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CN-122008473-A - Manufacturing method of attractive lampshade

CN122008473ACN 122008473 ACN122008473 ACN 122008473ACN-122008473-A

Abstract

The invention relates to the field of manufacturing of lighting devices, in particular to a manufacturing method of an attractive lampshade, which comprises the following steps of firstly, selecting one of a PC membrane, a PMMA+PC membrane, a PET membrane and a PU membrane with different thicknesses according to requirements to prepare a membrane layer of a lampshade blank, and obtaining a lampshade blank by cutting, printing patterns and hot pressing and laminating; the method comprises the steps of placing a blank in a high-pressure gas forming die, enabling the blank to be attached to a die cavity through high-temperature high-pressure gas with gradient pressurization to form a lamp shade primary product, detecting the primary product, cutting edges and corners, placing the primary product into an injection die after curing treatment, and performing injection molding to obtain a lamp shade finished product with a surface presenting a preset pattern. The method combines high-pressure gas forming and injection molding processes, realizes the precise preparation of the lampshade with the multilayer diaphragm structure, and effectively controls the shape and pattern quality of the product. The problems that the preparation of the energy-saving lampshade in the prior art cannot achieve uniform reflection of light spots and the quality of the lampshade are solved, and the optimization and unification of the pattern attractiveness and the structural strength of the lampshade are realized.

Inventors

  • CHENG JIANMING

Assignees

  • 东莞市恒维川塑胶模具科技有限公司

Dates

Publication Date
20260512
Application Date
20260204

Claims (10)

  1. 1. The manufacturing method of the beautiful lampshade is characterized by comprising the following steps: Step S1, selecting one of PC film, PMMA+PC film, PET film and PU film with different thickness according to patterns with different effects, specifications and different shapes of the lampshade to prepare a film layer of a lampshade blank; S2, dividing the membrane layer of the lampshade blank into membrane with preset size by using a cutting machine, and printing one or more of an electroplating process, a color printing process, a UV transfer process, a color plating process and a silk screen process on the pre-designed pattern to the printing layer of the membrane of the lampshade blank to obtain a lampshade blank after the printing process is completed; s3, transferring the lampshade blank into a forming die of a high-pressure gas forming machine; step S4, applying high-pressure gas with preset temperature to the blank in the die, gradually increasing the gas pressure from an initial pressure value to forming pressure according to a preset gradient, and maintaining the pressure for a preset period of time to enable the blank to be attached to a die cavity of the die to form a lampshade primary product; step S5, detecting whether the lamp shade primary product meets the pre-designed shape and requirement, and preprocessing the lamp shade primary product meeting the pre-set standard; s6, cutting the cut primary lampshade product, and then placing the primary lampshade product into an injection mold for injection molding to obtain an attractive lampshade product; And S7, displaying the pre-designed pattern on the surface of the lamp shade product after injection molding of the beautiful lamp shade product.
  2. 2. The method of claim 1, wherein the film thickness of the film layer of the green body of the lamp shade is one or more of 0.125mm,0.3mm,0.5mm,0.8mm,1.0mm,1.2mm,1.5mm,2.0mm,2.5mm, and 3.0 mm.
  3. 3. The method according to claim 2, wherein the high pressure is IR heating, specifically, a heating and baking procedure is set, the IR temperature is 280 ℃ to 500 ℃, and the baking time is 15 seconds to 80 seconds, so as to soften the film.
  4. 4. The method for manufacturing the beautiful lampshade according to claim 3, wherein the program parameters in the forming die of the high-pressure gas forming machine are 15 seconds to 80 seconds of baking time, and 15 kg to 80 kg of high-pressure gas is used for blowing after the membrane is softened to form a semi-finished product.
  5. 5. The method for manufacturing the beautiful lampshade according to claim 4, wherein the pretreatment of the primary lampshade product meeting the preset standard comprises the steps of punching leftover materials, taking out the needed semi-finished product, placing the semi-finished product into an injection mold for injection molding, and forming the needed finished lampshade product after injection molding is completed.
  6. 6. The method of claim 5, wherein detecting whether the pre-designed shape and requirements are met comprises: detecting the interface bonding strength of the membrane layer, the printing layer and the injection molding layer, and determining whether the preparation of the initial product of the lampshade meets a preset standard according to the interface bonding strength; If the interface bonding strength is smaller than a preset interface bonding strength threshold, determining that the preparation of the lamp shade primary product does not meet a preset standard, and increasing the pressure maintaining preset time according to the difference value between the preset interface bonding strength threshold and the interface bonding strength; and if the interface bonding strength is greater than or equal to a preset interface bonding strength threshold, determining that the preparation of the initial lamp shade product meets a preset standard.
  7. 7. The method of claim 6, wherein the magnitude of the increase in the predetermined dwell time is positive with respect to a difference between the predetermined interfacial bonding strength threshold and the interfacial bonding strength.
  8. 8. The method of claim 7, wherein applying a high pressure gas at a predetermined temperature to the blank in the mold, the gas pressure increasing gradually from an initial pressure value to a forming pressure according to a predetermined gradient, and maintaining the pressure for a predetermined period of time, the blank being bonded to the mold cavity to form the initial product of the lamp shade, comprises: Preheating a die to 60-180 ℃, and fixing the lampshade blank obtained in the step S2 between an upper die and a lower die of a forming die to ensure that the edge of the blank is clamped in a sealing manner; Stretching the baking tray above the die for 10-80 seconds at the temperature of 280-500 ℃, baking and softening the film, then closing the die, and then keeping the pressure state for 5-10 seconds by using high-pressure gas with the initial pressure value of 0.5-1.0 MPa; Gradually increasing the gas pressure according to a preset gradient of 0.3-0.5 MPa every 3-5 seconds until the forming pressure of 3.0-5.0 MPa is reached; After the forming pressure is reached, maintaining the pressure and the temperature for 30-60 seconds, and enabling the lampshade blank to be fully attached to the inner wall of the die cavity under the action of high-pressure gas, so that a lampshade primary product with a preset shape and structure is formed, wherein the diaphragms with different thicknesses use different temperatures and different baking times.
  9. 9. The method of claim 8, wherein the step-up of the predetermined gradient to the molding pressure further comprises the step of synchronously increasing the gas temperature to 150 ℃ to 180 ℃ at a temperature increasing rate of 2 ℃ to 3 ℃ per second during the step-up.
  10. 10. The method of claim 9, wherein the curing process comprises placing the lamp shade semi-finished product in a constant temperature curing oven, heating to 120-140 ℃ at a rate of 3 ℃ per minute, maintaining the temperature for 20-30 min, cooling to 80-90 ℃ at a rate of 2 ℃ per minute, maintaining the temperature for 15-20 min, and naturally cooling to room temperature, wherein the air flow rate in the curing oven is controlled to 0.8-1.2 m/s, and the relative humidity is maintained to 40% -50%.

