Christmas LED bulb and manufacturing method for christmas LED bulb

Abstract

Disclosed in the present invention are a Christmas LED bulb and a manufacturing method for a Christmas LED bulb. The Christmas LED bulb comprises: a housing made of glass, with an opening being provided at the bottom end thereof; a bottom cover made of an insulating material, wherein the bottom cover is fixedly connected with two conductors arranged spaced apart from each other, and two ends of each conductor respectively protrude from two end surfaces of the bottom cover; and an LED electrically connected to the conductors to conduct electricity and emit light, wherein the bottom cover is plug-fitted with the housing to drive the LED to pass through the opening and be disposed inside the housing; and the bottom cover and the housing are adhesively connected by means of an adhesive. The present invention utilizes a split design and adhesive connection, effectively protects an LED component from thermal damage, eliminates the risk of short-circuits, supports the selection of pins made of multiple materials, optimizes an automated assembly process, significantly improves production efficiency and flexibility, meets the requirements of large-scale production, brings innovation to the LED bulb manufacturing industry, and integrates the advantages of safety, efficiency and economy.

Description

Christmas led bulb and manufacturing method thereof TECHNICAL FIELD

[0001] The present invention relates to the technical field of Christmas lights, in particular to a Christmas LED bulb and a manufacturing method thereof. BACKGROUND

[0002] In recent years, with the rapid development of semiconductor lighting technology, LED bulbs have gradually become the mainstream product in the lighting field due to their energy-saving, environmental protection, long service life and other advantages. Especially in holiday decoration, commercial display and home lighting, the application of LED bulbs is increasingly widespread. Among them, Christmas LED bulbs, as a representative of festival decoration, have a growing market demand.

[0003] In the existing technology, most of the traditional LED bulb manufacturing technology follows part of the production process of early incandescent bulbs. In particular, in the aspect of lamp body packaging, high-temperature welding technology is generally used, that is, the pins (such as Dumet wire) are sealed and connected with the glass lamp body by flame heating and melting the glass. However, this method has several significant limitations and disadvantages:

[0004] 1. Heat-sensitive component protection problem: LED chips are extremely sensitive to temperature. Even with protective measures, it is still difficult to completely avoid the impact of thermal stress on LED performance and service life during high-temperature processing, which may cause problems such as accelerated light attenuation and color shift.

[0005] 2. Short circuit risk: During glass melting and sealing, it is a challenge to control the precise position of the pins to avoid short circuits. Any slight deviation may cause the pins to come into contact, thereby forming a short circuit in the circuit and affecting the normal operation of the bulb.

[0006] 3. Material and process limitations: Traditional melting sealing technology limits the choice of pin materials, which usually need to use materials compatible with glass. This not only limits design flexibility but also may increase costs.

[0007] 4. Obstacles to automated production: The high-temperature processing process is difficult to be compatible with modern automated production lines, and the proportion of manual operation is high, which affects the production efficiency and the consistency of product quality, making it difficult to meet the needs of large-scale customization and rapid response to the market.

[0008] In view of the above problems, there is an urgent need in the industry for a new LED bulb structure design and manufacturing method to solve the problems of heat damage, short circuit risk, material limitation and automated production in the existing technology, and to promote the development of LED lighting technology in a more efficient, safe, flexible and intelligent direction.

[0009] SUMMARY

[0010] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention proposes a Christmas LED light bulb, which adopts a split design and is glued together, effectively protecting the LED components from heat damage, eliminating the risk of short circuits, supporting the selection of multiple pin materials, optimizing the automated assembly process, significantly enhancing production efficiency and flexibility, meeting the needs of large-scale production, bringing innovation to the LED light bulb manufacturing industry, and possessing advantages in safety, efficiency, and economy.

[0011] The present invention also proposes a method for manufacturing a Christmas LED light bulb having the above-mentioned Christmas LED light bulb.

[0012] The Christmas LED light bulb according to the present invention comprises:

[0013] The housing is made of glass, and an opening is provided at the bottom end of the housing;

[0014] The bottom cover is made of insulating material, and two spaced-apart conductive bodies are fixedly connected to the bottom cover. The two ends of the conductive bodies protrude from the two end faces of the bottom cover, respectively.

[0015] LEDs are connected to the conductors to conduct electricity and emit light.

[0016] The bottom cover is inserted into the housing to drive the LED through the opening and place it inside the housing. The bottom cover and the housing are connected by an adhesive.

