CN110350062B - 一种带抗静电层的led支架镀膜工艺 - Google Patents
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Abstract
本发明涉及灯具制造技术领域，具体为一种带抗静电层的LED支架镀膜工艺，体包括如下步骤：LED支架除尘去油、喷涂底漆、固定LED支架、预热、真空镀膜，镀铝膜采用聚酯镀铝膜、CPP镀铝膜或聚酯镀铝膜，真空炉环境参数：脉冲偏压为150‑180V，反应气体为氩气，脉冲偏压的占空比为60%‑90%。本发明生产的生产的带抗静电层LED支架与传统制造的LED支架相比，表面光泽亮、硬度高、韧性强、抗静电效果好且放置一周后灰尘量极少，在进行真空镀膜前先进行底漆喷涂，增加产品的附着力和提升产品的光洁度，同时将LED支架除尘去油防止表面有油而喷不上底漆或素材表面有少量油而造成附着力不好和假性附着，防止喷涂底漆过程中有颗粒产生。
Description
技术领域
本发明涉及灯具制造技术领域，具体为一种带抗静电层的LED支架镀膜工艺。
背景技术
LED支架，LED灯珠在封装之前的底基座，在LED支架的基础上，将芯片固定进去，焊上正负电极，再用封装胶一次封装成形。LED支架一般是铜做的(也有铁材，铝材及陶瓷等)，因为铜的导电性很好，它里边会有引线，来连接led灯珠内部的电极，LED灯珠封装成形后，灯珠即可从支架上取下，灯珠两头的铜脚即成为了灯珠的正负极，用于焊接到LED灯具或其它LED成品。静电是表面电阻很高(通常在1013-1014Ω以上)的绝缘材料表面出现的电荷积累现象。静电会造成吸引灰尘、电荷击穿、电磁辐射等一系列问题，给生产和生活带来了很大不便和安全隐患。抗静电薄膜是附着于其它器件表面的很薄的一层涂层，通过其一定的导电性能将累积在器件表面的电荷导出从而达到防静电的效果的一种功能薄膜。通常其体电阻率103Ω·cm，方块电阻在105-109Ω之间的抗静电薄膜可以在几秒种内把器件表面的静电消除。
现如今的LED支架外表面采用塑料及陶瓷制成，表面会产生静电，易吸收灰尘，长期集尘造成表面污染严重，同时表面光泽暗、硬度差以及韧性差。鉴于此，我们提供一种带抗静电层的LED支架镀膜工艺。
发明内容
本发明的目的在于提供一种带抗静电层的LED支架镀膜工艺，以解决上述背景技术中提出现如今LED支架表面采用塑料及陶瓷制成，表面会产生静电，易吸收灰尘，长期集尘造成表面污染严重的问题。
为实现上述目的，本发明提供如下技术方案：
一种带抗静电层的LED支架镀膜工艺，具体包括如下步骤：
S1、LED支架除尘去油：先使用去油材料擦拭LED支架，去除LED支架表面油污和灰尘，或用超音波设备清洗，再通过静电设备和高压空气对LED支架表面进行除尘处理；
S2、喷涂底漆：通过喷枪对LED支架表面进行底漆喷涂，设定喷涂参数：涂装气压设定为4.5-5.5kg/cm²，涂装雾化气压设定为6.0-7.5kg/cm²，烘烤温度为50-55℃，时间设定为12-15分钟，烘烤能量值设定为900±50mj/cm²，底漆固化后膜厚为6±1μm，喷涂线速设定为30±2HZ；
S3、固定LED支架：将喷漆后的LED支架放入至镀膜机的真空炉内，并将LED支架放置于真空炉内的转盘上；
S4、预热：对真空炉内进行预热控制，预热电压为5±1V，预热电流为500±100A，预热时间为20-30S；
S5、真空镀膜：对真空炉内进行蒸发控制，蒸发电压为6.5V±0.5V，蒸发电流为800A±300A，蒸发时间为15-20S，选取铝合金作为靶材，LED支架镀铝膜厚度为50nm±30nm；
S6：产品下料。
作为优选，去油材料采用白电油或无水酒精。
作为优选，烘烤采用UV灯。
作为优选，真空炉其他环境参数：脉冲偏压为150-180V，反应气体为氩气。
作为优选，脉冲偏压的占空比为60%-90%。
