CN113446526A - LED light bar production method and production system applying same - Google Patents
LED light bar production method and production system applying same Download PDFInfo
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- CN113446526A CN113446526A CN202110741450.6A CN202110741450A CN113446526A CN 113446526 A CN113446526 A CN 113446526A CN 202110741450 A CN202110741450 A CN 202110741450A CN 113446526 A CN113446526 A CN 113446526A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
- F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
- F21K9/90—Methods of manufacture
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S4/00—Lighting devices or systems using a string or strip of light sources
- F21S4/20—Lighting devices or systems using a string or strip of light sources with light sources held by or within elongate supports
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
- F21Y2115/00—Light-generating elements of semiconductor light sources
- F21Y2115/10—Light-emitting diodes [LED]
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Abstract
The invention relates to the technical field of LED light bars, in particular to a production method of an LED light bar and a production system applying the method. The invention provides an LED light bar production method and a production system using the same, which improve the production efficiency of LED light bars, optimize the production process and improve the reliability of products, and the produced LED light bars can emit uniform and soft light without any external optical treatment.
Description
Technical Field
The invention relates to the technical field of LED light bars, in particular to a production method of an LED light bar and a production system applying the method.
Background
An LED is an abbreviation of Light Emitting Diode (LED), and its basic structure is a piece of electroluminescent semiconductor material. The LED lamp strip is also called as an LED soft lamp strip, an LED flexible lamp strip and an LED soft light strip. The LED light bar is a product in which LEDs are mounted on a band-shaped FPC (flexible printed circuit) or PCB (printed circuit board) and is named as a band. Because of long service life (generally, the normal service life is 8-10 ten thousand hours), green and environmental protection, the method gradually exposes the corners in various decoration industries.
The problem that the visible light spot of the conventional SMD surface mount type lamp strip is dazzling is solved, the whole process of SMD packaging welding wires is complex, the production efficiency is low, and the reliability of products is not high.
Disclosure of Invention
The invention aims to solve the technical problems at least to a certain extent, and provides an LED light bar production method and a production system applying the method, which improve the production efficiency of LED light bars, optimize the production process, and improve the reliability of products.
The technical scheme of the invention is as follows: a production method of an LED light bar comprises the following steps:
s1, fixing the LED chip on a circuit board through a die bonder, and fixing a corresponding current-limiting resistor or a constant-current IC on the circuit board;
s2, welding the LED chip and the current-limiting resistor or the constant-current IC on the circuit board through high-temperature welding to form a coiled bare light source;
s3, detecting and maintaining the coiled bare light source through reel-to-reel visual detection equipment, wherein the coiled bare light source is a good bare light source after detection and maintenance;
s4, cutting the good-product bare light source into boards and strips through roll-to-roll strip dividing equipment, and forming rolled strip-shaped bare light sources after cutting the boards and the strips;
s5, inputting the strip-shaped bare light source into extrusion molding equipment, and extruding the strip-shaped bare light source attached with fluorescent glue from the extrusion molding equipment;
s6, baking and hot vulcanizing the strip-shaped bare light source attached with the fluorescent glue through a high-temperature tunnel furnace to form a finished LED light bar;
s7, cutting the finished LED lamp strip into required lengths, and welding outgoing lines, wherein the LED lamp strip is in a roll shape;
and S8, placing the rolled LED lamp strip in a box body, sealing the box body, beating a belt, and packaging.
According to the invention, the design is optimized, and the circuit structure of the product and the production process of the LED lamp strip are optimized. The LED lamp bar produced by the method can emit uniform and soft light without any external optical treatment. The problem that the visible light spot of the conventional SMD patch type light bar is dazzling at present is solved. The application range of the product is enlarged. The method for producing the LED light bar directly saves an LED packaging factory from an upstream chip to LED packaging, and directly finishes the application of the finished light bar at one time. The SMD packaging bonding wire, the SMD support, the long baking, the light splitting braid, the steel mesh, the paster, the pre-dividing plate, the connecting plate and the like are omitted, so that the production efficiency is greatly improved, the reliability of the product is improved, and the cost performance of the product is improved.
Further, in step S1, the current limiting resistor or the constant current IC and the LED chip are arranged in a straight line at intervals.
