WO2011068431A1

WO2011068431A1 - Method for producing a led lamp, led lamp obtained by said method, and radiator for said lamp

Info

Publication number: WO2011068431A1
Application number: PCT/RU2009/000665
Authority: WO
Inventors: Юрий Борисович СОКОЛОВ
Original assignee: Общество с ограниченной ответственностью "ДиС ПЛЮС"
Priority date: 2009-12-03
Filing date: 2009-12-03
Publication date: 2011-06-09
Also published as: EA019873B1; EP2508797A4; EA201100895A1; EP2508797A1; CN102667332A

Abstract

The invention relates to LED lamps, and the technical result of the invention is an increase in the structure workability and a simpler assembly of the article that can be achieved due to a firm connection made between (Fig. 2) the hollow annular radiator (4), the light-emitting shell (1), and the transition cone (10), using a two-link closing mechanism including catches (3, 11), protrusions (12) and openings (7) that are formed during the production step of these parts of the lamp.

Description

A method of manufacturing an LED lamp, an LED lamp manufactured in this way and a radiator for this lamp.

The field of technology.

The invention relates to lighting equipment, namely, to the manufacturing technology and design of LED lighting devices intended for use as part of equipment for external and internal lighting.

The prior art.

It is known that the complexity of assembly operations is up to 50% of the total complexity of the production of devices. Optimization of the assembly process reduces the price of products and creates competitive advantages. Among the most time-consuming are operations associated with the mechanical connection of parts and assemblies, in particular, during the final assembly of the finished product.

In relation to LED lamps, assembly operations mean an integral fixed connection of assembly units - individual structural functional parts of the lamp: a radiator (cooling device), a light-emitting sheath, a radiation source assembly, an electronic converter assembly, means of connecting to an electric current source (in particular, an electric base) . Obviously, for assembly units must be equipped with appropriate technological means of connection, allowing to successfully perform assembly operations. Such tools include technological openings, guide grooves, technological protrusions, which, although they are part of the design of assembly units, are intended solely for assembly operations and do not participate in the operation of the light source.

The following identified methods for manufacturing electronic devices are known in the art.

The installation method of a receiving-amplifying lamp is described in detail in the book by E.I. Shekhmeister, “Assembly operations in electric vacuum production”, Moscow, Vysshaya Shkola, 1987, pp. 14-25, in which the mica insulator, equipped with teeth along the edges, pre-cut holes place electrodes, traverses, leads and fix leaf springs. The assembled electrode assembly is placed in a glass bulb in such a way that the said teeth on the mica insulator are deformed against the calibrated surface of the bulb and, due to the elasticity of the material, provide a sufficient density of the electrode assembly in the bulb of the lamp. It should be noted that the said insulator teeth and leaf springs do not participate in the operation of the receiving-amplifying lamp, but are absolutely necessary for the assembly operation of the product, that is, these elements are technological. Known methods for connecting parts and assemblies of an LED lamp in which a light-emitting sheath and a base are fixed to the lamp housing using only a threaded connection (Chinese application CN2760382, MKI F21S6 / 00, published 02.22.2006), or threaded connection and latch (Chinese application CN201106814, MKI F21V17 / 00, published on 08.27.2008).

The screwing operation is itself quite time-consuming, and in relation to plastic parts it requires the application of normalized forces, most often controlled by a special tool. The connection of the light-emitting casing with a latch made around the entire perimeter of the casing, provided with an annular protrusion on the lamp housing, also located around the entire perimeter of the casing, not only complicates the installation, but can also deform the casing during assembly.

Known LED lamp, in which the nodes and parts are provided with means for their connection. So, a case with an electronic converter is performed with latches on the outer surface, and the end panel of the metal cast radiator is provided with holes for accommodating the tabs of the latch. The connection of these assembly units is carried out by fixing the latches in the holes of the front panel of the radiator (patent EP2077415, MKI F21V29 / 00, published on 08.07.2009).

