Flat cup LED lamp bead manufacturing method and flat cup LED lamp bead

Abstract

The present application relates to a kind of flat cup LED lamp bead manufacturing method and flat cup LED lamp bead, manufacturing method includes the following steps: first step, making shell-shaped support, processing frosted surface on the cavity wall of shell-shaped support;Second step, installation light emitting chip assembly, light emitting chip assembly is installed in the cavity bottom of shell-shaped support;Third step, making concave lens, the first time that glue body of point glue is over light emitting chip assembly and can be along frosted surface and climb up, first solidification, form the concave lens of inner concave surface upward;Fourth step, making convex lens, after the second time that point glue ends, second solidification, after second solidification, form the convex lens of outer convex surface downward.In the present application, the glue body of first time that point glue is along frosted surface and climbs up, obtains concave lens, the glue body of second time that point glue is with inner concave surface as the profiling surface, obtains convex lens, to make flat cup LED lamp bead, this flat cup LED lamp bead manufacturing method has the advantages of simple, easy to operate and high yield.

Description

Technical Field

[0001] This invention relates to the field of LED technology, and in particular to a method for manufacturing flat-cup LED beads and flat-cup LED beads. Background Technology

[0002] LEDs have a wide range of applications, with different types of LED products used in various industries, including signal indication, display, backlighting, and lighting. Generally speaking, for a specific LED chip, its overall beam angle is negatively correlated with its front luminous brightness. In some specific LED application scenarios, the packaged LED chips need to have a wider beam angle, while in other specific LED application scenarios, the packaged LED chips need to have higher front luminous brightness.

[0003] Chinese invention patent CN105140379B discloses a white LED device with uniform color temperature emission from a spatial solid angle. This device belongs to the category of flat-cup LED chips. The white LED device includes an LED bracket with a reflector cup, within which an LED chip is housed. The LED bracket has a frustum structure, formed by a lower concave planar lens layer and an upper convex planar lens layer. The invention also provides a packaging method for this white LED device. The planar concave lens layer helps to expand the LED's emission divergence angle, and the inverted planar convex lens further expands the divergence angle, resulting in highly uniform white light color temperature across the three-dimensional emission angle range. The lower concave planar lens layer can be made of high-refractive-index silicone, and the upper convex planar lens layer can be made of low-refractive-index silicone. This gradient refractive index structure from the chip to the outer air layer helps improve the extraction rate of the emitted light from the white LED device. The above encapsulation method includes the following sequential steps: (1) Take high refractive index silicone and mix it evenly with silicone A and B in a 1:1 ratio. After vacuum degassing, use a dispensing machine to drop the mixed silicone onto the LED bracket. In a vacuum drying oven, bake at 150°C for different times by placing it in the forward and reverse directions respectively to create a planar concave lens layer; (2) Take low refractive index silicone and mix it evenly with a certain amount of phosphor in a 1:1 ratio with silicone A and B. After vacuum degassing, use a dispensing machine to inject the mixed silicone onto the planar concave lens layer. Bake and cure it at 150°C in a vacuum drying oven to create an inverted planar convex lens layer. In the above invention, the concave surface of the concave lens is formed by baking in the forward and reverse directions. The reverse baking method easily causes the concave lens layer to detach from the LED bracket, resulting in a low yield and high operation requirements. How to provide a flat cup LED lamp bead manufacturing method with high yield and low operation requirements is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0004] Therefore, the technical problem to be solved by the present invention is how to provide a method for manufacturing flat-cup LED beads with high yield and low operation requirements, and the flat-cup LED beads themselves.

[0005] To solve the above-mentioned technical problems, the present invention provides a method for manufacturing flat-cup LED beads, comprising the following steps:

[0006] The first step is to fabricate a shell-shaped support, which has a cavity, an opening, a bottom, and a wall. The opening faces the bottom, and the wall connects the opening and the bottom. A frosted surface or multiple frosted surfaces are machined on the wall, either connected end to end along the circumference of the wall or evenly distributed along the circumference of the wall.