作为优选，靶材采用平面靶、弧源靶或圆柱靶。
作为优选，镀铝膜采用聚酯镀铝膜或流延聚丙烯薄膜。
与现有技术相比，本发明的有益效果是：本带抗静电层的LED支架镀膜工艺生产的生产的带抗静电层LED支架与传统制造的LED支架相比，表面光泽亮、硬度高、韧性强、抗静电效果好且放置一周后灰尘量极少，在进行真空镀膜前先进行底漆喷涂，增加产品的附着力和提升产品的光洁度，同时将LED支架除尘去油防止表面有油而喷不上底漆或素材表面有少量油而造成附着力不好和假性附着，防止喷涂底漆过程中有颗粒产生。
具体实施方式
下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
一种带抗静电层的LED支架镀膜工艺，具体包括如下步骤：
S1、LED支架除尘去油：先使用去油材料擦拭LED支架，去除LED支架表面油污和灰尘，或用超音波设备清洗，再通过静电设备和高压空气对LED支架表面进行除尘处理；
S2、喷涂底漆：通过喷枪对LED支架表面进行底漆喷涂，设定喷涂参数：涂装气压设定为5kg/cm²，涂装雾化气压设定为6.5kg/cm²，烘烤温度为52℃，时间设定为13分钟，烘烤能量值设定为900mj/cm²，底漆固化后膜厚为6μm，喷涂线速设定为30HZ；
S3、固定LED支架：将喷漆后的LED支架放入至镀膜机的真空炉内，并将LED支架放置于真空炉内的转盘上；
S4、预热：对真空炉内进行预热控制，预热电压为5V，预热电流为500A，温度为600℃，预热时间为25S；
S5、真空镀膜：对真空炉内进行蒸发控制，温度为1150℃，蒸发电压为6.5VV，蒸发电流为800A，蒸发时间为17S，选取铝合金作为靶材，LED支架镀铝膜厚度为50nm；
S6：产品下料。
实施例2
一种带抗静电层的LED支架镀膜工艺，具体包括如下步骤：
S1、LED支架除尘去油：先使用去油材料擦拭LED支架，去除LED支架表面油污和灰尘，或用超音波设备清洗，再通过静电设备和高压空气对LED支架表面进行除尘处理；
S2、喷涂底漆：通过喷枪对LED支架表面进行底漆喷涂，设定喷涂参数：涂装气压设定为5.5kg/cm²，涂装雾化气压设定为7.5kg/cm²，烘烤温度为55℃，时间设定为12分钟，烘烤能量值设定为950mj/cm²，底漆固化后膜厚为7μm，喷涂线速设定为30HZ；
S3、固定LED支架：将喷漆后的LED支架放入至镀膜机的真空炉内，并将LED支架放置于真空炉内的转盘上；
S4、预热：对真空炉内进行预热控制，预热电压为5V，预热电流为500A，温度为700℃，预热时间为25S；
S5、真空镀膜：对真空炉内进行蒸发控制，温度为1200℃，蒸发电压为6.5V，蒸发电流为800A，蒸发时间为15S，选取铝合金作为靶材，LED支架镀铝膜厚度为60nm；
S6：产品下料。
将实施例1、实施例2生产的带抗静电层LED支架与传统制造的LED支架在表面光泽、硬度、韧性、抗静电效果以及放置一周后灰尘量进行对比，如下表所示：
| 对比属性 | 一周后灰尘量 | 光泽 | 硬度 | 韧性 | 抗静电效果 |
| 实施例1 | 2-4% | 亮 | 高 | 抗折弯 | 好 |
| 实施例2 | 1-4% | 亮 | 高 | 抗折弯 | 好 |
| 传统LED支架 | 60-80% | 暗 | 低 | 易折弯 | 差 |
由上表可以看出，实施例1、实施例2生产的带抗静电层LED支架与传统制造的LED支架相比，表面光泽亮、硬度高、韧性强、抗静电效果好且放置一周后灰尘量极少。
进一步的，去油材料采用白电油或无水酒精，防止表面有油而喷不上底漆或素材表面有少量油而造成附着力不好和假性附着，防止喷涂底漆过程中有颗粒产生。
具体的，烘烤采用UV灯，底漆通过吸收UV灯照射中的紫外线能量瞬间干固。