A disadvantage of the known solution is the low-tech design of the LED lamp, due to the placement of electronic

95 transducers in a closed case made up of two parts to be connected by means of a special technological operation; increased requirements for the accuracy of the manufacture of latch elements on the halves of the case, necessary for 100 guaranteed fixation on the radiator disk. In addition, in a closed case, efficient cooling of the electronic converter cannot be provided, apparently, therefore, a powerful but 105 single LED was used as a radiation source.

The closest analogue to the method of manufacturing an LED lamp is the solution according to EP2077415.

As the prior art for the HO design of the LED lamp, the already mentioned solutions to the applications CN2760382 and CN201106814 can be indicated. In addition to the above disadvantages of these solutions, it should be noted a large number of parts that must be pre-connected 115 before the final assembly of the LED lamp, which allows us to speak about the low-tech design of the lamp.

The closest analogue of the LED lamp is the solution according to EP2077415, an exhaustive criticism of which 120 is set out on page 3 of this description.

The prior art for a hollow radiator can be characterized by the following identified analogues. 125 A hollow radiator for an LED lamp is known, comprising a ribbed side surface, a top panel with a podium for accommodating LEDs, provided with ventilation holes, a wall around the perimeter of the upper panel with

130 thread, apparently for attaching a light-scattering sheath (application for utility model CN201059520, MKI F21V29 / 00, published on 05/14/2008).

Neither description nor graphic materials

135 known solutions do not contain information about the means of connection with other parts and components of the LED lamp. A visible drawback of the solution is the presence on the panel of a separately placed podium for the radiation source, which

140 increases the complexity of assembly operations.

The closest analogue of the cooling device for an LED lamp is the solution described in EP2077415, MKI F21V29 / 00, published on 08.07.2009. As the nearest

145, the option depicted in FIG. 4 of said patent is selected, which is a hollow radiator with double walls, the outer one of which is provided with longitudinal ventilation holes, and the end panel is provided with holes for

150 latches of the case of the electronic converter. The design flaws of the radiator are a consequence of the general design flaws of the LED lamp of the known patent, which are set forth on pages 3 and 4 of this description.

155 Disclosure of the invention.

The technical result of the invention is to increase the manufacturability of the structure, the possibility of using interchangeable 160 parts and assemblies in the assembly process without additional processing and without the use of fasteners, improving the cooling conditions of radiation sources, as well as reducing the complexity and cost of assembling an LED lamp.

165

A method of manufacturing a LED lamp according to the invention includes the following operations:

- manufacture of a light-emitting shell with the simultaneous formation of discrete latches on its 170 remote surface;

-making the transition cone with the simultaneous formation of discrete latches and ventilation holes on its surface;

- the manufacture of an annular radiator, 175 including the formation of the end panel of the housing; the formation of the side along the perimeter of the end panel; forming holes on the side with the possibility of placing discrete latches of the light-emitting shell in them; the formation on the common 180 axis of the holes on the end panel, slots on the housing and protrusions on the inner conical surface of the cavity of the housing, while the protrusions form with the possibility of connection with discrete latches of the transition cone; the formation of 185 guide grooves on the inner surface radiator cavities for placement of the electronic converter board;

-placing an electronic converter by translating its board along 190 groove guides on the inner surface of the radiator cavity;

-fixing the latches of the light-emitting shell in the holes of the side of the end panel of the radiator body;

195 -fixing the latches of the transition cone on the protrusions of the inner surface of the conical cavity of the radiator body;

-placing and fixing on the transitional cone means of connection with a current source (base).

200 The creation of a guaranteed connection between these assembly units is ensured by using a two-link locking mechanism, the first link of which is a latch, made on the first assembly unit, and the second link is a protrusion,

205 through or blind hole, made on the surface of the second assembly unit. The surface shape of these links of the lock is performed with the possibility of pairing and eliminating spontaneous opening without special

210 power effects. The number of locking mechanisms on assembly units is selected depending on the requirements for bond strength. Obviously, the minimum number of locking mechanisms cannot be less than one.