Further, between the step S4 and the step S5, the following step S4a is further included:
and (4) soaking the strip-shaped bare light source in the primer, drying the soaked strip-shaped bare light source by using an oven, and then performing step S5.
Further, between the step S6 and the step S7, the following step S6a is further included:
and cleaning the finished LED lamp bar by using a plasma cleaning agent, and sticking 3M glue on the back of the finished LED lamp bar after cleaning.
Further, after the step S6a is completed, laser marking is performed on the finished LED light bar, and then the step S7 is performed.
Further, the production system applying the LED light bar production method comprises: the device comprises a die bonder, a high-temperature welding mechanism, a detection and maintenance mechanism, a plate cutting machine, a separation mechanism, a primer mechanism, an oven, extrusion molding equipment, a tunnel furnace, a cleaning mechanism, a gluing mechanism, a laser marking mechanism, a cutting and welding line mechanism and a box sealing and tape-bonding machine which are sequentially connected.
Specifically, the production system further comprises a plurality of reel discharging mechanisms, and the reel discharging mechanisms are respectively arranged on one side of the die bonder, one side of the primer mechanism and one side of the cutting and wire bonding mechanism.
Specifically, the production system further comprises a plurality of reel receiving mechanisms, and the reel receiving mechanisms are respectively arranged between the detection and maintenance mechanism and the plate cutting machine, between the separating mechanism one side, between the adhesive tape pasting mechanism and the laser marking mechanism, and between the cutting welding wire mechanism and the box sealing and belt punching machine.
Further, the plate cutting machine comprises a material discharging mechanism, a pressing wheel, a counting mechanism, a roller, a plate separating mechanism and a pressing wheel which are connected in sequence;
the plate cutting machine further comprises a first support frame and a second support frame, the discharging mechanism is arranged on the first support frame, a workbench is arranged on the second support frame, and the pressing wheel and the counting mechanism are arranged on the workbench; the roller, the plate dividing mechanism and the lower pressing wheel are all arranged on the second supporting frame; separating mechanism and reel receiving agencies all locate second support frame one side.
Furthermore, the number of the pinch rollers is 2, and the pinch rollers are respectively arranged at two ends of the workbench.
Compared with the prior art, the beneficial effects are: the invention solves the problem that the SMD light bar emits light gladly at present, optimizes the production process, greatly shortens the production period and improves the production efficiency. The LED light bar production method is directly produced by a coil-to-coil process. The design is optimized, and the circuit structure of the product and the production process of the LED lamp strip are optimized. The LED lamp bar produced by the method can emit uniform and soft light without any external optical treatment.
Drawings
FIG. 1 is a schematic flow diagram of the process of the present invention.
FIG. 2 is a schematic view of a production system of the present invention.
Fig. 3 is a schematic view of the plate cutting machine of the present invention.
Detailed Description
The drawings are for illustrative purposes only and are not to be construed as limiting the patent; for the purpose of better illustrating the embodiments, certain features of the drawings may be omitted, enlarged or reduced, and do not represent the size of an actual product; it will be understood by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted. The positional relationships depicted in the drawings are for illustrative purposes only and are not to be construed as limiting the present patent.
The same or similar reference numerals in the drawings of the embodiments of the present invention correspond to the same or similar components; in the description of the present invention, it should be understood that if there is an orientation or positional relationship indicated by the terms "upper", "lower", "left", "right", etc. based on the orientation or positional relationship shown in the drawings, it is only for convenience of describing the present invention and simplifying the description, but it is not intended to indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and are not to be construed as limiting the present patent, and the specific meaning of the terms may be understood by those skilled in the art according to specific circumstances.
As shown in fig. 1, a method for producing an LED light bar includes the following steps:
s1, fixing the LED chip on a circuit board through a die bonder, and fixing a corresponding current-limiting resistor or a constant-current IC on the circuit board; in this embodiment, the LED chip is fixed to the circuit board by one or more dedicated die bonder, and is fixed to a corresponding current limiting resistor or a constant current IC.
