Injection Molding of Lighting Accessories - The Process and Manufacturing Configuration Behind Desk Lamps
Desk lamps are an indispensable companion for everyday lighting. Have you ever wondered about the process and manufacturing configuration behind them? Injection molding of lighting accessories plays a crucial role, being the key step in transforming a desk lamp from its individual components into a finished product. Let's explore the process and manufacturing configuration behind desk lamps.
Simple Components of a Desk Lamp (Mainly Made of Plastic)
Lamp Head: Bulb: LED; Plastic Lampshade
Lamp Stem: Plastic Stem
Base: Plastic Stem. Some bases may also include functional components, such as: A switch: used to turn the desk lamp on and off. Common types include push-button switches, rotary knobs, and touch switches. A dimmer: If a desk lamp has a dimming function, a dimmer will be located on the base or stem to adjust the light brightness to suit different lighting needs.
Power Supply Parts: Power Cord
III. Manufacturing Processes Involved in Various Accessories
1. Bulb Manufacturing Process:
For LED bulbs, the main processes include LED chip packaging and assembly.
LED Chip Manufacturing: Through semiconductor manufacturing processes, photolithography, epitaxial growth, and doping are performed on a substrate material to grow and etch a semiconductor structure with light-emitting function.
Chip Packaging: The manufactured LED chip is encapsulated with a transparent encapsulating material (such as epoxy resin), ensuring a good fit between the chip and the encapsulating material and free of defects such as bubbles. The electrodes are also connected to ensure that power is applied to the bulb and light is emitted.
Bulb Assembly: The encapsulated LED chip is assembled with heat dissipation components, driver circuitry, and other components, and then installed in the bulb housing. The housing can be secured by injection molding or bonding.
2. Plastic Lampshade Manufacturing: Injection molding and vacuum forming are primarily used.
3. Plastic Lamp Shade and Base Manufacturing: Injection molding is used.
4. Switch Manufacturing Process (Push-button Switch):
The outer shell is made through injection molding, and the internal metal contacts, springs, and other components are machined and assembled.
5. Dimmer Manufacturing Process
If the desk lamp has a dimming function, the dimmer is manufactured as follows:
The outer shell is made through injection molding, and the internal components undergo a series of electronic circuit manufacturing processes to achieve the dimming function.
6. Power Cord Manufacturing Process
Metal raw materials (such as copper and aluminum) are drawn into wires of the desired thickness through a wire drawing process. These wires are then twisted together to form a core wire through a stranding process. Finally, an insulating material (such as polyvinyl chloride) is coated around the core wire using an insulation coating process to create an insulated wire.
IV. Required Factory Production Equipment
1. Light Bulb Production
For LED light bulbs, the factory requires the following equipment:
Epitaxial growth equipment for growing semiconductor structures.
Photolithography equipment for performing photolithography.
Etching equipment for etching semiconductor structures.
Packaging equipment, such as automatic dispensing machines and curing ovens, is used for packaging operations.
Assembly equipment is used to assemble packaged chips with other components into light bulbs.
2. Plastic Lampshade Production: Injection molding machines are used to produce plastic lampshades through injection molding.
Mold making equipment (such as CNC milling machines and EDM machines) is used to make the molds required for injection molding. If the lampshade is produced using the vacuum forming process, a vacuum forming machine is also required.
3. Plastic Lamp Pole Production: Injection molding machines are used to process plastic raw materials into plastic lamp poles that meet the requirements.
Mold making equipment is used to make injection molds.
4.
Plastic Base Production: Injection molding machines are used to convert plastic raw materials into plastic bases of various shapes.
Mold making equipment is used to make injection molds.
5. Switch Production: Injection molding machines are used to produce switch casings.
Metalworking equipment (such as lathes, milling machines, and drilling machines) is used to manufacture metal contacts, springs, and other components within the switch.
6. Dimmer Production
Injection molding machines are used to manufacture the dimmer housing.
Electronic circuit manufacturing equipment is used to implement the dimming function.
7. Power Cord Production
Wire drawing machines are used to draw wires to the desired thickness.
Wire stranding machines are used to twist the wires to form the core wire.
Extruders are used to coat the core wire with insulation material to form the wire.
Analyzing the components of desk lamps, the injection molding process, and the factory's production setup reveals the intricate craftsmanship and complex processes behind a small desk lamp. The injection molding process for lighting accessories runs throughout the entire process, seamlessly connecting each step, allowing desk lamps to illuminate life and become practical lighting tools for homes, offices, and other spaces.
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