LED ENERGY-SAVING LAMP, MANUFACTURING METHOD THEREOF AND CORN LAMP

Abstract

This invention provides an integrated LED energy-saving lamp, a manufacturing method thereof and a corn lamp. The LED energy-saving lamp comprises at least one tube, at least one baseplate, a plurality of LED lamp beads and a heat conductive adhesive. Each tube comprises two parallel first parts and a second part for connecting the two first parts. Each baseplate comprises two parallel branch parts, located on the same plane, and a connecting part for connecting with the two branches; the two branches are respectively located in the two first parts of the tube. The LED lamp beads are respectively arranged on the two branches. The heat conductive adhesive is pasted between the two branches and the internal wall of the tube.

Claims

1. An LED energy-saving lamp, comprising: at least one tube, comprising two parallel first parts and a second part for connecting the two first parts; at least one baseplate, comprising two parallel branches located on a same plane and a connecting part for connecting the two branches, and the two branches being located inside the two first parts of the tube, respectively; a plurality of LED lamp beads disposed on the two branches, respectively; and a heat conductive adhesive pasted between the two branches and an internal wall of the tube.

2. The LED energy-saving lamp according to claim 1, wherein each branch further comprises an extending part, and the extending part is located inside the second part of the tube.

3. The LED energy-saving lamp according to claim 1, wherein the tube is H-shaped, U-shaped, or H-shaped.

4. The LED energy-saving lamp according to claim 1, wherein the baseplate is H-shaped, U-shaped, or H-shaped.

5. The LED energy-saving lamp according to claim 1, wherein the baseplate is an aluminum plate, an epoxy plate, or a soft lamp strip.

6. The LED energy-saving lamp according to claim 1, wherein a cavity is formed between each branch and the internal wall of the tube, a cross section of the cavity is D-shaped, and the D-shaped cavity is filled with the heat conductive adhesive.

7. The LED energy-saving lamp according to claim 1, wherein the tube is a glass tube, and a light dispersing agent is sprayed inside or outside the glass tube.

8. The LED energy-saving lamp according to claim 1, wherein the LED energy-saving lamp further comprises a drive module, and the drive module is electrically connected with the LED lamp beads through the baseplate.

9. A method for manufacturing the LED energy-saving lamp according to claim 1, the method comprising the following steps: manufacturing at least one tube and at least one baseplate, respectively, wherein each of the at least one tube comprises two parallel first parts and a second part for connecting the two first parts, each of the at least one baseplate comprises two parallel branches located on the same plane and the connecting part for connecting the two branches; disposing a plurality of LED lamp beads on one side of the two branches, respectively; coating the heat conductive adhesive on a back of the side having the LED lamp beads disposed thereon; inserting the branches of the baseplate into the first parts; and moving the tube or the baseplate such that the internal wall of the tube approaches the back until each branch is pasted on the internal wall of the tube through the heat conductive adhesive.

10. The manufacturing method of the LED energy-saving lamp according to claim 9, wherein coating the heat conductive adhesive on the back of the side having the LED lamp beads disposed thereon comprises the following steps: arranging the side having the LED lamp beads disposed thereon to face down, arranging the baseplate on a bearing rod of an adhesive spreader, and coating the heat conductive adhesive on the backs of the two branches at the same time.

11. The manufacturing method of the LED energy-saving lamp according to claim 10, wherein inserting the branches of the baseplate into the first parts comprises the following step: wherein the bearing rod carrys the baseplate such that the two branches are inserted into the two first parts of the tube at the same time.

12. The manufacturing method of the LED energy-saving lamp according to claim 10, wherein after moving the tube or the baseplate such that the internal wall of the tube approaches the back until each branch is pasted on the internal wall of the tube through the heat conductive adhesive, removing the bearing rod from the tube.