[0007] The second step is to install the light-emitting chip assembly, which is then installed at the bottom of the cavity.

[0008] The third step is to fabricate a concave lens. Keeping the cavity opening facing upwards, the first dispensing of adhesive is performed from the cavity opening into the cavity, so that the level of the adhesive liquid in the first dispensing is higher than the lower edge of the light-emitting chip assembly and the frosted surface and lower than the lower edge of the frosted surface, so that the adhesive liquid in the first dispensing can climb upwards along the frosted surface. After the first dispensing is completed, the first curing is performed, and after the first curing, a concave lens with the concave curved surface facing upwards is formed.

[0009] Fourth step: Fabricate a convex lens. Keep the cavity opening facing upwards, and perform a second dispensing of adhesive from the cavity opening into the cavity. After the second dispensing, perform a second curing. After the second curing, a convex lens with the outwardly convex curved surface facing downwards is formed. The concave lens and the convex lens form an optical lens assembly.

[0010] The third step employs either the first or second dispensing and curing scheme:

[0011] The first dispensing and curing scheme: The first dispensing adhesive is an amine-based curing epoxy resin or an acid anhydride curing epoxy resin with a viscosity >200 and a thixotropic agent specific gravity <3%. The first curing is carried out by heat curing in an atmospheric oven.

[0012] The second dispensing and curing scheme: The adhesive used for the first dispensing is an addition-type silicone or acrylic resin with a viscosity >200 and a thixotropic agent specific gravity <3%. Before the first dispensing, a ceramic sealing layer is made for the light-emitting chip component using atomic layer deposition. The first curing is performed using UV curing.

[0013] In one embodiment of the present invention, the distance between the surface of the first dispensing of the adhesive liquid and the bottom of the cavity is 0.15-0.35 mm.

[0014] In one embodiment of the present invention, the concave lens formed after the first curing encapsulates the light-emitting chip assembly in the cavity bottom.

[0015] In one embodiment of the present invention, when the cavity opening is facing upward, the concave surface has a lowest point, the lower edge of the frosted surface is lower than a preset position of the lowest point of the concave curved surface, and the lower edge of the frosted surface is spaced a certain distance from the bottom of the cavity or the lower edge of the frosted surface extends to the bottom of the cavity.

[0016] In one embodiment of the present invention, when the cavity is facing upward, the concave surface has an upper edge, the upper edge of the frosted surface is not lower than a preset position of the upper edge of the concave curved surface, and the upper edge of the frosted surface is spaced a certain distance from the cavity or the upper edge of the frosted surface extends to the cavity.

[0017] In one embodiment of the present invention, the concave curved surface is low in the middle and high at both ends. The cavity wall is machined with four frosted surfaces that are continuously connected in the circumferential direction of the cavity wall. Two of the frosted surfaces are arranged opposite each other and have horizontal straight edges at their upper edges. The other two frosted surfaces are arranged opposite each other and have downward curved edges at their upper edges. The two ends of the horizontal straight edges are respectively connected to the ends of the two downward curved edges, and the two ends of the downward curved edges are respectively connected to the ends of the two horizontal straight edges.

[0018] In one embodiment of the present invention, the concave curved surface is low in the middle and high at both ends, and two frosted surfaces are evenly distributed along the circumferential distance of the cavity wall. The two frosted surfaces are arranged opposite each other and their upper edges are horizontal straight edges.

[0019] In one embodiment of the present invention, the concave curved surface is low in the middle and high around the edges, and a frosted surface is machined on the cavity wall, which is connected end to end along the circumference of the cavity wall, and the upper edge of the frosted surface is an annular edge of equal height.

[0020] In one embodiment of the present invention, the first dispensing is performed using a contact dispensing method or a non-contact dispensing method, the first curing is performed using a thermosetting method, the second dispensing is performed using a contact dispensing method or a non-contact dispensing method, and the second curing is performed using a thermosetting method, a UV curing method, or a moisture curing method.

[0021] The present invention also provides a flat-cup LED light bead, which is manufactured according to the aforementioned manufacturing method.

