High-density top structure LED frame and cutting wheel

Abstract

The application provides a high-density LED frame with a TOP structure and a cutting wheel, and relates to the technical field of LED processing. The LED frame comprises a metal frame, a plurality of arrayed metal support functional areas formed on the metal frame by punching, a plurality of LED supports formed on the metal support functional areas by injection molding, metal support strips arranged between two adjacent columns of the LED supports to support and connect the two columns of the LED supports, and plastic support bodies arranged between two adjacent rows of the LED supports to connect the two rows of the LED supports. The plastic support bodies are suspended on the metal support functional areas. The cutting wheel for the LED frame comprises a cutting blade wheel body, a plurality of cutting blades corresponding to the plastic support bodies arranged on the cutting blade wheel body, and extrusion springs arranged on both sides of the cutting blades. The arrangement density of the LED frame is improved, and the problem of plastic defects of the LED support bodies caused by the traditional extrusion dislocation stripping mode is eliminated.

Description

Technical Field

[0001] This invention relates to the field of LED processing technology, specifically to a high-density TOP structure LED frame and cutting wheel. Background Technology

[0002] like Figures 1-4 As shown, in traditional TOP structure LED brackets, each LED bracket body is supported by rows and columns of metal frame support strips around its perimeter, such as... Figure 1 The LED assembly consists of a horizontal metal support strip 06 and a vertical metal support strip 07. During individual LED peeling after encapsulation, staggered upper and lower cutting wheels press the horizontal metal support strip 06, causing it to deform and change from a planar process to a side-standing separation. This allows the metal support strip to detach from the plastic body, forming a single LED. Due to the limitations of this staggered pressing peeling method, each LED bracket requires a metal frame for support. The metal frame itself needs a certain width, generally not less than 0.6mm; otherwise, peeling will be difficult or uneven due to the positioning accuracy of the cutting wheels. Summary of the Invention

[0003] This invention overcomes the shortcomings of the prior art by proposing a high-density TOP structure LED frame and cutting wheel to improve the arrangement density of the LED frame and improve packaging efficiency; at the same time, it solves the problem of plastic defects in the LED bracket body caused by the traditional extrusion misalignment stripping method.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solution.

[0005] A high-density TOP structure LED frame includes an LED metal frame, on which several arrays of metal support functional areas are punched and formed. Several LED supports are injection molded on the metal support functional areas. Adjacent columns of LED supports are supported and connected by metal support strips, and adjacent rows of LED supports are connected by injection-molded plastic supports. The plastic supports are suspended in the metal support functional areas.

[0006] Furthermore, adjacent pins of the two adjacent rows of LED brackets are connected.

[0007] Furthermore, positioning holes are provided in the middle and on both edges of the LED metal frame.

[0008] Furthermore, the height of the suspended section formed by the plastic support body above the functional area of ​​the metal bracket is >0.05mm.

[0009] A cutting wheel for the LED frame includes a cutting wheel body, on which a plurality of cutting blades corresponding to a plastic support are provided, and on both sides of the cutting blades are extrusion springs. The cutting wheel body is provided with protruding cylinders corresponding to positioning holes.

[0010] Furthermore, the head of the protruding cylinder is provided with a chamfer.

[0011] Furthermore, the cutting wheel body and the cutting blade adopt the gear transmission principle, and the rotation speed of the cutting blade is 5 to 20 times that of the cutting wheel body.

[0012] The beneficial effects of this invention compared to the prior art are as follows:

[0013] This invention improves the LED frame arrangement density, particularly in ultra-small LED packaging for display applications. Due to the large number of lateral supports and the large area ratio of the metal frame, eliminating these lateral supports significantly increases the LED bracket arrangement density, thereby greatly improving packaging efficiency and reducing LED packaging costs. It also eliminates the problem of incomplete plastic parts in the LED bracket body caused by the extrusion and misalignment of traditional stripping methods, reducing the risk of failure due to stress on the LED bracket body. Attached Figure Description

[0014] To make the technical problem to be solved, the technical solution, and the beneficial effects of the present invention clearer, the following description is provided in conjunction with the accompanying drawings:

[0015] Figure 1 This is a schematic diagram of the metal material structure of an existing traditional TOP structure LED bracket.

