WO2013189129A1 - 铜基板和铝基座焊接的led灯具散热结构的生产工艺 - Google Patents

铜基板和铝基座焊接的led灯具散热结构的生产工艺 Download PDF

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Publication number
WO2013189129A1
WO2013189129A1 PCT/CN2012/080998 CN2012080998W WO2013189129A1 WO 2013189129 A1 WO2013189129 A1 WO 2013189129A1 CN 2012080998 W CN2012080998 W CN 2012080998W WO 2013189129 A1 WO2013189129 A1 WO 2013189129A1
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Prior art keywords
aluminum base
copper substrate
solder paste
layer
dissipation structure
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PCT/CN2012/080998
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English (en)
French (fr)
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李冠桦
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林培林
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
    • B23K1/0016—Brazing of electronic components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/10—Aluminium or alloys thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/12—Copper or alloys thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • 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]

Definitions

  • the invention relates to the technical field of LED illumination, in particular to a production process of a heat dissipation structure of an LED lamp welded by a copper substrate and an aluminum base.
  • the use of aluminum substrates for LEDs is more effective when used in LED street lamps.
  • a layer of heat-dissipating adhesive is required to be bonded between the aluminum substrate and the aluminum alloy casing, and the thermal resistance is too large.
  • the heat of the LED is conducted to the aluminum substrate, the heat of the aluminum substrate can be directly transmitted to the street lamp outer casing through the heat-dissipating glue, resulting in high temperature of the LED and the outer casing.
  • the junction temperature of the LED lamp bead or LED module is greater than 75 °C, the life of the LED will be greatly shortened.
  • the present invention provides a production process for a heat dissipation structure of a copper lamp and an aluminum base welded LED lamp for improving the heat dissipation effect of the LED lamp.
  • the present invention provides a production process for a heat dissipation structure of an LED lamp and a copper pedestal soldered by an aluminum pedestal, comprising the following steps:
  • Nickel plating plating a nickel layer on the surface of the aluminum base
  • Aluminum base scraping paste removing the residue on the surface of the nickel-plated layer of the aluminum base and uniformly laminating a layer of chlorine-free and lead-free solder paste on the nickel plating layer;
  • Copper substrate solder paste remove residue on the surface of the copper substrate and evenly spread a layer of chlorine-free and lead-free solder paste on the cleaned surface;
  • Heat welding the surface on which the solder paste is placed on the copper substrate is bonded to the surface of the aluminum base on which the solder paste is applied, and then placed on a thermostat to heat the solder paste layer on the copper substrate and the solder paste layer on the aluminum base. Integration: Cooling: The assembly of the copper substrate and the aluminum base is taken out from the thermostat and cooled to a normal temperature to obtain a heat dissipation structure of the LED lamp welded by the copper substrate and the aluminum base.
  • the heating temperature of the thermostat is 180 ° C, and the heating time is 10 min ⁇ 0.5 min.
  • the thickness of the chlorine-free and lead-free solder paste is 0.2-0.3 mm, the melting point is 140 ° C, and the material of the solder paste is Sn42/Bi58.
  • the thickness of the chlorine-free and lead-free solder paste is 0.2-0.3 mm
  • the melting point is 140 ° C
  • the material of the solder paste is Sn42/Bi58.
  • the step of attaching the LED lamp bead to the copper substrate is further included.
  • the step of removing the residue of the surface of the heat dissipation structure of the LED lamp and the aluminum base soldered by the aluminum base at a normal temperature is further included.
  • the invention has the beneficial effects that the copper substrate and the aluminum base welded LED lamp heat dissipation structure are provided by the invention, and the surface of the aluminum base is plated with a nickel layer and then plated on the surface of the nickel layer.
  • a layer of solder is used to solder the aluminum pedestal and the copper substrate to obtain the heat dissipation structure of the present case.
  • the copper substrate soldered with the LED lamp bead is directly connected to the aluminum base through the solder layer, and the heat dissipation effect is good, and the high junction temperature of the heat dissipation adhesive does not affect the service life of the LED.
  • Fig. 1 is a flow chart showing the process of producing a heat dissipation structure of an LED lamp welded to a copper substrate and an aluminum base of the present invention. detailed description
  • FIG. 1 the production of the heat dissipation structure of the LED lamp of the copper substrate and the aluminum base of the present invention. Art, including the following steps:
  • Step 101 nickel plating: plating a nickel layer on the surface of the aluminum base;
  • Step 102 the aluminum base scraping paste: removing the residue on the surface of the nickel plating layer of the aluminum base and uniformly laminating a layer of chlorine-free and lead-free solder paste on the nickel plating layer;
  • Step 103 Soldering the copper substrate: removing the residue on the surface of the copper substrate and uniformly laminating a layer of chlorine-free and lead-free solder paste on the cleaned surface;
  • Step 104 heat welding: the surface of the copper substrate on which the solder paste is applied is bonded to the surface of the aluminum base on which the solder paste is applied, and then placed on a thermostat to heat the solder paste layer on the copper substrate and the aluminum base.
  • the solder paste layer is integrated into one;
  • Step 105 Cooling: the assembly of the copper substrate and the aluminum base is taken out from the thermostat and cooled to a normal temperature to obtain a heat dissipation structure of the LED lamp and the aluminum base soldered LED lamp.
  • the present invention provides a copper substrate and an aluminum pedestal for soldering a heat dissipation structure of an LED lamp.
  • the surface of the aluminum base is plated with a nickel layer, and then a layer of solder is plated on the surface of the nickel layer.
  • the aluminum base and the copper substrate were solder-welded to obtain the heat dissipation structure of the present invention.
  • the copper substrate soldered with the LED lamp bead is directly connected to the aluminum base through the solder layer, and the heat dissipation effect is good, and the high junction temperature of the heat-dissipating adhesive does not affect the service life of the LED.
  • the heating temperature of the thermostat is 180 ° C and the heating time is 10 min ⁇ 0.5 min.
  • the present invention is not limited to the specific heating temperature of the thermostat, and only the heating temperature and the melting point of the solder are changed, and it is a simple modification or transformation of the present invention, which falls within the scope of the present invention.
  • the thickness of the chlorine-free and lead-free solder paste is 0.2-0.3 mm
  • the melting point is 140 ° C
  • the material of the solder paste is Sn42/Bi58.
  • the present invention is not limited to the thickness, melting point and material of the solder paste, and any embodiment in which the aluminum base and the copper substrate with the nickel plating layer are soldered by solder paste is a simple deformation or transformation of the present invention. It is within the scope of protection of the present invention.
  • the thickness of the chlorine-free and lead-free solder paste is 0.2-0.3 mm
  • the melting point is 140 ° C
  • the material of the solder paste is Sn42/Bi58.
  • the present invention is not limited to the thickness, melting point and material of the solder paste, and any embodiment in which the aluminum base and the copper substrate with the nickel plating layer are soldered by solder paste is a simple deformation or transformation of the present invention. Into the invention Range of protection.
  • the step of attaching the LED lamp bead to the copper substrate is further included.
  • the lamp bead is directly attached to the copper substrate, and is fabricated by using a bracket or directly in the form of a COB package, and all of them belong to the simple deformation or transformation of the present invention, and fall within the protection scope of the present invention.
  • the copper substrate has the characteristics of high thermal conductivity and high heat dissipation.
  • the LED is soldered to the copper substrate, the power is turned on, and the copper substrate is absorbed first, which is limited by the small heat dissipation area of the copper substrate and the high price.
  • An aluminum base is needed to assist in heat dissipation.
  • the invention directly distributes the heat of the LED on the copper substrate to the rear heat sink (aluminum heat sink base), so that the best benefit is obtained, and the LED temperature is maintained at about 55 °C to ensure the long life of the lamp.
  • the step of removing the residue of the surface of the heat dissipation structure of the LED substrate and the aluminum base soldered LED lamp at a normal temperature is further included. Clearing the residue on the surface of the LED heat dissipation structure can improve the appearance of the LED and ensure its performance.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)

