KR100947657B1 - Rectangular-type led lighting and method for manufacturing the same - Google Patents

Abstract

The present invention relates to a four-sided LED lamp, the support surface to which the edge portion of the diffuser plate is in contact, the light source installation surface extending vertically from the support surface so that the light source can be disposed, and the support surface from the light source installation surface Four side frames each having a vertically extending fastening surface, each corner portion being connected by four corner brackets to form a quadrangular opening; A light guide plate disposed in the opening of the side frame and provided with a light diffusion pattern; A reflection plate laminated on the light guide plate to be in contact with the light diffusion pattern part; A diffuser plate having one surface in contact with an exit surface of the light guide plate and an edge portion of the other surface in contact with the support surface; A cover plate having a pressing part for pressing the reflecting plate toward the light guide plate and a fastening part formed stepped from the pressing part and fastened to the fastening surface; And four corner frames installed in each corner bracket to cover the corner portions.

Description

Rectangle-type LED lighting and method for manufacturing the same

The present invention relates to a quadrangular LED lighting lamp and a method of manufacturing the same, and more particularly, a quadrangular LED lighting lamp capable of emitting light in a planar shape by an LED light source disposed on a side of a light guide plate of a quadrangular shape and a manufacturing method thereof. It is about a method.

In recent years, LED elements have been spotlighted as light sources of various lighting devices. The LED device has advantages of low heat generation, low power consumption, excellent durability, and long life compared to light sources of conventional lighting devices such as incandescent and fluorescent lamps. LED lamps do not use mercury or discharge gases like fluorescent lamps, so they do not cause environmental pollution.

The LED device can last about 100,000 hours if provided with proper power supply and heat dissipation means. However, all light sources gradually decrease in light output. Since up to 80% of the initial brightness is not well felt by humans, according to this criterion, the lifetime of the LED lamp is expected to be about 40,000 to 50,000 hours. Therefore, the relative lifetime of LED lamps is estimated to be very long compared to 1500 hours of incandescent lamps and 10,000 hours of fluorescent lamps.

1 is a partially exploded perspective view schematically showing a front configuration of a four-angle LED lamp according to the prior art, Figure 2 is a cross-sectional view along the line II-II 'of Figure 1, Figure 3 is a schematic rear view of Figure 1 The exploded plan view shown.

1 to 3, the four-angle LED lamp 10 according to the prior art is connected to the four straight side frames 12 having a predetermined length by the 'b' shaped corner brackets 14, Edge portions of the diffuser plate 16, the light guide plate 18, the reflector plate 11, and the cover plate 13 are respectively inserted into the insertion portions 15 formed in the side frame 12, and the side frames 12 are Corner frames 17 are provided in the corner brackets 14 at the four corner portions in contact.

Referring to the assembly process of the four-corner LED lamp 10 according to the prior art as follows.

First, the two corner brackets 17 and the three side frames 12 are loosely bolted together to form an intermediate frame in the form of a Π with an opening. Subsequently, the edge portion of the stacked assembly is pushed through the opening of the intermediate frame by pushing the edge portion of the assembly in which the diffuser plate 16, the light guide plate 18, the reflecting plate 11, and the cover plate 15 are laminated. After inserting the insertion part 15 of (12), the corner bracket 17 and the side frame 12 which are loosely connected are fixed firmly. Next, the remaining two corner brackets 17 and the other side frame 12 are connected to close the opening of the intermediate frame. Finally, each corner frame 17 is attached to the corner bracket 14.

The quadrilateral LED lamp 10 according to the prior art manufactured by this process has the following problems.

Firstly, the process of loosely assembling the intermediate frame, the process of inserting the stacked assemblies into the inserting portion 15 of the side frame 12 in the state, the process of inserting the finishing portion of the opening of the stacked assembly, and the process of fully tightening the bolts Since the back, the assembly work itself is very difficult and the assembly time is increased. Particularly, in the case of large sized LEDs, for example, 600 mm × 600 mm square LED lamps, the thickness of the light guide plate used is not uniform on both sides thereof, so that the edge of the assembly laminated to the insertion part 15 of the side frame 12 is There is a problem that inserting a part is very difficult.

