LED Lamp Bead Injection Molding Encapsulation
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Solution Overview
Problem
Conventional modeled lamps have exposed lamp beads and solder joints, leading to oxidation and reduced service life and poor appearance due to exposure after installation.
Innovation Solution
A light emitting element comprising a light-emitting lamp bead welded to a connecting wire with a covering member formed by injection molding, which covers the lamp bead and welding joint, and a processing apparatus with an injection molding mechanism and molding die to form the covering member around the lamp bead and welding joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug-in lamps or patch LED lamp beads are used in modeled lamps, then the lamps can be manufactured and assembled, but the lamp beads and solder joints are exposed outside after installation, leading to oxidation and poor appearance
Solution Approach 1:
The patent applies a covering member (transparent or translucent shell) that encapsulates the lamp bead and solder joint, forming a protective barrier against oxidation. This shell acts as a flexible protective enclosure that prevents harmful environmental factors from reaching the exposed components while maintaining the aesthetic appearance of the modeled lamp.
2Ease of manufacture
If conventional plug-in lamps or patch LED lamp beads are used in modeled lamps, then the lamps can be manufactured and assembled, but the exposed solder joints result in poor appearance
Solution Approach 1:
The patent merges the previously separate components (lamp bead, solder joint, and protective covering) into an integrated assembly. The covering member is designed to be formed around all these components simultaneously, combining their functions into a single aesthetic unit that eliminates the need for separate protective elements and improves overall appearance quality.
Solution Approach 2:
The covering member serves as a thin film or shell structure that encapsulates the entire assembly, providing a smooth, uniform surface that hides the solder joints and creates an aesthetically pleasing appearance while maintaining ease of manufacture through a single-forming process.
3Reliability
If a covering member is added to cover the lamp bead and welding joint, then oxidation is prevented and appearance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by forming the covering member around the lamp bead and solder joint during the manufacturing process itself, rather than adding it as a separate post-assembly step. This preliminary encapsulation ensures protection from the outset and integrates the protective function into the base manufacturing process, reducing overall complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively covers the lamp beads and welding joints, preventing oxidation and enhancing the appearance and service life of the lamps by forming a stable and aesthetically pleasing covering member through injection molding.
Implementation Method 1
the covering member is integrally formed by injection molding
Data Source
AI summary
Embodiments of the present disclosure provide a light emitting element and a processing apparatus therefor and relate to the technical field of light emitting devices. The light emitting element includes a light-emitting lamp bead(s), a connecting wire, and a covering member(s). The light-emitting lamp bead is welded to the connecting wire to form a welding joint. The covering member covers the light-emitting lamp bead and the welding joint. The covering member is integrally formed by injection molding. The present disclosure solves the technical problem existing in the prior art that the service life is adversely affected and the appearance is deteriorated because the welding joints are oxidized after a period of time.