CN102788284B

CN102788284B - Flexible light-emitting diode (LED) lamp band and manufacturing method thereof

Info

Publication number: CN102788284B
Application number: CN201210292561.4A
Authority: CN
Inventors: 李述洲; 王兴龙; 胡刚
Original assignee: Chongqing Pingwei Enterprise Co Ltd
Current assignee: Chongqing Chushang Photoelectric Technology Co ltd
Priority date: 2012-08-16
Filing date: 2012-08-16
Publication date: 2014-06-18
Anticipated expiration: 2032-08-16
Also published as: CN102788284A

Abstract

The invention discloses a flexible light-emitting diode (LED) lamp band and a manufacturing method thereof. The lamp band is formed by arranging a plurality of LED light source modules. The flexible LED lamp band is characterized in that each LED light source module comprises an upper copper sheet, a lower copper sheet and an insulation sheet, wherein the upper copper sheet and the lower copper sheet are isolated; the insulation sheet is connected between the upper copper sheet and the lower copper sheet; heat conduction layers are respectively coated on the upper surface of the copper sheet and the upper surface of the insulation sheet; at least one string of LED chips is mounted on each heat conduction layer; the corresponding upper copper sheet and the corresponding lower copper sheet are respectively provided with an electrode soldering point; and the LED chips are connected in series between each upper electrode soldering point and each lower electrode soldering point. The manufacturing method comprises the following six steps of cutting, etching, packing, coating, mounting and wiring. The invention has the obvious effects that the lamp band is good in connectivity; chip on board (COB)-packaged LED light source modules are high in stability and convenient in assembly. The single LED light source module can be mounted or multiple LED light source modules can be combined; and large-scale mass production manufacturing can be realized. The flexible LED lamp band not only can be applied to corn lamps but also can be used for manufacturing various traditional lamps and also can be well utilized on street lamp light source modules or tunnel lamp light source modules.

Description

A kind of flexible LED rope light and preparation method thereof

Technical field

The present invention relates to LED technology, specifically, is a kind of flexible LED rope light and preparation method thereof.

Background technology

Traditional LED lamp adopts straw hat lamp conventionally, particularly, in the production process of LED corn lamp, need to utilize manual plug-in unit to assemble.Like this, no matter be cylinder or polyhedron lamp type, the secondary packing problem that all exists first plug-in unit to assemble again in manufacturing process, brings great inconvenience to mass and large-scale production.

The defect of bringing in order to improve LED straw hat lamp, people are by chip on board encapsulation technology (Chip On Board, COB) introduced in the manufacture craft of LED lamp, Chinese patent application 201110269255.5 discloses a kind of ultra-thin LED area source of the COB of employing encapsulation technology, it combines the packing forms of device and lamp casing, realize the direct heat conduction of chip and arrive again the thermally conductive pathways of lamp housing to substrate, reach better radiating effect, simultaneously by the arrangement mode of single-row chip, the thickness that reduces light fixture, is widely used in indoor and outdoor illumination.

Although above-mentioned document has proposed COB encapsulation technology; but what it mainly solved is the problem of Heat Conduction Problems and light fixture size; and existing COB substrate hardness is higher; often need polylith independently substantially to carry out secondary combination and could meet various lamp types, the installation between modules and adjusting are still made troubles to the production of scale and mass.

Summary of the invention

The object of this invention is to provide LED lamp band of a kind of flexibility and preparation method thereof; solve the existing assembly connection problem of rigid substrate in prior art by flexible base, board, utilize COB modularized encapsulation technology to meet mass, large-scale production requirement simultaneously.

For achieving the above object, for achieving the above object, scheme of the present invention is as follows:

A kind of flexible LED rope light, arrange and form by multiple LED light source modules, its key is: described LED light source module comprises the copper sheet of upper and lower two isolation and is connected to the insulating trip between upper and lower two copper sheets, the upper surface of described copper sheet and insulating trip is coated with heat-conducting layer, on described heat-conducting layer, be pasted with at least a string LED chip, on upper and lower two copper sheets, be respectively arranged with electrode welding point, described LED chip is serially connected between upper and lower two electrode welding points.