Abstract

一种铜基板和铝基座焊接的LED灯具散热结构的生产工艺，该工艺包括以下步骤：镀镍（步骤101）：在铝基座表面上电镀一镍层；铝基座刮锡膏（步骤102）：清除铝基座镀镍层表面的残留物并在该镀镍层上均匀平铺一层无氯无铅焊锡膏；铜基板刮锡膏（步骤103）：清除铜基板表面上的残留物并在该已清洁的表面上均匀平铺一层无氯无铅焊锡膏；加热焊接（步骤104）：将铜基板上铺有锡膏的一面与铝基座上铺有锡膏的表面贴合后，放入恒温台加热使得铜基板上的锡膏层与铝基座上的锡膏层融为一体；冷却（步骤105）：将铜基板和铝基座的组合件从恒温台拿出后冷却至常温，得到铜基板和铝基座焊接的LED灯具散热结构。该工艺利用焊锡焊接铝基座和铜基板，散热效果好，不会因散热粘合剂产生高结温而影响LED的使用寿命。

Description

铜基板和铝基座焊接的 LED灯具散热结构的生产工艺 技术领域
本发明涉及 LED 照明技术领域，尤其涉及一种铜基板和铝基座焊接的 LED灯具散热结构的生产工艺。 背景技术 说
在 LED行业中 ， LED路灯的散热是一项技术难题。 目前为止，各大 LED 路灯制造厂家都没有更好的办法解决这个散热问题。 现有的采用铝基板与散 热膏粘合的散热结构，造成 LED、 铝基板和书铝基座（路灯外壳 )间的散热温 差较大， LED结温较高。 当 LED结温在 70°C以上时， LED灯珠就会受到严 重损坏，造成光衰，影响整个 LED灯具的寿命。
目前，采用铝基板应用于 LED上，更多的应用于 LED路灯时，其散热效 果欠佳。 特别是铝基板与铝合金外壳间需要设置一层散热粘合剂粘合在一起， 热阻太大。 当 LED热量传导至铝基板后，铝基板的热量通过散热胶才能直接 传导到路灯外壳体上，造成 LED和外壳温度偏高。 而 LED灯珠或 LED模组 的结温大于 75°C时， LED的寿命会大大縮短。 另外，铝基板与铝基座间的焊 接工艺不好处理，散热膏经长期使用会老化，不能达到散热效果且易造成接 触不充分，散热不均匀也会使灯的局部温度过高而影响寿命。 发明内容
针对上述技术中存在的不足之处，本发明提供一种提高 LED灯散热效果 的铜基板和铝基座焊接的 LED灯具散热结构的生产工艺。
为实现上述目的，本发明提供一种铜基板和铝基座焊接的 LED灯具散热 结构的生产工艺，包括以下步骤：
镀镍：在铝基座表面上电镀上一镍层；
铝基座刮锡膏：清除铝基座镀镍层表面的残留物并在该镀镍层上均匀平 铺一层无氯无铅焊锡膏； 铜基板刮锡膏：清除铜基板表面上的残留物并在该已清洁的表面上均匀 平铺一层无氯无铅焊锡膏；
加热焊接：将铜基板上铺有锡膏的一面与铝基座上铺有锡膏的表面贴合 后，放入恒温台加热使得铜基板上的锡膏层与铝基座上的锡膏层融为一体； 冷却：将铜基板和铝基座的组合件从恒温台拿出后冷却至常温，得到铜 基板和铝基座焊接的 LED灯散热结构。
其中 ，在加热焊接步骤中 ，恒温台的加热温度为 180°C，加热时间为 10min ±0.5min。
其中 ，在铝基座刮锡膏的步骤中 ，无氯无铅焊锡膏的厚度为 0.2-0.3mm , 熔点为 140°C ,锡膏的材质为 Sn42/Bi58。
其中 ，在铜基板刮锡膏的步骤中 ，无氯无铅焊锡膏的厚度为 0.2-0.3mm , 熔点为 140°C ,锡膏的材质为 Sn42/Bi58。
其中 ，在铜基板刮锡膏的步骤之前，还包括在铜基板上贴上 LED灯珠的 步骤。
其中 ，在冷却的步骤之后，还包括在常温下清除铜基板和铝基座焊接的 LED灯散热结构表面的残留物的步骤。
