Anti-corrosion coating method for LED (light-emitting diode) module
By using anti-corrosion coating methods of epoxy resin, polyurethane, silicone and nanomaterials on the LED module, combined with brush coating and drying treatment, the corrosion problem of LED module in the corrosion environment is solved, and its anti-corrosion is significantly improved Performance and service life.
Patent Information
- Application Number
- CN202411279597.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-12
- Publication Date
- 2024-12-10
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
LED modules are prone to corrosion in humid and corrosive environments, affecting their performance and life. How to improve their anti-corrosion performance has become an urgent issue.
The mixture of epoxy resin, polyurethane and silicone resin is used as the base coating material, and nano-alumina and nano-silicon dioxide are added, and the surface of the LED module is evenly coated by brushing, combining benzotriazole and poly Ethylene glycol dispersant adjusts the viscosity and dispersion of the coating and finally cures in the drying equipment.
Significantly improves the corrosion resistance and mechanical strength of the LED module, extends its service life, enhances weather resistance to UV, moisture and temperature changes, reduces the risk of coating aging and falling off, and ensures coating uniformity and adhesion reduces faults and damage caused by corrosion.
Smart Images
Figure CN119101435A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of LED module manufacturing, and in particular to an LED module anti-corrosion coating method. Background Art
[0002] As an important component of modern lighting equipment, LED modules are widely used in various environmental conditions. However, in humid and corrosive environments, LED modules are susceptible to corrosion, which affects their performance and lifespan.
[0003] Therefore, how to ensure that the LED module has anti-corrosion performance has become a technical problem that urgently needs to be solved. Summary of the invention
[0004] In order to improve the anti-corrosion performance of LED modules and extend their service life, the present application provides an LED module anti-corrosion coating method.
[0005] The above-mentioned invention objective of the present application is achieved through the following technical solutions: A method for anti-corrosion coating of an LED module, the method comprising: Mixing epoxy resin, polyurethane and silicone resin in a preset ratio to form a base coating material; Adding nano-alumina and nano-silicon dioxide to the base coating material, and stirring them thoroughly to obtain a prepared anti-corrosion coating material; The prepared anti-corrosion coating material is coated on the surface of the LED module to be coated by brushing to obtain a treated LED module.
[0006] By adopting the above technical solution, the base coating material is formed by mixing epoxy resin, polyurethane and silicone resin. These materials themselves have good anti-corrosion properties and can provide multi-level protection. Nano-alumina and nano-silicon dioxide are added to the base coating material. These nano-materials have high surface area and excellent mechanical properties, can fill the tiny gaps in the coating, and enhance the sealing and corrosion resistance of the coating. The anti-corrosion coating material is evenly applied to the surface of the LED module by brushing to ensure that each part is fully protected and reduce local corrosion caused by uneven coating. Polyurethane and silicone resin improve the weather resistance of the coating in the base coating, which can better resist ultraviolet rays, moisture and temperature changes in the external environment, reduce the risk of coating aging and shedding, and thus extend the service life of the LED module. The addition of nano-alumina and nano-silicon dioxide not only improves the anti-corrosion performance of the coating, but also enhances the mechanical strength and wear resistance of the coating, so that the LED module can better resist physical damage in long-term use. Epoxy resin provides excellent adhesion properties, allowing the coating to adhere firmly to the surface of the LED module, avoiding peeling and falling off of the coating, and further extending the service life of the LED module.
[0007] In a preferred example, the present application can be further configured as follows: the epoxy resin, polyurethane, and silicone resin are mixed in a preset ratio to form a uniform base coating material, including: Pour 50% of epoxy resin into a mixing container by weight, add 25% of polyurethane to the container, and add 15% of silicone to the container; A mechanical stirrer is used to stir at a uniform speed for 10-15 minutes to ensure that the epoxy resin, the polyurethane and the silicone resin are fully mixed to form the uniform base coating material.
[0008] By adopting the above technical solution, epoxy resin, polyurethane and silicone resin are mixed in a ratio of 50%, 25% and 15% to form a multi-layer base coating material. Each material has its own unique anti-corrosion properties, and combined together can provide more comprehensive protection. The materials are stirred at a uniform speed by a mechanical stirrer for 10-15 minutes to ensure that the materials are fully mixed to form a uniform base coating material, which can better seal the surface of the LED module and prevent the intrusion of moisture and corrosive gases. The combination of epoxy resin, polyurethane and silicone resin in the base coating material can provide excellent environmental erosion resistance and protect the LED module from moisture, ultraviolet rays and temperature changes. Polyurethane and silicone resin improve the mechanical strength and flexibility of the coating, so that the coating can resist external force and environmental damage in long-term use, and reduce cracking and shedding of the coating. The uniform base coating material ensures consistent thickness and density of the coating, provides stable anti-corrosion performance, and thus extends the service life of the LED module.
[0009] In a preferred example, the present application can be further configured as follows: adding nano-alumina and nano-silicon dioxide to the base coating material and stirring them thoroughly to obtain a prepared anti-corrosion coating material, including: Adding the nano-alumina into the uniform base coating material at a weight percentage of 4%, stirring at a uniform speed using the mechanical stirrer, with an initial stirring time of 5 minutes, to obtain a preliminary anti-corrosion coating material; Adding the nano silicon dioxide into the preliminary anticorrosive coating material at a weight percentage of 2.5%, and stirring at a uniform speed for 5 minutes using the mechanical stirrer; Ensure that the nano-alumina and the nano-silicon dioxide are evenly dispersed in the base coating material, continue to use the mechanical stirrer to stir at a medium speed for 10-15 minutes to obtain the prepared anti-corrosion coating material.