S2, welding the LED chip and the current-limiting resistor or the constant-current IC on the circuit board through high-temperature welding to form a coiled bare light source;
s3, detecting and maintaining the coiled bare light source through reel-to-reel visual detection equipment, wherein the coiled bare light source is a good bare light source after detection and maintenance;
s4, cutting the good-product bare light source into boards and strips through roll-to-roll strip dividing equipment, and forming rolled strip-shaped bare light sources after cutting the boards and the strips;
s5, inputting the strip-shaped bare light source into extrusion molding equipment, and extruding the strip-shaped bare light source attached with fluorescent glue from the extrusion molding equipment; in this embodiment, do certain ratio fluorescent glue directly over the circuit board through the mode of roll-to-roll, for the shape of fine control fluorescent glue, wide high size has designed special mould to and the overall dimension of lamp strip is guaranteed to corresponding check out test set, ensure the uniformity of lamp strip, finally reach the luminous uniformity of LED lamp strip.
Through foretell extrusion moulding equipment, the cooperation of mould is compact, and the effect of silica gel cover on the circuit board is very good. The extrusion molding equipment is simple and convenient to operate, continuous batch production can be realized through the matching of specific structures, the cost is reduced, and the production efficiency of the LED lamp strip is greatly improved.
S6, baking and hot vulcanizing the strip-shaped bare light source attached with the fluorescent glue through a high-temperature tunnel furnace to form a finished LED light bar; the furnace body temperature of the high-temperature tunnel furnace is reasonable in setting, and fluorescent glue can be effectively cured.
S7, cutting the finished LED lamp strip into required lengths, and welding outgoing lines, wherein the LED lamp strip is in a roll shape; in this embodiment, a large roll of finished LED light bars is cut to a required length and then welded with outgoing lines. The finished LED lamp strip can work after being connected with a dimming controller and a corresponding power supply.
And S8, placing the rolled LED lamp strip in a box body, sealing the box body, beating a belt, and packaging. In this embodiment, combine joint sealing and two kinds of functions of beating the area together, the location of sealing is effectual, and the transmission of strapping is smooth and easy moreover. And the efficiency of joint sealing and banding is improved by the mode operation of the assembly line, and the joint sealing and banding device can be popularized and applied in a large range.
Specifically, in step S1, the current limiting resistor or the constant current IC and the LED chip are arranged in a straight line at intervals. The current-limiting resistor, the constant-current IC and the LED chip are all arranged on the same straight line, the arrangement is reasonable, the manufactured LED lamp strip is soft and uniform in light emitting and can also realize light modulation, products can customize various color temperatures, lengths and the like according to the requirements of customers, and the application is very wide.
Further, between the step S4 and the step S5, the following step S4a is further included: and (4) soaking the strip-shaped bare light source in the primer, drying the soaked strip-shaped bare light source by using an oven, and then performing step S5. In the embodiment, the step of soaking the primer in the strip-shaped bare light source is added, so that the adhesive force between the fluorescent glue and the circuit board can be increased, and the LED light bar is better in forming effect.
Further, between the step S6 and the step S7, the following step S6a is further included: and cleaning the finished LED lamp bar by using a plasma cleaning agent, and sticking 3M glue on the back of the finished LED lamp bar after cleaning. Because the surface of the LED lamp strip which forms a finished product after being baked and thermally vulcanized from the high-temperature tunnel furnace is probably not clean, the surface of the product is more attractive by cleaning the surface with a plasma cleaning agent, and the LED lamp strip can be fixed in any place after 3M glue is pasted on the back surface of the LED lamp strip.
Further, after the step S6a is completed, laser marking is performed on the finished LED light bar, and then the step S7 is performed. In the step, according to the actual requirements of the user, the brand, model and other information of the user can be marked on the finished LED lamp strip by laser.
As shown in fig. 2, a production system using the LED light bar production method is provided, in which: the device comprises a die bonder 100, a high-temperature welding mechanism 101, a detection and maintenance mechanism 102, a plate cutting machine 103, a separation mechanism 104, a primer mechanism 105, an oven 106, an extrusion molding device 107, a tunnel furnace 108, a cleaning mechanism 109, a rubberizing mechanism 110, a laser marking mechanism 111, a cutting and welding line mechanism 112 and a box sealing and tape bonding machine 113 which are connected in sequence. The process equipment to be passed in the whole LED light bar production process is shown in FIG. 2. Through foretell production system, optimized the design, optimized product circuit structure and LED lamp strip production technology. The produced LED lamp strip can emit uniform and soft light without any external optical treatment. The problem that the visible light spot of the conventional SMD patch type light bar is dazzling at present is solved. The application range of the product is enlarged. The method for producing the LED light bar directly saves an LED packaging factory from an upstream chip to LED packaging, and directly finishes the application of the finished light bar at one time. The SMD packaging bonding wire, the SMD support, the long baking, the light splitting braid, the steel mesh, the paster, the pre-dividing plate, the connecting plate and the like are omitted, so that the production efficiency is greatly improved, the reliability of the product is improved, and the cost performance of the product is improved. And the production system has high automation degree, can realize batch production, improves the production efficiency and the product quality, and reduces the cost.