值得说明的是，真空炉其他环境参数：脉冲偏压为150-180V，反应气体为氩气，脉冲偏压的占空比为60%-90%，处理时采用氩气保护折弯效果更好不易断裂，可以有效阻隔空气等对镀铝膜的影响，对镀铝膜起到了良好的保护作用，延长其使用时长，且保护膜的反射率保持的比较平稳。
此外，靶材采用平面靶、弧源靶或圆柱靶，可以根据不同的需要使用不同类型的靶材。
值得注意的是，镀铝膜采用聚酯镀铝膜或流延聚丙烯薄膜，在高真空状态下通过高温将金属铝融化蒸发，使铝的蒸汽沉淀堆积到塑料薄膜表面上，从而使塑料薄膜表面具有金属光泽。由于它既具有塑料薄膜的特性，又具有金属的特性，是一种廉价美观、性能优良、实用性强的包装材料，大大减少了用铝量，节省了能源和材料，降低了成本，复合用铝箔厚度多为7gpm，而镀铝薄膜的铝层厚度约为0.05nm左右，其耗铝量约为铝箔的1/140-1/180，且生产速度可高达450m/min，镀铝层导电性能好，能消除静电效应，其封口性能好。
本实施例的带抗静电层的LED支架镀膜工艺拉伸强度佳，柔韧性好，不易产生静电，有效杜绝吸附粉末状物品。
本发明的带抗静电层的LED支架镀膜工艺生产的带抗静电层LED支架与传统制造的LED支架相比，表面光泽亮、硬度高、韧性强、抗静电效果好且放置一周后灰尘量极少，在进行真空镀膜前先进行底漆喷涂，增加产品的附着力和提升产品的光洁度，同时将LED支架除尘去油防止表面有油而喷不上底漆或素材表面有少量油而造成附着力不好和假性附着，防止喷涂底漆过程中有颗粒产生。
以上显示和描述了本发明的基本原理、主要特征和本发明的优点。本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的仅为本发明的优选例，并不用来限制本发明，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (7)
1.一种带抗静电层的LED支架镀膜工艺，其特征在于：具体包括如下步骤：
S1、LED支架除尘去油：先使用去油材料擦拭LED支架，去除LED支架表面油污和灰尘，或用超音波设备清洗，再通过静电设备和高压空气对LED支架表面进行除尘处理；
S2、喷涂底漆：通过喷枪对LED支架表面进行底漆喷涂，设定喷涂参数：涂装气压设定为4.5-5.5kg/cm²，涂装雾化气压设定为6.0-7.5kg/cm²，烘烤温度为50-55℃，时间设定为12-15分钟，烘烤能量值设定为900±50mj/cm²，底漆固化后膜厚为6±1μm，喷涂线速设定为30±2HZ；
S3、固定LED支架：将喷漆后的LED支架放入至镀膜机的真空炉内，并将LED支架放置于真空炉内的转盘上；
S4、预热：对真空炉内进行预热控制，预热电压为5±1V，预热电流为500±100A，预热时间为20-30S；
S5、真空镀膜：对真空炉内进行蒸发控制，蒸发电压为6.5V±0.5V，蒸发电流为800A±300A，蒸发时间为15-20S，选取铝合金作为靶材，LED支架镀铝膜厚度为50nm±30nm；
S6：产品下料。
2.根据权利要求1所述的带抗静电层的LED支架镀膜工艺，其特征在于：去油材料采用白电油或无水酒精。
3.根据权利要求1所述的带抗静电层的LED支架镀膜工艺，其特征在于：烘烤采用UV灯。
4.根据权利要求1所述的带抗静电层的LED支架镀膜工艺，其特征在于：真空炉其他环境参数：脉冲偏压为150-180V，反应气体为氩气。
5.根据权利要求4所述的带抗静电层的LED支架镀膜工艺，其特征在于：脉冲偏压的占空比为60%-90%。
6.根据权利要求1所述的带抗静电层的LED支架镀膜工艺，其特征在于：靶材采用平面靶、弧源靶或圆柱靶。
7.根据权利要求1所述的带抗静电层的LED支架镀膜工艺，其特征在于：镀铝膜采用聚酯镀铝膜或流延聚丙烯薄膜。
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