CN117894904A - 一种fpc-cob灯带及其制作方法 - Google Patents
一种fpc-cob灯带及其制作方法 Download PDFInfo
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Abstract
本发明公开了一种FPC‑COB灯带及其制作方法,属于照明设备技术领域,包括FPC柔性电路板和封装胶,FPC柔性电路板为柔性印制线路板,呈长条状,在FPC柔性电路板的顶层沿长度方向设置有若干LED裸片,LED裸片以串并联的方式集成安装到FPC柔性电路板上,然后在FPC柔性电路板上包裹有一层封装胶,封装胶的材质为硅胶,并且在封装胶内掺杂有不同颜色的荧光粉,封装胶覆盖在所有LED裸片上,中和灯带的亮度。在生产过程中,当成型压轮装置向外将灯带释放装置中的FPC柔性电路板向外拉拽出时,位于灯带释放装置与成型压轮装置之间的点胶器对FPC柔性电路板涂敷熔融的封装胶,继而凝固的封装胶会覆盖到FPC柔性电路板底层,从而将FPC柔性电路板嵌入进封装胶内。
Description
技术领域
本发明涉及照明设备技术领域,具体涉及一种FPC-COB灯带及其制作方法。
背景技术
COB灯带是Chip On Board(芯片级集成技术)的缩写,其核心结构主要是将LED芯片封装在一个小面积的FPC电路板上。这种技术可以让COB灯带在一个小面积内集成更多的LED芯片,从而提高光效。
与常见的LED灯带不同,COB灯带不仅可以在单位面积集成安装更多数量的LED芯片,而且为了避免在灯带上出现热点(固定装置或条带上出现较亮区域的术语),需要在LED芯片上涂敷一层磷光体(掺杂有荧光粉的硅胶),从而中和光线,使得光带形成一个平滑的光源。
这种工艺在制作COB灯带上十分常见,但由于LED芯片在点亮时不仅会发出较亮的光线,而且会产生大量的热量,磷光体本身的材质为硅胶,在受到光线照射以及反复的温差变化的影响下,硅胶就会发生变性,不仅颜色会变暗,同时硅胶的弹性还会下降,变得易碎且难以附着在FPC电路板上,而一旦磷光体脱落,COB灯带就会很快失效报废,因此,在应用材料没有得到升级的情况下,如何提高磷光体硅胶的耐用性,防止磷光体脱落对于提高COB灯带的使用寿命就显得十分重要。
发明内容
为此,本发明提供一种FPC-COB灯带及其制作方法,以解决现有技术中由于磷光体变性脱落而降低COB灯带的使用寿命的问题。
为了实现上述目的,本发明提供如下技术方案:
根据本发明的第一方面。
本发明公开了一种FPC-COB灯带,包括:
FPC柔性电路板,呈长条状,顶层沿长度方向设置有若干LED裸片;
封装胶,包裹在所述FPC柔性电路板上、并覆盖在任意一个LED裸片上;
其中,所述封装胶覆盖到所述FPC柔性电路板底层。
在一个可能的实施方式中,所述封装胶内掺杂有荧光粉。
进一步的,所述FPC柔性电路板的底层贴敷有锡纸条,所述锡纸条的边沿与所述封装胶密封相接。
在一个可能的实施方式中,所述锡纸条暴露在外的部分设置有背胶。
在一个可能的实施方式中,锡纸条包括锡纸和细铁丝,所述锡纸两侧包裹有一对细铁丝。
本发明具有如下优点:
本发明公开的FPC-COB灯带,主要将封装胶涂敷在若干LED裸片上,同时通过滚轮挤压的方式,使得封装胶在半凝固的状态下,向下延伸到柔性电路板背面,从而将柔性电路板嵌入到封装胶内。相比较现有技术单纯通过点胶机将封装胶涂敷在软板上的方法,本发明公开的灯带具有更高的牢固性和耐用性,并具有良好的防水性能,可以有效提高了灯带的使用寿命。
根据本发明的第二方面。
本发明公开了一种FPC-COB灯带的制作方法,用于生产如上所述的FPC-COB灯带,包括如下步骤:
步骤一、将装有LED裸片的FPC柔性电路板缠绕在灯带释放装置上;