[0016] Figure 2 This is a schematic diagram of the structure of a semi-finished product after injection molding of existing traditional metal materials.

[0017] Figure 3 yes Figure 2 A schematic diagram of the framed LED structure after encapsulation.

[0018] Figure 4 yes Figure 3 A diagram of the metal frame structure after the LED packaged product has been stripped of its components.

[0019] Figure 5 This is a schematic diagram of the metal part of the TOP structure LED frame of the present invention.

[0020] Figure 6 This is a schematic diagram of the semi-finished product structure of the metal material after injection molding according to the present invention.

[0021] Figure 7This is a schematic diagram of the entire LED bracket structure after the LED bracket pins are cut, bent, and wrapped.

[0022] Figure 8 This is an enlarged schematic diagram of the plastic support body described in this invention.

[0023] Figure 9 This is a schematic diagram of the complete finished product after the LED frame of this invention has been packaged.

[0024] Figure 10 This is a structural diagram of the metal frame of the LED packaged product after stripping.

[0025] Figure 11 This is a schematic diagram of the cutting wheel described in this invention.

[0026] In the diagram, 02-lower edge positioning hole, 03-middle positioning hole, 04-upper edge positioning hole, 05-metal functional area, 06-horizontal metal support strip, 07-vertical metal support strip, 08-injection molded LED bracket body, 09-LED packaged finished product, 10-empty frame after LED peeling, 11-metal part of LED frame, 16-plastic support body, 21-suspension distance;

[0027] 30-Cut wheel body, 31-Cut blade, 32-Protruding cylinder, 35-Extrusion spring. Detailed Implementation

[0028] To make the technical problems to be solved, the technical solutions, and the beneficial effects of this invention clearer, the invention will be further described in detail with reference to the embodiments and accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. The technical solutions of this invention are described in detail below with reference to the embodiments and accompanying drawings, but the scope of protection is not limited thereto.

[0029] like Figure 5-7 As shown, this is a high-density TOP structure LED bracket, comprising a sheet of metal material. LED frame metal portions 11 are divided into the sheet of metal material by stamping or etching. Several metal functional areas 05 are formed in a matrix arrangement by stamping or etching on the LED frame metal portions 11. A row of LED brackets is then injection molded within each metal functional area 05. Adjacent rows of LED brackets are connected by longitudinal metal support strips 07. Each row of LED brackets contains four injection-molded LED bracket bodies 08, and adjacent injection-molded LED bracket bodies 08 are connected by plastic supports 16. The LED frame metal portion 11 of this invention removes the transverse metal support strips 06 from the traditional TOP structure LED frame metal portion and replaces them with plastic supports 16, as shown... Figure 8As shown, the horizontal support of each injection-molded LED bracket body 08 is provided by a plastic support body 16 formed in one injection molding process. The plastic support body 16 is suspended at a distance 21 from the surface of the metal functional area 05 by at least 0.05mm.

[0030] After the bracket is encapsulated, the LED packaged product 09 is peeled off using a special cutting and stripping method (see [link]). Figure 9 and Figure 10 This stripping method uses a specially designed cutting device with cutting wheels, such as... Figure 11 The cutting wheel includes a cutting wheel body 30, on which multiple sets of cutting blades 31 corresponding to the plastic support 16 are provided. On both sides of the cutting blades 31, extrusion springs 35 are provided. On the cutting wheel body 30, there are raised cylinders 32 corresponding to the lower edge positioning hole 02, the middle positioning hole 03, and the upper edge positioning hole 04, respectively.

