CN113524568A - 一种led铝基板模内注塑方法 - Google Patents
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 97
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 97
- 239000000758 substrate Substances 0.000 title claims abstract description 92
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- 239000012778 molding material Substances 0.000 claims description 19
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 8
- 239000011889 copper foil Substances 0.000 claims description 8
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- 229920000647 polyepoxide Polymers 0.000 claims description 7
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- 229920006351 engineering plastic Polymers 0.000 claims description 4
- 239000000463 material Substances 0.000 claims 1
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- 229920003023 plastic Polymers 0.000 abstract description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 abstract 1
- 230000009286 beneficial effect Effects 0.000 description 6
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- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
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- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
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- 229910052710 silicon Inorganic materials 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14008—Inserting articles into the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/78—Measuring, controlling or regulating of temperature
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76498—Pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76531—Temperature
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76551—Time
Abstract
本发明公开了一种LED铝基板模内注塑方法步骤为采用无铅波峰焊对抗氧化铝基板进行焊接;将LED铝基板元器件放入注塑模具内进行注塑;给予注塑模具压力并保压,然后依次进行冷却、开模、取件、静置,得到LED铝基板模内注塑器件。本发明方法可用于要求防水、防尘和较高散热能力的LED灯具。使用这种工艺,LED铝基板边缘被塑胶完全包覆密封,从而可以保证灯具能够完全防水、防尘;同时,因LED铝基板的背面暴露于外界空气中,可以直接对外界空气进行散热,从而大大提高了灯具的散热能力,防止热量在灯体内部集聚。
Description
技术领域
本发明涉及注塑成型技术领域,具体的说涉及一种LED铝基板模内注塑方法。
背景技术