Specifically, the production system further comprises a plurality of reel discharging mechanisms 114, and the reel discharging mechanisms 114 are respectively arranged on one side of the die bonder 100, one side of the primer mechanism 105 and one side of the cutting wire mechanism 112. The production system further comprises a plurality of reel material receiving mechanisms 115, wherein the reel material receiving mechanisms 115 are respectively arranged between the detection maintenance mechanism 102 and the plate cutting machine 103, on one side of the separation mechanism 104, between the adhesive sticking mechanism 110 and the laser marking mechanism 111, and between the cutting welding line mechanism 112 and the box sealing and tape beating machine 113. In this embodiment, in some processes, the reel discharging mechanism 114 and the reel receiving mechanism 115 are provided, so that the whole LED light bar production method can be performed without strips, for example, the reel receiving mechanism 115 between the detection maintenance mechanism 102 and the plate cutting machine 103 is a good product bare light source; the reel material receiving mechanism 115 on one side of the separation mechanism 104 is a stripped and coiled strip-shaped bare light source; a reel material receiving mechanism 115 between the gluing mechanism 110 and the laser marking mechanism 111 sticks 3M glue on the back of the LED light bar; the reel material receiving mechanism 115 between the cutting and welding line mechanism 112 and the box sealing and tape beating machine 113 is used for cutting the LED lamp strip into a required length and welding an outgoing line.
Specifically, as shown in fig. 3, the plate cutting machine includes a material discharging mechanism 1, a pressing wheel 3, a counting mechanism 4, a roller 5, a plate separating mechanism 6 and a pressing wheel 7, which are connected in sequence;
the plate cutting machine further comprises a first support frame 10 and a second support frame 11, the discharging mechanism 1 is arranged on the first support frame 10, the second support frame 11 is provided with a workbench 2, and the pressing wheel 3 and the counting mechanism 4 are arranged on the workbench 2; the roller 5, the plate separating mechanism 6 and the lower pressing wheel 7 are all arranged on a second support frame 11; the separating mechanism 104 and the reel receiving mechanism 115 are both disposed on one side of the second supporting frame 11. The number of the pinch rollers 3 is 2 groups, and the pinch rollers are respectively arranged at two ends of the workbench 2.
In this embodiment, the bare optical source of non-cutting yields is being loaded in drop feed mechanism 1, the bare optical source of non-cutting yields is on roll-type drop feed mechanism 1 is located, then the bare optical source of non-cutting yields conveys on workstation 2, pinch roller 3 can press the bare optical source of non-cutting yields and make it move along workstation 2, the length of the bare optical source of yields that the count mechanism 4 can calculate the process, then the bare optical source of non-cutting yields conveys gyro wheel 5, reach branch board mechanism 6 behind gyro wheel 5, be equipped with the cutter of the bare optical source of cutting yields in branch board mechanism 6, cut the bare optical source of yields. The cut good bare light sources are conveyed to the separating mechanism 104 through the lower pressing wheel 7, the separating mechanism 104 separates the cut bare light sources, and the separated bar-shaped bare light sources are collected through the winding disc material receiving mechanism 115.
Furthermore, the number of the pinch rollers 3 is 2, and the pinch rollers are respectively arranged at two ends of the workbench 2. In this embodiment, through setting up 2 bare light sources of non-cutting non-defective products that compress tightly that group's pinch roller 3 can be better, make it more steady safety when transmitting on workstation 2.
It should be understood that the above-described embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection scope of the claims of the present invention.
