Pre-Cast Insert Die Casting Technology

Old light: cable cover plate, independent assembly scheme

New light: pre-cast tube, integrated solution

Technical Introduction

Process forming technology: During the die casting process, the fabricated metal inserts are placed in the designated mold cavity position, and after forming, the metal inserts and die-casting aluminum are melted together to form a complete product.

Reason for Technical Transformation

Existing state 1:

Wiring between the light source cavity and the power cavity: Currently, in luminaire, the light source cavity and the power cavity are connected by post-processing (or by moving the mold) of the die-casting part in such a way that they are directly wired through.

Disadvantages:

1. There are requirements for the distance between the power cavity and the light source cavity. If the distance is too far, it cannot be achieved or the cost is extremely high.

2. Die-casting parts must be increased in thickness and weight to achieve this, resulting in increased costs for the parts.

3. If you use a sliding block, there will inevitably be requirements for the size of the power cavity, requiring a dimensional space for the mold slide.

Existing state 2:

The full-page multi-module product adopts wiring chambers for wiring: Currently, the wiring between multiple modules is completed by adding wiring chambers on the back of the light body to complete the wiring between multiple modules.

Disadvantages:

1. The need to add cable cover plates and sealing rings will inevitably increase the overall cost of the luminaire.

2. The appearance of new cavities increases the risk of waterproof failure.

Purpose of Technical Transformation

During the wiring process inside the light body, a low-input, low-cost cavity wiring structure is provided to ensure stable waterproofing and reliable production performance.

Technical Advantages

Waterproof: Eliminates the risk of water leakage from the back cover, improving waterproof performance

Operability: Reduction of process steps and overall work hours

Cost-effective: The price of the main light shell of the integrated solution is better than that of the assembly solution

This technology has been applied for a utility model patent

Patent No.: ZL 202220836210.4

Transformation Effectiveness

Taking tunnel lights as an example, the average number of workstations is reduced by 2-3 after product iteration and upgrading, effectively reducing manufacturing costs.