215 The condition on the conical shape of the surface of the radiator cavity is due, on the one hand, the need for the formation on one axis of slots on the housing and protrusions on the inner surface of the housing, and on the other hand, technological 220 requirements for the injection mold that implements the method.

On the mating surfaces of the transition cone and the radiator, to prevent their rotation relative to each other, additional fixation means are possible that perform 225 in the form of protruding elements on one of the parts to be joined and corresponding recesses on the reciprocal part, for example, a pin on the radiator and recesses on the transition cone.

To achieve this goal, a material with a coefficient of elasticity, on the one hand, sufficient to establish the elements of the lock, but on the other hand, providing reliable fixation of the connected parts, is used as the 230 material of the latches. In this case, the optimum is 235 the formation of latches simultaneously with the manufacture of the light-emitting shell and the transition cone. The formation of the structural elements of the radiator case is advisable to carry out simultaneously with the manufacture of the case in one technological 240 operation, taking into account the subsequent connection of the assembly units and clutch links of the locking mechanisms.

It is preferable to form limiters on the end panel, preventing the radial movement of the light-emitting shell and capable of simultaneously serve as a guide link when connecting assembly units. These the stops should preferably be formed concentrically on the flange on the end face 250 of the radiator.

The sequence of joining the assembly units is not significant and depends on the specific conditions of the assembly production. For example, the operation of connecting the light emitting shell 255 and the radiator may precede the connection of the radiator and the transition cone.

As mentioned above, the formation of all structural elements of the radiator casing is advisable to produce at the same time. Based on 260 of these conditions, in the case of receiving a radiator by casting, the injection mold at the time of the operation should already contain all the molds necessary for obtaining structural elements of the radiator. So, in order to achieve the set goal, a body of a given configuration, its end panel, all openings in the end panel, slots in the body and protrusions at the end of each slot, longitudinal grooves on the conical surface of the cavity of the body, other elements must be formed during the casting process. For a specialist it should be clear that this is possible only if there is such an injection mold on which there are all forming inserts necessary to obtain a casting containing the elements necessary for the subsequent operations of manufacturing an LED lamp. The LED lamp made according to the method comprises a hollow annular radiator with

280 end panel and through holes on the side surface; a radiation source mounted on the end panel and a light emitting shell; a transition element between the radiator and the means of connection to the current source; electronic

285 converter and means for connecting parts and assemblies, characterized in that the light emitting shell and the transition cone are provided with discrete latches; the end panel has technological holes located on the same axis with slots

290 on the housing and protrusions on the inner conical surface of the housing cavity narrowing towards the panel, on which the electronic converter board is mounted in longitudinal grooves, and latches of the transition cone equipped with

295 air vents.

The preferred option is the formation of limiters on the end panel, preventing the radial movement of the light-emitting shell and capable of simultaneously

300 with this serve as a guide link.

These stops must be formed concentrically on the side on the front of the radiator.

The shape of the outer and inner surfaces of a real hollow ring-shaped radiator in any

305 embodiment can be characterized as a conical surface formed by a p-angle guide and with an angle Ψ between the generators, the value of which is selected from the expressions: 3 <n <oo and

0 <Ψ <180, where

η is the number of vertices of the polygon of the guide line,

Ψ is the angle between the generators of the conical surface.

The meaning of choosing the boundary values of the indicated parameters of the conical surface should be clear to the specialist and does not need special justifications. It is only worthwhile to note that the choice of the value of Ψ essentially determines the height of the hollow ring-shaped radiator, and the small value of Ψ at the maximum value of соответствует corresponds to the choice of shape in the form of a conical surface.

According to the invention, an optically transparent component is used as a binder material for the light-emitting sheath, which can be supplemented with particles of a certain type of phosphor or with a mixture of phosphors of different colors and / or afterglow.