步骤二、成型压轮装置向外将灯带释放装置中的所述FPC柔性电路板向外拉拽出来、同时位于所述灯带释放装置与成型压轮装置之间的点胶器对FPC柔性电路板涂敷熔融的封装胶;
步骤三、将锡纸条贴合在所述FPC柔性电路板底层,并与处于熔融流动状态的封装胶粘接在一起;
步骤四、经过成型压轮装置挤压成型的所述FPC柔性电路板经气流冷却降温,完全固定形状。
进一步的,所述成型压轮装置包括一级成型压轮组、二级成型压轮组和三级成型压轮组,经过所述点胶器点胶过的FPC柔性电路板依次通过一级成型压轮组、二级成型压轮组和三级成型压轮组;
所述一级成型压轮组适于将位于所述FPC柔性电路板上层的封装胶压平;
所述二级成型压轮组适于挤压所述封装胶向FPC柔性电路板两侧延伸;
所述三级成型压轮组适于从所述FPC柔性电路板两侧将封装胶挤压到FPC柔性电路板底层。
进一步的,所述二级成型压轮组包括:
上压辊,中部设置有凸槽;
下压辊,与所述FPC柔性电路板底部相抵、并在下压辊与FPC柔性电路板之间插入锡纸条。
进一步的,所述三级成型压轮组由左、右两个竖直设置的挤压辊组成:
所述挤压辊中部开设有挤压槽,所述封装胶与锡纸条在挤压槽内粘合在一起。
进一步的,所述成型压轮装置两侧设置有出风孔,所述成型压轮装置顶部设置有防尘罩。
进一步的,所述挤压辊内设置有用于通电加热的热电阻丝。
本发明具有如下优点:
本制作方法在原有点胶机涂胶的基础上,采用一级成型压轮组、二级成型压轮组和三级成型压轮组依次对封装胶进行挤压,从而使得封装胶包裹在电路板以及锡纸上,封装胶经过挤压定型后可与电路板更好的结合,并提高封装胶的牢固性。
附图说明
为了更清楚地说明本发明的实施方式或现有技术中的技术方案,下面将对实施方式或现有技术描述中所需要使用的附图作简单地介绍。显而易见地,下面描述中的附图仅仅是示例性的,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据提供的附图引伸获得其它的实施附图。
本说明书所绘示的结构、比例、大小等,均仅用以配合说明书所揭示的内容,以供熟悉此技术的人士了解与阅读,并非用以限定本发明可实施的限定条件,故不具技术上的实质意义,任何结构的修饰、比例关系的改变或大小的调整,在不影响本发明所能产生的功效及所能达成的目的下,均应仍落在本发明所揭示的技术内容得能涵盖的范围内。
图1为本发明提供的FPC-COB灯带成型示意图;
图2为本发明提供的三级成型压轮组示意图;
图3为本发明提供的二级成型压轮组示意图;
图4为本发明提供的灯带释放装置示意图;
图5为本发明提供的FPC-COB灯带层级结构示意图;
图6为本发明提供的FPC-COB灯带立体图;
图7为本发明提供的现有技术COB灯带示意图;
图8为本发明提供的锡纸条层级结构示意图;
图中:01 FPC柔性电路板;02锡纸条;021锡纸;022铁丝;03封装胶;04 LED裸片;1灯带释放装置;2点胶器;3成型压轮装置;31一级成型压轮组;32二级成型压轮组;321上压辊;322下压辊;323凸槽;33三级成型压轮组;331挤压辊;332挤压槽;4出风孔;5防尘罩。
具体实施方式
以下由特定的具体实施例说明本发明的实施方式,熟悉此技术的人士可由本说明书所揭露的内容轻易地了解本发明的其他优点及功效,显然,所描述的实施例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。
