Disclosure of Invention
Based on the above, it is necessary to provide an LED lamp and a manufacturing method thereof, aiming at the problems of complicated installation operation and high cost caused by the complicated structure of the conventional LED lamp.
The invention provides a preparation method of an LED lamp for realizing the purpose, which comprises the following steps:
Pasting an LED light source module at a position with a preset distance d1 from the first edge of the diffusion film; wherein, the LED light source module is stuck on the inner surface of the diffusion film;
the diffusion film is curled around the LED light source module to form a cylindrical structure;
and plugging the diffusion film with the cylindrical structure into the lamp tube, and then performing heating treatment to ensure that the outer surface of the diffusion film is thermally attached to the inner wall of the lamp tube.
In one embodiment, when the LED light source module is adhered at a preset distance from the first edge of the diffusion film, an adhesive manner or a heat treatment manner is adopted.
In one embodiment, when the LED light source module is adhered to the inner surface of the diffusion film by adopting a heating treatment mode, the heating area is a diffusion film area where the LED light source module is placed.
In one embodiment, when the diffusion film is curled around the LED light source module to form a cylindrical structure, the second edge of the diffusion film is bent around the LED light source module, and after crossing the first edge, the second edge of the diffusion film is overlapped with the first edge;
wherein the second edge is positioned opposite the first edge.
In one embodiment, after the first edge overlaps the second edge, the inner surface and the outer surface of the diffusion membrane partially overlap; and is also provided with
The length of the overlapping area of the inner surface and the outer surface of the diffusion film is greater than or equal to the length of the LED light source module.
In one embodiment, the length of the overlap region of the inner surface and the outer surface of the diffusion membrane is greater than or equal to 20mm.
In one embodiment, when the diffusion film with the cylindrical structure is plugged into the lamp tube for heating treatment, the outer wall of the lamp tube is heated by adopting a heat radiation mode.
In one embodiment, the preset distance d1 is greater than or equal to 5mm.
Correspondingly, the invention also provides an LED lamp, which comprises an LED light source module, a diffusion film and a lamp tube;
The diffusion membrane having an inner surface and an outer surface;
the LED light source module is stuck on the inner surface of the diffusion film;
The diffusion film is of a cylindrical structure, and the outer surface of the diffusion film is attached to the inner wall of the lamp tube.
In one embodiment, the number of the LED light source modules is a plurality of LED light source modules; and is also provided with
The LED light source modules are sequentially arranged and adhered on the inner surface of the diffusion film along the length direction of the lamp tube.
According to the preparation method of the LED lamp, the LED light source module is stuck at the preset distance from the first edge of the inner surface of the diffusion film, and then the diffusion film stuck with the LED light source module is curled, so that the diffusion film forms a cylindrical structure, the diffusion film with the cylindrical structure is directly plugged into the lamp cavity of the lamp tube and is subjected to heating treatment, the outer surface of the diffusion film is thermally stuck with the inner wall of the lamp tube, and finally the preparation of the LED lamp tube is completed. Compared with the traditional preparation of the LED lamp tube, the LED lamp tube has the advantages that the LED light source module is only required to be stuck on the diffusion film, and the diffusion film is plugged into the lamp cavity of the lamp tube, so that the preparation process of the LED lamp tube is effectively simplified. In addition, the clamping groove or the end cover is not required to be arranged in the lamp cavity of the lamp tube, so that the production cost is saved. Finally, the problems of complicated installation operation and higher cost caused by the complex structure of the traditional LED lamp tube are effectively solved.
Detailed Description
In order to make the technical scheme of the invention clearer, the invention is further described in detail below with reference to the attached drawings and specific embodiments.
Firstly, it should be noted that in the method for manufacturing an LED lamp of the present invention, the LED light source module may be an individual LED lamp bead, or may be an LED lamp bead array formed by arranging a plurality of LED lamp beads on a lamp panel in a serial and/or parallel manner.
When the LED light source module is an independent LED lamp bead, after the LED light source module is adhered to the inner surface of the diffusion film, the LED light source module is electrically connected with the driving power supply of the LED lamp tube, and the welding line of the LED lamp bead can be directly electrically connected with the output end of the driving power supply through a connecting line. When the LED light source module is an LED lamp bead array formed by a plurality of LED lamp beads in a serial-parallel connection mode, the electric connection between the LED light source module and the driving power supply is as follows: bonding pads at two ends of the lamp panel (namely, the anode and the cathode of the LED lamp bead array) are directly and electrically connected with the output end of the driving power supply.
