CN103213276B - Led球泡灯的激光焊接方法 - Google Patents

Led球泡灯的激光焊接方法 Download PDF

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CN103213276B
CN103213276B CN201310074684.5A CN201310074684A CN103213276B CN 103213276 B CN103213276 B CN 103213276B CN 201310074684 A CN201310074684 A CN 201310074684A CN 103213276 B CN103213276 B CN 103213276B
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陈锡然
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BEIJING UGETLIGHT CO Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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Abstract

本发明提供一种LED球泡灯的激光焊接方法，解决现有LED节能灯焊接方法易造成的焊缝强度较底、气密性不好的问题。一种LED球泡灯的激光焊接方法，所述LED球泡灯包括泡壳和灯芯基柱，包括以下步骤：将待焊接部位的泡壳和灯芯基柱在一定压力下被夹紧在一起，激光穿过透光性很好的泡壳，然后被灯芯基柱吸收，吸收的激光能量将光能转化为热能，使泡壳和灯芯基柱的接触面熔化，形成一个焊接区。采用本发明的方法使LED球泡灯泡壳和灯芯基柱做到百分百的气密性焊接，保证LED球泡灯的绝对气密性；且焊缝部位的强度大于聚碳酸酯材料的本体强度。

Description

LED球泡灯的激光焊接方法
技术领域
本发明涉及LED节能灯技术领域，特别涉及一种LED球泡灯的泡壳和灯芯基柱的激光焊接方法。
背景技术
由于LED节能灯相关技术的发展，在节能灯罩的生产和研发过程中，需要在灯罩里面放入体积较大的灯管和电气元件等零部件，然后进行焊接封装。现有的LED灯制造行业中，焊接工作一直是采用燃烧氧气、煤气等燃料以火焊的方式来实现的。火焊的方式由于受热面积大、温度高、温度难以实现精确控制等原因，易造成焊接的LED节能灯焊缝强度较低、气密性不好、电气元件易被损坏等缺陷，使焊接的良品率较低。另外，在环保的要求越来越迫切，不可再生能源的逐渐枯竭的情况下，如何将激光焊接这种环保的工艺方法应用于LED节能灯类似产品的焊接，就是业界所不得不加以解决的技术问题。
发明内容
本发明提供一种LED球泡灯的激光焊接方法，解决现有LED节能灯焊接方法易造成的焊缝强度较底、气密性不好的问题。
本发明的技术方案是这样实现的：一种LED球泡灯的激光焊接方法，所述LED球泡灯包括泡壳和灯芯基柱，包括以下步骤：
1）将泡壳套装到灯芯基柱上，待焊接部位要求过盈配合，然后放置在定位装置上；
2）采用激光束照射待焊接部位，使待焊接部位接触面的灯芯基柱和泡壳熔化，从而将两层熔接到一起。
其中，优选地，所述泡壳和灯芯基柱为熔点相近的热塑性材料制成的。
其中，优选地，所述泡壳为聚碳酸酯制成的。
其中，优选地，所述泡壳的透光率不低于60%。
其中，优选地，所述灯芯基柱为聚碳酸酯制成的。
其中，优选地，所述灯芯基柱炭黑含量不低0.3%。
其中，优选地，在步骤2中，激光束从侧面照射侍焊接部位，待焊接部位随着定位装置旋转。
其中，优选地，所述定位装置以1-50M/秒的线速度旋转。
其中，优选地，在步骤2中，采用激光放射状镜头进行焊接。
其中，优选地，在步骤2中，还包括与焊接过程同步的吹风降温处理的步骤。
本发明采用激光焊接的方式代替了现有技术中采用火焊的方式焊接LED节能灯，其基本原理为：将待焊接部位的泡壳和灯芯基柱在一定压力下被夹紧在一起，激光穿过透光性很好的泡壳，然后被灯芯基柱吸收，吸收的激光能量将光能转化为热能，使泡壳和灯芯基柱的接触面熔化，形成一个焊接区。
采用本发明的方法使LED球泡灯泡壳和灯芯基柱做到百分百的气密性焊接，保证LED球泡灯的绝对气密性；且焊缝部位的强度大于聚碳酸酯材料的本体强度。采用本发明的方法焊接LED球泡灯不仅更加节能环保，改善工作环境，而且还降低了生产成本，提高了良品率。
具体实施方式
下面对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
本实施例提供一种LED球泡灯的激光焊接方法，所述LED球泡灯包括泡壳和灯芯基柱，包括以下步骤：
1）将泡壳套装到灯芯基柱上，待焊接部位要求过盈配合，然后放置在定位装置上；
2）采用激光束照射待焊接部位，使待焊接部位接触面的灯芯基柱和泡壳熔化，从而将两层熔接到一起。灯芯基柱底层吸收激光束，将光能转化为热能，并将热量传递到待焊接部位的泡壳使之熔化从而将两层熔接到一起。
在本方法中，可以采用普通的激光发射器进行照射，激光束从侧面照射焊接部位，焊接工件旋转以达到焊接部位的均匀焊接。也可采用放射状镜头进行焊接，这种放射状镜头产生环状激光束，放射状镜头正对着待焊工件，待焊工件不需旋转，即可做到焊接部位的均匀焊接。
本实施例的步骤1中，定位装置以40M/秒的线速度旋转。根据所要焊接LED球泡灯的泡壳和灯芯基柱的材质和厚度，选择不同的旋转速度，旋转速度的线速度一般为1-50M/秒的线速度旋转。
其中，所述泡壳和灯芯基柱均为聚碳酸酯材料；本发明中，泡壳和灯芯基柱的材料并不局限于此，只要泡壳和灯芯基柱为熔点相近的热塑性材料均可采用本方法进行焊接。
其中，泡壳的透光率不低于60%。焊接部位的外层为透明或透光性很好的材质，以保证激光很好的穿过外层照射在要焊接的部位。激光束通过上层透明材料，然后被下层材料吸收，激光能量被吸收使得下层材料温度升高，熔化上层以及和下层的塑料。上层材料可以是透明的或者是有颜色的，但是必须能够保证有足够的激光通过。
其中，所述灯芯基柱炭黑含量不低0.3%。即保证灯芯基柱的颜色为黑色或灰色的，能吸收激光束，产生热量。
其中，在步骤2中，还包括与焊接过程同步的吹风降温处理的步骤。在焊接的过程同步进行退热处理，避免了焊接部位因局部过热产生局部变形、导致焊接质量降低的问题。
在本发明的焊接方法中，在焊接前还可增加采用较低功率的激光束进行预热的过程，使焊接部位温度平稳升高，进一步的避免了焊接部位因局部过热产生局部变形、导致焊接质量降低的问题。
采用本实施例提供的激光焊接装置焊接LED球泡灯，使LED球泡壳和相配合的密封件做到百分百的气密性焊接，保证LED球泡灯的绝对气密性。使密封做到绝对的可靠，且焊缝部位的强度大于聚碳酸酯材料的本体强度。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (5)