[0010] By adopting the above technical solutions, nano-alumina and nano-silicon dioxide have excellent anti-corrosion properties. They can effectively block the penetration of moisture, oxygen and other corrosive substances, thereby protecting the metal parts of the LED module from corrosion. Nano-alumina has high hardness and good wear resistance. After being added to the base coating, it can improve the mechanical strength of the coating, making it less susceptible to wear and scratches in harsh environments. Nano-silicon dioxide has excellent chemical stability and weather resistance, which can effectively improve the stability of the coating under various environmental conditions and prevent the coating from deteriorating under the action of ultraviolet rays, temperature changes and chemicals. The addition of nanomaterials can improve the adhesion between the coating and the substrate, making the coating more firm, thereby increasing the durability of the LED module. Nanomaterials can fill in tiny defects and gaps in the coating, making the coating denser and smoother, and further enhancing its protective properties.
[0011] In a preferred example, the present application can be further configured as follows: the step of ensuring that the nano-alumina and nano-silicon dioxide are uniformly dispersed in the base coating material, and continuing to use the mechanical stirrer to stir at a medium speed for 10-15 minutes to obtain the prepared anti-corrosion coating material, further comprising: The prepared anticorrosive coating material is placed in an ultrasonic disperser for 5-10 minutes, which helps to destroy the aggregates of the nanofiller and ensure its uniform distribution in the coating material.
[0012] By adopting the above technical scheme, ultrasonic dispersion treatment can effectively destroy the aggregates of nano-alumina and nano-silicon dioxide, so that they are more evenly dispersed in the coating material. This uniform dispersion can ensure that each nanoparticle can play its due anti-corrosion role and improve the overall performance of the coating. The uniformly dispersed nanofiller can fill the tiny pores and defects in the coating, making the coating denser and smoother, thereby further improving its anti-corrosion performance. The dense coating can more effectively block the penetration of corrosive substances and protect the internal structure of the LED module. Through ultrasonic dispersion treatment, the nanofiller can be more evenly distributed in the coating, thereby enhancing the mechanical strength and wear resistance of the coating. This helps the coating to be less susceptible to mechanical damage during use and prolong its service life. Uniformly dispersed nanomaterials can improve the stability and durability of the coating under various environmental conditions. Ultrasonic dispersion treatment can make the nanofiller better combined with the substrate, thereby enhancing the adhesion and durability of the coating. Uniformly distributed nano-silicon dioxide and nano-alumina can enhance the anti-oxidation and anti-ultraviolet properties of the coating, prevent the coating from oxidative decomposition when exposed to sunlight and air for a long time, thereby prolonging the service life of the LED module. Ultrasonic dispersion treatment can reduce tiny defects and bubbles in coating materials, reduce quality problems of coatings during application, and improve product reliability.
[0013] In a preferred example, the present application can be further configured as follows: the prepared anti-corrosion coating material is applied to the surface of the LED module to be coated by brushing to obtain a treated LED module, which includes: Adding 0.5% of benzotriazole anticorrosive additive and 0.5% of polyethylene glycol dispersant to the prepared anticorrosive coating material, and continuing to stir for 5-10 minutes using the mechanical stirrer to ensure that the anticorrosive additive and the dispersant are evenly distributed in the coating material; According to the viscosity requirements of the prepared anti-corrosion coating material, ethanol (10%-15% of the total weight) is gradually added. After each addition of the ethanol, the mechanical stirrer is used to stir for 3-5 minutes until the preset coating requirements are met.
[0014] By adopting the above technical scheme, benzotriazole is an efficient anti-corrosion additive with good antioxidant and anti-corrosion properties. It can form a protective film on the metal surface to prevent the penetration of oxygen and moisture, thereby reducing the corrosion of the metal. The addition of benzotriazole can further improve the anti-corrosion effect of the coating and protect the metal parts of the LED module. Polyethylene glycol dispersant can effectively improve the dispersibility of nanofillers in the coating material and avoid the agglomeration of nanoparticles. Uniformly dispersed nanofillers can better play their anti-corrosion and reinforcing roles, making the coating performance more uniform and stable. Gradually adding ethanol can effectively adjust the viscosity of the coating material to meet the preset coating requirements. Appropriate viscosity can ensure that the coating has good fluidity and coverage during the application process and forms a uniform and dense protective layer. Ethanol, as a solvent, can evaporate during the drying process of the coating, leaving a uniform coating material. This can improve the adhesion of the coating and ensure that the coating forms a firm protective film on the surface of the substrate to prevent peeling and cracking. By adding anti-corrosion additives and dispersants and adjusting the viscosity of the coating, the overall durability and stability of the coating can be improved. The coating can maintain its performance under various environmental conditions and is not prone to degradation and damage, thereby extending the service life of the LED module.
[0015] In a preferred example, the present application can be further configured as follows: the prepared anti-corrosion coating material is applied to the surface of the LED module to be coated by brushing to obtain a processed LED module, including: Clean the surface of the LED module to be coated to ensure that there is no oil, dust or impurities on the surface; Use a brush tool to evenly coat the prepared anti-corrosion coating material on the surface of the LED module, with a coating thickness of 50-100 microns.