本发明的有益效果是：与现有技术相比，本发明提供的铜基板和铝基座 焊接的 LED灯散热结构的生产工艺，将铝基座表面镀有一镍层，然后在镍层 表面镀一层焊锡，利用焊锡焊接铝基座和铜基板，得到本案的散热结构。 这 样，焊接有 LED灯珠的铜基板直接通过焊锡层与铝基座连接，散热效果好， 不会因散热粘合剂产生高结温而影响 LED的使用寿命。 附图说明
图 1为本发明的铜基板和铝基座焊接的 LED灯散热结构的生产工艺的工 艺流程图。 具体实施方式
为了更清楚地表述本发明 ，下面结合附图对本发明作进一步地描述。
请参阅图 1 ,本发明的铜基板和铝基座焊接的 LED灯散热结构的生产工 艺，包括以下步骤：
步骤 101 ,镀镍：在铝基座表面上电镀上一镍层；
步骤 102 ,铝基座刮锡膏：清除铝基座镀镍层表面的残留物并在该镀镍 层上均匀平铺一层无氯无铅焊锡膏；
步骤 103 ,铜基板刮锡膏：清除铜基板表面上的残留物并在该已清洁的 表面上均匀平铺一层无氯无铅焊锡膏；
步骤 104 ,加热焊接：将铜基板上铺有锡膏的一面与铝基座上铺有锡膏 的表面贴合后，放入恒温台加热使得铜基板上的锡膏层与铝基座上的锡膏层 融为一体；
步骤 105 ,冷却：将铜基板和铝基座的组合件从恒温台拿出后冷却至常 温，得到铜基板和铝基座焊接的 LED灯具散热结构。
相较于现有技术的情况，本发明提供的铜基板和铝基座焊接的 LED灯具 散热结构的生产工艺，将铝基座表面镀有一镍层，然后在镍层表面镀一层焊 锡，利用焊锡焊接铝基座和铜基板，得到本案的散热结构。这样，焊接有 LED 灯珠的铜基板直接通过焊锡层与铝基座连接，散热效果好，不会因散热粘合 剂产生高结温而影响 LED的使用寿命。
在本实施例中 ，在加热焊接步骤中 ，恒温台的加热温度为 180°C ,加热 时间为 10min±0.5min。 当然，本发明并不局限于恒温台具体的加热温度，仅 仅是对加热温度和对焊锡熔点进行改变，属于对本发明的简单变形或者变换， 落入本发明的保护范围。
在本实施例中 ，在铝基座刮锡膏的步骤中 ， 无氯无铅焊锡膏的厚度为 0.2-0.3mm ,熔点为 140°C ,锡膏的材质为 Sn42/Bi58。 当然，本发明并不局 限于锡膏的厚度、 熔点和材质，只要是通过锡膏焊接带有镀镍层的铝基座和 铜基板的实施方式，均属于对本发明的简单变形或者变换，落入本发明的保 护范围。
在本实施例中 ，在铜基板刮锡膏的步骤中 ， 无氯无铅焊锡膏的厚度为 0.2-0.3mm ,熔点为 140°C ,锡膏的材质为 Sn42/Bi58。 当然，本发明并不局 限于锡膏的厚度、 熔点和材质，只要是通过锡膏焊接带有镀镍层的铝基座和 铜基板的实施方式，均属于对本发明的简单变形或者变换，落入本发明的保 护范围。
在本实施例中 ，在铜基板刮锡膏的步骤之前，还包括在铜基板上贴上 LED 灯珠的步骤。灯珠直接贴在铜基板上，采用支架或者直接用 COB封装的形式 制作，均属于对本发明的简单变形或者变换，落入本发明的保护范围。 可以 理解的是，铜基板具有高导热、 高散热的特性，当 LED焊接到铜基板上，接 通电源，首先吸收热量的就是铜基板，受限于铜基板的散热面积小、 价格高 的问题，需要用到铝基座来协助散热。 本发明直接将铜基板上的 LED热量散 发到后面的散热器（铝散热基座 )上，使其有最佳效益，并确保 LED温结保 持在 55°C左右，保证灯具的长寿命工作。
在本实施例中 ，在冷却的步骤之后，还包括在常温下清除铜基板和铝基 座焊接的 LED灯具散热结构表面的残留物的步骤。清除 LED灯散热结构表面 的残留物，可以改善 LED的外观，保证其性能。
以上公开的仅为本发明的几个具体实施例，但是本发明并非局限于此， 任何本领域的技术人员能思之的变化都应落入本发明的保护范围。