[0031] The raised cylinder 32 has a chamfered head, which facilitates quick insertion into the bracket positioning hole. When the cutter wheel rotates, the cutting wheel body 30 drives the raised cylinder 32 to match the corresponding positioning hole of the bracket during cutting and stripping, thus moving the bracket forward. At the same time, utilizing the principle of coaxial different speeds of a clock, the rotation speed of the cutting blade 31 of the cutting wheel is about 5 to 20 times that of the cutter wheel body. The rotation speed of the cutting blade can be adjusted by changing and adjusting the internal gears to achieve a suitable cutting effect. When the cutter wheel rotates, it drives the bracket to move forward in a stable position. The high-speed rotating cutting blade cuts and separates the plastic support 16 at the bottom of each LED package 09. The suspension distance 21 between the plastic support 16 and the surface of the metal functional area 05 ensures that the blade will not cut the metal part of the LED frame. Each LED package 09 is suspended and peeled off. As for the longitudinal metal support strip 07, it has already been cut and bent during the bracket wrapping process. For the large horizontal rib where the positioning holes are located near the LED frame metal part 11, each row of LED packaged products 09 is stuck on the large horizontal rib on one side and has been cut off on the other side. After cutting, the extrusion spring 35 is set to extrude and peel off the LED packaged products 09 near the large horizontal rib. The finished product formed after cutting and peeling is as follows: Figure 10 As shown, the remaining plastic support 16 cuts after cutting do not affect the product's use. Plastic debris is easily generated after cutting; this debris is completely separated from the finished LED product using a sieve and vacuum method.

[0032] This invention improves the LED frame arrangement density, particularly in ultra-small LED packaging for display applications. Due to the large number and area of ​​lateral supports, eliminating them significantly improves packaging efficiency and reduces LED packaging costs. It also eliminates the problem of incomplete plastic parts in the LED bracket body caused by traditional extrusion and misalignment stripping methods, reducing the risk of stress-induced failure in the LED bracket body.

[0033] The above description is a further detailed explanation of the present invention in conjunction with specific preferred embodiments. It should not be considered that the specific embodiments of the present invention are limited to this. For those skilled in the art, several simple deductions or substitutions can be made without departing from the present invention, and all of these should be considered as belonging to the present invention.

Claims

1. A cutting wheel for high density TOP structure LED frame, characterized in that, The high-density TOP structure LED frame comprises an LED metal frame, a plurality of arrayed metal support functional areas are punched on the LED metal frame, a plurality of LED supports are injection molded on the metal support functional areas, two adjacent columns of LED supports are connected by metal support strips, and two adjacent rows of LED supports are connected by injection molded plastic support bodies; the plastic support bodies are suspended on the metal support functional areas; positioning holes are arranged on the middle and edge portions of the LED metal frame; The cutting wheel comprises a cutting knife wheel body, a plurality of cutting blades corresponding to the plastic support bodies are arranged on the cutting knife wheel body, extrusion elastic pieces are arranged on both sides of the cutting blades, and a convex cylinder corresponding to the positioning hole is arranged on the cutting knife wheel body; the head of the convex cylinder is provided with an inverted bevel; the cutting knife wheel body and the cutting blades adopt a gear transmission principle, the rotating speed of the cutting blades is 5-20 times that of the cutting knife wheel body; the rotating speed of the cutting blades is adjusted by replacing and adjusting the internal gears to achieve a suitable cutting effect; when the knife wheel rotates, the supports are driven to advance at a stable position; the high-speed rotating cutting blades cut and separate the plastic support bodies at the bottom of each LED package product.

2. The cutting wheel for a high-density TOP structure LED frame according to claim 1, wherein The adjacent pins of two adjacent rows of LED supports are connected.

3. The cutting wheel for a high-density TOP structure LED frame according to claim 1, wherein The height of the suspended section of the plastic support bodies suspended on the metal support functional areas is greater than 0.05 mm.

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