The end surface of the radiator, designed to interface with the surface of the transition cone, can be equipped with additional fixation means, eliminating the possibility of rotation of the transition cone around the axis of the radiator. In this case, the configuration of the fixing elements is not of fundamental importance. As a special case of their implementation, you can specify the pair of pin - hole, radial protrusion - radial groove, or the execution of both mating surfaces with a toothed profile. 340 An embodiment of an LED lamp comprises a transition cone configured to fasten a threaded base to it. For this, the cylindrical part of the transition cone may be provided with a screw guide.

345 To improve the cooling conditions of the electronic converter and create a cooling air flow through the radiator cavity, create a ventilation channel formed by through cuts on the side surface of the radiator and

350 holes in the transition cone and / or the gap between the transition cone and the radiator.

The radiator for the LED lamp manufactured in the above manner contains:

355 an annular body with a developed outer surface, one of the end sides of which is provided with a panel having along the perimeter of the means of connection with the latches of the light-emitting shell; wherein said panel is provided

360 technological holes located on the same axis with slots on the radiator body and with protrusions on the tapered surface of the radiator cavity tapering to the panel, on which grooves are made with the possibility of placement in them

365 electronic converter boards.

The surface of the radiator, designed to interface with the surface of the transition cone, can be equipped with additional fixation means that exclude the possibility of rotation

370 radiators relative to the axis of the transition cone, for example, in the form of a pin formed at the end of the radiator.

A variant of the developed surface of the radiator may be transverse and / or longitudinal cooling fins.

375 In the latter case, the slots on the casing are located in the plane of the cooling fin so that the formed ventilation openings do not create conditions for unauthorized penetration of electronic components

380 converters. The number of slots made in this way depends on the type of electronic converter used.

Means for connecting the radiator to the light-emitting shell can be made in

385 in the form of holes, recesses or protrusions formed in the rim with the possibility of interaction with the latches of the light-emitting shell.

The end panel, in addition to these holes, 390 may have at least one hole adapted to accommodate current conductors and / or to fix the radiation source board with a collet latch.

For efficient cooling of radiation sources 395, the hollow radiator should be made of highly heat-conducting material, for example, copper, aluminum, their alloys, or from ceramics based on aluminum oxide. An important condition for the accurate manufacture of a hollow radiator is a good 400 molding ability of the selected material. A brief description of the drawings.

The invention is illustrated by the following graphic materials:

405 in Fig. 1 shows a side view of the LED lamp;

in Fig. 2 shows a three-dimensional image of the LED lamp in the analysis shown in Fig.1; Fig. 3 shows a three-dimensional image of the radiator from above from the side;

410 in Fig. 4 shows a three-dimensional image of the radiator bottom side;

in Fig. 5 is a three-dimensional image of the cross section of the radiator and the transition cone in disassembled form.

LED lamp, contains light emitting

415 a shell 1, on a remote surface 2 of which there are latches 3 of a locking mechanism; a hollow radiator 4 provided with an end panel 5, along the perimeter of which a rim b with holes 7 is formed to accommodate the latches 3

420 light emitting shell 1; a cluster 8 of radiation sources 9 mounted on a board and mounted on said panel 5 of a hollow radiator 4; transition cone 10 provided with latches 11 for connection with protrusions 12 made on the inner

425 of the surface 13 of the hollow radiator 4; an electronic transducer 14 mounted in longitudinal grooves (not shown) formed on the surface 13 of the cavity 15 of the radiator 4 and electrically connected to the cluster 8 of radiation sources 9 and

430 by means 16 for connecting to an electric current source. Radiator 4, in an optimal embodiment, which is essentially a complex casting part, consists of an annular body, one of

435 of the ends of which is provided with a panel 5 containing technological holes 17 and having a perimeter 6, in which through holes 7 are formed with the possibility of connection with latches 3 of the light-emitting shell 1; external

440, the housing surface 18 is made developed, for example, in the form of longitudinal ribs 18, and its internal cavity 15 is formed by a conical surface 13, tapering to the panel 5 and provided with ventilation slots 19, protrusions 12 for

445 securing the latches 11 of the transition cone 10 and longitudinal guide grooves (not shown) to accommodate the electronic transducer.

