TW423168B - The manufacturing method of LED unit body - Google Patents

Abstract

The present invention reveals a manufacturing method of LED unit body which can shorten the production time, enhance the quality, reduce the cost, increase the revenue without huge resin-instilling space and baking oven, and reduce the secondary damage of non-uniform luminance resulted from the long duration, high temperature baking.

Description

V. Creation Instructions (5 10 15 C7 D7 PA870I95.AMD-3/12 Yinzheng Central Consumers ’Bureau, Zhengong Consumer Cooperative Co., Ltd. Seal 20 [Technical Field] The present invention relates to a method for manufacturing an LED unit body, and more particularly to a method for manufacturing an LED unit body. Full-color (three primary colors of R, G, B) high-brightness light-emitting diode electronic display screen structure and its light mixing method. [Previous technology] According to the general semiconductor and traditional LED manufacturing methods, epoxy resin The hardening agent can be formed after baking at a high temperature of 90 ° C to 110 ° C. As described in the Chinese Patent No. 31 1269 (hereinafter referred to as the cited case), the cited case is a plastic packaging method, but The material used is a recyclable resin (softening at room temperature requires a hardener), and the resin is coated or sprayed into the micro-junction structure on the surface of the semiconductor body. 'After it is hardened naturally, After the latter process is performed, because it uses a sprinkler or coating packaging method, it will lead to a coarser sugar surface after packaging, which cannot show flatness and smoothness, and is currently used in the production of semiconductor packages. "The technique is not yet able to withstand the injection impact of more than 40 pieces of pressure, so the production method described in the cited case is only applicable to the semiconductor packaging industry; and the main material in this case is polypropylene (plastic, rigid Need to increase the heat) 'The polypropylene must be melted at a high temperature of more than 200 degrees, and then directly injection molding using a pressure of 40 or more, so that the lamp string, shape and waterproofing can be completed at one time; The production method results in a smooth and beautiful surface. For LED manufacturers, 'the ability to improve competition such as people, things, objects, vision, and yield is a key research and development point, and the present invention is towards this end. Move towards the direction. -3-This paper size is applicable to one Chinese company (橾 阳) 8 4 * ^ 洛 (2 〖0 father 297 mm) (Please read the precautions on the back before filling this page)

423168 C7 D7 V. Creative Instructions (PA87Q195.ΛΜΡ-4/12 5 10 15) Central standard of the Ministry of Economic Affairs and Industrial Consumer Cooperatives printed m 20 LED high-brightness blue light source, after the advent of the full-color kanban, it gradually became popular in multimedia computers. In the world, general users and foreign orders require that the light emission angle and color must be fairly uniform, but it is extremely difficult for automatic dispensers to complete the above requirements. LED processing is sealed with epoxy resin or silicone in the shell, and the oven is 120 ° C Above, and the factors such as positioning, glue amount, and flatness are all indeterminate, the production rate is less than 90%, and it cannot be repaired after the sealing failure. A single LED lamp body is easy to stick to the front, causing uneven shadow brightness. After the advent of high-brightness blue and green LED light sources, LED outdoor signage has become the new darling of the information age, but it needs to be waterproof when placed outdoors. The traditional manufacturing method is not enough for the cost of use, and it has a long production time and low yield. The quality cannot be fully grasped in the production process of the glue drying process, so the cost is high. It can be seen that there are still many shortcomings in the above-mentioned conventional items, which is not a good design. In view of the various shortcomings derived from the above-mentioned conventional LED unit body manufacturing method, the inventor of this case was eager to improve and innovate, and after years of painstaking research, he successfully developed the LED unit body. [Objective of the invention] The purpose of the present invention is to provide a method for manufacturing an LED unit body, which has three contributions to environmental protection: 1. It can remove traditional hard epoxy resin or stone rubber, and the two materials mentioned above are solid-formed when it is solid-formed. Will emit toxic chemicals, causing air dullness problems -4 This paper size applies to the Chinese national standard (CNS) A4 size (210X297 mm) (Please read the precautions on the back before filling this page) Thread, 4 23168, C7 ___ PA87Q195.AMD-5/12 5. Creation instructions () 2. It takes up to 1 hour and 30 minutes to use epoxy resin to bake in the oven, causing secondary high temperature damage and reducing service life; and the use of plastic injection molding has a fast time The environmental protection problem is small. 3. The epoxy resin lamp body cannot be recycled and rebuilt, and the plastic injection molding 5 shell can be recycled. One objective is to provide a method for manufacturing an LED unit assembly, in terms of production speed: in terms of injection molding, the LED does not need to be destroyed by excessive temperature for a long time to affect the normal life of the LED lamp body, because the plastic injection molding time is about 40 seconds , From 110 degrees Celsius to 60 degrees Celsius below 10, fully in line with the LED lamp body operating specifications, the production speed is about 130 times faster, and can reduce production and quality assurance personnel costs, improve quality 'increase production capacity * defective products can also After dissolving the plastic in the shell, and then repairing the LED, the production rate can be as high as 99% or more, and the production materials are easier to control. Another object of the present invention is to provide a method for manufacturing an LED unit body, which is in terms of overall competitiveness. ; In this professional field, in the past, high-brightness blue light and green light sources were controlled by Japanese companies. In order to improve competitiveness, we reduced the production process of the back-end process by 50% with innovative methods. The time required for the process is shortened, wages are reduced, manufacturing costs are saved, and air pollution and electricity and energy consumption are significantly reduced. 20 In addition, the cost is reduced, the production time is shortened, the quality is improved, the delivery time is accurate, and the international competitiveness is enhanced. It is a creation that reforms production technology and increases the international competitiveness of products.