As preferably, described insulating trip is the epoxy resin being filled between upper and lower two copper sheets.

As preferably, described heat-conducting layer is heat-conducting silicone grease.

Adopt scale copper and the epoxy resin installation base plate as LED light source module, pliability is better, module can distortion or bending, at the upper surface coated with thermally conductive silicone grease of copper sheet and insulating trip, the heat that heat-conducting silicone grease can well distribute LED chip imports in the radiator that light fixture separately establishes, there is good heat dispersion, the quantity of LED chip and combination can be according to the power settings of light fixture, in light fixture assembling process, directly adopt modularization to install, while dispatching from the factory, multiple LED light source modules are parallel join, the length of the quantity of direct shearing module or lamp band as required, particularly cylindrical or polygonal fitting structure, install very convenient, needn't be to straw hat lamp single grafting like that, to mass, large-scale production has brought convenience.

In conjunction with said structure, the present invention discloses a kind of preparation method of LED flexible light band, carries out according to following steps:

Step 1: material cutting, cuts into band shape by copper sheet;

Step 2: etching, banded copper sheet is etched into upper and lower two, and at the inner side of upper and lower two copper sheets equally spaced etching N section isolation recess;

Step 3: filler, filling epoxy resin in the etching area of copper sheet, connects upper and lower copper sheet insulation;

Step 4: apply coated with thermally conductive silicone grease on copper sheet and epoxy resin;

Step 5: mount, mount LED chip on heat-conducting silicone grease;

Step 6: wiring arranges electrode welding point, and utilizes gold thread that LED chip is serially connected on upper and lower two electrode welding points on upper and lower two copper sheets.

As further describing, in step 5 LED chip mount employing Reflow Soldering, make LED chip firm welding.

Remarkable result of the present invention is: the connectivity of lamp band is good, the LED light source module stability of COB encapsulation is high, easy to assembly, can single module mount or even dress of multimode, can realize large-scale batch production manufacture, not only can be applied on corn lamp, can also make all kinds of conventional lights types, on street lamp light source module or Tunnel Lamp light source module, also can finely utilize.

Accompanying drawing explanation

Fig. 1 is the front view of LED light source module of the present invention;

Fig. 2 is the cutaway view of LED light source module of the present invention;

Fig. 3 is another embodiment of LED light source module figure of the present invention;

Fig. 4 is the copper sheet structure chart after material cutting;

Fig. 5 is the copper sheet structure chart after etching;

Fig. 6 is the copper sheet structure chart after filler;

Fig. 7 is the copper sheet structure chart after applying;

Fig. 8 is the lamp band structure schematic diagram after wiring completes;

Fig. 9 is bent into triangular prism shaped lamp band structure schematic diagram.

The specific embodiment

Below in conjunction with the drawings and specific embodiments, the present invention is described in further detail.

As Fig. 1, shown in Fig. 2, a kind of flexible LED rope light, arrange and form by multiple LED light source modules, described LED light source module comprises the copper sheet 1 of upper and lower two isolation and is connected to the insulating trip 5 between upper and lower two copper sheets 1, and the upper surface of described copper sheet 1 and insulating trip 5 is coated with heat-conducting layer 4, is pasted with at least a string LED chip 3 on described heat-conducting layer 4, on upper and lower two copper sheets 1, be respectively arranged with electrode welding point 2, described LED chip 3 is serially connected between upper and lower two electrode welding points 2.

In implementation process, LED light source module is designed to a rectangular blockage, by insulating trip 5, upper and lower two copper sheets 1 are connected, play the effect of electricity isolation simultaneously, in conjunction with concrete production technology, described insulating trip 5, for being filled in the epoxy resin between upper and lower two copper sheets 1, also can adopt other insulating materials, as long as meet corresponding pliability and reliable connectivity.

On copper sheet 1 and insulating trip 5, be coated with one deck Heat Conduction Material as heat-conducting layer 4, mounting for the ease of LED chip 3 on the one hand, also be in order to realize good thermal conduction effect on the other hand, being convenient to LED chip 3 dispels the heat, conventionally adopt heat-conducting silicone grease as heat-conducting layer 4, also do not get rid of and adopt other equal Heat Conduction Materials of replacing.