Second, the '-' structure of the corner bracket 14 coupled to the corner portions of the side frames 12 forms an empty space between the side frame 12 and the corner bracket 14, thereby preventing the lighting of the lamp 10. Part of the light source 19 protruding from the edge portion or the edge portion of the laminated assembly such as the light guide plate 18 may not be completely protected. This is a problem in that when a quadrangular LED lamp is suspended or embedded in a ceiling, impurities or foreign matter penetrates into the empty space to generate a short at a connection portion connecting the light source 19 and the cable 19a. To this end, according to the prior art, there is a case where a secondary process for blocking such empty space by using a separate insulating member (not shown) such as epoxy resin.

Third, in the process of installing the corner frame 17 in the corner bracket 14, the pair of through holes 14a formed in the corner bracket 17 and the bolt holes 17a formed in the corner frame 17 are formed. If the positions do not coincide with each other, the position of the corner frame 17 with respect to the corner bracket 14 may be shifted, which may make it difficult to install the corner frame 17 or may not be possible to assemble itself.

The present invention has been made in view of the above-described problems, and has the following objectives.

First, the present invention is to change the structure of the side frame and bolt the cover plate to the side frame so that the assembly of the light guide plate, etc. can be laminated in a batch operation through the pre-formed closed-loop opening with side frames combined By simplifying the assembly process as well as providing a square LED lamp and a manufacturing method for reducing the assembly time.

Secondly, the present invention is a quadrangular LED whose structure is improved to prevent a failure such as a short by foreign matter or impurities by connecting each side frame by a corner bracket having a corner protection portion extending from the '-' shaped bracket body. It provides a lamp and a method of manufacturing the same.

Third, the quadrilateral LED lamp and its manufacturing method have been improved to secure assembly speed and design flexibility by freely adjusting the installation position of the corner frame with respect to the corner bracket by changing the through hole of the corner bracket to the long hole shape. To provide.

In order to achieve the above object, the square LED lamp according to a preferred embodiment of the present invention, the support surface is in contact with the edge of the diffusion plate, and the light source installation surface extending vertically from the support surface so that the light source can be disposed And four side frames each having a fastening surface vertically extending from the light source mounting surface to face the support surface, and having four corner brackets connected to respective corner portions to form a quadrangular opening. ; A light guide plate disposed in the opening of the side frame and provided with a light diffusion pattern; A reflection plate stacked on the light guide plate to be in contact with the light diffusion pattern part; A diffuser plate having one surface in contact with an exit surface of the light guide plate and an edge portion of the other surface in contact with the support surface; A cover plate having a pressing part for pressing the reflective plate toward the light guide plate and a fastening part which is formed stepped from the pressing part and fastened to the fastening surface; And four corner frames installed on each of the corner brackets so as to cover the corner portions.

Preferably, the corner brackets may include: a 'b' shaped bracket bodies respectively coupled to the side frames; And a corner protector extending from the bracket body to protect the light guide plate protruding to the corner portions of the side frames and the light source.

Preferably, the corner protector is formed with a cable hole through which the cable connected to the light source can pass.

Preferably, the corner bracket includes holes formed corresponding to the positions of the bolt holes formed in the corner frame.

Preferably, the quadrangular LED lamp according to the present embodiment further includes a cushion plate interposed between the cover plate and the reflecting plate.

Preferably, the light source includes an LED module in which the LED chips are disposed on the LED circuit board at predetermined intervals.

According to a preferred embodiment of the present invention for achieving a four-way LED lamp according to the present invention, (a) four side frames each having a light source mounting surface and a support surface extending therefrom, and four corner brackets prepared Making; (b) installing a light source on the side of at least one side frame; (c) connecting the corner brackets to respective corner portions of the side frames so that a quadrangular opening can be formed; (d) stacking a diffusion plate, a light guide plate, and a reflecting plate on the support surface so as to be sequentially disposed in the opening; (e) coupling a cover plate having a pressing portion fitted in the opening and a fastening portion in contact with the side frame to the side frame; And (f) installing a corner frame on each of the corner brackets so as to cover the corner portions.