13. The manufacturing method of the LED energy-saving lamp according to claim 9, wherein moving the tube or the baseplate such that the internal wall of the tube approaches the back until each branch is pasted on the internal wall of the tube through the heat conductive adhesive comprises the following steps: pressing down the tube or moving up the baseplate until edges of each branch are against the internal wall of the tube and cavities are formed between the backs of the branches and the internal wall of the tube; and wherein the cross section of each of the cavities is D-shaped, and the heat conductive adhesive is a semi-liquid adhesive filled in the D-shaped cavities.

14. The manufacturing method of the LED energy-saving lamp according to claim 9, wherein after moving the tube or the baseplate such that the internal wall of the tube approaches the back until each branch is pasted on the internal wall of the tube through the heat conductive adhesive, welding and fixing the baseplate on a drive module.

15. An LED corn lamp, comprising: a central column; at least four LED energy-saving lamps according to claim 1 arranged around the central column, wherein the side having the LED lamp beads disposed thereon of the baseplate of each LED energy-saving lamp faces outward, and the back of the baseplate faces toward the central column; and a top lamp fixed on the central column.

16. The LED corn lamp according to claim 15, wherein the numbers of the LED lamp beads on each branch of each LED energy-saving lamp are the same, and the number of the LED lamp beads of each top lamp is equal to that of the LED lamp beads of each LED energy-saving lamp.

17. The LED corn lamp according to claim 15, wherein the sum of the heights of the top lamp and the central column is slightly higher than the height of the tube of each LED energy-saving lamp.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is a structural schematic diagram of an existing straight-strip-shaped aluminum baseplate or epoxy plate;

[0028] FIG. 2 is a structural schematic diagram of an LED energy-saving lamp provided by a first embodiment of the invention;

[0029] FIG. 3 is a structural schematic diagram of a baseplate provided by a second embodiment of the invention;

[0030] FIG. 4 is a manufacturing flow schematic diagram of the LED energy-saving lamp provided by one embodiment of the invention; and

[0031] FIG. 5 is a structural schematic diagram of a corn lamp provided by one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0032] Please refer to FIG. 2, FIG. 3, and FIG. 5 together. The LED energy-saving lamp comprises at least one tube 1, at least one baseplate 2, a plurality of LED lamp beads 3 and a heat conductive adhesive 4. Only one tube 1 and one baseplate 2 are shown in the FIG. 2. However, the invention is not limited thereto. In other embodiments, the LED energy-saving lamp can consist of three tubes, the number of the baseplates corresponds to that of the tubes and is also three.

[0033] Each tube 1 includes two parallel first parts 11 and a second part 12 (as shown in FIG. 5) for connecting the two first parts 11. In the embodiment, the tube 1 is a glass tube. A light-dispersing agent, such as fluorescent powder, is sprayed inside or outside the glass tube. Compared with a full-plastic tube, the glass tube has better light transmission, is highly insulated and is heat conductive and durable. Compared with an aluminum-plastic tube, the glass tube has lower cost and is more environmental-friendly. In this embodiment, the tube 1 is U-shaped (as shown in FIG. 5). More particularly, the first parts 11 are the two branches of the U-shaped tube and the second part 12 is an arc-shaped part for connecting the two branches of the U-shaped tube. However, the invention is not limited thereto. In other embodiments, the tube 1 can be H-shaped, H-shaped or of other shapes.

[0034] Each baseplate 2 includes two parallel branches 21 located on the same plane and a connecting part 22 for connecting the two branches 21. In the embodiment, the baseplate 2 is an aluminum baseplate, including a circuit layer, an insulation layer, and a metal basic layer. However, the invention is not limited thereto. In other embodiments, the baseplate 2 can be an epoxy plate or a soft lamp strip.

[0035] In the embodiment, the baseplate 2 further includes two welding parts 23, which extend along the opposite directions of the branches 21. The branches 21, the connecting part 22, and the welding parts 23 are located on the same plane. In the embodiment, the whole baseplate 2 is H-shaped. In detail, two branches 21 are the two upper branches of the H shape, the connecting part 22 is the horizontal line of the H shape, and the two welding parts 23 are the two lower branches of the H shape. Since the length of the welding parts 23 is much shorter than that of the branches 21, the baseplate 2 is a non-standard H-shaped structure. However, the invention is not limited thereto. In other embodiments, the baseplate 2 can be U-shaped, H-shaped, or of other shapes. When the baseplate is U-shaped, the connecting part is the arc-shaped part of the U shape. Although no welding part is specially arranged under this condition, a part of the whole connecting part can be welded to a circuit board.