[0016] By adopting the above technical solutions, cleaning the surface can remove oil, dust and impurities, providing a clean substrate surface. This helps the anti-corrosion coating material to better adhere to the LED module, forming a strong protective layer and avoiding the coating from peeling or falling off. Using a brush tool can ensure that the coating material is evenly distributed on the surface of the LED module to avoid the problem of uneven coating thickness. A uniform coating can provide a consistent protective effect and effectively block the intrusion of corrosive substances. A coating thickness of 50-100 microns can provide sufficient anti-corrosion protection without being too thick to affect the heat dissipation performance. The appropriate thickness can ensure that the coating maintains its anti-corrosion effect during long-term use and extend the service life of the LED module. Cleaning the surface and evenly coating can reduce defects and voids in the coating, making the coating more dense and smooth. This can improve the durability and stability of the coating, so that it can maintain good performance under various environmental conditions. An efficient anti-corrosion coating can significantly reduce the failure and damage of the LED module caused by corrosion, extend its service life, thereby reducing maintenance and replacement costs and improving the economic benefits of the product. The uniform and strong anti-corrosion coating can provide long-term protection, reduce electrical failures and safety hazards caused by corrosion, and improve the reliability and safety of LED modules.
[0017] In a preferred example, the present application can be further configured as follows: using a brushing tool to evenly coat the prepared anti-corrosion coating material on the surface of the LED module, with a coating thickness of 50-100 microns, and further comprising: Place the coated LED module in a drying device, set the temperature to 60-80°C, and dry for 2-4 hours to ensure that the coating is completely cured.
[0018] By adopting the above technical solution, the coated LED module is placed in the drying equipment and the appropriate temperature (60-80℃) and time (2-4 hours) are set to effectively promote the chemical reaction and curing process of the coating. This ensures that the coating can quickly form a solid protective layer after coating, improving its durability and stability. Controlling the temperature and time during the drying process can ensure that the coating is evenly cured over the entire surface, avoiding the appearance of inconsistent local properties or fragile areas of the coating.
[0019] In a preferred example, the present application can be further configured as follows: the LED module anti-corrosion coating method includes: After the coated LED module is dried and cured, a quality inspection is performed on it to ensure that it meets the factory standards, and the quality inspection includes coating thickness, adhesion, corrosion resistance and appearance quality; If an LED module is found to be non-compliant with the standards, it must be re-coated and re-cured until it meets the factory standards.
[0020] By adopting the above technical solutions, the coating thickness is checked to ensure that the coating reaches a sufficient thickness to provide adequate anti-corrosion protection. Adhesion inspection ensures that the coating is tightly bonded to the surface of the LED module to prevent the coating from falling off or peeling off, thereby maintaining a long-term anti-corrosion effect. Corrosion resistance inspection ensures that the LED module can be used for a long time in harsh environments without being affected by corrosion. Reduce failures and damage caused by corrosion.
[0021] In summary, the present application includes at least one of the following beneficial technical effects: 1. The base coating material is formed by mixing epoxy resin, polyurethane and silicone resin. These materials themselves have good anti-corrosion properties and can provide multi-level protection. Nano-alumina and nano-silicon dioxide are added to the base coating material. These nano-materials have high surface area and excellent mechanical properties, can fill the tiny gaps in the coating, and enhance the sealing and corrosion resistance of the coating. The anti-corrosion coating material is evenly applied to the surface of the LED module by brushing to ensure that each part is fully protected and reduce local corrosion caused by uneven coating. Polyurethane and silicone resin in the base coating improve the weather resistance of the coating, can better resist ultraviolet rays, moisture and temperature changes in the external environment, reduce the risk of coating aging and shedding, and thus extend the service life of the LED module. The addition of nano-alumina and nano-silicon dioxide not only improves the anti-corrosion performance of the coating, but also enhances the mechanical strength and wear resistance of the coating, so that the LED module can better resist physical damage in long-term use. Epoxy resin provides excellent adhesion properties, allowing the coating to firmly adhere to the surface of the LED module, avoiding peeling and shedding of the coating, and further extending the service life of the LED module; 2. Benzotriazole is an efficient anti-corrosion additive with good antioxidant and anti-corrosion properties. It can form a protective film on the metal surface to prevent the penetration of oxygen and moisture, thereby reducing the corrosion of the metal. The addition of benzotriazole can further improve the anti-corrosion effect of the coating and protect the metal parts of the LED module. Polyethylene glycol dispersant can effectively improve the dispersibility of nanofillers in the coating material and avoid the agglomeration of nanoparticles. Uniformly dispersed nanofillers can better play their anti-corrosion and reinforcing roles, making the coating performance more uniform and stable. Gradually adding ethanol can effectively adjust the viscosity of the coating material to meet the preset coating requirements. Appropriate viscosity can ensure that the coating has good fluidity and coverage during the application process and forms a uniform and dense protective layer. Ethanol, as a solvent, can evaporate during the drying process of the coating, leaving a uniform coating material. This can improve the adhesion of the coating and ensure that the coating forms a firm protective film on the surface of the substrate to prevent peeling and cracking. By adding anti-corrosion additives and dispersants and adjusting the viscosity of the coating, the overall durability and stability of the coating can be improved. The coating can maintain its performance under various environmental conditions and is not prone to degradation and damage, thus extending the service life of the LED module; 3. Check the coating thickness to ensure that the coating is thick enough to provide adequate corrosion protection. Adhesion inspection ensures that the coating is tightly bonded to the surface of the LED module to prevent the coating from falling off or peeling off, thereby maintaining long-term corrosion protection. Corrosion resistance inspection ensures that the LED module can be used for a long time in harsh environments without being affected by corrosion. Reduce failures and damage caused by corrosion. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Figure 1 is a flow chart of a method for anti-corrosion coating of an LED module in one embodiment of the present application; Figure 2 This is a flowchart of the implementation of step S10 of the LED module anti-corrosion coating method in one embodiment of the present application; Figure 3 This is a flowchart of the implementation of step S20 of the LED module anti-corrosion coating method in one embodiment of the present application; Figure 4 This is a flowchart of the implementation of step S23 of the LED module anti-corrosion coating method in one embodiment of the present application; Figure 5 This is a flowchart of the LED module anti-corrosion coating method before step S30 in one embodiment of the present application; Figure 6 This is a flowchart of the implementation of the LED module anti-corrosion coating method after step S30 in one embodiment of the present application; Figure 7 This is a flowchart of the implementation of step S32 of the LED module anti-corrosion coating method in one embodiment of the present application; Figure 8 This is a flowchart of the implementation of the LED module anti-corrosion coating method after step S10 in one embodiment of the present application; DETAILED DESCRIPTION The present application is further described in detail below in conjunction with the accompanying drawings.