The end surface 20 of the radiator 4, designed to interface with the surface

450 of the transition cone 10, may be provided with additional fixing means, for example, in the form of a pin 21, eliminating the possibility of rotation of the transition cone 10 around the axis of the radiator 4.

455 An embodiment of the invention.

A method of manufacturing an LED lamp is as follows:

form in one injection operation a light emitting shell 1 and latches 3 on it. 460 The material used to obtain the light-emitting shell 1 may include particles phosphor, the composition and quantity of which are not considered in this invention;

form a transitional 465 cone 10 with latches 11 in one injection operation;

metal melt is cast, for example, into a metal mold (not shown) to form a molding part including an annular radiator casing 4, a panel 5 with 470 technological holes 17, a b side, limiters 22, holes 7 for connecting with latches 3 of the light-emitting shell 1 and hole 23 for fastening with a collet latch 24 of the cluster board 8 radiation sources 9, slots 475 19 and protrusions 12 on the inner conical surface 13 of the cavity 15 of the radiator housing 4. The relative location of these radiator elements ra is defined a mold, taking into account the subsequent connection of parts and components LED lamp 480;

- place the cluster board 8 radiation sources 9 on the end panel 5 of the hollow radiator 4 and fix the collet latch 24;

- place the light-emitting shell 1 between the 485 side b and the limiters 22 on the end panel 5 of the radiator body 4 and fix the latches 3 in the holes 7 of the side b of the end panel 5 of the hollow radiator body 4;

- fix the latches 11 of the transition cone 10 on 490 protrusions 12 formed on the conical surface 13 of the cavity 15 of the annular body of the radiator 4. In an embodiment of a method for manufacturing an LED lamp, a surface screw guide 26 is formed on the transition cone 10 to enable the threaded base to be fixed.

LED lamp manufactured in the described manner operates as follows.

500 Cluster 8 radiation sources 9, under the action of a supply voltage created by an electronic converter 14, electrically connected to a source (not shown) of electrical energy by means of a threaded

505 of the cap 16, a luminous flux of the ultraviolet or blue region of the spectrum is generated, which excites the luminescence of the phosphor particles embedded in the mass of the light-emitting shell 1 made of an optically transparent material.

510 Heat emitted by radiation sources 9 is transferred due to thermal conductivity to the radiator panel 5, the surface of which is in thermal contact with radiation sources 9, and is scattered from the ribbed outer surface 18

515 of the radiator housing 4. The heat generated by the electronic transducer 14 located in the cavity 15 of the radiator housing 4 is removed from the board by heat transfer through the housing and dissipated from its surface into the environment, and is also removed

520 convection flow flowing through the ventilation holes 25 in the adapter base 10 through the cavity 15 and is carried out of the housing through the slots 19 in the side surface of the radiator 4.

525

Industrial applicability

Parts and assemblies for LED lamps can be manufactured by known methods of casting metals, ceramics and plastics. Mounting

530 boards with radiation sources can be easily automated. The final assembly of the product does not require highly qualified personnel, which can significantly reduce the cost of manufacturing an LED lamp. Information

535 described in the description, it is sufficient for a specialist to understand the manufacturing procedure and design features of the device.

540

545

Claims

550 claims

1. A method of manufacturing a LED lamp, including the manufacture of a light-emitting shell with the simultaneous formation of discrete latches on its remote surface; manufacturing

555 transition cone with the simultaneous formation of discrete latches on its surface; the manufacture of an annular radiator, including the formation of an end panel on its body; the formation of the side along the perimeter of the end panel;

560 forming on the side of the fastening elements of the light-emitting shell; the formation on one axis of the holes on the end panel, slots on the body and protrusions on the inner surface of the conical cavity of the radiator, while the protrusions

565 form with the possibility of connection with discrete latches of the transition cone; the formation of guide grooves on the inner surface of the radiator cavity with the possibility of placing the electronic converter board; latching

570 light-emitting shell on the edge of the end panel; fixing the latches of the transition cone on the protrusions of the inner surface of the conical cavity radiator body; placement and fixation on the transition cone of the means of connection with the source 575 current.