[0022] Compared with the prior art, the above-mentioned technical solution of the present invention has the following advantages: The flat cup LED lamp bead manufacturing method and the flat cup LED lamp bead of the present invention, by processing a frosted surface on the cavity wall of the shell-shaped bracket, the adhesive applied in the first application climbs along the frosted surface to obtain a concave lens, and the adhesive applied in the second application uses the concave curved surface as the contour surface to obtain a convex lens, thereby producing a flat cup LED lamp bead. The flat cup LED lamp bead manufacturing method has the advantages of being simple, easy to operate and having a high yield. Attached Figure Description

[0023] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0024] Figure 1 This is a flowchart of the method for manufacturing flat-cup LED beads disclosed in Embodiment 1 of the present invention;

[0025] Figure 2 This is a schematic diagram of the shell-shaped support structure disclosed in Embodiment 1 of the present invention;

[0026] Figure 3 This is a schematic diagram of the shape of the frosted surface disclosed in Embodiment 1 of the present invention;

[0027] Figure 4 This is a schematic diagram of the structure of the flat-cup LED lamp bead disclosed in Embodiment 1 of the present invention;

[0028] Figure 5 This is a schematic diagram of the shapes of two opposing frosted surfaces disclosed in Embodiment 2 of the present invention;

[0029] Figure 6 This is a schematic diagram of the shapes of two other opposing frosted surfaces disclosed in Embodiment 2 of the present invention;

[0030] Figure 7 This is a schematic diagram of the shape of the frosted surface disclosed in Embodiment 3 of the present invention;

[0031] Figure 8 This is a schematic diagram of the structure of the flat-cup LED lamp bead disclosed in Embodiment 3 of the present invention;

[0032] Figure 9 This is a schematic diagram of the light emission of the flat-cup LED lamp bead disclosed in Embodiment 4 of the present invention;

[0033] Figure 10 A comparison table showing the light-emitting angles of LED beads obtained by the traditional dispensing method and those obtained by the dispensing method of this invention;

[0034] Figure 11 This is a schematic diagram of the light emission of the flat-cup LED lamp bead disclosed in Embodiment 5 of the present invention.

[0035] Explanation of reference numerals in the accompanying drawings: 1. Shell-shaped support; 11. Cavity; 12. Cavity opening; 13. Cavity bottom; 14. Cavity wall; 15. Frosted surface; 2. Light-emitting chip assembly; 3. Concave lens; 4. Convex lens. Detailed Implementation

[0036] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0037] Example 1

[0038] See Figures 1 to 4 As shown, a method for manufacturing a flat-cup LED light bead includes the following steps:

[0039] The first step is to fabricate a shell-shaped support 1. A shell-shaped support 1 is provided. The shell-shaped support 1 has a cavity 11. The cavity 11 has a cavity opening 12, a cavity bottom 13, and a cavity wall 14. The cavity opening 12 is directly opposite the cavity bottom 13. The cavity wall 14 is connected between the cavity opening 12 and the cavity bottom 13. A frosted surface 15 connected end to end along the circumference of the cavity wall or multiple frosted surfaces 15 evenly distributed along the circumference of the cavity wall are machined on the cavity wall 14.

[0040] The second step is to install the light-emitting chip assembly 2, which is installed in the bottom of the cavity 13.

[0041] The third step is to make the concave lens 3. Keep the cavity opening facing upwards and perform the first dispensing of adhesive from the cavity opening 12 to the cavity 11. The surface of the adhesive liquid in the first dispensing is higher than the lower edge of the light-emitting chip component 2 and the frosted surface 15 and lower than the upper edge of the frosted surface 15 so that the adhesive liquid in the first dispensing can climb upwards along the frosted surface 15. After the first dispensing is completed, the first curing is performed. After the first curing, the concave lens 3 with the concave curved surface facing upwards is formed.