Preferably, the step (c) includes the step of protecting the end of the light source or the edge of the light guide plate by a corner protector extending from the 'b' shaped corner bracket.

Preferably, after the step (c), further comprising the step of passing the cable connected to the light source through the cable hole provided in the corner protection portion of the corner bracket.

Preferably, the step (f) includes adjusting the position of the corner frame through the long hole formed in the corner bracket.

Preferably, after the step (d), further comprising the step of laminating a cushion plate on the reflecting plate.

The square LED lamp and the manufacturing method according to the present invention has the following effects.

First, the present invention forms a frame assembly using four corner brackets and four side frames in advance, and laminates an assembly in which a light guide plate or the like is stacked in an opening of the frame assembly, and then bolts the cover plate to the side frame. By changing, the assembly process can be simplified and the assembly time can be shortened.

Second, the present invention can prevent the short by the foreign matter or impurities by connecting the respective side frames by the corner bracket having a corner protector extending from the 'b' shaped bracket body.

Third, by changing the through hole of the conventional corner bracket in the form of long holes, it is possible to secure the fastness of assembly and flexibility of the design by freely adjusting the installation position of the corner frame relative to the corner bracket.

The terms or words used in this specification and claims are not to be construed as being limited to their ordinary or dictionary meanings, and the inventors may appropriately define the concept of terms in order to best describe their invention. It should be interpreted as meaning and concept corresponding to the technical idea of the present invention based on the principle that the present invention. Therefore, the embodiments described in the specification and the drawings shown in the drawings are only the most preferred embodiment of the present invention and do not represent all of the technical idea of the present invention, various modifications that can be replaced at the time of the present application It should be understood that there may be equivalents and variations.

Hereinafter, a quadrilateral LED lamp and a method of manufacturing the same according to a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

Figure 4 is a schematic exploded perspective view of the configuration of a four-sided LED lighting lamp according to a preferred embodiment of the present invention to the rear, Figure 5 is a cross-sectional view of the combination of Figure 4, Figure 6 is a four-angle LED according to a preferred embodiment of the present invention A schematic partially exploded perspective view of the configuration of the lamp from the front. 4 and 5 are upper surfaces of the ceiling, and the lower portion is a portion from which light of the lamp is emitted. The upper part of FIG. 6 is a part from which light is emitted and the lower part is a surface facing the ceiling.

4 to 6, the quadrangular LED illuminator 100 according to the present embodiment is generally connected to each end of the four straight side frames 110 at right angles by the four corner brackets 120. A frame assembly 119 having a quadrangular (square or square) shape and having an opening 111 formed therein, and a light source 130 and a frame assembly 119 disposed at sides of two side frames 110 facing each other. Corners so as to cover the front portions of the respective corners of the diffuser plate 140, the light guide plate 150, the reflector plate 160, the cushion plate 170, and the frame assembly 119 sequentially stacked in the opening 111 of Four corner frames 190 are installed on the bracket 120.

The side frame 110 is used to cut a strip of a predetermined shape produced by the extrusion method using aluminum, stainless steel, metal or other metal alloy as long as necessary for the square LED lamp 100.

The side frame 110 has a support surface 112 on which the edge portion of the diffusion plate 140 is placed and contacts, and a light source installation surface extending substantially vertically from the support surface 112 so that the light source 130 can be disposed. 114, a fastening surface 116a having a plurality of fastening holes 116a through which the fastening portion 182 of the edge portion of the cover plate 180 may be contacted, and a fastening surface 116 extending vertically from the light source mounting surface 114. And a heat dissipation unit 118 provided in the form of a fin on a surface opposite to the light source installation surface 114.