[0023] In one embodiment, if Figure 1 As shown, the present application discloses a method for anti-corrosion coating of LED modules, which specifically includes the following steps: S10: Mix epoxy resin, polyurethane and silicone resin according to a preset ratio to form a base coating material.
[0024] In the present embodiment, epoxy resin means that epoxy resin is a high-performance thermosetting polymer, and the epoxy resin used in the present embodiment is Epon 828. Polyurethane refers to an elastomeric material with excellent wear resistance and chemical stability. The polyurethane used in the present embodiment is Desmodur N75. Silicone resin means that silicone resin is a polymer that is resistant to high temperatures and chemical corrosion. The silicone resin used in the present embodiment is Dow Corning 3140. The preset ratio refers to mixing the components according to a certain weight percentage. In the present embodiment, the preset ratio of epoxy resin, polyurethane and silicone resin is 50:25:15 (weight percentage). The base coating material refers to a uniform mixture formed by mixing epoxy resin, polyurethane and silicone resin according to a preset ratio.
[0025] Specifically, make sure that all equipment and containers used are clean and free of contamination. Wipe the mixing container with a clean cloth or paper towel to ensure that there is no dust, oil or other impurities inside. Use a high-precision electronic scale to weigh the required materials separately. Weigh 100 grams of epoxy resin (Epon 828), 50 grams of polyurethane (Desmodur N75) and 30 grams of silicone resin (Dow Corning 3140). Make sure the weight of each material is accurate to ensure the correct ratio of the final base coating materials. Slowly pour 100 grams of epoxy resin (Epon 828) into a clean mixing container. Make sure to avoid splashing or overflowing during the pouring process. Subsequently, slowly add 50 grams of polyurethane (Desmodur N75) to the container. At this time, you need to pay attention to avoid bubbles. You can use a spatula to assist the pouring process. Finally, gradually add 30 grams of silicone resin (Dow Corning 3140). Again, pay attention to avoid bubbles. Start stirring using a mechanical stirrer. The initial stirring speed should be slow to avoid material splashing and air mixing. The stirring head of the mixer should be inserted deeply into the material and maintained at a constant speed. During the initial stirring stage (about 2-3 minutes), make sure that the three materials begin to mix evenly. As the materials are gradually mixed, the stirring speed can be gradually increased, but avoid being too fast to prevent bubbles. The total stirring time should be 10-15 minutes. During the stirring process, check the uniformity of the mixture regularly. Use a scraper to scrape the materials from the walls and bottom of the container into the mixing area to ensure that there are no unmixed dead corners. After the stirring is finished, use a scraper to carefully check the uniformity of the mixture. The scraper can help identify and eliminate any areas that are not fully mixed. Scrape the mixture from one side of the container to the other to ensure that all ingredients are fully combined. If any uneven parts are found, continue stirring for 3-5 minutes until the materials are completely uniform.
[0026] S20: adding nano-alumina and nano-silicon dioxide to the base coating material, and stirring the mixture thoroughly to obtain a prepared anti-corrosion coating material.
[0027] In this embodiment, nano-alumina refers to aluminum oxide particles with an average particle size of 20-50 nanometers, which have excellent wear resistance and chemical stability. Nano-silicon dioxide refers to silicon dioxide particles with an average particle size of 10-30 nanometers, which have a high surface area and good dispersibility. The prepared anti-corrosion coating material refers to a uniform coating material with anti-corrosion properties obtained after nano-alumina and nano-silicon dioxide are fully mixed.
[0028] Specifically, ensure that the mixing equipment and container are clean and free of contamination. Wipe the mixing container with a clean cloth or paper towel to ensure that there is no dust, oil or other impurities in it. Prepare the required nano-alumina and nano-silica and weigh the required amounts using a high-precision electronic scale. Weigh 8 grams of nano-alumina and 5 grams of nano-silica using a high-precision electronic scale. Ensure that the weighing is accurate to ensure the correct proportion of the final anti-corrosion coating material. Slowly add 8 grams of nano-alumina to the already mixed base coating material. Use a scraper to assist and ensure that the nano-alumina is evenly dispersed in the base coating material. Use a mechanical stirrer to stir at a uniform speed for 5 minutes to ensure that the nano-alumina is initially evenly dispersed to obtain a preliminary anti-corrosion coating material. Slowly add 5 grams of nano-silica to the preliminary anti-corrosion coating material. Use a scraper to assist and ensure that the nano-silica is evenly dispersed in the preliminary anti-corrosion coating material. Use a mechanical stirrer to stir at a uniform speed for 5 minutes to ensure that the nano-silica is initially evenly dispersed. Adjust the stirring speed to medium speed and continue stirring for 10-15 minutes. During the mixing process, regularly use a scraper to scrape the material from the wall and bottom of the container into the mixing area to ensure that there are no unmixed dead corners. During the mixing process, observe the uniformity of the mixture. If any uneven parts are found, continue to stir until the material is completely uniform.
