A method for manufacturing an integrated dual-color LED lamp

Abstract

The present invention discloses an integrated two-color LED lamp and a manufacturing method thereof, wherein the integrated two-color LED lamp comprises a substrate and a plurality of LED chips mounted on the substrate, wherein the substrate is provided with a light-emitting surface, the light-emitting surface is provided with a groove, the LED chip is mounted on the light-emitting surface, and part of the LED chip is located in the groove; a first fluorescent glue layer is provided in the groove, and a second fluorescent glue layer is provided on the entire light-emitting surface. The integrated two-color LED lamp of the present invention has a simple structure and a simple manufacturing process, which is conducive to reducing the manufacturing cost of the lamp; moreover, since the size of each LED wick unit is small, a dense and uniform arrangement can be achieved, which is conducive to reducing the light-emitting area, facilitating later optical processing, achieving directional irradiation, long-distance irradiation, and ensuring illumination, etc.; at the same time, the mixing effect is good, which can avoid the problem of different colors of the generated light spots.

Description

Technical Field

[0001] The invention relates to the technical field of LED packaging, and in particular to a method for manufacturing an integrated two-color LED lamp. Background Art

[0002] There are two main types of existing two-color lamps. One is to evenly arrange two colors of LED patch lamps alternately and weld them on the substrate, which can achieve uniform color mixing; however, its manufacturing process is complicated, and because the LED patch lamp bracket is large, one LED patch lamp unit requires at least 980mm 2 The arrangement area of ​​the LEDs is limited, so the luminous area is large, the materials used are large, the light is scattered, and it is not conducive to the use of optical lenses in the later stage. It is impossible to achieve directional irradiation, long-distance irradiation, and illumination guarantee. The other method is to set strip or semicircular series LED chips on the luminous area of ​​the substrate, and separate each series chip with opaque glue, and then apply two different colors of phosphor glue mixture to the corresponding areas and bake them. The manufacturing process of the second method is also more complicated, and the two colors of light will be distributed at intervals during the light-emitting process. Therefore, although the luminous area is small, there is also the problem of uneven mixing resulting in poor light spot effect. Summary of the invention

[0003] In order to overcome the deficiencies of the prior art, the present invention provides an integrated two-color LED lamp with a simple structure and a simple manufacturing process and a manufacturing method thereof.

[0004] The technical solution adopted by the present invention to solve its technical problem is:

[0005] An integrated two-color LED lamp comprises a substrate and a plurality of LED chips mounted on the substrate, wherein the substrate is provided with a light-emitting surface, the light-emitting surface is provided with a groove, the LED chips are mounted on the light-emitting surface, and part of the LED chips are located in the groove; a first fluorescent glue layer is provided in the groove, and a second fluorescent glue layer is provided on the entire light-emitting surface.

[0006] As an improvement of the above technical solution, the LED chip is a blue light chip, the second fluorescent glue layer is evenly distributed with fluorescent powder required to convert blue light into pure white light, and the first fluorescent glue layer is evenly distributed with fluorescent powder that converts blue light into warm white light more than that converted into pure white light.

[0007] Furthermore, the LED chips are evenly arranged on the light-emitting surface, and there is one LED chip located in the groove every other LED chip in the same row and column.

[0008] Furthermore, the depth of the groove is between 0.1 mm and 0.3 mm.

[0009] Furthermore, the groove is square, and the length and width are both between 12 mm and 20 mm.

[0010] Furthermore, integrated circuits required for connecting the LED chips in series and in parallel are arranged around the grooves.

[0011] A manufacturing method for an integrated two-color LED lamp comprises the following steps: a first step of carving a groove on the light-emitting surface of the substrate; a second step of arranging integrated circuits required for serial and parallel connection around the groove; a third step of pasting LED chips in the groove and other areas of the light-emitting surface; a fourth step of connecting the LED chips in series and parallel connection; a fifth step of dripping a first fluorescent powder glue mixture in the groove; a sixth step of baking so that the first fluorescent powder glue mixture forms a first fluorescent glue layer in the groove; a seventh step of coating a second fluorescent powder glue mixture on the entire light-emitting surface; and an eighth step of baking so that the second fluorescent powder glue mixture forms a second fluorescent glue layer on the entire light-emitting surface.

[0012] As an improvement of the above technical solution, the second phosphor-glue mixture is added with phosphors required for pure white, and the first phosphor-glue mixture is added with more warm white phosphors than pure white.

[0013] Furthermore, the LED chips are evenly arranged on the light-emitting surface, and there is one LED chip located in the groove every other LED chip in the same row and column.

[0014] Furthermore, the first phosphor-glue mixture contains 0.5% to 1% by mass of red phosphor and 1% to 3.5% by mass of yellow-green phosphor; the second phosphor-glue mixture contains 2% to 3% by mass of red phosphor, 1% to 2% by mass of green phosphor, and 11% to 13% by mass of yellow-green phosphor.