Claims (10)
1. A production method of an LED light bar is characterized by comprising the following steps:
s1, fixing the LED chip on a circuit board through a die bonder, and fixing a corresponding current-limiting resistor or a constant-current IC on the circuit board;
s2, welding the LED chip and the current-limiting resistor or the constant-current IC on the circuit board through high-temperature welding to form a coiled bare light source;
s3, detecting and maintaining the coiled bare light source through reel-to-reel visual detection equipment, wherein the coiled bare light source is a good bare light source after detection and maintenance;
s4, cutting the good-product bare light source into boards and strips through roll-to-roll strip dividing equipment, and forming rolled strip-shaped bare light sources after cutting the boards and the strips;
s5, inputting the strip-shaped bare light source into extrusion molding equipment, and extruding the strip-shaped bare light source attached with fluorescent glue from the extrusion molding equipment;
s6, baking and hot vulcanizing the strip-shaped bare light source attached with the fluorescent glue through a high-temperature tunnel furnace to form a finished LED light bar;
s7, cutting the finished LED lamp strip into required lengths, and welding outgoing lines, wherein the LED lamp strip is in a roll shape;
and S8, placing the rolled LED lamp strip in a box body, sealing the box body, beating a belt, and packaging.
2. The method for producing the LED light bar of claim 1, wherein the method comprises the following steps: in step S1, the current limiting resistor or the constant current IC and the LED chip are arranged in a line at intervals.
3. The method for producing the LED light bar of claim 2, wherein the method comprises the following steps: between the step S4 and the step S5, the following step S4a is further included:
and (4) soaking the strip-shaped bare light source in the primer, drying the soaked strip-shaped bare light source by using an oven, and then performing step S5.
4. The method for producing the LED light bar of claim 3, wherein the method comprises the following steps: between the step S6 and the step S7, the following step S6a is further included:
and cleaning the finished LED lamp bar by using a plasma cleaning agent, and sticking 3M glue on the back of the finished LED lamp bar after cleaning.
5. The method for producing the LED light bar of claim 4, wherein the method comprises the following steps: and after the step S6a is finished, laser marking is carried out on the finished LED lamp strip, and then the step S7 is carried out.
6. The production system applying the LED light bar production method of claim 5 is characterized in that: the device comprises a die bonder (100), a high-temperature welding mechanism (101), a detection and maintenance mechanism (102), a plate cutting machine (103), a separation mechanism (104), a primer mechanism (105), an oven (106), an extrusion molding device (107), a tunnel furnace (108), a cleaning mechanism (109), a rubberizing mechanism (110), a laser marking mechanism (111), a cutting and welding line mechanism (112) and a box sealing and tape stamping machine (113) which are sequentially connected.
7. The production system according to claim 6, wherein: the production system also comprises a plurality of reel discharging mechanisms (114), wherein the reel discharging mechanisms (114) are respectively arranged on one side of the die bonder (100), one side of the primer mechanism (105) and one side of the cutting welding line mechanism (112).
8. The production system according to claim 7, wherein: the production system further comprises a plurality of reel material receiving mechanisms (115), wherein the reel material receiving mechanisms (115) are respectively arranged between the detection maintenance mechanism (102) and the plate cutting machine (103), one side of the separation mechanism (104), between the adhesive sticking mechanism (110) and the laser marking mechanism (111), and between the cutting welding line mechanism (112) and the box sealing and tape punching machine (113).
9. The production system according to claim 6, wherein: the plate cutting machine (103) comprises a material discharging mechanism (1), a pressing wheel (3), a counting mechanism (4), a roller (5), a plate separating mechanism (6) and a lower pressing wheel (7) which are connected in sequence;
the plate cutting machine further comprises a first support frame (10) and a second support frame (11), the discharging mechanism (1) is arranged on the first support frame (10), a workbench (2) is arranged on the second support frame (11), and the pressing wheel (3) and the counting mechanism (4) are arranged on the workbench (2); the roller (5), the plate separating mechanism (6) and the lower pressing wheel (7) are all arranged on the second supporting frame (11); the separating mechanism (104) and the reel material receiving mechanism (115) are arranged on one side of the second support frame (11).
10. The production system according to claim 9, wherein: the number of the pinch rollers (3) is 2 groups, and the pinch rollers are respectively arranged at two ends of the workbench (2).
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| CN202110741450.6A CN113446526A (en) | 2021-07-01 | 2021-07-01 | LED light bar production method and production system applying same |
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Application publication date: 20210928 |