The support surface 112 protrudes in the direction of the opening 111 of the frame assembly 119 along the longitudinal direction of the side frame 110, one side of which is the front of the quadrupole LED lamp 110, the other side of the diffuser plate It is a portion where the frame 140 is placed. Each end of the heat dissipation unit 118 is provided with a bracket insertion groove 113 into which the corner bracket 120 can be inserted and fixed.

The corner brackets 120 are respectively inserted into the bracket insertion grooves 113 at the ends of the side frames 110 and have a 'b' shaped bracket body having a coupling hole 124 coupled by the bracket bolts 122. 126 and protruding from the ends of the side frames 110 and extending from the bracket body 126 to protect the light guide plate 150 and the end portions of the light source 130 positioned at the corner portions of the frame assembly 119. It is provided with a corner protector (128). The bracket body 126 and the corner protector 128 are preferably manufactured integrally.

The corner protector 128 of the corner bracket 120 has a cable hole 121 through which the cable 137 connected to the light source 130 can pass. That is, when the corner protector 128 is installed and used with the square LED lamp 100, impurities, foreign substances, and the like, which are separated from the ceiling, penetrate into the frame assembly 119, and thus the light source 130 and the cable 137. ) To prevent damaging the connection site.

The bracket body 126 of the corner bracket 120 includes long holes 123 formed corresponding to the positions of the bolt holes 192 formed in the corner frame 190. Each long hole 123 is for facilitating positioning and coupling of the corner frame 190 installed in the corner bracket 120. The corner bracket 120 has sufficient rigidity to firmly support the side frame 110 to be connected, and is preferably made of a metal having high thermal conductivity, for example, stainless steel.

The light source 130 is attached to the light source mounting surface 114 of the side frame 110 by an adhesive such as a double-sided adhesive 131, a plurality of LED chips 133 are spaced on the circuit board 135 at predetermined intervals. It includes an LED module disposed. Each LED chip 133 is manufactured using a commercially available LED. The LED module is powered from the outside by the cable 137. In addition, the light source 130 is preferably installed in the side frame 110 facing each other. That is, although the light source 130 may be installed on all four sides of the quadrilateral LED lamp 100, the light source 130 may be determined depending on the size of the lamp and the pattern of the light diffusion pattern unit 152 of the light guide plate 150. . In addition, in the case of the rectangular LED lamp 100, it is preferable that the light source 130 is provided on the long side frame 110.

The light guide plate 150 has substantially the same size and shape (square) as the opening 111 of the frame assembly 119. The light guide plate 150 is made of acrylic resin. The light diffusion pattern part 152 is formed on one surface of the light guide plate 150, that is, the back side. The light diffusion pattern unit 152 may have a circular or egg-shaped dot formed in a predetermined pattern, or 'v' grooves orthogonal to each other by using a so-called V-cutting machine or a laser device at predetermined intervals and a predetermined pattern. It may be formed.

The reflective plate 160 is disposed to contact the light diffusion pattern portion 152 of the light guide plate 150 and has the same shape as the opening 111 of the frame assembly 119. The reflecting plate 160 is made of so-called Pomax (compressed foam PVC).

The diffusion plate 140 has a shape substantially the same as that of the opening 111 of the frame assembly 119 and is stacked on the exit surface of the light guide plate 150. The diffusion plate 140 is made of a transparent polycarbonate material.

The cushion plate 170 is stacked to be in contact with the reflecting plate 160 and has a function of bringing the reflecting plate 160, the light guide plate 150, and the diffusion plate 140 into close contact with the front side of the lamp 100.