[0017] The Christmas LED bulb according to the present invention has at least the following beneficial effects: The adhesive bonding between the bottom cover and the housing replaces the traditional high-temperature fusion, completely eliminating the potential damage of high temperature to the LED, protecting the electrical performance and optical characteristics of the LED, and extending the bulb's lifespan; furthermore, since the bottom cover has two spaced-apart conductors, short circuits between the pins are effectively prevented, enhancing the bulb's electrical safety and stability; additionally, the split design facilitates modular design and automated assembly of the LED bulb, promoting increased production efficiency, making it particularly suitable for high-volume manufacturing needs, reducing production costs, and enhancing market competitiveness.

[0018] According to some embodiments of the Christmas LED light bulb of the present invention, an adhesive injection groove is provided on the inner side of the bottom cover, the bottom end of the housing is inserted into the adhesive injection groove, and is fixed by the adhesive material located in the adhesive injection groove.

[0019] According to some embodiments of the Christmas LED light bulb of the present invention, the junction of the housing and the bottom cover is a circular structure.

[0020] According to some embodiments of the Christmas LED light bulb, the outer wall of the housing and the outer wall of the bottom cover are smoothly connected.

[0021] According to some embodiments of the Christmas LED light bulb, the bottom cover is made of glass.

[0022] According to some embodiments of the Christmas LED light bulb of the present invention, the bottom cover is an elastic component, the shape of the bottom cover matches the shape of the opening, the bottom cover is interference-fitted with the inner wall of the housing, and the bottom cover and the housing are sealed together by the adhesive.

[0023] According to some embodiments of the present invention, the Christmas LED light bulb has a housing comprising an extension and a light-expanding portion. One end of the extension is used to connect to the bottom cover. The LED light is located above the extension and placed inside the light-expanding portion. The maximum outer diameter of the light-expanding portion is greater than the maximum outer diameter of the extension.

[0024] According to some embodiments of the present invention, the Christmas LED light bulb is a surface-mount LED.

[0025] According to some embodiments of the present invention, the Christmas LED light bulb includes a conductor comprising a vertical section and an inclined section that are interconnected, the centerline of the vertical section being parallel to the centerline of the housing, the inclined section being arranged at an angle to the vertical section, and the LED being mounted on the inclined section to emit light toward the top of the housing.

[0026] The method for manufacturing a Christmas LED light bulb according to the present invention includes the Christmas LED light bulb of the present invention, comprising the following steps: Manufacturing a housing: using glass as raw material, manufacturing a housing; Assembling conductors: using glass as raw material, heating and melting, and positioning two conductors to integrally form a bottom cover and conductors; Assembling LEDs: after assembling the conductors, performing patch processing on the conductors to connect the LEDs to the conductors; Assembling the light bulb: after manufacturing the housing and assembling the LEDs, aligning and inserting the bottom cover into the housing, and fixing it with glue in the glue injection groove.

[0027] The Christmas LED light bulb manufacturing method according to the present invention has at least the following beneficial effects: by using the glue injection fixing technology, not only are the complex steps in the traditional manufacturing process simplified and the production cost reduced, but the safety hazards caused by high-temperature operations are also effectively avoided, improving production safety and environmental protection, and greatly promoting overall production efficiency and product quality.

[0028] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0029] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0030] Figure 1 is an exploded view of the Christmas LED light bulb according to an embodiment of the present invention;

[0031] Figure 2 is a schematic cross-sectional view of the Christmas LED light bulb according to an embodiment of the present invention;

[0032] Figure 3 is a schematic diagram of the overall structure of a Christmas LED light bulb according to another embodiment of the present invention;

[0033] Figure 4 is a schematic diagram of the overall structure of a Christmas LED light bulb according to another embodiment of the present invention;

[0034] Figure 5 is a flowchart of the Christmas LED light bulb manufacturing method according to an embodiment of the present invention.

[0035] Reference numerals: 100 for housing; 101 for opening; 110 for extension; 120 for light-expanding section; 200 for bottom cover; 201 for injection groove; 300 for conductor; 310 for vertical section; 320 for inclined section; 400 for LED; 500 for protective adhesive. Detailed Implementation

[0036] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0037] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description. They are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0038] In the description of this invention, "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. The use of "first" and "second" in the description is merely 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.

[0039] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0040] In the description of this invention, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0041] In recent years, with the rapid development of semiconductor lighting technology, LED bulbs have gradually become the mainstream product in the lighting field due to their advantages such as energy saving, environmental protection, and long lifespan. Especially in holiday decorations, commercial displays, and home lighting, the application of LED bulbs is becoming increasingly widespread. Among them, Christmas LED bulbs, as a representative of festive decorations, have seen continuous growth in market demand.