I [Brief description of the drawings] Please refer to the following detailed description of a preferred embodiment of the present invention and its -5-This paper size uses the Chinese National Standard (CNS) A4 specification (210X297 mm) (please read the back first) (Notes for filling in this page)

.1T Printed bags for consumer labor cooperatives of the Central Bureau of Standards of the Ministry of Economic Affairs 4 23168 C7 _____ PAS7Q195.AMD-6/12 V. Creation instructions () The drawings will further understand the technical content of the present invention and its effects; related to this embodiment The drawings are: Figure 1 is the first step diagram of the LED unit body manufacturing method of the present invention; Figure 2 is the second step diagram of the LED unit body manufacturing method; 5 Figure 3 is the third step diagram of the LED unit body manufacturing method ; Figure 4 is a diagram of the fourth step of the method for manufacturing the LED unit body; Figure 5 is a diagram of the fifth step of the method for manufacturing the LED unit body; Figure 6A is a section view of a conventional LED unit body; Figure 6B is the LED unit Partial cross-sectional view of the body; 10 FIG. 7 is a diagram of another embodiment of the manufacturing method of the LED unit body; FIG. 8 is a diagram of the first step of another manufacturing method of the LED unit body of the present invention; The second step diagram; Figure 10 is the third step diagram of the LED unit body manufacturing method; Figure 11 is the fourth step diagram of the LED unit body manufacturing method; and 15 Table 1 is the use of polypropylene materials and epoxy resin Comparison of materials table. [Representative symbols of main parts] _ ^ — 丨 4 II (Please read the notes on the back before filling in this page) Printed by the Central Sample Rate Bureau of the Ministry of Economic Affairs, Shellfish Consumer Cooperatives 10 LED lamp body 11 Circuit board 12 Connection line 13 Mould 14 Mould 15 Inlet 16 PU plastic 17 Copper pillar 18 Ring groove 19 Rubber ring 20 Wire hole 21 LED finished product 22 Curved 23 Light -6-This paper size is applicable to China National Standard (CNS) A4 (210X297) (Centre) 423168 C7 D7 PA870195.AMD-7/12 Central Standards Bureau of the Ministry of Economic Affairs, Consumer Cooperatives Cooperative Seal 25 LED lamp body 27 base 31 circuit board 33 guide hole 35 mold core 37a ~ b two spaces 39 LED lamp body Creation instructions (24 planes, 26 sun caps, 30 LED lamp bodies, 32 connecting wires, 34 card grooves, 36 molds, 38a ~ b glue inlets [Preferred Embodiment] Please refer to FIG. 1 for the manufacturing method of the LED unit body provided by the present invention. First, a plurality of LED lamp bodies 10 are soldered on the cut circuit board 11, and then the connecting wires 12 and the circuit board 11 are soldered at appropriate positions. Among them, the arrangement of the LED 5 lamp body 10 needs certain rules and methods. Only when the light is mixed later to express the color will it have bright colors and high quality performance. Please refer to Figure 2, and then embed the LED lamp body 10 in the mold core 13 to fix it; because in the next step of filling, it is necessary to ensure that the PU plastic will not overflow and affect the quality, so it must be With the 10 phase of the LED lamp body 10, the size and distance must be just right. Please refer to Fig. 3, put the assembled LED mold 13 into the mold 14, and the mold 14 will cooperate with each other from the left and right to tightly close the center until it stops and stops. Please refer to Figure 4. After the mold clamping is completed, the poly 15 acrylic plastic 16 can be injected from the glue inlet 15. At the same time, the fixed copper column 17 is inserted and shot out; it is worth mentioning that After injection, a ring-shaped groove 18 will be formed on the back, and a rubber band 19 can be inserted to prevent water droplets from falling when it rains. The paper size applies to the Chinese National Standard (CNS) Α4 size (210X297 mm) (please first Read the note on the back and fill in this page) ^ 4 2 3 16 8 C7 D7 PA870195.AMD-8/12 Printed by Zhengong Consumer Cooperative of the Central Ladder Bureau of the Ministry of Economic Affairs 5. Creation Instructions () Carefully dip into the wire hole 20 , Causing a malfunction. Referring to FIG. 5, the finished LED finished product 21 is taken out. The material used in the present invention is polypropylene plastic 16. The injection molding time is about 30 seconds. During molding, the temperature is reduced from 90 degrees Celsius to 60 degrees Celsius, which fully meets the LED 5 lamp body operation specifications, and the production rate is as high as 99%. However, the conventional use of epoxy resin or silicone in the shell, through the oven above 120 degrees Celsius, and in the positioning, the amount of glue, flatness are uncertain factors, the production rate is about 90% or less. Please refer to Figure 6A and Figure 6B. In Figure 6A, epoxy resin or silicone is used as the material. After long-time high-temperature baking, the situation shown in Figure 6A 10 will be formed. An arc 22 will be formed between the lamp bodies, and the light 23 (light (Or sunlight) when it is irradiated, it produces a diffuse effect, the color and brightness are not uniform, and the daytime effect naturally needs to be strengthened; in Figure 6B, the use of PU plastic, the injection molding time is about 30 seconds, The temperature is reduced to below 60 degrees Celsius. In the temperature and short time that the LED lamp body can withstand, there is a plane 15 24 structure between the lamp bodies. When the light 23 (light or sunlight) is illuminated, it directly reflects the effect. Does not cause the same disadvantages as conventional items. Please refer to FIG. 7, which is another highly creative extension of the present invention. At the current intersections, traffic lights will be set as instructions to guide pedestrians and vehicles to pass, stop, etc., because the traffic lights have a lampshade in front, so you can see more than 20 lights in front, even when you come to the left and right to see, acute Of drivers or pedestrians often rush out when the yellow light flashes, and many traffic accidents often occur ... Therefore, we will make the LED lamp body 25 into the commonly known red, green, yellow and other traffic light colors, plus the sun hat 26, the base 27 is made of a fixed rotation of the bulb, and does not require a lampshade, it will be -8- This paper size applies to China National Standard (CNS) A4 (210X297 mm) (read the precautions on the back before filling in this page)