The cover plate 180 may include a pressing part 184 capable of pressing the cushion plate 170 toward the front side of the lamp 110, and extending from the pressing part 184 to the fastening surface of the side frame 110. And a fastening portion 182 fastened to 116. The pressing part 184 and the fastening part 182 are connected by the step part 186. The stepped portion 186 is fitted to the edge of the opening 111 of the frame assembly 119. That is, when the diffuser plate 140, the light guide plate 150, the reflector plate 160, and the cushion plate 170 are stacked on the frame assembly 119 and the cover plate 180 is installed, the pressing unit 184 is a cushion plate. In contact with 170, the stepped portion 186 is fitted to the edge of the opening 111, and the fastening portion 182 comes into contact with the fastening surface 116. In this state, the bolt 188 is coupled through the bolt hole 182a of the fastening part 182. In addition, the cover plate 180 may be made of a metal having excellent thermal conductivity, and may help to release heat generated from the light source 130 to the outside.

The corner frame 190 is to cover the end portion of each side frame 110 connected by the corner bracket 120, and has the same shape as the structure and shape of the side surface in the longitudinal direction of the side frame 110 The front surface 196 having the same shape as the front surface of the side surface 194 and the support surface 112 of the side frame 110 is provided. The corner frame 190 has a bolt hole 192 formed at a position corresponding to the long holes 123 of the corner bracket 120. The corner frame 190 may be made of aluminum, but is preferably manufactured by injection molding a material such as ABS in consideration of manufacturing cost.

Referring to the manufacturing method of the square LED lamp according to a preferred embodiment of the present invention.

First, four side frames 110 having a length suitable for a necessary lighting and four corner brackets 120 for connecting the ends of the side frames 110 are prepared.

Subsequently, as shown in FIG. 7, the light source 130 packaged in a module form on the light source installation surface 114 of the side frame 110 is installed using a double-sided adhesive (double-sided tape) 131. The length of the LED module of the light source 130 uses slightly longer than the length of the side frame 110. This is to inject light uniform to the entire length of the light guide plate 150.

Next, as shown in FIG. 8, after the corner bracket 120 is positioned at the bracket insertion portion 113 of each corner portion of the side frames 110, each coupling hole of the corner bracket 120 ( Fastening bolts 122 through 124. In this process, the cable 137 connected to the light source 130 is inserted through the cable hole 121 of the corner bracket 120 and pulled upward. Here, only one of the cable holes 121 of the cable holes 121 formed in the two corresponding corner brackets 120 is used. Then, as illustrated in FIG. 9, a frame assembly 119 having a quadrangular opening 111 and formed by four side frames 110 is formed. Here, the protruding portions such as the light source 130 and the light guide plate 150 protruding to the corner portions of both side surfaces of the side frames 110 are completely covered by the edge protector 128 of the corner bracket 120.

Next, as shown in FIG. 5, in the state in which the support surface 112 of the side frame 110 is located below, the diffusion plate 140, the light guide plate 150, and the reflector 160 on the support surface 112. , The cushion plate 170 is sequentially stacked. Subsequently, the cable 137 connected to the light source 130 is inserted through the holes 34 of the cover plate 180. Next, the cover plate 180 is installed on the upper portion of the cushion plate 170. In this process, the pressing portion 184 of the cover plate 180 presses the cushion plate 170 and the stepped portion 186 is fitted to the edge of the opening 111 of the frame assembly 119. Thereafter, the bolt 188 is fastened through the bolt hole 182a formed in the fastening part 182 of the cover plate 180 and the fastening hole 116a of the side frame 110.

Subsequently, as shown in FIG. 6, the long holes 123 of the respective corner brackets 120 and the bolt holes 192 of the corner frames 190 are finished to cover the corner portions of the frame assembly 119. After fitting the screws 198 through the holes 123 and 192. Finally, the cable 137 is connected with a power supply (not shown) such as a switched-mode power supply (SMPS).

In the above, although the present invention has been described by means of limited embodiments and drawings, the present invention is not limited thereto and is described below by the person skilled in the art and the technical spirit of the present invention. Various modifications and variations are possible without departing from the scope of the appended claims.

The following drawings, which are attached to this specification, illustrate exemplary embodiments of the present invention, and together with the detailed description of the present invention serve to further understand the technical spirit of the present invention, the present invention includes matters described in such drawings. It should not be construed as limited to.

1 is a partially exploded perspective view schematically showing the front configuration of a four-angle LED lamp according to the prior art.