Claims

权 利 要 求 书
1、 一种铜基板和铝基座焊接的 LED灯具散热结构的生产工艺，其特征 在于，包括以下步骤：
镀镍：在铝基座表面上电镀上一镍层；
铝基座刮锡膏：清除铝基座镀镍层表面的残留物并在该镀镍层上均匀平 铺一层无氯无铅焊锡膏；
铜基板刮锡膏：清除铜基板表面上的残留物并在该已清洁的表面上均匀 平铺一层无氯无铅焊锡膏；
加热焊接：将铜基板上铺有锡膏的一面与铝基座上铺有锡膏的表面贴合 后，放入恒温台加热使得铜基板上的锡膏层与铝基座上的锡膏层融为一体； 冷却：将铜基板和铝基座的组合件从恒温台拿出后冷却至常温，得到铜 基板和铝基座焊接的 LED灯具散热结构。
2、 根据权利要求 1所述的铜基板和铝基座焊接的 LED灯具散热结构的 生产工艺，其特征在于，在加热焊接步骤中 ，恒温台的加热温度为 180°C , 加热时间为 10min±0.5min。
3、 根据权利要求 1所述的铜基板和铝基座焊接的 LED灯具散热结构的 生产工艺，其特征在于，在铝基座刮锡膏的步骤中 ，无氯无铅焊锡膏的厚度 为 0.2-0.3mm ,熔点为 140°C ,锡膏的材质为 Sn42/Bi58。
4、 根据权利要求 1所述的铜基板和铝基座焊接的 LED灯具散热结构的 生产工艺，其特征在于，在铜基板刮锡膏的步骤中 ，无氯无铅焊锡膏的厚度 为 0.2-0.3mm ,熔点为 140°C ,锡膏的材质为 Sn42/Bi58。
5、 根据权利要求 1 -4任一项所述的铜基板和铝基座焊接的 LED灯具散 热结构的生产工艺，其特征在于，在铜基板刮锡膏的步骤之前，还包括在铜 基板上贴上 LED灯珠的步骤。
6、 根据权利要求 5所述的铜基板和铝基座焊接的 LED灯具散热结构的 生产工艺，其特征在于，在冷却的步骤之后，还包括在常温下清除铜基板和 铝基座焊接的 LED灯具散热结构表面的残留物的步骤。
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