4 ^ 3168 C7 D7 PA870195.AMD-9/12 Printed by the Consumer Standards Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs V. Creation Instructions () Because of the principle of direct light from the LED light source, only the cars in front can see the lights, left and right cars have to wait until It can only start after changing the lights. The production process is not different from the aforementioned production process. Please refer to FIG. 8 ′, which is a step diagram of the fifth step of another manufacturing method of the LED unit body of the present invention. A plurality of LED lamp bodies 30 are first welded to the cut circuit board 31. Please refer to FIG. 9, which is different from FIG. 1 in that the connecting wire 32 is not connected with the circuit board 31 in advance, but the connecting wire 32 is passed through the pre-molded shell guide hole 33 before being connected to the circuit board 31. Then, after completion, the circuit board 31 is pushed back to the slot 34 in the housing to be positioned, and then buried in the mold core 35 * to fix it. Please refer to FIG. 10, the installed LED mold 35 is placed in the mold 36, because the circuit board 31 is internally blocked, so that the two front and rear spaces 37a and 37b are formed. The plastic ports 38a and 38b 1S are injected into the PU plastic. Referring to FIG. 11, the molded LED lamp body 39 is released from the mold. The injection molding time is about 30 seconds, from 90 degrees Celsius to below 60 degrees Celsius, which fully meets the operating specifications of LED lamp bodies, and the production rate is as high as 99%. Table 1 is a comparison table between the polypropylene material used in the present invention and the epoxy resin material used in the conventional technology. [Features and effects], The LED unit manufacturing method disclosed in the present invention has the following advantages when compared with the aforementioned citations and other conventional technologies: Position positioning: light-emitting diodes and printed circuit boards Combined with solder furnace soldering-9-This paper size applies Chinese National Standard (CNS) M specifications (210X297 mm) (Please read the precautions on the back before filling in this I) " Order 423168 C7 D7 PA870195.AMD-10 / 12 Employees' Cooperatives of the Central Government Bureau of the Ministry of Economic Affairs of the People's Republic of China. V. Creation Instructions () When fixed, first use a plastic mold to fix the center position of the light-emitting diode to reduce the error of the light-emitting angle caused by the offset. Flatness: The molded shell is injected with a mold, including the sun hat and its flat positioning tongue.