[0029] S30: coating the prepared anti-corrosion coating material on the surface of the LED module to be coated by brushing, so as to obtain a treated LED module.
[0030] In this embodiment, the processed LED module refers to an LED module with a smooth and uniform surface and excellent anti-corrosion performance after being coated and cured with an anti-corrosion coating material.
[0031] Specifically, ensure that the operating environment is clean and dust-free, and wear appropriate personal protective equipment, such as gloves and goggles. Prepare the required brushing tools, including a clean brush and a tray or container for coating. Use a dust-free cloth and an appropriate cleaning agent (such as isopropyl alcohol) to clean the surface of the LED module to ensure that the surface is free of oil, dust and other impurities. After cleaning, wipe the surface of the LED module with a clean dust-free cloth to ensure that there is no residual liquid. Pour the prepared anti-corrosion coating material into a clean tray or container for coating to ensure that the material is evenly distributed. If the anti-corrosion coating material has undergone slight stratification or precipitation during storage, use a mechanical stirrer to stir at a low speed for 2-3 minutes to make the material uniform again. Use a clean brush to dip an appropriate amount of anti-corrosion coating material, ensuring that there is no excessive material on the brush to avoid dripping or over-thick coating. Apply the anti-corrosion coating material evenly on the surface of the LED module with uniform force and speed. When applying, start from one direction to ensure uniform coating thickness. Each time you dip new material, make sure the brush bristles are evenly covered with coating material and tap the edge of the container to remove excess material. During the coating process, regularly check the uniformity and thickness of the coating. Use a thickness measurement tool to check whether the coating thickness is between 50-100 microns. If the coating thickness is found to be insufficient or too thick in a local area, make adjustments in time to ensure the uniformity of the overall coating.
[0032] In one embodiment, if Figure 2 As shown, in step S10, epoxy resin, polyurethane, and silicone resin are mixed in a preset ratio to form a uniform base coating material, including: S11: Pour 50% of epoxy resin into a mixing container by weight, add 25% of polyurethane into the container, and add 15% of silicone into the container.
[0033] Specifically, use a high-precision electronic scale to weigh the required epoxy resin, polyurethane and silicone resin. Assuming the total mixing amount is 200 grams, weigh 100 grams of epoxy resin (50% by weight), 50 grams of polyurethane (25% by weight) and 30 grams of silicone resin (15% by weight). Pour 100 grams of epoxy resin (Epon 828) into a clean mixing container. Add 50 grams of polyurethane (Desmodur N75) to the container. Add 30 grams of silicone resin (Dow Corning 3140).
[0034] S12: Use a mechanical stirrer to stir at a uniform speed for 10-15 minutes to ensure that the epoxy resin, polyurethane and silicone resin are fully mixed to form a uniform base coating material.
[0035] Specifically, use a mechanical stirrer to stir at a uniform speed for 10-15 minutes. The speed of the stirrer should be set to medium speed to ensure that the materials are fully mixed. During the stirring process, use a scraper to scrape the materials from the wall and bottom of the container into the mixing area regularly to ensure that there are no unmixed dead corners. Observe the uniformity of the mixture. If any uneven parts are found, continue to stir until the material is completely uniform. The initial stirring speed should be set to low speed for 2-3 minutes to avoid material splashing and bubble generation. Adjust the stirrer to medium speed and continue stirring for 7-10 minutes to ensure that the three resins are fully mixed. Finally, reduce the stirring speed to low speed and stir for another 1-2 minutes to eliminate possible bubbles and ensure the uniformity of the mixture.
[0036] In one embodiment, if Figure 3 As shown, in step S20, nano-alumina and nano-silicon dioxide are added to the base coating material, and the mixture is stirred evenly to obtain a prepared anti-corrosion coating material, including: S21: Add 4% by weight of nano-alumina into a uniform base coating material, stir at a uniform speed using a mechanical stirrer, with an initial stirring time of 5 minutes, to obtain a preliminary anti-corrosion coating material.
[0037] In this embodiment, the preliminary anti-corrosion coating material refers to a coating material with preliminary anti-corrosion performance formed by adding nano-alumina to a basic coating material and performing preliminary stirring.
[0038] Specifically, use a high-precision electronic scale to weigh the required nano-alumina and nano-silicon dioxide. Assuming that the total amount of the base coating material is 200 grams, weigh 8 grams of nano-alumina (4% by weight). Pour the base coating material into a clean stirring container. Gradually add 8 grams of nano-alumina to the base coating material. Use a mechanical stirrer to stir at a uniform speed for an initial stirring time of 5 minutes to ensure that the nano-alumina is evenly dispersed in the base coating material to obtain a preliminary anti-corrosion coating material.