As shown in Figure 3, each LED light source module can arrange LED chip 3 numbers according to concrete power demand, can adopt the mode of single channel or multiple series series to be connected between two electrode welding points 2, as long as meet electric connection and the power demands of LED chip 3.

Owing to adopting soft scale copper 1 and thering is the substrate of flexible insulating trip 5 as LED light source module, mutually multiple modules of combination can free distortion or bending, assemble very convenient, be convenient to mass, large-scale production, adopt COB encapsulation technology simultaneously, guaranteed the stability of LED light source module.

The preparation method of above-mentioned LED flexible light band is as follows:

Step 1: material cutting, as shown in Figure 4, copper sheet 1 is cut into band shape, be the copper strips of a slice rectangle here;

Step 2: etching, as shown in Figure 5, banded copper sheet 1 is etched into upper and lower two, and at the inner side of upper and lower two copper sheets 1 equally spaced etching N section isolation recess, a corresponding LED light source module between adjacent two recesses;

Step 3: filler, as shown in Figure 6, filling epoxy resin in the etching area of copper sheet 1, make, lower copper sheet 1 insulation connects, on guaranteeing, on the reliable basis connecting of lower copper sheet 1, the epoxy resin of filling as far as possible keeps identical thickness with copper sheet 1, make its installation base plate as LED light source module, thus, on the installation base plate of this piece band shape, can walk abreast multiple LED light source modules are set, two adjacent LEDs light source module is connected by a small amount of copper sheet of epoxy resin and edge of indent, can realize like this between module bending at any angle, cut out also more convenient simultaneously, according to the requirement of lamp strip length, can directly utilize scissors that flexible LED rope light is cut into single led light source module or the combined form of multiple LED light source modules, very easy to use,

Step 4: apply, as shown in Figure 7, coated with thermally conductive silicone grease on copper sheet 1 and epoxy resin, in implementation process, can be on whole piece lamp band coated with thermally conductive silicone grease, also can only in the effective coverage of each LED light source module, apply, can save like this material, as shown in Figure 7, this example adopts the mode described in the latter, the coating area of a rectangle is only set in each LED light source module, and need not applies between the isolation strip of two LED light source modules that is connected.

Step 5: mount, as shown in Figure 8, mount LED chip 3 on heat-conducting silicone grease, in order to guarantee the stability of LED chip 3, adopt Reflow Soldering technology while mounting;

Step 6: wiring arranges electrode welding point 2, and utilizes gold thread that LED chip 3 is serially connected on upper and lower two electrode welding points 2 on upper and lower two copper sheets 1.

Can obtain a complete LED lamp band by above-mentioned steps, because the pliability of copper sheet 1 and epoxy resin is relatively good, so lamp band can bending or kinking.

As shown in Figure 9; above-mentioned lamp band can directly adopt a lamp band to surround into corn lamp cylindrical or that be bent into hexagon, triangular prism shaped and other regular polygons and use; also can be stretching as common planar light source; can select single led light source module independently to use; also can select multiple LED light source modules to be used in combination; the cutting voluntarily of the length of lamp band, for mass, large-scale production have brought convenience.

Claims

1. a preparation method for LED flexible light band, is characterized in that carrying out according to following steps:

Step 1: material cutting, cuts into band shape by copper sheet (1);

Step 2: etching, banded copper sheet (1) is etched into upper and lower two, and at the inner side of upper and lower two copper sheets (1) equally spaced etching N section isolation recess;

Step 3: filler, filling epoxy resin in the etching area of copper sheet (1), connects upper and lower copper sheet (1) insulation;

Step 4: apply coated with thermally conductive silicone grease on copper sheet (1) and epoxy resin;

Step 5: mount, mount LED chip (3) on heat-conducting silicone grease;

Step 6: wiring arranges electrode welding point (2), and utilizes gold thread that LED chip (3) is serially connected on upper and lower two electrode welding points (2) on upper and lower two copper sheets (1).

2. the preparation method of a kind of LED flexible light band according to claim 1, is characterized in that: LED chip in step 5 (3) mount employing Reflow Soldering.