请一并参考图1-图8,本发明公开了一种FPC-COB灯带,其主要包括FPC柔性电路板01和封装胶03,其中,FPC柔性电路板01为柔性印制线路板,呈长条状,简称软板,它是通过在一种可曲饶的基材表面利用光成像图形转移和蚀刻工艺方法而制成导体电路图形,其中双面和多层电路板的表层与内层通过金属化孔实现内外层电气联通,并且在FPC柔性电路板01的顶层沿长度方向设置有若干LED裸片04,LED裸片04通电释放可见光、并以串并联的方式集成安装到FPC柔性电路板01上,由此可以随意裁剪短柔性电路板01、并保持LED裸片04常亮。在FPC柔性电路板01上包裹有一层封装胶03,封装胶03的材质为硅胶,该封装胶03内可以掺杂有不同颜色的荧光粉,并覆盖在所有LED裸片04上。进一步的,凝固的封装胶03会覆盖到FPC柔性电路板01底层,从而将FPC柔性电路板01嵌入进封装胶03内。
相比较现有技术,单纯通过点胶机将封装胶03涂敷在软板上的灯带,如图8所示,本产品在结构上具有更高的牢固性和耐用性,并具有良好的防水性能,能有效提高了灯带的使用寿命。
在本实施例中,FPC柔性电路板01的底层贴敷有锡纸条02,通过锡纸条02可以起到良好的散热效果,并且锡纸条02的边沿与封装胶03密封相接,对FPC柔性电路板01起到密封保护作用。
在本实施例中,锡纸条02暴露在外的部分设置有背胶,以便将FPC-COB灯带粘贴在目标上,并且利用锡纸条02良好的光洁性反射光线,还可以有效减少漏光,提高灯带的亮度。另一方面,锡纸条02包括锡纸021和铁丝022,其中,锡纸021的两侧包裹有一对细铁丝022,细铁丝022容易弯折变形,由此,可以通过铁丝022为FPC-COB灯带造型,方便灯带使用。
基于同一发明构思,本发明公开的技术方案,提出了一种FPC-COB灯带的制作方法,以批量生产如上提出的FPC-COB灯带,包括如下步骤:
步骤一、将装有LED裸片04的FPC柔性电路板01缠绕在灯带释放装置1上,在步骤一中,灯带释放装置1为一个缠绕灯条的滚轴,滚轴转动设置在滚架上,并随向外拉拽柔性电路板01而转动;
步骤二、成型压轮装置3向外将灯带释放装置1中的FPC柔性电路板01向外拉拽出来、同时位于灯带释放装置1与成型压轮装置3之间的点胶器2对FPC柔性电路板01涂敷熔融的封装胶03;
步骤三、将锡纸条02贴合在FPC柔性电路板01底层,并与处于熔融流动状态的封装胶03粘接在一起;
步骤四、经过成型压轮装置3挤压成型的FPC柔性电路板01经气流冷却降温,完全固定形状。
在一些实施例中,如图1,成型压轮装置3包括一级成型压轮组31、二级成型压轮组32和三级成型压轮组33,经过点胶器2点胶过的FPC柔性电路板01依次通过一级成型压轮组31、二级成型压轮组32和三级成型压轮组33,其中,一级成型压轮组31适于将位于FPC柔性电路板01上层的封装胶03压平;二级成型压轮组32适于挤压封装胶03向FPC柔性电路板01两侧延伸,三级成型压轮组33适于从FPC柔性电路板01两侧将封装胶03挤压到FPC柔性电路板01底层。
在一些实施例中,如图3,二级成型压轮组32包括上压辊321和下压辊322,上压辊321的中部设置有凸槽323,凸槽323用于挤压封装胶03,在使得封装胶03向FPC柔性电路板01两侧延伸的同时,在封装胶03顶部形成一个类似凸透镜的凸面,由此当光线通过封装胶03后,有利于光线折射聚集,从而提高灯带的光效。
进一步的,在下压辊322与FPC柔性电路板01之间插入锡纸条02,由此使得锡纸条02与封装胶03结合在一起,从而起到良好的密封效果。
在一些实施例中,如图2,三级成型压轮组33由左、右两个竖直设置的挤压辊331组成,挤压辊331上安装有电机,可以带动挤压辊331转动,并利用挤压辊331与灯带封装胶之间产生的摩擦力,对灯带形成拖拽的效果。此外,在挤压辊331中部开设有挤压槽332,挤压槽332可以对封装胶进一步挤压成型,从而给封装胶03与锡纸条02在挤压槽332内粘合在一起,并使得封装胶03与FPC柔性电路板01牢固镶嵌在一起,在保护FPC柔性电路板01同时,还起到避免封装胶03脱落的效果。
挤压辊331内设置有用于通电加热的热电阻丝,由此可以通过挤压辊331对封装胶03加热软化,便于封装胶03最终成型。