[0042] The fourth step is to make the convex lens 4. Keep the cavity opening facing upwards and apply adhesive a second time from the cavity opening 12 to the cavity 11. After the second application of adhesive, perform a second curing. After the second curing, a convex lens 4 with the outward convex curved surface facing downwards is formed. The concave lens 3 and the convex lens 4 form an optical lens assembly.

[0043] The third step employs either the first or second dispensing and curing scheme:

[0044] The first dispensing and curing scheme: The first dispensing adhesive is an amine-based curing epoxy resin or an acid anhydride curing epoxy resin with a viscosity >200 and a thixotropic agent specific gravity <3%. The first curing is carried out by heat curing in an atmospheric oven.

[0045] The second dispensing and curing scheme: The adhesive used for the first dispensing is an addition-type silicone or acrylic resin with a viscosity >200 and a thixotropic agent specific gravity <3%. Before the first dispensing, a ceramic sealing layer is made for the light-emitting chip component using atomic layer deposition. The first curing is performed using UV curing.

[0046] Shell-shaped supports are generally formed by injection molding, extrusion, or compression molding. The mold has a mold surface for forming the cavity wall of the shell-shaped support. According to the design requirements of the flat-cup LED lamp bead, a frosted surface is made on the corresponding mold surface, thereby forming the required frosted surface on the cavity wall of the shell-shaped support. This guides the glue to climb along the required path during the molding of the concave lens, thus forming the concave curved surface of the required shape. Due to the mold design, after the shell-shaped support is cured and demolded from the mold, the cavity wall of the shell-shaped support also retains a frosted surface corresponding to the mold surface.

[0047] The aforementioned cavity is generally a frustum-shaped cavity, with the cavity opening larger than the cavity bottom, and the angle between the cavity wall and the cavity bottom is an obtuse angle.

[0048] According to the design requirements of flat-cup LED beads, the cavity walls of the shell-shaped bracket can be made entirely of frosted surface, or only partially. Depending on the initial mold and the different frosted surfaces of the shell-shaped bracket, the concave surface of the final concave lens can be divided into two types. When all four cavity walls of the shell-shaped bracket are frosted, the adhesive will climb along the frosted surfaces after the first application, resulting in a concave surface that is low in the middle and high around the edges. When only two opposite cavity walls of the shell-shaped bracket are frosted, with the other two opposite cavity walls being smooth, the adhesive will only climb along the two opposite frosted surfaces after the first application, resulting in a concave surface that is low in the middle and high at both ends. The thickness at the lowest point of the adhesive is affected by the amount of adhesive, the rheological properties of the adhesive, and the design of the other two cavity walls.

[0049] Due to the height of the light-emitting chip assembly used, it is necessary to ensure that after the concave lens is fabricated, the lowest point of the concave surface of the concave lens colloid is positioned higher than the light-emitting chip assembly (light-emitting chip and bonding wire).

[0050] When applying the adhesive for the first time, use a relatively small amount of adhesive to apply it inside the shell-shaped support, forming a concave lens (concave cup shape). After the first application is completed and cured, the adhesive actually forms a concave lens shape. The curvature and focal length of the concave lens are related to the type of adhesive, the amount of adhesive set, and the design of the frosted surface.

[0051] During the second dispensing, the adhesive is applied to the flat cup and cured on the concave cup. As long as the reliability requirements are met, after the second dispensing is completed and cured, the adhesive actually forms a convex lens-like shape, enabling the LED beads to achieve the flat cup effect.

[0052] In actual production, it was found that some adhesives could climb to the desired shape after dispensing, but did not maintain this climbing shape after curing. Analysis revealed that this phenomenon was related to the adhesive formulation and dispensing / curing method. After dispensing, all adhesives may exhibit selective climbing, but not all adhesive systems can maintain this selective climbing after curing, especially during heat curing. This is because adhesives volatilize during heat curing. For example, commonly used silicone or cationic epoxy resins have very little volatilization during curing. During heat curing, the increased fluidity simply causes the adhesive climbing to disappear; in other words, the concave lens effect also disappears.