LED灯具工作时会产生高温,不断向外传递热量,为解决散热问题,一般会采用铝基板,必要时还会使用散热风扇等方法,将热量传导分散,以降低LED灯板的工作温度。
现有技术中对于有防水、防尘要求的灯具,常常采用将LED铝基板、散热器等封闭在灯具内部的方法。但是,使用这种方法时,LED灯具工作时产生的热量很容易在灯具内部集聚,往往使灯具内部温度过高。
因此,提供一种制备防水、防尘同时具有较高散热能力的LED铝基板模内注塑器件的方法是本领域技术人员亟需解决的技术问题。
发明内容
有鉴于此,本发明提供了一种LED铝基板模内注塑方法。
为了实现上述目的,本发明采用如下技术方案:
一种LED铝基板模内注塑方法,包括以下步骤:
(1)采用无铅波峰焊对抗氧化铝基板进行焊接,得到LED铝基板元器件;
(2)将LED铝基板元器件放入注塑模具内,然后将注塑材料加入至注塑模具内进行注塑;
(3)给予注塑模具压力并保压,然后依次进行冷却、开模、取件、静置,得到LED铝基板模内注塑器件。
进一步,所述抗氧化铝基板包括铝基板基层、绝缘层和线路层;所述绝缘层涂覆在所述铝基板基层的表面,所述线路层蚀刻在所述绝缘层表面。
更进一步,所述铝基板基层为6061铝板或5052铝板;
采用上述进一步方案的有益效果在于:本发明采用的铝板为冷处理铝锻造产品,其主要含有镁和硅两种元素,具有优良的接口特征、容易涂层、强度高、可使用性好,抗腐蚀性强。
更进一步,所述绝缘层为环氧树脂;
采用上述进一步方案的有益效果在于:本发明的绝缘层由高导热、高绝缘的陶瓷粉末填充而成的聚合物构成,具有良好的热传导性能、很高的绝缘强度、良好的粘接性能。
更进一步,所述线路层为电解铜箔。
采用上述进一步方案的有益效果在于:本发明线路层采用电解铜箔经过蚀刻形成印制电路,用于实现器件的装配和连接,与传统的FR-4相比,采用相同的厚度,相同的线宽,铝基板能够承载更高的电流。
进一步,所述注塑材料为防火工程塑料。
更进一步,所述防火工程塑料由PA66和玻璃纤维按7:3的质量比组成。
采用上述进一步方案的有益效果在于:尼龙加纤(PA66+30%GF)的RTI温度是130℃,热变形温度是230-260度,就是短时间使用可以达到230度。
尼龙加纤(PA66+30%GF)的热膨胀系数为:23.3*10-6/K,其热膨胀系数几乎与铝板一样(23.2*10-6/K),所以将LED铝基板模内注塑后,铝基板与塑胶外壳两者的热膨胀系数差别导致的尺寸差别几乎可以忽略。
进一步,所述注塑模具的材质为S136-D模具钢。
采用上述进一步方案的有益效果在于:尼龙加纤(PA66+30%GF)的模具型腔的磨损很大,对耐磨性要求很高。S136-D模具钢经过六面锻造,致密性好,耐磨性好。
进一步,步骤(1)中所述焊接温度为260℃,焊接时间为3-5s。
进一步,步骤(2)中所述注塑料筒温度为60-90℃,注塑喷嘴温度为280-290℃,模具温度为70-95℃,注塑射胶时间为5-15s。
进一步,步骤(3)中所述保压压力为80-150MPa,保压时间为2-5s。
更进一步,步骤(3)中所述冷却时间为20-40s;所述静置时间为10-15s。
本发明的有益效果在于:本发明方法可用于要求防水、防尘和较高散热能力的LED灯具。使用这种工艺,LED铝基板边缘被塑胶完全包覆密封,从而可以保证灯具能够完全防水、防尘;同时,因LED铝基板的背面暴露于外界空气中,可以直接对外界空气进行散热,从而大大提高了灯具的散热能力,防止热量在灯体内部集聚。
具体实施方式
下面将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LED铝基板模内注塑方法:
(1)采用无铅波峰焊对抗氧化铝基板260℃焊接3s,得到LED铝基板元器件;抗氧化铝基板包括铝基板基层、绝缘层和线路层;绝缘层涂覆在铝基板基层的表面,线路层蚀刻在所述绝缘层表面;铝基板基层为6061铝板;绝缘层为环氧树脂;线路层为电解铜箔;
(2)将LED铝基板元器件放入S136-D模具钢材质的注塑模具内,然后将注塑材料加入至注塑模具内进行注塑;注塑材料由PA66和玻璃纤维按7:3的质量比组成;注塑料筒温度为60℃,注塑喷嘴温度为280℃,模具温度为70℃,注塑射胶时间为15s;
(3)给予注塑模具压力并150MPa保压5s,然后冷却20s、开模、取件、静置15s,得到LED铝基板模内注塑器件。
实施例2
一种LED铝基板模内注塑方法:
(1)采用无铅波峰焊对抗氧化铝基板260℃焊接5s,得到LED铝基板元器件;抗氧化铝基板包括铝基板基层、绝缘层和线路层;绝缘层涂覆在铝基板基层的表面,线路层蚀刻在所述绝缘层表面;铝基板基层为5052铝板;绝缘层为环氧树脂;线路层为电解铜箔;
(2)将LED铝基板元器件放入S136-D模具钢材质的注塑模具内,然后将注塑材料加入至注塑模具内进行注塑;注塑材料由PA66和玻璃纤维按7:3的质量比组成;注塑料筒温度为90℃,注塑喷嘴温度为290℃,模具温度为95℃,注塑射胶时间为5s;