1.一种LED球泡灯的激光焊接方法，所述LED球泡灯包括泡壳和灯芯基柱，其特征在于，包括以下步骤：
1)将泡壳套装到灯芯基柱上，待焊接部位要求过盈配合，然后放置在定位装置上；
2)采用激光束照射待焊接部位，使待焊接部位接触面的灯芯基柱和泡壳熔化，从而将两层熔接到一起；
在步骤2中，还包括与焊接过程同步的吹风降温处理的步骤；在焊接前采用激光束进行预热，使焊接部位温度平稳升高；所述灯芯基柱为聚碳酸酯制成的，所述灯芯基柱炭黑含量不低0.3％；激光束从侧面照射待焊接部位，待焊接部位随着定位装置旋转；采用激光放射状镜头进行焊接。
2.根据权利要求1所述的LED球泡灯的激光焊接方法，其特征在于：所述泡壳和灯芯基柱为熔点相近的热塑性材料制成的。
3.根据权利要求2所述的LED球泡灯的激光焊接方法，其特征在于：所述泡壳为聚碳酸酯制成的。
4.根据权利要求3所述的LED球泡灯的激光焊接方法，其特征在于：所述泡壳的透光率不低于60％。
5.根据权利要求1所述的LED球泡灯的激光焊接方法，其特征在于：所述定位装置以1-50M/秒的线速度旋转。
CN201310074684.5A 2013-03-08 2013-03-08 Led球泡灯的激光焊接方法 Expired - Fee Related CN103213276B (zh)

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CN1951675A (zh) * 2005-10-19 2007-04-25 丰田自动车株式会社 用于激光焊接热塑树脂部件的方法和装置
CN102470606A (zh) * 2009-07-22 2012-05-23 欧司朗股份有限公司 灯的制造方法

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JP2006114262A (ja) * 2004-10-13 2006-04-27 Koito Mfg Co Ltd 車輌用灯具
CN201487648U (zh) * 2009-08-06 2010-05-26 郑麟秀 一种led球泡灯
CN103213276B (zh) * 2013-03-08 2016-02-24 北京优格莱照明科技有限公司 Led球泡灯的激光焊接方法

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Publication number Priority date Publication date Assignee Title
CN1951675A (zh) * 2005-10-19 2007-04-25 丰田自动车株式会社 用于激光焊接热塑树脂部件的方法和装置
CN102470606A (zh) * 2009-07-22 2012-05-23 欧司朗股份有限公司 灯的制造方法

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