[0053] Using the first and second dispensing and curing methods described above ensures that the cured adhesive maintains its initial climbing shape. Due to the type of adhesive used in the first dispensing, there is significant evaporation during curing. The use of an atmospheric oven (not a vacuum oven) results in differences in airflow velocity and uneven evaporation (more evaporation in the center, less around the edges), ensuring the cured adhesive maintains its initial climbing state. Because the thixotropic agent in the first dispensing has a specific gravity of <3%, it ensures that the adhesive will not bulge after curing. The thixotropic agent could be, for example, an anti-settling powder, and the atmospheric oven could be a hot air box, tunnel oven, or vertical oven.

[0054] In this preferred embodiment, the distance between the surface of the adhesive liquid and the bottom 13 of the cavity during the first application is 0.15-0.35 mm, preferably 0.26-0.3 mm. Specifically, the distance is 0.26 mm, 0.27 mm, 0.28 mm, 0.29 mm, or 0.3 mm. Through experiments, the relationship between the roughness of the frosted surface, the amount of adhesive applied during the first application, the viscosity of the adhesive during the first application, the climbing height, and the light emission angle can be determined. The frosted surface, the amount of adhesive applied during the first application, and the viscosity of the adhesive can be selected according to actual needs. The experiment revealed that the roughness of the frosted surface and the viscosity of the adhesive applied in the first application had little effect on the climbing height and the light emission angle. The main factor was the amount of adhesive applied in the first application. The less adhesive applied in the first application, the smaller the thickness of the adhesive at the lowest point, and the greater the curvature of the resulting concave surface. The lower the viscosity or the lower the thixotropy of the adhesive applied in the first application, the better the climbing effect on the frosted surface of the shell-shaped support, and the smaller the minimum thickness of the concave lens that can be achieved (but the minimum thickness of the adhesive is mainly affected by the chip and bonding wire height in the initial design).

[0055] In this preferred embodiment, the concave lens 3 formed after the first curing encapsulates the light-emitting chip assembly 2 in the cavity bottom 13. The adhesive used for the first application must directly meet the sealing requirements of the LED encapsulation, while also meeting the requirements for thermal expansion, water absorption, and other characteristics. Generally, epoxy resin and other powders and modified additives are selected, and curing is generally carried out by thermosetting.

[0056] In this preferred embodiment, the cavity 11 of the shell-shaped support is frustum-shaped, and the concave lens 3 includes a frustum body. The large end face of the frustum body is a concave curved surface. When the cavity opening 12 faces upward, the concave curved surface is low in the middle and high around the edges, having approximately equal height edges. A frosted surface 15 is machined on the cavity wall 14, with the ends connected circumferentially along the cavity wall. When the cavity opening faces upward, the upper edge of the frosted surface is an equal height annular edge, the lower edge of the frosted surface 15 extends to the bottom of the cavity, and the upper edge of the frosted surface 15 extends to the cavity opening (e.g., ...). Figure 3 (As shown). In the above text, the cavity of the shell-shaped support is frustum-shaped, that is, the shell-shaped support has a circular cross-section perpendicular to the depth of the cavity.

[0057] In this preferred embodiment, the first dispensing is performed using a contact dispensing method or a non-contact dispensing method, the first curing is performed using a thermosetting method, the second dispensing is performed using a contact dispensing method or a non-contact dispensing method, and the second curing is performed using a thermosetting method, a UV curing method, or a moisture curing method.

[0058] The flat-cup LED lamp bead manufactured in this embodiment includes a shell-shaped bracket 1, a light-emitting chip assembly 2, and an optical lens assembly. The shell-shaped bracket 1 has a cavity 11, which has a cavity opening 12, a cavity bottom 13, and a cavity wall 14. The cavity opening 12 is directly opposite the cavity bottom 13. The two edges of the cavity wall 14 extend to the cavity opening 12 and the cavity bottom 13, respectively. The light-emitting chip assembly 2 is installed on the cavity bottom 13. The optical lens assembly includes a concave lens 3 and a convex lens 4 that sequentially receive the light emitted by the light-emitting chip assembly 2. The light-emitting surface of the concave lens 3 is an inwardly concave curved surface, and the light-receiving surface of the convex lens 4 is an outwardly convex curved surface. The inwardly concave curved surface and the outwardly convex curved surface are in contact. The light-emitting surface of the convex lens 4 is approximately flat, and the flat surface does not protrude from the cavity opening or is flush with or slightly protrudes from the cavity opening.