[0036] A plurality of the LED lamp beads 3 are disposed on the two branches 21, respectively. In the embodiment, the quantities of the LED lamp beads 3 on each branch 21 are the same. The heat conductive adhesive 4 is pasted between the two branches 21 and an internal wall 111 of the tube 1.

[0037] More particularly, the baseplate 2 is provided with a front 211 (the side 211 having the LED lamp beads 3 disposed thereon) and a back 212. The LED lamp beads 3 can be fixedly on the front 211 of each branch 21 by surface mounting or a welding process (the entire baseplate 2 is a plane, so that the front of each branch 21 is the front 211 of the baseplate). The heat conductive adhesive 4 is coated on the back 212 of each branch 21. Two branches 21 of the baseplate 2 are inserted into the two first parts 11 of the tube 1, and a cavity 112 is formed between each branch 21 and the internal wall 111 of the tube 1. The heat conductive adhesive 4 is of a semi-liquid shape, so that the heat conductive adhesive 4 fills the whole cavity 112 after being pressed by the baseplate 2.

[0038] In the embodiment, the cross section of each cavity 112 is D-shaped, and the D-shaped cavities 112 are filled with heat conductive adhesive 4. The heat conductive adhesive is solidified to be D-shaped finally, so that the thickness at the centre is higher than that at two sides. The thickest in the centre is just located on the back of the positions of the LED lamp beads 3. Since the central position of the baseplate 2 is at the highest temperature, the thermal precipitation performance of the heat conductive adhesive 4 in the invention is obviously better than that of the existing heat conductive adhesive 4 which has a uniform thickness. Moreover, the existing heat conductive adhesive in the form of pasting strip easily produces air bubbles during pasting, so that uniform thermal-conduction cannot be realized. The heat conductive adhesive in the invention is of a semi-liquid form and can be completely filled in the cavity, so that the production of air bubbles can be avoided.

[0039] In the embodiment, the LED energy-saving lamp further includes a drive module 5, which is electrically connected with the LED lamp beads 3 through the baseplate 2.

[0040] FIG. 3 is the structural schematic diagram of the baseplate provided by the second embodiment of the invention. In the embodiment, the baseplate further includes extending parts 24, and the extending parts are located in the second part 12 of the tube 1. The extending parts 24 are additionally arranged, so that the illuminance of the top end of the LED energy-saving lamp is increased and the problem of the dark area at the top end of the LED energy-saving lamp is solved.

[0041] FIG. 4 is the production flow chart of the LED energy-saving lamp provided by one embodiment of the invention.

[0042] First of all, at least one tube 1 and at least one baseplate 2 are manufactured, respectively, each of the at least one tube 1 includes two parallel first parts 11 and a second part 12 for connecting the two first parts 11, and each baseplate 2 includes two parallel branches located on the same plane and a connecting part 22 for connecting the two branches 21.

[0043] A plurality of the LED lamp beads 3 are arranged on one side (that is the front 211) of the two branches 21, respectively. The heat conductive adhesive 4 is coated on the backs opposite to the front 211 having the LED lamp beads disposed thereon. The branches of the baseplate are inserted into the first parts of the tube, the tube or the baseplate is moved so that the internal wall of the tube approaches the back until each branch is pasted on the internal wall of the tube through the heat conductive adhesive.

