Two-color car lamp double-layer powder spraying process

Abstract

The application discloses a double-color vehicle lamp double-layer powder spraying process and relates to the technical field of LED lamp powder spraying processes.The process comprises the following steps: yellow-green powder is used to spray all of the warm color temperature zones and the cold color temperature zones on an LED blue light chip; the corresponding coordinates of the cold color temperature zones are found according to the corresponding relationship between the color temperatures and the coordinates; the cold color temperature zones are baked according to the corresponding coordinates of the cold color temperature zones; the cold color temperature zones that have been sprayed are covered by using a powder spraying fixture; and red powder is used to spray the warm color temperature zones on the LED blue light chip.Through the double-layer powder spraying process, the brightness of the warm color temperature zones can be improved, the red powder blue light excitation effect is better, and the height consistency of the warm color temperature zones and the cold color temperature zones is better than that of single-layer powder spraying, and the use experience is improved.

Description

Technical Field

[0001] This invention relates to the technical field of LED lamp powder coating process, and more particularly to a dual-color automotive lamp double-layer powder coating process. Background Technology

[0002] The penetrating power of headlights plays a crucial role in vehicle operation, especially in adverse weather conditions. Color temperature is a standard for measuring the intensity of light (and is unrelated to headlight brightness). The higher the color temperature of a headlight, the worse its penetrating power through fog and rain. The powder coating process used in headlights is extremely important for achieving the desired color temperature.

[0003] Currently, single-layer powder coating is commonly used to achieve dual color temperature. Single-layer powder coating requires the use of a mesh cover plate, which can easily lead to a large difference in the height of the finished product on the left and right sides of the LED blue light chip during the powder coating process; the brightness of the finished product in the warm color temperature area and the cool color temperature area is also different, affecting the use; directly spraying red powder results in poor blue light excitation effect; two powder coating covers are required in the operation process, which is complicated and increases the cost, and the use of covers also has the problem of blue light leakage around the edges.

[0004] Therefore, existing technologies still need improvement and development. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a dual-color vehicle headlight double-layer powder coating process to address the above-mentioned defects of the prior art. This process aims to solve the problem that the display effect of LED blue light chips manufactured by the single-layer powder coating process in the prior art is poor, which in turn affects the use of vehicle headlights.

[0006] This application provides a dual-color automotive light double-layer powder coating process, employing the following technical solution:

[0007] A dual-color automotive headlight double-layer powder coating process includes:

[0008] Yellow-green powder is used to spray all the warm and cool color temperature areas on the LED blue light chip;

[0009] Find the coordinates of the cool color temperature zone based on the correspondence between color temperature and coordinates, and bake the cool color temperature zone according to the coordinates of the cool color temperature zone.

[0010] Use a powder coating fixture to cover the already sprayed cool color temperature areas;

[0011] Red powder is used to spray the warm color temperature area on the blue LED chip.

[0012] Furthermore, the yellow-green phosphor is prepared from a yellow-green phosphor body, a first silica gel, a second silica gel, and a diluent; wherein, the ratio of yellow-green phosphor body: first silica gel: second silica gel: diluent is 20:0.9:9:5.

[0013] Furthermore, the yellow-green powder coating is applied at a temperature of 6500K and has a thickness of 0.04mm.

[0014] Furthermore, the coordinates of the cool color temperature zone are (0.3147, 0.3279).

[0015] Furthermore, the yellow-green powder is sprayed at the center of the warm color temperature zone and the cool color temperature zone, respectively, and the red powder is sprayed at the center of the warm color temperature zone.

[0016] Furthermore, the thickness of the powder spraying fixture is 0.3 mm.

[0017] Furthermore, the thickness of the red powder coating ranges from 0.01 to 0.02 mm.

[0018] Furthermore, the height range of the warm color temperature zone after spraying is 0.05 to 0.06 mm, and the height of the cool color temperature zone after spraying is 0.04 mm.

[0019] Furthermore, the warm color temperature range after spraying is 3100–3300K, and the cool color temperature range is 6000–7000K.