[0059] Example 2

[0060] See Figure 5 and Figure 6 As shown, the rest is the same as in Embodiment 1, except that the cavity of the shell-shaped support is frustum-shaped, the concave lens includes a frustum body, the large end face of the frustum body is a concave curved surface, when the cavity opening is facing upward, the middle of the concave curved surface is low and the two ends are high, the concave curved surface has two opposite downward curved side edges and two opposite high end edges, and four frosted surfaces 15 are machined on the cavity wall 14 and are continuously connected along the circumference of the cavity wall. When the cavity opening is facing upward, two of the frosted surfaces 15 (such as Figure 5 (As shown) arranged opposite each other with the upper edge being a downward-curved arc edge, the downward-curved arc edge being flush with the preset position of the downward-curved side edge of the concave curved surface, and the other two frosted surfaces 15 (as shown) Figure 6As shown, the two sides are arranged opposite each other and the upper edge is a horizontal straight edge. The horizontal straight edge is higher than the preset position of the high edge of the concave curved surface. The two ends of the downward curved edge are connected to the ends of the two horizontal straight edges respectively. The two ends of the horizontal straight edge are connected to the ends of the two downward curved edges respectively.

[0061] In the above text, the cavity of the shell-shaped support is frustum-shaped, that is, the shell-shaped support has a rectangular cross-section perpendicular to the cavity depth, and four frosted surfaces are respectively set on the four sides of the cavity wall.

[0062] In the preferred embodiment of this example, when the cavity opening is facing upwards, the upper edge of the frosted surface 15 used to climb the high-end edge of the concave curved surface extends to the cavity opening.

[0063] In the preferred embodiment of this example, when the cavity opening faces upward, the lower edge of the frosted surface 15 extends to the bottom of the cavity.

[0064] In this preferred embodiment, the shell-shaped support has a square cross-section perpendicular to the cavity depth.

[0065] In this preferred embodiment, the non-abrasive surfaces of the cavity wall are all smooth surfaces.

[0066] Example 3

[0067] See Figure 7 and Figure 8 As shown, the rest is the same as in Embodiment 1, except that when the cavity opening is facing upward, the lower edge of the frosted surface 15 extends to the bottom of the cavity, the upper edge of the frosted surface 15 is not lower than the preset position of the equal height edge of the concave curved surface, and the upper edge of the frosted surface 15 is a certain distance away from the cavity opening.

[0068] In the preferred embodiment of this example, when the cavity opening faces upward, the upper edge of the frosted surface 15 is a straight edge, and the upper edge of the frosted surface is flush with the preset position of the equal-height edge of the concave curved surface.

[0069] In this preferred embodiment, when the cavity opening faces upward, the upper region of the cavity wall 14 is a smooth surface.

[0070] In this embodiment, since the frosted surface on the shell-shaped bracket 1 is close to the bottom of the cavity, the preset position of the lowest point of the concave lens 3 is relatively low, but still higher than the light-emitting chip assembly 2, and the preset position of the lowest point of the convex lens 4 is also relatively low.

[0071] Example 4

[0072] See Figure 9 As shown in the illustration, the rest is the same as in Example 1, except that the refractive index of the adhesive applied in the second application is greater than that of the adhesive applied in the first application. The refractive index of the concave lens 3 is less than that of the convex lens 4. The aforementioned flat-cup LED lamp bead is an LED lamp bead with a focusing effect.

[0073] The adhesive used for the first application must directly meet the sealing requirements of LED packaging, as well as the requirements for thermal expansion and water absorption. Generally, epoxy resin and other powders and modified additives are selected. The first curing is generally heat curing. From the actual production practice, the refractive index N1 of the adhesive used for the first application is generally difficult to exceed 1.55.