[0039] S22: Add 2.5% by weight of nano-silicon dioxide to the preliminary anti-corrosion coating material, and stir at a uniform speed using a mechanical stirrer for 5 minutes.
[0040] Specifically, use a high-precision electronic scale to weigh the required nano-silicon dioxide. Assuming that the total amount of the preliminary anti-corrosion coating material is 200 grams, weigh 5 grams of nano-silicon dioxide (2.5% by weight). Continue to place the preliminary anti-corrosion coating material in the stirring container. Gradually add 5 grams of nano-silicon dioxide to the preliminary anti-corrosion coating material. It is recommended to add in batches, adding a small amount each time, to ensure uniform stirring. Use a mechanical stirrer to stir at a uniform speed for an initial stirring time of 5 minutes to ensure that the nano-silicon dioxide is evenly dispersed in the preliminary anti-corrosion coating material.
[0041] S23: Ensure that the nano-alumina and nano-silicon dioxide are evenly dispersed in the base coating material, and continue to use the mechanical stirrer to stir at a medium speed for 10-15 minutes to obtain the prepared anti-corrosion coating material.
[0042] Specifically, the preliminarily mixed coating material is continued to be placed in the stirring container. A mechanical stirrer is used to stir at medium speed for 10-15 minutes to ensure that the nano-alumina and nano-silicon dioxide are evenly dispersed in the base coating material. During the stirring process, a scraper is used to scrape the material from the wall and bottom of the container into the mixing area regularly to avoid unmixed dead corners. The stirring speed is set to medium speed, within the range of 300-500RPM (revolutions per minute).
[0043] In one embodiment, if Figure 4 As shown, in step S23, that is, ensuring that the nano-alumina and nano-silicon dioxide are evenly dispersed in the base coating material, continue to use the mechanical stirrer to stir at a medium speed for 10-15 minutes to obtain the prepared anti-corrosion coating material, and also include: S231: The prepared anti-corrosion coating material is placed in an ultrasonic disperser for 5-10 minutes, which helps to destroy the aggregates of the nanofiller and ensure its uniform distribution in the coating material.
[0044] In this embodiment, the ultrasonic disperser refers to a device that uses ultrasonic energy to evenly disperse tiny particles and is used to process nanomaterials.
[0045] Specifically, ensure that the ultrasonic disperser is clean and in good working condition. Check the cleanliness of the equipment to ensure that there are no residues or impurities. Prepare the prepared anti-corrosion coating material. Prepare an appropriate amount of material based on the capacity of the disperser, not exceeding the maximum processing capacity of the equipment. Turn on the ultrasonic disperser power and set the required ultrasonic frequency and power. The ultrasonic frequency range is 20-40 kHz. Set the processing time to 5-10 minutes. Adjust the processing time appropriately based on the viscosity of the material and the dispersion requirements of the nanofiller. Pour the prepared anti-corrosion coating material into the processing container of the ultrasonic disperser, ensuring that the material completely covers the ultrasonic probe. Start the ultrasonic disperser and start processing. Excessive overflow and excessive foaming should be avoided during processing. At the same time, gently stir the material during processing to enhance the dispersion effect.
[0046] In one embodiment, if Figure 5 As shown, before step S30, the prepared anti-corrosion coating material is applied to the surface of the LED module to be coated by brushing to obtain a treated LED module, which includes: S201: Add 0.5% of benzotriazole anticorrosive additive and 0.5% of polyethylene glycol dispersant to the prepared anticorrosive coating material, and continue stirring for 5-10 minutes using a mechanical stirrer to ensure that the anticorrosive additive and dispersant are evenly distributed in the coating material.
[0047] In this embodiment, the benzotriazole anticorrosion additive refers to a metal anticorrosion agent, which can prevent the corrosion of metal materials. The polyethylene glycol dispersant refers to a dispersant, which can improve the dispersion effect of nanomaterials in the matrix.
[0048] Specifically, a high-precision electronic scale is used to weigh 0.5% of the benzotriazole anticorrosion additive and 0.5% of the polyethylene glycol dispersant. Assuming that the total weight of the prepared anticorrosion coating material is 1000 grams, the weight of each additive should be 5 grams. Pour the prepared anticorrosion coating material into a stirring container. Add the weighed 5 grams of benzotriazole anticorrosion additive to the anticorrosion coating material. Add the weighed 5 grams of polyethylene glycol dispersant to the anticorrosion coating material. Start the mechanical stirrer and stir at a uniform speed for 5-10 minutes. The stirring speed is set in the range of 300-500 RPM (revolutions per minute). During the stirring process, the scraper scrapes the material from the wall and bottom of the container into the mixing area to avoid unmixed dead corners. Ensure that the benzotriazole anticorrosion additive and the polyethylene glycol dispersant are evenly distributed in the coating material.
[0049] S202: According to the viscosity requirements of the prepared anti-corrosion coating material, gradually add ethanol (10%-15% of the total weight). After each addition of ethanol, use a mechanical stirrer to stir for 3-5 minutes until the preset coating requirements are met.
[0050] In this embodiment, the preset coating requirement refers to the viscosity range of the coating material.
