Flexible LED lamp strip manufacturing method

Abstract

A flexible LED lamp strip manufacturing method comprises the following steps that S1, a base strip is punched for the first time, the base strip is made of strip-shaped conductive metal, a first frame and a second frame which are parallel to each other are formed on the two sides of the base strip through punching, rectangular frames are formed between the first frame and the second frame, and a light-emitting unit is formed by continuously adjacent rectangular frames; a connecting circuit is integrally formed between the adjacent rectangular frames in the same light-emitting unit; s2, stamping an upper-layer insulating film, stamping two sides of the upper-layer insulating film to form two rows of strip-shaped holes, and forming a plurality of through holes; s3, combining, namely laying the upper insulating film on the top surface of the base band in a hot pressing or bonding manner; s4, the base band is punched for the second time, the ends, corresponding to the through holes, of the rectangular frame are cut, and first supporting strips and second supporting strips which are parallel to each other and arranged at intervals are formed in the rectangular frame; and S5, assembling the LED chip. According to the scheme, the process is simple, the production efficiency can be effectively improved, the production cost can be reduced, and waste water can be avoided.

Description

Technical Field

[0001] The invention belongs to the technical field of lighting, and in particular relates to a method for manufacturing a flexible LED light strip. Background Art

[0002] Existing flexible LED light strips are usually composed of flexible printed circuits (FPC) and lamp beads. Existing flexible printed circuits are usually formed using a printed circuit production process, which mainly includes: exposure, development, etching, film stripping, ink application, antioxidant treatment and other processes, after which the production capacity forms a circuit pattern. The production process is complicated, the production efficiency is difficult to further improve, and the production cost is high; and multiple processes in the production will generate a large amount of wastewater, so it is also necessary to set up a special sewage device, which further increases the production cost. Summary of the invention

[0003] In order to solve the deficiencies of the prior art, the present invention provides a method for manufacturing a flexible LED light strip, which has a simple process, can effectively improve production efficiency, reduce production costs, and avoid generating wastewater.

[0004] In order to achieve the purpose of the present invention, the following scheme is proposed: A method for manufacturing a flexible LED light strip comprises the following steps: S1: The baseband is punched for the first time. The baseband is a strip-shaped conductive metal. A first frame and a second frame parallel to each other are formed by punching on both sides of the baseband. A rectangular frame arranged at intervals is formed between the first frame and the second frame. N consecutive adjacent rectangular frames form a light-emitting unit. A connecting line is integrally formed between adjacent rectangular frames in the same light-emitting unit. A first connecting portion is formed between the rectangular frame at one end of the light-emitting unit and the first frame, and a second connecting portion is formed between the rectangular frame at the other end of the light-emitting unit and the second frame. S2: punching the upper insulating film, punching two rows of strip holes on both sides of the upper insulating film, along the length direction of the upper insulating film, the distance between adjacent strip holes is consistent with the length of the light-emitting unit, and punching a plurality of through holes on the upper insulating film, the through holes corresponding to the ends of the rectangular frame one by one; S3: Combine, lay the upper insulating film on the top surface of the base tape by hot pressing or bonding, the strip holes are correspondingly arranged between adjacent light-emitting units, and two rows of strip holes are respectively located on the top surfaces of the first frame and the second frame, and the tops of the opposite ends of the rectangular frame are correspondingly provided with through holes; S4: The base tape is punched for the second time, and the ends of the rectangular frame corresponding to the through holes are cut, so that the rectangular frame forms a first support bar and a second support bar that are parallel to each other and spaced apart, and both ends of the first support bar and the second support bar are exposed within the corresponding through hole range; in the same light-emitting unit, the first support bar of the rectangular frame is connected to the second support bar of the adjacent rectangular frame through a connecting line; the first support bar and the second support bar located at both ends of the light-emitting unit and not connected to the connecting line are connected to the first frame or the second frame through the first connecting portion or the second connecting portion; S5: Assembling LED chips. The positions corresponding to the through holes on the base band are all provided with LED chips, and the LED chips are connected to the same end of the first support bar and the second support bar at the same time.

[0005] The beneficial effects of the present invention are: 1. Compared with the traditional flexible circuit board process, this solution has fewer steps, simpler process, higher production efficiency, can greatly reduce the generation of sewage, and can effectively reduce production costs.

[0006] 2. A first frame and a second frame are formed on both sides of the base strip, which can effectively improve the tensile strength of the light strip after plastic sealing. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present invention.

[0008] Figure 1 A flow chart of the method of the present application is shown.

[0009] Figure 2 The schematic diagram shows the local structure after the upper insulating film is punched.

[0010] Figure 3 A schematic diagram of the local structure formed by the first stamping of the base strip is shown.

[0011] Figure 4 A schematic diagram of the local structure formed by the second stamping of the base strip is shown.

[0012] Figure 5 Shows Figure 4 A partial enlarged view of point A in the middle.

[0013] Figure 6 A partial schematic diagram showing a preferred structure formed by the second punching of the base strip.

[0014] Markings in the figure: first frame -11, second frame -12, rectangular frame -13, first connecting part -131, second connecting part -132, first supporting bar -133, second supporting bar -134, connecting piece -135, connecting line -14, bar hole -21, through hole -22, through hole -23, LED chip -3, resistor -4. DETAILED DESCRIPTION

[0015] To make the objectives, technical solutions and advantages of the embodiments of the present invention more clear, the implementation modes of the present invention are described in detail below with reference to the accompanying drawings. However, the embodiments described in the present invention are only part of the embodiments of the present invention, rather than all the embodiments.