[0074] The refractive index N2 of the colloid in the second dispensing needs to be designed to be greater than 1.55. The colloid type is not limited to epoxy resin; it can include epoxy resins with high refractive index groups such as benzene rings, sulfur elements, and halogens, silicone, acrylic resins, thermosetting polyurethanes, and cyclosulfide resins. High refractive index ultrafine powders or nanoparticles such as ZnO, ZrO2, TiO2, Ta2O5, and Nb2O5 can be added as fillers. Depending on the actual colloid characteristics, the second curing method includes thermosetting, UV curing, or moisture curing. Ultimately, the obtained N2 is generally between 1.55 and 1.8. After the second dispensing and curing, the high refractive index colloid layer of the convex lens, combined with the relatively lower refractive index of the atmosphere and the relatively lower refractive index of the concave lens (sealing layer), effectively forms a plano-convex lens, which inherently possesses a light-focusing effect.

[0075] Both concave lens 3 and convex lens 4 are molded into the cavity of the shell-shaped support 1 after being glued together. The refractive index of concave lens 3 is less than 1.55, and the refractive index of convex lens 4 is 1.55-1.8. Concave lens 3 encapsulates the light-emitting chip assembly 2 at the bottom of the cavity. Preferably, the glue for concave lens 3 is an epoxy resin layer, and preferably, the glue for convex lens 4 is an epoxy resin cured body, silicone cured body, acrylic resin cured body, thermosetting polyurethane cured body, or epoxy sulfide resin cured body. Preferably, the glue for convex lens 4 contains a high-refractive-index filler. Preferably, the plane of the convex lens does not protrude from the cavity opening, and preferably, the light-emitting chip assembly 2 is a light-emitting chip assembly that emits divergent light. That is, the light-emitting chip assembly emits a diffused beam, and the optical lens assembly converts the divergent beam into a parallel beam, achieving a focusing effect.

[0076] Figure 10 The table compares the light-emitting angle of LED beads obtained by the traditional dispensing method with the light-emitting angle of LED beads obtained by the dispensing method of the present invention.

[0077] As can be seen, due to the surface tension and thixotropic properties of the colloid, the light-emitting surface of the optical lens assembly formed after dispensing can be flush with the cavity opening or higher than the cavity opening, mainly depending on the amount of dispensing. As can be seen from the table above, the light-emitting angle of LED beads manufactured using the dispensing method of this invention is significantly smaller than that of LED beads manufactured using the traditional dispensing method.

[0078] Example 5

[0079] See Figure 11As shown in the illustration, the rest is the same as in Embodiment 4, except that the light-emitting chip component 2 is a parallel light-emitting chip component. That is, the light-emitting chip component emits a parallel straight beam of light, and the optical lens component converts the parallel beam of light into a focused beam, thereby achieving a focusing effect.

[0080] Example 6

[0081] The rest is the same as in Embodiment 2, except that two frosted surfaces are machined on the cavity wall at circumferential intervals. When the cavity opening faces upward, the two frosted surfaces are arranged opposite each other, and the upper edge of the frosted surface is not lower than the preset position of the high-end edge of the concave curved surface. The cavity in this embodiment is frustum-shaped.

[0082] In the preferred embodiment of this example, when the cavity opening faces upward, the upper edge of the frosted surface extends to the cavity opening, the lower edge of the frosted surface extends to the bottom of the cavity, and the other two surfaces of the cavity wall are smooth surfaces.