[0015] The beneficial effects of the present invention are as follows: the integrated two-color LED lamp of the present invention has a simple structure and a simple manufacturing process, which is beneficial to reducing the manufacturing cost of the lamp; moreover, since each LED wick unit is small in size, a dense and uniform arrangement can be achieved, which is beneficial to reducing the light-emitting area, facilitating subsequent optical processing, achieving directional irradiation, long-distance irradiation, and ensuring illumination, etc.; at the same time, since the light emitted by the LED chips in the same row or column passes through two layers of fluorescent glue at the same time and the LED chips that only pass through one layer of fluorescent glue are evenly spaced, the mixing effect is good, and the problem of different colors of the light spots can be avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0017] Figure 1 is a partial cross-sectional view of the integrated dual-color LED lamp of the present invention;

[0018] Figure 2 is a front view of the integrated dual-color LED lamp of the present invention. DETAILED DESCRIPTION

[0019] Reference Figure 1 and Figure 2 An integrated two-color LED lamp of the present invention comprises a substrate 1 and a plurality of LED chips 4 mounted on the substrate 1, wherein the substrate 1 is provided with a light-emitting surface 2, a groove 3 is provided on the light-emitting surface 2, the LED chips 4 are mounted on the light-emitting surface 2, and part of the LED chips 4 is located in the groove 3; a first fluorescent glue layer 5 is provided in the groove 3, and a second fluorescent glue layer 6 is provided on the entire light-emitting surface 2.

[0020] The manufacturing method of the integrated dual-color LED lamp of the present invention mainly includes the following steps:

[0021] The first step is to carve a groove 3 on the light emitting surface 2 of the substrate 1;

[0022] The second step is to arrange the integrated circuits required for serial and parallel connection around the groove 3;

[0023] Step 3: attaching LED chips 4 in the groove 3 and other areas of the light-emitting surface 2;

[0024] Step 4: Connect the LED chips 4 in series and in parallel;

[0025] Step 5: drip the first phosphor glue mixture into the groove 3;

[0026] Step 6: baking, so that the first phosphor powder glue mixture forms a first fluorescent glue layer 5 in the groove 3;

[0027] Step 7: coating the second phosphor glue mixture on the entire light emitting surface 2;

[0028] The eighth step is baking, so that the second phosphor powder glue mixture forms a second fluorescent glue layer 6 on the entire light-emitting surface 2.

[0029] Therefore, compared with the existing similar lamps, the integrated two-color LED lamp of the present invention has a simpler structure and a simpler manufacturing process, which is conducive to reducing the manufacturing cost of the lamp. It should be noted that the first phosphor glue mixture and the second phosphor glue mixture should be vacuum degassed in advance to avoid the formation of bubbles in the formed phosphor glue layer; at the same time, in order to ensure the consistency of product quality, during the manufacturing process, a spectrophotometer can be used to analyze and confirm the light composition and electrical parameters of the light source.

[0030] Specifically, the LED chip 4 is a blue light chip that emits blue light; and the second phosphor glue mixture is added with the phosphor required to convert blue light into positive white light (color temperature 4000K-7000K), and the first phosphor glue mixture is added with more phosphor that converts blue light into warm white light (color temperature 2600K-4000K) than into positive white light; specifically, the first phosphor glue mixture contains 0.5% to 1% of red phosphor and 1% to 3.5% of yellow-green phosphor by mass; the second phosphor glue mixture contains 2% to 3% of red phosphor, 1% to 2% of green phosphor, and 11% to 13% of yellow-green phosphor by mass. Therefore, after drying and solidification, the second phosphor glue layer 6 is evenly distributed with the phosphor required to convert blue light into positive white light, and the first phosphor glue layer 5 is evenly distributed with more phosphor that converts blue light into warm white light than into positive white light. In this way, the light emitted by the LED chip 4 located in the groove 3 will pass through the first fluorescent glue layer 5 and the second fluorescent glue layer 6 in sequence, and the combination of the phosphor functions inside the two fluorescent glue layers will convert the blue light into warm white light, while the LED chips 4 in other areas will only pass through the second fluorescent glue layer 6, and the blue light will be converted into pure white light. Preferably, in the first embodiment of the present invention, the first phosphor glue mixture contains 0.5% red phosphor and 3.2% yellow-green phosphor, and the second phosphor glue mixture contains 2.8% red phosphor, 1.8% green phosphor, and 11% yellow-green phosphor; in the second embodiment of the present invention, the first phosphor glue mixture contains 0.7% red phosphor and 1.2% yellow-green phosphor, and the second phosphor glue mixture contains 2.3% red phosphor, 1.6% green phosphor, and 11.9% yellow-green phosphor; in the third embodiment of the present invention, the first phosphor glue mixture contains 0.9% red phosphor and 2.8% yellow-green phosphor, and the second phosphor glue mixture contains 2% red phosphor, 1% green phosphor, and 13% yellow-green phosphor.