[0020] Furthermore, the brightness of both the warm color temperature zone and the cool color temperature zone is 1800-2000 lm.

[0021] The beneficial effects of this invention are as follows: By employing a dual-layer powder coating process, yellow-green powder is sprayed onto both the warm and cool color temperature zones, followed by baking of the cool color temperature zone and spraying red powder onto the warm color temperature zone. This enhances the brightness of the warm color temperature zone, improves the blue light excitation effect of the red powder, and achieves better consistency between the warm and cool color temperature zones compared to single-layer powder coating, thus improving the user experience. The dual-layer powder coating process also reduces the number and frequency of cover plates used during powder coating, thereby improving blue light leakage around the chip and reducing production costs and overall process time. Attached Figure Description

[0022] Figure 1 This is a flowchart of the dual-color vehicle headlight double-layer powder coating process provided in the embodiments of this application.

[0023] Figure 2 This is a color temperature and common coordinate correspondence diagram provided in the embodiments of this application. Detailed Implementation

[0024] This invention discloses a dual-color automotive headlight double-layer powder coating process. To make the objectives, technical solutions, and effects of this invention clearer and more explicit, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the invention.

[0025] Color temperature is a unit of measurement indicating the color components contained in light, expressed in Kelvin (K). It's calculated by heating a standard black body; as the temperature rises, the color temperature gradually changes from deep red, light red, orange-yellow, white-brown, to bluish-brown. When a light source matches the color of the black body, the black body's color temperature is its absolute temperature color, also known as the light source's color temperature. The higher the color temperature, the weaker the penetrating power of the headlights; the lower the color temperature, the stronger the penetrating power. Stronger penetrating power means the driver can see further and more clearly in adverse weather conditions such as rain and fog, improving driving safety.

[0026] Powder coating is used to coat LED blue light chips (flip-chip) to achieve the desired color temperature, and this process is crucial for the color temperature of automotive lights. Currently, the commonly used powder coating process involves first covering the cool color temperature area of ​​the LED blue light chip with a mesh cover plate. Two types of phosphors (yellow and red) are mixed with sealant and sprayed onto the warm color temperature area. After testing the coordinate landing point, the warm color temperature area is baked. Then, the mesh cover plate is used to cover the warm color temperature area of ​​the LED blue light chip, and a single phosphor (yellow-green) is mixed with sealant and sprayed onto the cool color temperature area, with the coordinate landing point also tested.

[0027] The above-mentioned powder coating process is a single-layer powder coating. This process requires the use of two mesh cover plates during operation, resulting in a large difference in the coating height between the warm and cool color temperature areas on the chip, which affects its use. Direct coating also results in poor red powder and blue light excitation, with a brightness difference of 500lm between the two color temperature areas. The process requires the use of two cover plates, which requires a very precise match between the cover plates and the areas; otherwise, blue light leakage is likely to occur around the edges. Because two separate cover plates are required for powder coating, the operation process is complicated and the cost is increased.

[0028] To address the shortcomings of the prior art, this application discloses a dual-color automotive headlight double-layer powder coating process, such as... Figure 1 As shown, the process includes:

[0029] Step S10. Apply yellow-green powder to all warm and cool color temperature areas on the LED blue light chip;

[0030] Step S20. Find the coordinates of the cool color temperature zone according to the correspondence between color temperature and coordinates, and bake the cool color temperature zone according to the coordinates of the cool color temperature zone.

[0031] Step S30. Use a powder spraying fixture to cover the already sprayed cool color temperature areas;

[0032] Step S40. Apply red powder to the warm color temperature area on the LED blue light chip.

[0033] This application employs a dual-layer powder coating process. After coating both the warm and cool color temperature regions of the chip with yellow-green powder, the cool color temperature regions are baked separately, and red powder is applied to the warm color temperature regions. This enhances the brightness of the warm color temperature regions, improves the blue light excitation effect of the red powder, and achieves better consistency between the warm and cool color temperature regions compared to single-layer powder coating, thus improving the user experience. The dual-layer powder coating process reduces the number and number of cover plates used during powder coating, lowering production costs and overall process time. Through repeated experiments and tests, it also improves the blue light leakage around the chip's periphery.