[0083] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A method for manufacturing a flat-cup LED lamp bead, characterized in that, Includes the following steps: The first step is to fabricate a shell-shaped support, which has a cavity, an opening, a bottom, and a wall. The opening faces the bottom, and the wall connects the opening and the bottom. A frosted surface or multiple frosted surfaces are machined on the wall, either connected end to end along the circumference of the wall or evenly distributed along the circumference of the wall. The second step is to install the light-emitting chip assembly, which is then installed at the bottom of the cavity. The third step is to fabricate a concave lens. Keeping the cavity opening facing upwards, the first dispensing of adhesive is performed from the cavity opening into the cavity, so that the level of the adhesive liquid in the first dispensing is higher than the lower edge of the light-emitting chip assembly and the frosted surface and lower than the upper edge of the frosted surface, so that the adhesive liquid in the first dispensing can climb upwards along the frosted surface. After the first dispensing is completed, the first curing is performed, and after the first curing, a concave lens with the concave curved surface facing upwards is formed. Fourth step: Fabricate a convex lens. Keep the cavity opening facing upwards, and perform a second dispensing of adhesive from the cavity opening into the cavity. After the second dispensing, perform a second curing. After the second curing, a convex lens with the outwardly convex curved surface facing downwards is formed. The concave lens and the convex lens form an optical lens assembly. The third step employs either the first or second dispensing and curing scheme: The first dispensing and curing scheme: The first dispensing adhesive is an amine-based curing epoxy resin or an acid anhydride curing epoxy resin with a viscosity >200 and a thixotropic agent specific gravity <3%. The first curing is carried out by heat curing in an atmospheric oven. The second dispensing and curing scheme: The adhesive for the first dispensing is an addition-type silicone or acrylic resin with a viscosity >200 and a thixotropic agent specific gravity <3%. Before the first dispensing, a ceramic sealing layer is made for the light-emitting chip component by atomic layer deposition. The first curing is performed by UV curing. When the cavity opening faces upward, the concave surface has a lowest point, the lower edge of the frosted surface is lower than the preset position of the lowest point of the concave curved surface, and the lower edge of the frosted surface is spaced a certain distance from the bottom of the cavity or the lower edge of the frosted surface extends to the bottom of the cavity. When the cavity opening faces upward, the concave surface has an upper edge, the upper edge of the frosted surface is not lower than the preset position of the upper edge of the concave curved surface, and the upper edge of the frosted surface is spaced a certain distance from the cavity opening or the upper edge of the frosted surface extends to the cavity opening.

2. The method for manufacturing flat-cup LED beads according to claim 1, characterized in that, The distance between the surface of the first dispensing of adhesive liquid and the bottom of the cavity is 0.15-0.35 mm.

3. The method for manufacturing flat-cup LED beads according to claim 1, characterized in that, The concave lens formed after the first curing encapsulates the light-emitting chip assembly at the bottom of the cavity.

4. The method for manufacturing flat-cup LED beads according to claim 1, characterized in that, The concave curved surface is low in the middle and high at both ends. Four frosted surfaces are machined on the cavity wall and are continuously connected in the circumference of the cavity wall. Two of the frosted surfaces are arranged opposite each other and have horizontal straight edges at their upper edges. The other two frosted surfaces are arranged opposite each other and have downward curved edges at their upper edges. The two ends of the horizontal straight edges are respectively connected to the ends of the two downward curved edges, and the two ends of the downward curved edges are respectively connected to the ends of the two horizontal straight edges.

5. The method for manufacturing flat-cup LED beads according to claim 1, characterized in that, The concave curved surface is low in the middle and high at both ends. Two frosted surfaces are machined on the cavity wall and are evenly distributed along the circumferential distance of the cavity wall. The two frosted surfaces are arranged opposite each other and their upper edges are horizontal straight edges.

6. The method for manufacturing flat-cup LED beads according to claim 1, characterized in that, The concave curved surface is low in the middle and high around the edges. A frosted surface is machined on the cavity wall, with the upper edge of the frosted surface being a ring edge of equal height.

7. The method for manufacturing flat-cup LED beads according to claim 1, characterized in that, The first dispensing can be done using either contact or non-contact dispensing methods, and the first curing can be done using a heat-curing method. The second dispensing can be done using either contact or non-contact dispensing methods, and the second curing can be done using a heat-curing method, a UV curing method, or a moisture curing method.

8. A flat-cup LED lamp bead, characterized in that, It is manufactured according to any one of the manufacturing methods described in claims 1 to 7.

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