[0044] In detail, the side of the baseplate having the LED lamp beads disposed thereon is arranged to face down, the baseplate is arranged on the bearing rod of an adhesive spreader, and the heat conductive adhesive is coated on the backs of the two branches at the same time. The bearing rod carrys the baseplate such that the two branches are inserted into the two first parts of the tube at the same time. The tube is pressed down or the baseplate is moved up until edges of each branch are against the internal wall of the tube and the D-shaped cavities are formed between the backs of the branches and the internal wall of the tube. Since the heat conductive adhesive 4 is a semi-liquid adhesive so that it can be filled in the D-shaped cavities. The bearing rod is removed from the tube, and the baseplate is welded and fixed on the drive module.

[0045] In the embodiment, adhesive-coating operation and adhesive-pasting operation on the two branches 21 are synchronously carried out. However, the invention has no limit in this aspect. In other embodiments, the heat conductive adhesive 4 on one branch 21 can be coated and pasted at first. Then the step is repeated and the heat conductive adhesive 4 on the other branch 21 is coated and pasted again.

[0046] FIG. 5 is the structural schematic diagram of the corn lamp. The corn lamp includes a central column 7, at least four LED energy-saving lamps 8, and a top lamp 9. The four LED energy-saving lamps 8 are arranged around the central column 7, the side of the baseplate having the LED lamp beads disposed thereon of each LED energy-saving lamp 8 is arranged outward, and the back of the baseplate faces toward the central column 7. As mentioned above, the LED lamp beads on two branches of the LED energy-saving lamp emit lights toward the same direction. Through this disposition, the light-emitting sides are uniformly arranged outward and the dark areas are arranged inward, so that accurate control and the illumination of the light-emitting area can be ensured. Meanwhile, in order to guarantee the uniform illumination of the whole corn lamp, the numbers of the LED lamp beads on each branch of each LED energy-saving lamp are the same, and the number of the LED lamp beads of each top lamp is equal to that of the LED lamp beads of each energy-saving lamp.

[0047] The glass at the top end of the LED energy-saving lamp is prone to be broken during transportation and installation. In order to avoid the problem as possible, the sum of the heights of the lamps and the central column in the embodiment is a little higher than the height of the tube of each LED light-emitting lamp, so that the top end of the LED energy-saving lamp is protected.

[0048] In conclusion, the baseplate 2 in the invention comprises two branches 21 and one connecting part 22 integrally formed, and the whole baseplate 2 is located on the same horizontal plane to ensure all the LED lamp beads 3 on the baseplate 2 are located on the same horizontal plane. Therefore, all LED lamp beads 3 emit light toward the same side and all light-emitting dark areas are the back sides. The two branches are directly made of the same material and have no difference, so that the LED lamp beads 3 on the two branches 21 have no difference in brightness and colors during illumination. The existing baseplates are of a straight strip shape and the levelness of two baseplates cannot be the same, so that the LED lamp beads 3 cannot emit light toward the same direction. In particular, those skilled in the art install the two baseplates aslant, although the illumination angle is bigger than that applied in the invention, within the original scope of the illumination angle. the illuminance is greatly reduced; moreover, the dark area always exists (the illumination angle of one row of the LED lamps is only 120 degrees and two rows of the LED lamps cannot achieve 360-degree illumination); finally, the bright area has not enough brightness and the dark area is still dark. In addition, the levelness of the baseplate 2 of the invention can be ensured. Therefore, when the heat conductive adhesive 4 is coated, the entire heat conductive adhesive 4 can be uniformly filled between the whole branches 21 and the internal wall 111 of the tube 1 without causing the problems in the prior art that the heat conductive adhesive 4 is not uniformly coated due to non-uniform stressing and the thermal conduction is not uniform or the glass tube is damaged due to pressing. Moreover, if the present straight baseplate is applied to a U-shaped, H-shaped or Π-shaped tube, two baseplates must be separately arranged, the circuit wiring is more complex, the process is more complicated, and the cost is increased accordingly. The connecting part 22 is arranged in the invention, so that the tail ends of the two branches 21 in need of being wired respectively in the prior art can be wired unifiedly, so that the two branches 21 can be directly connected to the drive module 5, the wiring layout is optimized, the process is simplified and the cost is reduced. In addition, the connecting part 22 during installation plays a role of fixing during installation.