[0051] Specifically, the amount of ethanol to be added is calculated based on the total weight of the prepared anti-corrosion coating material. Assuming that the total weight of the prepared anti-corrosion coating material is 1000 grams, the amount of ethanol used should be 100-150 grams (i.e., 10%-15% of the total weight). Take a small amount of ethanol each time (about 10%-20% of the total amount) and slowly pour it into the mixing container of the anti-corrosion coating material. Use a mechanical stirrer to stir at a uniform speed for 3-5 minutes. The stirring speed is set in the range of 300-500 RPM (revolutions per minute). During the stirring process, use a scraper to scrape the material from the wall and bottom of the container into the mixing area to avoid unmixed dead corners. Check the viscosity of the anti-corrosion coating material to ensure that the ethanol is evenly dispersed in the coating material. Add ethanol gradually according to the required viscosity, and the amount added each time is 10%-20% of the total ethanol. Stir evenly for 3-5 minutes after each addition until the ethanol is completely mixed.
[0052] In one embodiment, if Figure 6As shown, in step S30, the prepared anti-corrosion coating material is coated on the surface of the LED module to be coated by brushing to obtain a treated LED module, including: S31: Clean the surface of the LED module to be coated to ensure that there is no oil, dust or impurities on the surface. Specifically, the surface of the LED module to be coated refers to the exposed part of the LED module that needs to be treated with an anti-corrosion coating, including but not limited to the surfaces of components such as LED chips, pins, and brackets.
[0053] Specifically, remove dust and loose impurities on the surface of the LED module, use a dust-free cloth soaked in detergent to gently wipe the surface of the LED module, and use a dry dust-free cloth to gently wipe the surface of the LED module to remove excess detergent residue.
[0054] S32: Use a brushing tool to evenly apply the prepared anti-corrosion coating material on the surface of the LED module, with a coating thickness of 50-100 microns.
[0055] Specifically, use a brushing tool (fine-bristle brush or sponge brush) to lightly dip an appropriate amount of anti-corrosion coating material. Apply the coating material evenly on the surface of the LED module. When applying, pay attention to keep the brush moving evenly to avoid too thick or too thin coating. During the coating process, maintain uniform brushing force and speed to ensure that the coating is evenly distributed on the surface of the LED module. Use a wet film thickness comb to measure the thickness of the coating to ensure that the coating thickness is between 50-100 microns.
[0056] In one embodiment, if Figure 7 As shown, in step S32, the prepared anti-corrosion coating material is evenly coated on the surface of the LED module using a brushing tool, and the coating thickness is 50-100 microns, and further includes: S321: Place the coated LED module into a drying device, set the temperature to 60-80°C, and dry for 2-4 hours to ensure that the coating is completely cured.
[0057] Specifically, turn on the drying equipment and set the temperature to 60-80℃. Preheat the drying equipment until the temperature is stable within the set range. Ensure that there is no dust and other impurities on the surface of the coated LED module. Wear protective gloves to prevent burns during operation. Place the coated LED module in the drying equipment and ensure that there is enough spacing between the LED modules to ensure air circulation and uniform heating. Avoid the LED module from contacting the heating element or other high-temperature surfaces of the drying equipment to prevent local overheating. Set the temperature of the drying equipment between 60-80℃. The specific temperature selection can be determined according to the characteristics of the anti-corrosion coating material and the heat resistance of the LED module. Set the drying time to 2-4 hours, and adjust the drying time appropriately according to the coating thickness and ambient humidity. Start the drying equipment and start the drying process. Use a thermometer to regularly monitor the temperature in the drying equipment to ensure that the temperature is within the set range. Use a timer to record the drying time to ensure that the drying process meets the preset parameters. During the drying process, regularly check the status of the LED module to ensure that there is no overheating, deformation or other abnormal conditions. If the temperature is found to be too high or the time is too long, adjust the drying parameters in time to avoid damaging the LED module or affecting the coating quality. After the drying time reaches the set value, turn off the drying equipment.
[0058] In one embodiment, if Figure 1 As shown, after step S10, the LED module anti-corrosion coating method includes: S301: After the coated LED module is dried and cured, it is subjected to quality inspection to ensure that it meets the factory standards. The quality inspection includes coating thickness, adhesion, corrosion resistance and appearance quality.
[0059] In this embodiment, the factory standard means that the coating thickness is between 50-100 microns to ensure anti-corrosion effect and mechanical protection. The adhesion between the coating and the surface of the LED module should meet national or industry standards. The coating performs well in the salt spray test and has no obvious signs of corrosion. The coating is uniform and smooth, without defects such as bubbles, cracks, and peeling.
[0060] Specifically, use a coating thickness gauge (such as a magnetic thickness gauge or an eddy current thickness gauge) to measure the coating thickness. Select multiple measurement points on the surface of the LED module and record the coating thickness value at each point. Calculate the average value of the coating thickness to ensure that it is within the range of 50-100 microns. Use the cross-hatch method to test the coating adhesion. Use a knife to scratch a square grid on the coating surface, and the grid size and knife spacing are set according to standard requirements. Use tape to stick on the grid and quickly tear off the tape. Observe the peeling of the coating, evaluate the adhesion level according to the ASTMD3359 standard, and ensure that it reaches the 5B level (i.e., no peeling or minimal peeling). Perform a salt spray test (SaltSprayTest) in accordance with the ASTMB117 standard. Place the LED module in a salt spray test chamber and test it according to the set temperature, humidity and time (such as 5% saline solution, 35°C, and the test time is 24-72 hours). After the test, take out the LED module, clean it, and check whether there are signs of corrosion on the coating surface (such as spots, discoloration, blistering, etc.). Record the test results to ensure that the coating shows no obvious signs of corrosion during the salt spray test. Visually inspect the coating surface to ensure that it is smooth, uniform, and free of defects such as bubbles, cracks, and peeling.