5 Water resistance: When the plastic mold of the housing is combined with the injection molding, the LED and the housing plastic are completely combined and sealed to form a leak-proof LED lamp body product. In addition, in terms of personnel and affairs, the number of working hours can be reduced, and fewer personnel are employed. The cost of management and sales is reduced, and the integrated plastic injection molding method improves the working environment and does not cause environmental pollution. If the LED lamp body is damaged (only one of the red, green, and blue colors is damaged), its shell can be recycled. After the PC is dissolved, the PCB and plastic parts can be rebuilt in the future. Visually, because the mold completes the positioning of the lamp body at the time of injection, the visual angle and brightness are more uniform in its brightness, color, and flatness than the general pouring method. And in terms of yield, because the lamp body is molded by injection, the yield can be increased to more than 99%, the production cost is reduced, and the profit is improved. The above detailed description is a specific description of a feasible embodiment of the present invention, but this embodiment is not intended to limit the scope of the patent of the present invention. Any equivalent implementation or change without departing from the technical spirit of the present invention should be Included in the patent scope of this case. To sum up, this case is not only technically innovative, but also enhances the above-mentioned multiple effects compared with conventional items. It should have fully met the requirements for statutory invention patents that are novel and progressive, and applied for it in accordance with the law. 1〇- This paper size is applicable to China National Standard (CNS) Α4 specification (210 × 297 mm) --------- 1 ------ ΐτ -------- ^ · :: -).) (Please read the precautions on the back before writing this page) ^ 23168 C7 _ _D7_PA870195.AMD · I " I2 V. Creative Instructions () Approve this invention patent application to encourage inventions . (Please read the notes on the back before filling out this S)

'1T Central Bureau of Standards, Ministry of Economic Affairs—Industrial-Consumer Cooperation Du Yin 褽 1 This paper size is in accordance with China National Standards (CNS) Α4 size (210 × 297 mm)

Claims (1)

^ 3168 Q100.AI \ j1〇 ^! £ / !: Patent application scope 1. An LED unit system edge method, which includes five steps: Step 1: First, solder several LED lamp bodies to the cut circuit board. Connect the connecting wire again; Step 2: Embed the assembled components in Step 1 into the mold core, fix the LED lamp body tightly and expose the proper parts to be filled with polypropylene; Step 3: Put the assembled LED The mold core is placed in the mold group; Step 4: Insert the fixed copper pillar at the same time, and close the mold to inject polypropylene from the plastic inlet and injection molding; Step 5: The finished product is ejected from the mold. Remove the mold. 10 2. A method for manufacturing an LED unit body, which includes four steps: Step one: first welding several LED lamp bodies to a cut circuit board: step two: placing the assembled components in step one in advance In the molded shell, pass the connecting wire through the shell to the circuit board and solder; 15 Step 3: Send the circuit board back to the case, there will be a card slot against the circuit board, and the shells are separated to form the front and back. Two spaces, and then inject polypropylene through two plastic inlets at the same time, and injection molding; Step 4: Take out the finished finished product from the mold and remove it from the mold. 3. The method for manufacturing an LED unit body as described in item 1 of the patent application scope, wherein the LED lamp body can be made into a single color and used as various types of lamps. 4. The method for manufacturing an LED unit body as described in item 2 of the patent application scope, wherein the LED lamp body can be made into a single color and used as various types of lamps. -12-This paper size applies the Chinese national standard CNS) Α4 specification (210 × 297 mm) (Please read the precautions on the back before filling out this page) * 1T Printed by the Intellectual Property Bureau of the Ministry of Economic Affairs and Consumer Cooperatives 3 2 4 Economy Printed by the Consumer Standards Cooperative of the Ministry of Standards of the People's Republic of China 6 8 A9 B9 C9 D9 Type Epoxy Resin (Liquid Plastic) Polypropylene; ^ (Solid Plastic) Use method requires hardener and anti-ultraviolet agent. 1 object LED die, IC chip, LED, 1C overall waterproof filling method after coating, spraying, injection, injection, extrusion, injection pressure using coating and injection nearly 40-80 pounds high pressure extrusion die hardening method 85 degrees = 4HR, 10〇i = 2HR 155 degrees molding within 10 seconds after mold-in. Available time after blending 25 degrees = 4HR, 40 degrees = 5HR Permanent (not affected by the environment) Thermal deformation temperature 122 degrees 135 degrees Flammability Anti-combustion (will support combustion) Anti-combustion (not support combustion) 3.94 at IKHz dielectric constant 3.12 at ΙΟΟΟΚΗζ Volume resistance Ohra-cm 1.3x100,000 Ohra-cm 1, 000, 000, 000UP Arc resistance No arc resistance 130 seconds Hardness 114 R-Scal 90 R-Scal Boiling water absorption for 1 hour 0.42% (23 degrees = 0%) 1 hour 0.02% (23 degrees = 0%) Thermal expansion coefficient 6.0 X (-100,000) 6.0 X (-100,000) The size of this paper is Chaojia County (⑽) from the specifications (21Qx297 mm)