[0042] In existing technologies, traditional LED bulb manufacturing largely follows some production processes from early incandescent bulbs, especially in the bulb casing, where high-temperature welding technology is commonly used. This involves sealing the leads (such as Dummes) to the glass bulb casing by heating and melting the glass with a flame. However, this method has several significant limitations and drawbacks:

[0043] 1. Protection of heat-sensitive components: LED chips are extremely sensitive to temperature. Even with protective measures during high-temperature processing, it is still difficult to completely avoid the impact of thermal stress on LED performance and lifespan, which may lead to problems such as accelerated light decay and color shift.

[0044] 2. Short Circuit Risk: Controlling the precise position of the pins to avoid short circuits during the glass melting and sealing process is a challenge. Any minute deviation can cause pin contact, resulting in a short circuit in the circuit and affecting the normal operation of the bulb.

[0045] 3. Material and process limitations: Traditional fusion sealing technology limits the choice of pin materials, usually requiring the use of materials compatible with glass. This not only limits design flexibility but may also increase costs.

[0046] 4. Obstacles to automated production: High-temperature processing is difficult to integrate with modern automated production lines, resulting in a high proportion of manual operation, which affects production efficiency and product quality consistency, making it difficult to meet the needs of mass customization and rapid market response.

[0047] In view of the above problems, the industry urgently needs a new LED bulb structure design and manufacturing method to solve the problems of thermal damage, short circuit risk, material limitations and automated production in the existing technology, and promote the development of LED lighting technology towards a more efficient, safe, flexible and intelligent direction.

[0048] Therefore, as shown in Figures 1 and 2, the Christmas LED light bulb proposed in this invention includes a housing 100, a bottom cover 200, conductors 300, and LEDs 400. The housing 100 is made of glass, the bottom cover 200 is made of insulating material, and there are two conductors 300 spaced apart and fixedly connected to the bottom cover 200. Both ends of the conductors 300 protrude from the end faces of the bottom cover 200. The LEDs 400 are connected to the conductors 300 to conduct electricity and emit light. Specifically, the bottom end of the housing 100 has an opening 101, and the bottom cover 200 is inserted into the housing 100 to drive the LEDs 400 through the opening 101 and into the housing 100. The bottom cover 200 and the housing 100 are connected by an adhesive, commonly glue. It should be noted that the use of adhesive bonding between the bottom cover 200 and the housing 100 instead of traditional high-temperature fusion completely eliminates the potential damage of high temperature to the LED, protects the electrical performance and optical characteristics of the LED, and extends the life of the bulb. Furthermore, since the bottom cover 200 has two spaced conductors 300 fixed in place, short circuits between the pins are effectively prevented, enhancing the electrical safety and stability of the bulb. In addition, the split design facilitates the modular design and automated assembly of the LED bulb, promoting improved production efficiency. It is particularly suitable for high-volume manufacturing needs, reduces production costs, and enhances market competitiveness.

[0049] Optionally, the LED 400 is a surface-mount LED, which improves integration. Furthermore, the high-efficiency heat dissipation and luminous efficacy of surface-mount LEDs make the bulb more energy-efficient, while also facilitating automated production and improving production efficiency and consistency. In some applications, after the LED 400 is connected to the conductor 300, the outer surface of the LED 400 is wrapped with protective adhesive 500 to protect the LED 400 from external damage and to make the connection between the LED 400 and the conductor 300 more secure.

[0050] In some related technologies, the surface-mount LEDs in Christmas LED bulbs are mounted laterally on the metal wires within the bulb. During use, the surface-mount LEDs emit light only from one side of the housing, failing to create a three-dimensional light effect and resulting in poor performance. To address this, in some embodiments of the present invention, referring to FIG2, the conductor 300 includes a vertical segment 310 and an inclined segment 320 that are mutually conductive. The centerline of the vertical segment 310 is parallel to the centerline of the housing 100. The inclined segment 320 is arranged at an angle to the vertical segment 310. The LED 400 is mounted on the inclined segment 320 to emit light towards the top of the housing 100. Furthermore, the LED 400 emits light towards the top, creating a three-dimensional light effect and improving performance. Optionally, the inclined segment 320 and the vertical segment 310 form an angle of 30° to 60°, for example, an angle of 45°. In some embodiments, the angle between the inclined section and the vertical section is 90° (not shown in the figure), that is, the inclined section 320 and the vertical section 310 are arranged perpendicularly, and the light-emitting LED 400 shines directly on the top of the housing 100. It should be noted that common conductors 300 include metal wires such as copper wire, silver wire, platinum wire, and Dummey wire.