(3)给予注塑模具压力并80MPa保压2s,然后冷却40s、开模、取件、静置10s,得到LED铝基板模内注塑器件。
实施例3
一种LED铝基板模内注塑方法:
(1)采用无铅波峰焊对抗氧化铝基板260℃焊接4s,得到LED铝基板元器件;抗氧化铝基板包括铝基板基层、绝缘层和线路层;绝缘层涂覆在铝基板基层的表面,线路层蚀刻在所述绝缘层表面;铝基板基层为6061铝板;绝缘层为环氧树脂;线路层为电解铜箔;
(2)将LED铝基板元器件放入S136-D模具钢材质的注塑模具内,然后将注塑材料加入至注塑模具内进行注塑;注塑材料由PA66和玻璃纤维按7:3的质量比组成;注塑料筒温度为70℃,注塑喷嘴温度为285℃,模具温度为85℃,注塑射胶时间为10s;
(3)给予注塑模具压力并120MPa保压3s,然后冷却30s、开模、取件、静置13s,得到LED铝基板模内注塑器件。
实施例4
一种LED铝基板模内注塑方法:
(1)采用无铅波峰焊对抗氧化铝基板260℃焊接4s,得到LED铝基板元器件;抗氧化铝基板包括铝基板基层、绝缘层和线路层;绝缘层涂覆在铝基板基层的表面,线路层蚀刻在所述绝缘层表面;铝基板基层为6061铝板;绝缘层为环氧树脂;线路层为电解铜箔;
(2)将LED铝基板元器件放入S136-D模具钢材质的注塑模具内,然后将注塑材料加入至注塑模具内进行注塑;注塑材料由PA66和玻璃纤维按7:3的质量比组成;注塑料筒温度为80℃,注塑喷嘴温度为283℃,模具温度为75℃,注塑射胶时间为8s;
(3)给予注塑模具压力并100MPa保压4s,然后冷却35s、开模、取件、静置12s,得到LED铝基板模内注塑器件。
实施例5
一种LED铝基板模内注塑方法:
(1)采用无铅波峰焊对抗氧化铝基板260℃焊接5s,得到LED铝基板元器件;抗氧化铝基板包括铝基板基层、绝缘层和线路层;绝缘层涂覆在铝基板基层的表面,线路层蚀刻在所述绝缘层表面;铝基板基层为6061铝板;绝缘层为环氧树脂;线路层为电解铜箔;
(2)将LED铝基板元器件放入S136-D模具钢材质的注塑模具内,然后将注塑材料加入至注塑模具内进行注塑;注塑材料由PA66和玻璃纤维按7:3的质量比组成;注塑料筒温度为85℃,注塑喷嘴温度为287℃,模具温度为90℃,注塑射胶时间为12s;
(3)给予注塑模具压力并140MPa保压5s,然后冷却30s、开模、取件、静置14s,得到LED铝基板模内注塑器件。
试验例
将实施例1-5制得的LED铝基板模内注塑器件分别用于灯具上,测试其防水防尘等级和散热能力,其中灯具功率为7w;结构如表1所示。
表1
尽管上面已经示出和描述了本发明的实施例,可以理解的是,上述实施例是示例性的,不能理解为对本发明的限制,本领域的普通技术人员在本发明的范围内可以对上述实施例进行变化、修改、替换和变型。
Claims (10)
1.一种LED铝基板模内注塑方法,其特征在于,包括以下步骤:
(1)采用无铅波峰焊对抗氧化铝基板进行焊接,得到LED铝基板元器件;
(2)将LED铝基板元器件放入注塑模具内,然后将注塑材料加入至注塑模具内进行注塑;
(3)给予注塑模具压力并保压,然后依次进行冷却、开模、取件、静置,得到LED铝基板模内注塑器件。
2.根据权利要求1所述一种LED铝基板模内注塑方法,其特征在于,所述抗氧化铝基板包括铝基板基层、绝缘层和线路层;所述绝缘层涂覆在所述铝基板基层的表面,所述线路层蚀刻在所述绝缘层表面。
3.根据权利要求2所述一种LED铝基板模内注塑方法,其特征在于,所述铝基板基层为6061铝板或5052铝板;
所述绝缘层为环氧树脂;
所述线路层为电解铜箔。
4.根据权利要求1所述一种LED铝基板模内注塑方法,其特征在于,所述注塑材料为防火工程塑料。
5.根据权利要求4所述一种LED铝基板模内注塑方法,其特征在于,所述防火工程塑料由PA66和玻璃纤维按7:3的质量比组成。
6.根据权利要求1所述一种LED铝基板模内注塑方法,其特征在于,所述注塑模具的材质为S136-D模具钢。
7.根据权利要求1所述一种LED铝基板模内注塑方法,其特征在于,步骤(1)中所述焊接温度为260℃,焊接时间为3-5s。
8.根据权利要求1所述一种LED铝基板模内注塑方法,其特征在于,步骤(2)中所述注塑料筒温度为60-90℃,注塑喷嘴温度为280-290℃,模具温度为70-95℃,注塑射胶时间为5-15s。
9.根据权利要求1所述一种LED铝基板模内注塑方法,其特征在于,步骤(3)中所述保压压力为80-150MPa,保压时间为2-5s。
10.根据权利要求1所述一种LED铝基板模内注塑方法,其特征在于,步骤(3)中所述冷却时间为20-40s;所述静置时间为10-15s。
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