption of such a structure, the frame or reflector cup is provided with a positioning reference structure for improving the consistency of the light distribution curve; it is not necessary to use a circular hole on the sheet metal as a reference for assembling the light source chip as in the prior art. The present invention adopts an alignment reference structure set on the bracket or reflector cup, which can ensure that the position between the light source chip and the bracket is relatively consistent, reduce the accumulation of tolerances, and thus prevent the position between the light source chip and the bracket from shifting, thereby giving the LED lamp the advantage of consistent light distribution curve.

[0072] The above description is only a preferred embodiment of the present invention. It should be noted that, for those skilled in the art, several improvements and modifications can be made without departing from the principles of the present invention, which are also considered to be within the scope of protection of the present invention.

Claims

1. An assembly device for an LED lamp, comprising a sheet metal part made of copper material, a bracket, a light source chip and a lens, wherein the bracket comprises a frame body and a reflective cup, the bracket is arranged on the sheet metal part, and the lens is arranged behind the reflective cup and matched with the light source chip; It is characterized in that The frame or reflective cup is provided with a positioning reference structure for improving the consistency of the light distribution curve; when assembling the light source chip, the light source chip uses the positioning reference structure as a reference point, and the light source chip is arranged on the frame through the positioning reference structure.

2. The LED lamp assembly device according to claim 1, characterized in that: The alignment reference structure includes two positioning points arranged on the frame; The frame is provided with a plurality of mutually spaced placement areas, each of which is used to embed the corresponding light source chip, and the two positioning points are respectively spaced at the outer periphery of the placement area.

3. The LED lamp assembly device according to claim 2, characterized in that: The placement area is in the shape of a cuboid or a cube; One of the positioning points is set at the edge of the top side of the placement area along the length direction, and the other positioning point is set at the edge of the bottom side of the placement area along the length direction. The straight line formed by the two positioning points coincides with the longitudinal center line of the placement area.

4. The LED lamp assembly device according to claim 2, characterized in that: The two positioning points are both arc portions that are away from the placement area, and the two arc portions are symmetrically arranged along the transverse center line of the placement area.

5. The LED lamp assembly device according to claim 1, characterized in that: The alignment reference structure includes a right-angled side arranged on the reflective cup; When the light source chip is assembled, the right angle side of the light source chip is parallel to the reflective The right angle side of the cup.

6. A method for manufacturing an LED lamp using the assembly device of the LED lamp according to any one of claims 1 to 5, characterized in that: The following steps are included The first step is to form the bracket by injection molding and cover the sheet metal part during assembly; Step 2: After the light source chip is sucked by a die bonding machine during die bonding, the two positioning points set on the bracket or the right-angled edge set on the reflective cup are used as alignment references, and the manipulator adjusts the position so that the light source chip is accurately placed in the placement area of ​​the bracket; The third step is to arrange the lens at the front end of the bracket to obtain an LED lamp with a consistent light distribution curve.

7. The LED lamp assembly device according to claim 1, characterized in that: The bracket has an open accommodating cavity; The alignment reference structure includes a guide slope arranged on the outer wall of the bracket opening. There are multiple guide slopes, and the multiple guide slopes are respectively arranged at the corners between the length side of the outer wall of the bracket opening and the width side of the outer wall of the bracket opening.

8. The LED lamp assembly device according to claim 7, characterized in that: Also included is a bridge plate for limiting the position where the sheet metal part is placed; The bridge plate has a plurality of inner cavities, and the bracket is embedded in the inner cavity of the corresponding bridge plate.

9. The LED lamp assembly device according to claim 7, characterized in that: The top of the bracket is provided with a plurality of rounded corners, and the plurality of rounded corners are respectively arranged at the corners between the length side of the accommodating cavity of the bracket and the width side of the accommodating cavity of the bracket.

10. A method for manufacturing an LED lamp using the assembly device of the LED lamp according to any one of claims 7 to 9, characterized in that: The following steps are included The first step is to place the bracket with the guide slope on the sheet metal part by injection molding during assembly; Step 2: After the die is fixed, the sheet metal part is placed on the upper surface of the bridge plate, and the bracket is embedded in the corresponding inner cavity of the bridge plate; Step 3: During the gluing process, the machine will press the bracket tightly. At this time, the sheet metal part and the bracket are brought as a whole into a place coaxial with the injection cavity of the gluing equipment for gluing and gluing; Step 4: The lens is arranged at the front end of the bracket with the guide slope, so that an LED lamp with a consistent light distribution curve can be obtained.

Images