[0051] In some embodiments, a plug-in positioning structure is provided between the housing 100 and the bottom cover 200 to control the plug-in depth. Referring again to Figures 1 and 2, in some embodiments of the present invention, an adhesive injection groove 201 is provided on the inner side of the bottom cover 200. The bottom end of the housing 100 is inserted into the adhesive injection groove 201 and fixed by an adhesive material located in the adhesive injection groove 201. The built-in design of the adhesive material ensures the effect after assembly, preventing external factors from damaging the adhesive material. Furthermore, the design of the adhesive injection groove 201 can better utilize the adhesive material to fix the housing 100 and the bottom cover 200, achieving a more precise and reliable sealing effect, enhancing the waterproof and dustproof performance of the bulb, and extending its service life. Further, the joint between the housing 100 and the bottom cover 200 is a circular structure. Compared with square or angular alignment structures, the circular structure is easier to align, further improving the ease of assembly. Moreover, the circular structure design can effectively disperse stress, reduce the risk of breakage due to excessive local stress, and enhance the overall mechanical strength and stability of the bulb. Furthermore, in some embodiments of the present invention, the outer wall of the housing 100 and the outer wall of the bottom cover 200 are smoothly connected, which not only improves the smoothness and aesthetics of the appearance, but also improves the optical performance of the bulb, such as reducing light refraction loss, making the light output more uniform and softer, and improving the lighting quality. At the same time, the smooth surface is easier to clean and maintain.

[0052] Optionally, the bottom cover 200 is made of glass, the same material as the housing 100, which together ensures the transparency and visual appeal of the bulb, making it suitable for lighting scenarios requiring high light transmittance. Furthermore, glass has excellent insulation and high hardness, and will not age, ensuring electrical safety and broadening the application range of the bulb.

[0053] Referring again to Figure 3, in some embodiments of the present invention, the bottom cover 200 is inserted into the inner wall of the housing 100. Specifically, the bottom cover 200 is an elastic component, the shape of the bottom cover 200 matches the shape of the opening 101, the bottom cover 200 is interference-fitted with the inner wall of the housing 100, and the bottom cover 200 and the housing 100 are sealed together by an adhesive. The bottom cover 200 is tightly connected to the housing 100 by the interference fit, combined with the adhesive seal, which not only simplifies the assembly steps and improves production efficiency, but also enhances the bulb's vibration resistance and sealing performance, making it particularly suitable for use in dynamic environments and improving the bulb's stability and reliability. In some applications, the adhesive is applied to the connection between the bottom cover 200 and the bottom surface of the housing 100, and after drying, forms a film layer to seal the connection between the bottom cover 200 and the bottom surface of the housing 100. Alternatively, the adhesive is applied to the entire bottom surface of the bottom cover 200 and the housing 100, and after drying, forms a film layer to seal the entire bottom surface of the bulb. Optionally, the bottom cover 200 is fully inserted into the housing 100, and the assembled bottom cover 200 is not easily pulled out, resulting in better overall product integrity.

[0054] Referring again to Figure 4, in some embodiments of the present invention, the housing 100 includes an extension 110 and a light-expanding section 120. One end of the extension 110 is used to connect to the bottom cover 200. The LED 400 is located above the extension 110 and placed inside the light-expanding section 120. The maximum outer diameter of the light-expanding section 120 is larger than the maximum outer diameter of the extension 110. This not only rationally arranges the internal space, facilitating the installation and heat dissipation of the LED 400, but also the expanded diameter design of the light-expanding section 120 effectively enhances the light diffusion, improves the lighting effect, makes the light distribution more uniform, and improves the comfort and practicality of the lighting. Conventional Christmas LED bulbs are cylindrical structures with a fixed outer diameter, resulting in a simple shape. In some embodiments of the present invention, the light-expanding section 120 can be designed into various shapes, such as lanterns or fruits, offering a richer variety of shapes and better fitting the festive atmosphere.

[0055] Referring again to Figure 5, the method for manufacturing a Christmas LED light bulb according to an embodiment of the present invention includes a Christmas LED light bulb according to an embodiment of the present invention. Specifically, the manufacturing method includes the following steps performed sequentially:

[0056] S100, Manufacturing the shell 100: Using glass as the raw material, the shell 100 is manufactured;

[0057] S200, Assemble the conductors 300: Using glass as the raw material, heat and melt it, then position and place two conductors 300 to form a single piece, creating the bottom cover 200 and the conductors 300.