2. A method of manufacturing an LED lamp according to paragraph 1, characterized in that on the end surface of the transition cone and on the end surface of the radiator, additional

580 means of fixation in the form of protruding elements and / or recesses.

3. A method of manufacturing an LED lamp according to paragraph 2, characterized in that the additional means of fixation are in the form, for example,

585 pin or radial protrusion on the end surface of the radiator and the corresponding recess on the end surface of the transition cone, or in the form of execution of both mating surfaces with a toothed profile.

590 4. A method of manufacturing an LED lamp according to claim 2, characterized in that the limiters of the radial movement of the light-emitting shell are formed on the front panel of the radiator.

5. A method of manufacturing an LED lamp according to

595 paragraph 4, characterized in that the limiters form a concentric rim on the front panel of the radiator.

6. LED lamp containing a housing in the form of an annular radiator, equipped with

600 end panel and through holes on the side surface; a radiation source and a light emitting envelope fixed to the end panel; electronic converter; transition cone between the radiator and the means of connection with

605 current source, characterized in that

the light-emitting shell and the transition cone are provided with discrete latches; the end panel is equipped with holes located on the same axis with slots in the housing and protrusions on the inner

610 of the conical surface of the body cavity, on which the electronic converter board is mounted in the longitudinal grooves, and the latches of the transition cone are fixed on the said protrusions.

7. The LED lamp according to paragraph b, characterized in that 615 in that the mating end surfaces of the transition cone and the radiator are provided with additional fixing means in the form of protruding elements and / or recesses.

8. The LED lamp according to paragraph 7, characterized in that 620 in that additional fixing means are made in the form of, for example, a pin or a radial protrusion on the end surface of the radiator and a corresponding recess on the end surface of the transition cone; or in the form of 625 the execution of both mating surfaces with a gear profile.

9. The LED lamp according to paragraph 7, characterized in that the end panel of the radiator is equipped with radial limiters

630 light emitting sheath.

10. The LED lamp according to paragraph 9, characterized in that the limiters are located concentrically to the side of the end panel of the radiator.

11. The LED lamp according to paragraph 6, 635, characterized in that the end panel is provided with at least one hole made with the possibility of placing means for mounting the board of radiation sources and / or current conductors.

12. The LED lamp according to paragraph 11, 640, characterized in that the means for fixing the board radiation sources made in the form of a collet latch.

13. The LED lamp according to paragraph 6, characterized in that the radiator is equipped with transverse

645 and / or longitudinal cooling fins.

14. The LED lamp according to paragraph 13, characterized in that the slot on the housing is located in the plane of the longitudinal cooling fin of the radiator.

650 15. A radiator for an LED lamp, comprising an annular housing with a developed external surface, one of the end sides of which is provided with a panel having perimeter means for connecting with latches of the light-emitting shell;

655, the end panel is provided with holes located on the same axis with slots in the housing and protrusions made on the inner conical surface of the cavity of the housing with the possibility of connection with the latches of the transition cone.

660 16. Radiator for LED lamp according to paragraph

15, characterized in that on the conical surface of the cavity of the housing is made longitudinal grooves with the possibility of placing an electronic converter board in them.

665 17. Radiator for an LED lamp according to item

16, characterized in that the developed surface of the radiator is made in the form of transverse and / or longitudinal cooling fins.

18. The radiator for the LED lamp according to paragraph 670 16, characterized in that the slot on the housing is located in the plane of the longitudinal cooling fin.

19. The radiator for the LED lamp according to paragraph 15, characterized in that the end surface

675 radiator is equipped with additional fixing means in the form of protruding elements and / or recesses.

20. The radiator for the LED lamp according to paragraph 19, characterized in that the additional means

680 fixations are made in the form of, for example, a pin or a radial protrusion or in the form of a surface with a gear profile.