Description

Manufacturing method of attractive lampshade Technical Field The invention relates to the technical field of manufacturing of lighting devices, in particular to a manufacturing method of an attractive lampshade. Background Along with the rapid development of lighting technology, the attractive lampshade is used as a key component for improving the light source utilization efficiency and reducing the energy consumption, and the optimization of the preparation process of the attractive lampshade has become an important point of industrial research. However, the traditional lampshade preparation method has obvious defects in the aspects of material molding control, optical performance regulation, deformation resistance enhancement and the like, and is specifically expressed as follows: Firstly, the traditional cutting process only pays attention to the dimensional accuracy, and neglects the influence of the texture change of the cutting surface of the PC board on the internal stress, so that the initial blank is easy to generate dimensional deviation or local cracking due to uneven internal deformation in the subsequent high-pressure forming process. Meanwhile, the design of a forming chamber with a fixed heating rate cannot be adjusted according to the actual deformation degree of the plate, so that the thermal stress concentration of the material is easily caused, and the yield of finished products is affected. Secondly, the conventional printing treatment mostly adopts fixed spraying parameters, and the reflectivity of the bottom surface is lack of accurate quantitative control. The traditional method only judges the printing effect through a single reflectivity value, and does not consider the influence of the difference of local area reflectivity on the whole optical performance, so that the problems of uneven light spots, energy scattering and the like are easily generated under the irradiation of a rated power light source of the lampshade, and the requirements of the attractive lampshade on high uniform light distribution are difficult to meet. Third, the conventional high pressure gas forming process lacks a reverse regulation mechanism based on the forming effect. When the light spot area ratio of the primary product of the lampshade exceeds the standard, optimization cannot be realized by adjusting parameters such as gas flow rate and the like, so that the quality fluctuation in mass production is large. The solidification treatment is carried out for a fixed period of time, and when the deformation resistance of the primary product of the lampshade does not reach the standard, a targeted adjustment strategy is lacked, so that the lampshade is easy to deform due to thermal stress or mechanical stress in long-term use, and the service life and the energy-saving effect are influenced. In summary, there is a need in the art for a method for manufacturing an aesthetic lampshade with precise control of material molding, quantitative optimization of optical performance, and enhancement of deformation resistance by multi-parameter dynamic regulation, so as to solve the problems of low material utilization rate, unstable optical performance, large quality fluctuation, short service life, and the like in the conventional process. Disclosure of Invention Therefore, the invention provides a manufacturing method of an attractive lampshade, which is used for solving the problem that the preparation of the attractive lampshade in the prior art cannot achieve uniform reflection of light spots and the quality of the lampshade. In order to achieve the above object, the present invention provides a method for manufacturing an attractive lampshade, comprising: Step S1, selecting one of PC film, PMMA+PC film, PET film and PU film with different thickness according to patterns with different effects, specifications and different shapes of the lampshade to prepare a film layer of a lampshade blank; S2, dividing the membrane layer of the lampshade blank into membrane with preset size by using a cutting machine, and printing one or more of an electroplating process, a color printing process, a UV transfer process, a color plating process and a silk screen process on the pre-designed pattern to the printing layer of the membrane of the lampshade blank to obtain a lampshade blank after the printing process is completed; s3, transferring the lampshade blank into a forming die of a high-pressure gas forming machine; step S4, applying high-pressure gas with preset temperature to the blank in the die, gradually increasing the gas pressure from an initial pressure value to forming pressure according to a preset gradient, and maintaining the pressure for a preset period of time to enable the blank to be attached to a die cavity of the die to form a lampshade primary product; step S5, detecting whether the lamp shade primary product meets the pre-designed shape and requirement, and preprocessing the lamp shade primary product meeti