[0058] S300, Assemble the LED 400: After assembling the conductor 300, the conductor 300 is surface-mounted to connect the LED 400 to the conductor 300;

[0059] S400, Assemble the bulb: After making the housing 100 and assembling the LED 400, the bottom cover 200 is aligned and inserted into the housing 100 and fixed by the glue in the glue injection groove 201.

[0060] According to the Christmas LED light bulb manufacturing method of the present invention, by using the Christmas LED light bulb of the present invention and employing the glue injection fixing technology, not only are the complex steps in the traditional manufacturing process simplified and the production cost reduced, but the safety hazards caused by high-temperature operation are also effectively avoided, improving production safety and environmental protection, and greatly promoting overall production efficiency and product quality.

[0061] Other components and operations of the Christmas LED light bulb manufacturing method according to embodiments of the present invention are known to those skilled in the art and will not be described in detail here.

[0062] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A Christmas LED light bulb characterized in that, The application relates to a Christmas LED bulb manufacturing method, which comprises the following steps: a shell made of glass, the bottom end of the shell being provided with an opening; a bottom cover made of insulating material, the bottom cover being fixedly connected with two spaced-apart conductive bodies, the two ends of the conductive bodies respectively protruding from the two end faces of the bottom cover; LEDs for emitting light, the LEDs being connected with the conductive bodies respectively to conductively emit light; wherein the bottom cover is inserted into the shell in a plug-in mode to drive the LEDs to pass through the opening and be arranged in the shell, and the bottom cover and the shell are adhesively connected through an adhesive.

2. The Christmas LED bulb of claim 1, wherein: The inner side of the bottom cover is provided with a glue injection groove, the bottom end of the shell is inserted into the glue injection groove, and the bottom cover is fixed through the adhesive in the glue injection groove.

3. The Christmas LED bulb of claim 2, wherein: The joint of the shell and the bottom cover is in a circular structure.

4. The Christmas LED bulb according to any one of claims 1 to 3, wherein: The outer wall of the shell and the outer wall of the bottom cover are smoothly and transitionally connected.

5. The Christmas LED bulb according to any one of claims 1 to 3, wherein: The bottom cover is made of glass.

6. The Christmas LED bulb of claim 1, wherein: The bottom cover is made of elastic material, the shape of the bottom cover matches the shape of the opening, the bottom cover is in interference fit with the inner wall of the shell, and the bottom cover and the shell are sealingly connected through the adhesive.

7. The Christmas LED bulb of claim 1, wherein: The shell comprises an extension part and a light expansion part, one end of the extension part is used for being connected with the bottom cover, the LEDs are arranged above the extension part and in the light expansion part, and the maximum outer diameter of the light expansion part is greater than the maximum outer diameter of the extension part.

8. The Christmas LED bulb of claim 1, wherein: The LEDs are patch LEDs.

9. The Christmas LED bulb of claim 1 or 8, wherein: The conductive bodies comprise vertical segments and inclined segments which are in mutual conduction, the center line of the vertical segments is parallel to the center line of the shell, the inclined segments are arranged obliquely to the vertical segments, and the LEDs are installed on the inclined segments to emit light towards the top of the shell.

10. A Christmas LED bulb manufacturing method, which comprises the following steps: a shell made of glass, the bottom end of the shell being provided with an opening; a bottom cover made of glass, the bottom cover being fixedly connected with two spaced-apart conductive bodies, the two ends of the conductive bodies respectively protruding from the two end faces of the bottom cover; LEDs for emitting light, the LEDs being connected with the conductive bodies respectively to conductively emit light; wherein the bottom cover is inserted into the shell in a plug-in mode to drive the LEDs to pass through the opening and be arranged in the shell; the inner side of the bottom cover is provided with a glue injection groove, the bottom end of the shell is inserted into the glue injection groove, and the bottom cover is fixed through the adhesive in the glue injection groove; characterized in that the following steps are comprised: manufacturing the shell: using glass as raw material to manufacture the shell; assembling the conductive bodies: using glass as raw material, heating, melting and positioning two conductive bodies to integrally form the bottom cover and the conductive bodies; assembling the LEDs: after assembling the conductive bodies, the conductive bodies are subjected to patch processing, and the LEDs are connected to the conductive bodies; assembling the bulb: after manufacturing the shell and assembling the LEDs, the bottom cover is inserted into the shell in a plug-in mode, and is fixed through the glue in the glue injection groove. ​

Images