[0061] S302: If an LED module that does not meet the standards is found, it needs to be re-coated and cured until it meets the factory standards.
[0062] Specifically, use sandpaper to polish until all old coatings are completely removed. Use a clean cloth dipped in acetone to thoroughly wipe the surface to remove residual coating and oil stains. Reweigh and mix all ingredients according to the original formula and proportion. Use a mechanical stirrer to stir at a uniform speed for 15 minutes to ensure that all ingredients are fully mixed. Use a brush to evenly apply the coating material to the surface of the LED module to ensure that the coating thickness meets the requirements. Set the appropriate temperature and time in the drying equipment to ensure that the coating is fully cured. During the curing process, check the temperature and time regularly to ensure that the drying equipment is operating normally. Use a thickness gauge to check the coating thickness to ensure that it meets the standards. Conduct an adhesion test to ensure that the coating is firm. Conduct a corrosion resistance test to ensure that the coating has good anti-corrosion properties. Perform a visual inspection of the coating surface to ensure that it is smooth and flawless. If unqualified again, repeat the above steps until the LED module meets the factory standards.
[0063] It should be understood that the size of the serial numbers of the steps in the above embodiments does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.
[0064] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application, and should all be included in the protection scope of the present application.
Claims
1. A method for anti-corrosion coating of LED modules, characterized in that: The LED module anti-corrosion coating method comprises: Mixing epoxy resin, polyurethane and silicone resin in a preset ratio to form a base coating material; Adding nano-alumina and nano-silicon dioxide to the base coating material, and stirring them thoroughly to obtain a prepared anti-corrosion coating material; The prepared anti-corrosion coating material is coated on the surface of the LED module to be coated by brushing to obtain a treated LED module.
2. The LED module anti-corrosion coating method according to claim 1, characterized in that: The epoxy resin, polyurethane and silicone resin are mixed in a preset ratio to form a uniform base coating material, including: Pour 50% of epoxy resin into a mixing container by weight, add 25% of polyurethane to the container, and add 15% of silicone to the container; A mechanical stirrer is used to stir at a uniform speed for 10-15 minutes to ensure that the epoxy resin, the polyurethane and the silicone resin are fully mixed to form the uniform base coating material.
3. The LED module anti-corrosion coating method according to claim 1, characterized in that: The step of adding nano-alumina and nano-silicon dioxide to the base coating material and stirring the mixture to obtain a prepared anti-corrosion coating material comprises: Adding the nano-alumina into the uniform base coating material at a weight percentage of 4%, stirring at a uniform speed using the mechanical stirrer, with an initial stirring time of 5 minutes, to obtain a preliminary anti-corrosion coating material; Adding the nano silicon dioxide into the preliminary anticorrosive coating material at a weight percentage of 2.5%, and stirring at a uniform speed for 5 minutes using the mechanical stirrer; Ensure that the nano-alumina and the nano-silicon dioxide are evenly dispersed in the base coating material, continue to use the mechanical stirrer to stir at a medium speed for 10-15 minutes to obtain the prepared anti-corrosion coating material.
4. The LED module anti-corrosion coating method according to claim 3, characterized in that: The step of ensuring that the nano-alumina and nano-silicon dioxide are uniformly dispersed in the base coating material, and continuing to use the mechanical stirrer to stir at a medium speed for 10-15 minutes to obtain the prepared anti-corrosion coating material, further comprises: The prepared anticorrosive coating material is placed in an ultrasonic disperser for 5-10 minutes, which helps to destroy the aggregates of the nanofiller and ensure its uniform distribution in the coating material.
5. The LED module anti-corrosion coating method according to claim 1, characterized in that: The method of coating the prepared anti-corrosion coating material on the surface of the LED module to be coated by brushing to obtain a treated LED module comprises: Adding 0.5% of benzotriazole anticorrosive additive and 0.5% of polyethylene glycol dispersant to the prepared anticorrosive coating material, and continuing to stir for 5-10 minutes using the mechanical stirrer to ensure that the anticorrosive additive and the dispersant are evenly distributed in the coating material; According to the viscosity requirements of the prepared anti-corrosion coating material, ethanol (10%-15% of the total weight) is gradually added. After each addition of the ethanol, the mechanical stirrer is used to stir for 3-5 minutes until the preset coating requirements are met.
6. The LED module anti-corrosion coating method according to claim 1, characterized in that: The step of applying the prepared anti-corrosion coating material on the surface of the LED module to be coated by brushing to obtain a treated LED module comprises: Clean the surface of the LED module to be coated to ensure that there is no oil, dust or impurities on the surface; Use a brush tool to evenly coat the prepared anti-corrosion coating material on the surface of the LED module, with a coating thickness of 50-100 microns.
7. The LED module anti-corrosion coating method according to claim 6, characterized in that: The method uses a brush tool to evenly coat the prepared anti-corrosion coating material on the surface of the LED module, with a coating thickness of 50-100 microns, and further includes: Place the coated LED module in a drying device, set the temperature to 60-80°C, and dry for 2-4 hours to ensure that the coating is completely cured.
8. The LED module anti-corrosion coating method according to claim 1, characterized in that: The LED module anti-corrosion coating method comprises: After the coated LED module is dried and cured, a quality inspection is performed on it to ensure that it meets the factory standards, and the quality inspection includes coating thickness, adhesion, corrosion resistance and appearance quality; If an LED module is found to be non-compliant with the standards, it must be re-coated and re-cured until it meets the factory standards.