[0031] In order to make the integrated two-color LED lamp of the present invention mix light more evenly, during the manufacturing process, the LED chips 4 should be arranged evenly on the light-emitting surface 2, and one LED chip 4 is located in the groove 3 for every LED chip 4 in the same row and column. In this way, among the LED chips 4 in the same row or column, the light emitted by the LED chips 4 that pass through two layers of fluorescent glue at the same time and the LED chips 4 that pass through only one layer of fluorescent glue will be evenly spaced and distributed, avoiding the problem that some areas of the generated light spot are warm white and some areas are pure white.

[0032] In the present invention, the depth of the groove 3 is between 0.1mm and 0.3mm, specifically, it can be 0.1mm, 0.2mm, 0.3mm, etc. At the same time, since the size of a single LED chip 4 is very small, and is generally a square with a length and width of 1.2mm, in this embodiment, preferably, the groove 3 is square, and the length and width are both between 1.2mm and 2.0mm. Of course, according to actual conditions, the shape of the groove 3 can also be selected from other shapes such as circle, triangle, etc., as long as its size can accommodate an LED chip 4. Since the size of the groove 3 is small, the first step of its production process is preferably to use laser engraving. At the same time, since the size of a single LED chip 4 is very small, the LED chips 4 can be densely and evenly arranged. Taking the length and width of the groove 3 as 1.8mm and 1.4mm, and the interval between the LED chips 4 is one groove 3 as an example, the arrangement area of ​​each LED chip 4 unit is only 2.52mm 2 , its arrangement density will be greatly improved, which can greatly reduce the light-emitting area and reduce the material consumption in the manufacturing process. It is also beneficial to the later optical processing, so that it can achieve directional irradiation, long-distance irradiation, and ensure sufficient illumination.

[0033] The LED chips 4 in the groove 3 are connected in series and parallel, and the LED chips 4 outside the groove 3 are connected in series and parallel; and the LED chips 4 inside the groove 3 and the LED chips 4 outside the groove 3 are controlled separately, so that the integrated two-color LED lamp of the present invention can emit pure white light or warm white light separately; at the same time, by controlling the number of lit LED chips 4, the mixing amount of light color can also be controlled, so as to achieve the effect of mixed light color and adjustable brightness.

[0034] In the second step of the manufacturing process of the integrated dual-color LED lamp, in order to facilitate the serial-parallel connection of the LED chips 4, an integrated circuit required for the serial-parallel connection of the LED chips 4 is arranged around the groove 3. Specifically, in the fourth step of the manufacturing process, the serial-parallel connection of the LED chips 4 can be completed by using a gold wire ball bonding machine, wherein the LED chips 4 in the groove 3 are connected to the integrated circuits around them to achieve serial-parallel connection, and the LED chips 4 outside the groove 3 are directly connected in series and parallel.

[0035] In order to prevent the waste caused by overflow from the surrounding of the light-emitting surface 2 during the coating process of the second phosphor glue mixture, in the seventh step, before coating the second phosphor glue mixture, an opaque silicone rubber ring is firstly placed around the entire light-emitting surface 2. At the same time, in order to achieve a better heat dissipation effect, in this embodiment, the substrate 1 is made of metal copper.

[0036] The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the above embodiments. As long as the technical effects of the present invention are achieved by any same or similar means, they should fall within the protection scope of the present invention.

Claims

1. A method for manufacturing an integrated dual-color LED lamp, characterized in that: The following steps are included: The first step is to carve a groove (3) on the light-emitting surface (2) of the substrate (1); The second step is to arrange the integrated circuits required for serial and parallel connection around the groove (3); The third step is to attach an LED chip (4) in the groove (3) and other areas of the light-emitting surface (2); Step 4, connecting the LED chips (4) in series and parallel; Step 5: dripping the first phosphor glue mixture into the groove (3); Step 6: baking, so that the first phosphor powder-glue mixture forms a first fluorescent glue layer (5) in the groove (3); Step 7: surround the entire light-emitting surface (2) with an opaque silicone rubber ring, and apply the second phosphor glue mixture on the entire light-emitting surface (2); The eighth step is baking, so that the second phosphor powder glue mixture forms a second fluorescent glue layer (6) on the entire light-emitting surface (2).

2. The method for manufacturing an integrated dual-color LED lamp according to claim 1, characterized in that: The LED chip (4) is a blue light chip, the second phosphor-glue mixture contains phosphors required for converting blue light into pure white light, and the first phosphor-glue mixture contains phosphors that convert more blue light into warm white light than into pure white light.

3. The method for manufacturing an integrated dual-color LED lamp according to claim 2, characterized in that: The first phosphor-glue mixture contains 0.5% to 1% red phosphor and 1% to 3.5% yellow-green phosphor by mass; the second phosphor-glue mixture contains 2% to 3% red phosphor, 1% to 2% green phosphor and 11% to 13% yellow-green phosphor by mass.

4. The method for manufacturing an integrated dual-color LED lamp according to claim 1, characterized in that: The LED chips (4) are evenly arranged on the light-emitting surface (2), and one LED chip (4) is located in the groove (3) every other LED chip (4) in the same row and column.

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