Referring to fig. 1 and 2, as a specific embodiment of the method for manufacturing an LED lamp of the present invention, first, the method includes step S100 of attaching an LED light source module 110 at a predetermined distance from a first edge 123 of a diffusion film 120. Among other things, it should be noted that the diffusion membrane 120 generally has an inner surface 121 and an outer surface 122. In this step, when the LED light source module 110 is attached, the LED light source module 110 is attached to the inner surface 121 of the diffusion film 120. It should be noted that, when the LED light source module 110 is adhered to the inner surface 121 of the diffusion film 120, the backlight surface 112 of the LED light source module 110 contacts with the inner surface of the diffusion film 120 and is adhered and fixed by an adhesive, and the light emitting surface 111 of the LED light source module 110 is far from the inner surface 121 of the diffusion film 120 compared with the backlight surface 112. Meanwhile, the attaching position of the LED light source module 110 is at a preset distance from the first edge 123 of the diffusion film 120. In order to facilitate the subsequent crimping of the diffusion film 120 and ensure the stability of the LED light source module 110 on the inner surface 121 of the diffusion film 120 when the crimping of the diffusion film 120 is performed, the preset distance d1 should preferably have a value greater than or equal to 5mm.
Specifically, in step S100, the LED light source module 110 may be directly adhered to the inner surface 121 of the diffusion film 120 by means of gluing. When the LED light source module 110 is mounted by adopting the adhesive method, the adhesive is directly coated on the corresponding area of the inner surface 121 of the diffusion film 120 at normal temperature, and then the backlight surface 112 of the LED light source module 110 is directly adhered on the adhesive position. The operation is simple and easy to realize.
Preferably, in order to reduce the production cost, the LED light source module 110 may be adhered to the inner surface 121 of the diffusion film 120 by a heat treatment. This is because the diffusion membrane 120 itself has a certain viscosity, and when the ambient temperature thereof reaches a certain temperature, it itself generates a certain viscosity. Therefore, when the heating treatment is adopted, only the area of the inner surface 121 of the diffusion film 120, where the LED light source module 110 needs to be mounted, is heated, so that a certain viscosity is generated on a portion of the diffusion film 120 at the area, and the backlight surface 112 of the LED light source module 110 is then placed at the heated area, so that the LED light source module 110 is adhered to the inner surface 121 of the diffusion film 120. The LED light source module 110 can be fixed on the diffusion film 120 without using other adhesives due to the heat treatment mode, so that the mounting operation of the LED lamp is effectively simplified, and meanwhile, the production cost is further saved.
Meanwhile, it should be noted that, when the attachment and fixation of the LED light source module 110 on the inner surface 121 of the diffusion film 120 is performed by a heat treatment, the heating temperature and the heating time thereof are specifically set according to different kinds of diffusion films 120.
Further, referring to fig. 1 and 3, after the LED light source module 110 is adhered to the inner surface 121 of the diffusion film 120 through step S100, the diffusion film 120 is curled around the LED light source module 110 through step S200 such that the diffusion film 120 forms a cylindrical structure. Here, in the curling of the diffusion film 120, since the LED light source module 110 is adhered adjacent to the first edge 123 of the diffusion film 120, in order to facilitate the curling of the diffusion film 120, the second edge 124 opposite to the first edge 123 of the diffusion film 120 is bent around the LED light source module 110 by operating the second edge 124 so that the second edge 124 spans the first edge 123 and overlaps the first edge 123. That is, after the second edge 124 of the diffusion film 120 is curled around the LED light source module 110 and overlapped with the first edge 123, the inner surface 121 and the outer surface 122 of the diffusion film 120 are partially overlapped. The diffusion film 120 adhered with the LED light source module 110 is curled into a cylindrical structure, so that the curled diffusion film 120 can be matched with the lamp tube 130, the operation of plugging the diffusion film 120 into the lamp tube 130 is facilitated, and the preparation difficulty of the LED lamp is further reduced.
It is understood by those skilled in the art that, when the diffusion film 120 is curled, bending the second edge 124 of the diffusion film 120 around the LED light source module 110 by operating the second edge 124 of the diffusion film 120 refers to bending the second edge 124 of the diffusion film 120 along a circumference corresponding to the light emitting surface 111 of the LED light source module 110, so that the inner surface 121 of the diffusion film 120 after bending surrounds the LED light source module 110.
In addition, it should be further noted that, referring to fig. 3, in order to further enhance the stability of the LED light source module 110 on the inner surface 121 of the diffusion film 120, the length D of the overlapping area portion of the inner surface 121 and the outer surface 122 of the diffusion film 120 is preferably greater than or equal to the length D2 of the LED light source module 110 when the crimping operation of the diffusion film 120 is performed. Therefore, the thickness of the diffusion film 120 at the bottom surface (i.e., the backlight surface 112) of the LED light source module 110 is equal to the thickness of the two diffusion films 120, so that the adhesion between the LED light source module 110 and the diffusion film 120 can be more effectively increased when the diffusion film 120 and the inner wall of the lamp tube 130 are thermally bonded later, thereby enhancing the adhesion between the LED light source module 110 and the diffusion film 120 and ensuring the reliability of the finally prepared LED lamp tube 130.