FIG. 2 is a cross-sectional view taken along line II-II ′ of FIG. 1.

3 is an exploded plan view schematically illustrating the rear surface of FIG. 1.

Figure 4 is a schematic exploded perspective view of the rear side of the configuration of a four-angle LED lamp according to a preferred embodiment of the present invention.

5 is a cross-sectional view of the combination of FIG.

Figure 6 is a schematic exploded perspective view of a front view of the configuration of a four-angle LED lamp according to a preferred embodiment of the present invention.

7 is an exploded perspective view illustrating main parts of a side frame and a light source of a quadrangular LED lamp according to a preferred embodiment of the present invention.

8 is an exploded perspective view illustrating main portions of a side frame and a corner bracket of a quadrangular LED lamp according to a preferred embodiment of the present invention.

9 is a plan view of a frame assembly formed by assembling four side frames and four corner brackets of a quadrangular LED lamp according to a preferred embodiment of the present invention.

Claims (11)

And a support surface to which the edges of the diffusion plate are in contact, a light source installation surface extending vertically from the support surface so that the light source can be disposed, and a fastening surface vertically extending opposite to the support surface from the light source installation surface, respectively. Four side frames connected to respective corner portions by four corner brackets to form an opening having a quadrangular shape; A light guide plate disposed in the opening of the side frame and provided with a light diffusion pattern; A reflection plate stacked on the light guide plate to be in contact with the light diffusion pattern part; A diffuser plate having one surface in contact with an exit surface of the light guide plate and an edge portion of the other surface in contact with the support surface; A cover plate having a pressing part for pressing the reflective plate toward the light guide plate and a fastening part which is formed stepped from the pressing part and fastened to the fastening surface; And Four corner frames installed on each of the corner brackets to cover the corner portions; The cover plate is made of a metal having excellent thermal conductivity, and is inserted into the opening is in contact with the side frame to emit a heat generated from a light source to the quadruple LED lamp. The method of claim 1, The corner brackets are: 'B' shaped bracket bodies respectively coupled with the side frames; And And a corner protector extending from the bracket body to protect the light guide plate protruding to the corner portions of the side frames and the light source. The method of claim 2, The corner protector is a quadrangular LED lamp, characterized in that the cable hole is formed through which the cable connected to the light source can pass. The method of claim 1, The corner bracket is a quadrangular LED lamp, characterized in that it comprises long holes provided corresponding to the position of the bolt holes formed in the corner frame. The method of claim 1, And a cushion plate interposed between the cover plate and the reflecting plate. The method of claim 1, The light source is a quadrangular LED lamp, characterized in that the LED chip comprises an LED module disposed on the LED circuit board at predetermined intervals. (a) preparing four side frames each having a light source mounting surface and a supporting surface extending therefrom and four corner brackets; (b) installing a light source on the side of at least one side frame; (c) connecting the corner brackets to respective corner portions of the side frames so that a quadrangular opening can be formed; (d) stacking a diffusion plate, a light guide plate, and a reflecting plate on the support surface so as to be sequentially disposed in the opening; (e) coupling a cover plate having a pressing portion fitted in the opening and a fastening portion in contact with the side frame to the side frame; And and (f) installing a corner frame to each of the corner brackets so as to cover the corner portions. The method of claim 7, wherein The step (c) is a quadrangular LED lamp manufacturing method further comprises the step of protecting the end of the light source or the edge of the light guide plate by a corner protector extending from the 'b' shaped corner bracket. The method of claim 7, wherein After the step (c), passing through the cable connected to the light source through the cable hole provided in the corner protection portion of the corner bracket, the quadruple LED lamp manufacturing method characterized in that it further comprises. The method of claim 7, wherein Wherein the step (f) comprises the step of adjusting the position of the corner frame through the long hole formed in the corner bracket, the quadrilateral LED lamp manufacturing method. The method of claim 7, wherein After the step (d), further comprising the step of laminating a cushion plate on the reflector plate.

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