在一些实施例中,如图4,成型压轮装置3两侧设置有出风孔4,出风孔4可以向外释放清洁的空气气流,成型压轮装置3顶部设置有防尘罩5,防尘罩5不仅可以防止灰尘进入设备,同时可以使得空气气流在防尘罩5内流动,加速密封胶冷却固化。
虽然,上文中已经用一般性说明及具体实施例对本发明作了详尽的描述,但在本发明基础上,可以对之作一些修改或改进,这对本领域技术人员而言是显而易见的。因此,在不偏离本发明精神的基础上所做的这些修改或改进,均属于本发明要求保护的范围。
Claims (10)
1.一种FPC-COB灯带,其特征在于,包括:
FPC柔性电路板(01),呈长条状,顶层沿长度方向设置有若干LED裸片(04);
封装胶(03),包裹在所述FPC柔性电路板(01)上、并覆盖在任意一个所述LED裸片(04)上;
其中,所述封装胶(03)覆盖到所述FPC柔性电路板(01)底层。
2.如权利要求1所述的FPC-COB灯带,其特征在于,所述封装胶(03)内掺杂有荧光粉。
3.如权利要求2所述的FPC-COB灯带,其特征在于,所述FPC柔性电路板(01)的底层贴敷有锡纸条(02),所述锡纸条(02)的边沿与所述封装胶(03)密封相接。
4.如权利要求3所述的FPC-COB灯带,其特征在于,所述锡纸条(02)暴露在外的部分设置有背胶。
5.一种FPC-COB灯带的制作方法,用于生产如权利要求4中的FPC-COB灯带,其特征在于,包括如下步骤:
步骤一、将装有LED裸片(04)的FPC柔性电路板(01)缠绕在灯带释放装置(1)上;
步骤二、成型压轮装置(3)向外将灯带释放装置(1)中的所述FPC柔性电路板(01)向外拉拽出来、同时位于所述灯带释放装置(1)与成型压轮装置(3)之间的点胶器(2)对FPC柔性电路板(01)涂敷熔融的封装胶(03);
步骤三、将锡纸条(02)贴合在所述FPC柔性电路板(01)底层、并与处于熔融流动状态的封装胶(03)粘接在一起;
步骤四、经过成型压轮装置(3)挤压成型的所述FPC柔性电路板(01)经气流冷却降温,完全固定形状。
6.如权利要求5所述的FPC-COB灯带的制作方法,其特征在于,所述成型压轮装置(3)包括一级成型压轮组(31)、二级成型压轮组(32)和三级成型压轮组(33),经过所述点胶器(2)点胶过的FPC柔性电路板(01)依次通过一级成型压轮组(31)、二级成型压轮组(32)和三级成型压轮组(33);
所述一级成型压轮组(31)适于将位于所述FPC柔性电路板(01)上层的封装胶(03)压平;
所述二级成型压轮组(32)适于挤压所述封装胶(03)向FPC柔性电路板(01)两侧延伸;
所述三级成型压轮组(33)适于从所述FPC柔性电路板(01)两侧将封装胶(03)挤压到FPC柔性电路板(01)底层。
7.如权利要求6所述的FPC-COB灯带的制作方法,其特征在于,所述二级成型压轮组(32)包括:
上压辊(321),中部设置有凸槽(323);
下压辊(322),与所述FPC柔性电路板(01)底部相抵、并在下压辊(322)与FPC柔性电路板(01)之间插入锡纸条(02)。
8.如权利要求7所述的FPC-COB灯带的制作方法,其特征在于,所述三级成型压轮组(33)由左、右两个竖直设置的挤压辊(331)组成:
所述挤压辊(331)中部开设有挤压槽(332),所述封装胶(03)与锡纸条(02)在挤压槽(332)内粘合在一起。
9.如权利要求8所述的FPC-COB灯带的制作方法,其特征在于,所述成型压轮装置(3)两侧设置有出风孔(4),所述成型压轮装置(3)顶部设置有防尘罩(5)。
10.如权利要求9所述的FPC-COB灯带的制作方法,其特征在于,所述挤压辊(331)内设置有用于通电加热的热电阻丝。
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