Here, it should be noted that the length D2 of the LED light source module 110 generally does not exceed 20mm, and thus, it is preferable that the length D of the overlapping region of the inner surface 121 and the outer surface 122 of the diffusion film 120 should be greater than or equal to 20mm.
After the diffusion film 120 adhered with the LED light source module 110 is curled into a cylindrical structure in step S200, the diffusion film 120 with the cylindrical structure is plugged into the cavity of the lamp tube 130 and is subjected to heat treatment in step S300, so that the outer surface 122 of the diffusion film 120 is thermally adhered to the inner wall of the lamp tube 130. In the case of thermal bonding between the diffusion film 120 and the inner wall of the lamp tube 130, the heat treatment is preferably a heat radiation method. Meanwhile, when the diffusion film 120 is heated by a heat radiation method, an external heating method is preferable. That is, by heating the outer wall of the lamp tube 130 by heat radiation, the heat treatment of the diffusion film 120 is realized, and the viscosity of the diffusion film 120 is increased, so that the diffusion film 120 can be thermally bonded with the inner wall of the lamp tube 130, and meanwhile, the condition that the LED light source module 110 is easily damaged by the internal heating mode of the lamp tube 130 is avoided.
According to the LED light source module 110, the LED light source module 110 is directly adhered to the diffusion film 120, the diffusion film 120 curled into a cylindrical structure is further plugged into the lamp cavity of the lamp tube 130, and the diffusion film 120 plugged into the lamp cavity is subjected to heating treatment, so that the diffusion film 120 is thermally adhered to the inner wall of the lamp tube 130, and compared with a traditional fixed mounting mode that a clamping groove is arranged on the inner wall of the lamp tube 130 or an end cover is arranged on the lamp tube 130 for an LED light source, the difficulty coefficient of the preparation of the LED lamp tube 130 is effectively reduced. Meanwhile, the lamp tube 130 does not need to be processed, so that the traditional fluorescent lamp tube 130 can be fully utilized, the LED lamp 100 prepared by the invention can utilize the traditional fluorescent lamp tube 130, the flexibility and the high adaptability of the preparation method of the LED lamp 100 are effectively improved, the waste of resources is avoided, and the environment protection is facilitated.
In addition, it should be noted that, any combination of the technical features of the above-described embodiments may be used, and for brevity, all of the possible combinations of the technical features of the above-described embodiments are not described, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.
Correspondingly, based on any one of the preparation methods of the LED lamp, the invention further provides the LED lamp 100. The LED lamp 100 provided by the invention is prepared by adopting any one of the preparation methods of the LED lamp 100. Specifically, referring to fig. 4, as an embodiment of the LED lamp 100 of the present invention, it includes an LED light source module 110, a diffusion film 120 and a lamp 130. Wherein the diffusion membrane 120 has an inner surface 121 and an outer surface 122. The LED light source module 110 is adhered to the inner surface 121 of the diffusion film 120. The diffusion film 120 has a cylindrical structure, and the outer surface 122 of the diffusion film 120 is attached to the inner wall of the lamp tube 130. According to the LED lamp, the LED light source module 110 is adhered to the diffusion film 120, and the LED light source module 110 is adhered to be of a cylindrical structure, so that the fluorescent lamp tube 130 can be used as the lamp tube 130 of the LED lamp 100, the diffusion film 120 is directly plugged into the lamp tube 130 and is thermally adhered to the inner wall of the lamp tube 130, the structure of the LED lamp 100 is effectively simplified, and the difficulty and the complexity of the preparation of the LED lamp 100 are reduced.
In addition, in an embodiment of the LED lamp 100 of the present invention, the number of the LED light source modules 110 may be plural. The plurality of LED light source modules 110 are sequentially arranged and adhered on the inner surface 121 of the diffusion film 120 along the length direction of the lamp tube 130. Here, it should be noted that, when the lamp 130 is in a straight bar shape, the plurality of LED light source modules 110 are disposed along the axial direction of the lamp 130. When the lamp 130 has a ring shape, an arc shape or an S shape, the plurality of LED light source modules 110 are sequentially arranged from one end of the lamp 130 to the other end of the lamp 130.
The LED light source modules 110 are sequentially arranged and adhered on the inner surface 121 of the diffusion film 120, so that the light emitted from the outer wall of the lamp tube 130 is more uniform, and the light emitting effect of the LED lamp 100 is improved.
The foregoing examples illustrate only a few embodiments of the invention and are described in detail herein without thereby limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of protection of the present invention is to be determined by the appended claims.