[0034] In step S10, the yellow-green phosphor is prepared from a yellow-green phosphor body, a first silica gel, a second silica gel, and a diluent. The specific ratio is: yellow-green phosphor body : first silica gel : second silica gel : diluent = 20 : 0.9 : 9 : 5.

[0035] The yellow-green phosphor body uses BS304D, the first silica gel uses S6300A, the second silica gel uses S6300B, and the diluent uses AR.

[0036] The yellow-green powder coating temperature is 6500K, and the thickness is 0.04mm.

[0037] Specifically, in step S20, referring to Figure 2 The coordinates of the cool color temperature region are (0.3147, 0.3279).

[0038] In step S30, the thickness of the powder spraying fixture is 0.3 mm.

[0039] In step S40, the thickness of the red powder coating ranges from 0.01 to 0.02 mm.

[0040] Yellow-green powder is sprayed onto the center of the warm and cool color temperature zones, respectively, while red powder is sprayed onto the center of the warm color temperature zone. During spraying, the center of each color temperature zone needs to be targeted to improve powder uniformity.

[0041] The height range of the warm color temperature zone after spraying is 0.05 to 0.06 mm, and the height of the cool color temperature zone after spraying is 0.04 mm.

[0042] The warm color temperature range after spraying is 3100-3300K, and the cool color temperature range is 6000-7000K.

[0043] The brightness of both the warm and cool color temperature zones after spraying is 1800-2000 lm.

[0044] Compared with the prior art, the present invention has the following advantages:

[0045] 1. This invention employs a double-layer powder coating process, in which yellow-green powder is sprayed onto both the warm and cool color temperature zones, the cool color temperature zone is baked, and red powder is sprayed onto the warm color temperature zone. This enhances the brightness of the warm color temperature zone. Compared to single-layer powder coating, the red powder has a better blue light excitation effect, and the consistency between the warm and cool color temperature zones is also better than with single-layer powder coating, thus improving the user experience.

[0046] In addition, the use of a dual-layer powder spraying process reduces the number and frequency of cover plates used during powder spraying, thereby improving the blue light leakage around the chip and reducing production costs and the overall process time.

[0047] It should be understood that the application of the present invention is not limited to the examples above. Those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A dual-color automotive headlight double-layer powder coating process, characterized in that, The process includes the following steps: Yellow-green powder is used to spray all the warm and cool color temperature areas on the LED blue light chip; Find the coordinates of the cool color temperature zone based on the correspondence between color temperature and coordinates, and bake the cool color temperature zone according to the coordinates of the cool color temperature zone. Use a powder coating fixture to cover the already sprayed cool color temperature areas; Red powder is used to spray the warm color temperature area on the blue LED chip; The warm color temperature range after spraying is 3100~3300K, and the cool color temperature range is 6000~7000K; The yellow-green phosphor is prepared from a yellow-green phosphor body, a first silica gel, a second silica gel, and a diluent; wherein the ratio of yellow-green phosphor body: first silica gel: second silica gel: diluent is 20:0.9:9:

5. The thickness of the yellow-green powder coating is 0.04 mm; The thickness of the powder spraying fixture is 0.3 mm; The thickness of the red powder coating ranges from 0.01 to 0.02 mm; The height range of the warm color temperature zone after spraying is 0.05~0.06mm, and the height of the cool color temperature zone after spraying is 0.04mm; The brightness of both the warm and cool color temperature zones is 1800~2000lm.

2. The dual-color automotive headlight double-layer powder coating process according to claim 1, characterized in that, The coordinates corresponding to the cool color temperature zone are (0.3147, 0.3279).

3. The dual-color automotive headlight double-layer powder coating process according to claim 1, characterized in that, The yellow-green powder is sprayed in the center of the warm color temperature zone and the cool color temperature zone, respectively, and the red powder is sprayed in the center of the warm color temperature zone.

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