[0016] like Figure 1 As shown, a method for manufacturing a flexible LED light strip includes the following steps: S1: The first stamping of the base tape, the base tape is a strip of conductive metal, and the base tape is made of copper or aluminum. Figure 3 As shown, a first frame 11 and a second frame 12 are formed on both sides of the baseband by stamping to form a mutually parallel first frame 11 and a second frame 12, and a rectangular frame 13 is formed between the first frame 11 and the second frame 12. The interval setting here refers to the interval setting between the rectangular frame 13 and the first frame 11 and the second frame 12; a plurality of rectangular frames 13 are arranged at intervals along the length direction of the baseband, and the interval here refers to the interval between adjacent rectangular frames 13; wherein, N consecutive adjacent rectangular frames 13 form a light-emitting unit, and N is greater than 2; a connecting line 14 is formed integrally between adjacent rectangular frames 13 in the same light-emitting unit. A first connecting portion 131 is integrally stamped between the rectangular frame 13 at one end of the light-emitting unit and the first frame 11, and a second connecting portion 132 is integrally stamped between the rectangular frame 13 at the other end of the light-emitting unit and the second frame 12. The waste generated by this stamping mainly includes two parts: Figure 3 As shown in the dark grey shadow, part of it is the waste material generated by forming the hollow structure in the middle of the rectangular frame 13. Figure 3 As shown in the light grey shadow, another part of the waste material is located between the first frame 11 and the second frame 12, and is located outside the rectangular frame 13, the first connecting portion 131, the second connecting portion 132 and the connecting line 14. This part of the waste material is mostly a continuous structure, so that it can be separated from the base tape. After the waste material of the base tape is removed, the light-emitting unit is connected between the first frame 11 and the second frame 12 through the first connecting portion 131 and the second connecting portion 132, and the rectangular frames 13 in the same light-emitting unit are connected to each other through the connecting line 14, so as to ensure the position stability of each rectangular frame 13 on the base tape, so as to facilitate the subsequent setting of the upper insulating film.

[0017] S2: Punching of the upper insulating film, e.g. Figure 2As shown, two rows of strip holes 21 are punched on both sides of the upper insulating film. Along the length direction of the upper insulating film, the distance between adjacent strip holes 21 is consistent with the length of the light-emitting unit, and a plurality of through holes 22 are punched on the upper insulating film. The through holes 22 correspond to the ends of the rectangular frame 13 one by one.

[0018] S3: Combine, lay the upper insulating film on the top surface of the base tape by hot pressing or bonding, the strip holes 21 are correspondingly arranged between adjacent light-emitting units, and two rows of strip holes 21 are respectively located on the top surfaces of the first frame 11 and the second frame 12, and the tops of the opposite ends of the rectangular frame 13 correspond to through holes 22.

[0019] S4: Second stamping of the base tape, such as Figure 4 and Figure 5 As shown, the end of the rectangular frame 13 corresponding to the through hole 22 is cut, so that the rectangular frame 13 forms a first support bar 133 and a second support bar 134 which are parallel to each other and arranged at intervals. Both ends of the first support bar 133 and the second support bar 134 are exposed within the corresponding through hole 22, and are used to set the LED chip 3. In the same light-emitting unit, the first support bar 133 of the rectangular frame 13 is connected to the second support bar 134 of the adjacent rectangular frame 13 through the connecting line 14; the first support bar 133 and the second support bar 134 located at both ends of the light-emitting unit and not connected to the connecting line 14 are connected to the first frame 11 or the second frame 12 through the first connecting portion 131 or the second connecting portion 132. In this embodiment, the first support bar 133 located at one end of the light-emitting unit and not connected to the connecting line 14 is connected to the first frame 11 through the first connecting portion 131; and the second support bar 134 located at the other end of the light-emitting unit and not connected to the connecting line 14 is connected to the second frame 12 through the second connecting portion 132. This solution is combined with an upper insulating film and then separately provided with a stamping process for forming independent first support bars 133 and second support bars 134. The purpose is to use the upper insulating film to fix the first frame 11, the second frame 12, the rectangular frame 13 and the connecting line 14. More importantly, the first support bars 133 and the second support bars 134 formed by separation are immediately fixed during forming to prevent the first support bars 133 and the second support bars 134 from deformation and displacement, so as to improve the position accuracy of the two.

[0020] S5: Assemble LED chips 3. LED chips 3 are set at positions corresponding to through holes 22 on the base tape. LED chips 3 can be located outside through holes 22, or can cover through holes 22, or can be set at positions corresponding to through holes 22 on the bottom surface of the base tape. It can be seen that the purpose of opening through holes 22 in step S2 is not only to set LED chips 3, but also to facilitate the discharge of waste generated when cutting rectangular frame 13 in step S4, so as to avoid the waste from adhering to the upper insulating film. Figure 5As shown, the LED chip 3 is connected to the same end of the first support bar 133 and the second support bar 134 at the same time. Specifically, the LED chip 3 is connected to the first support bar 133 and the second support bar 134 by means of fixed welding.

[0021] Compared with the traditional flexible circuit board process, the flexible LED light strip made using the above solution has fewer steps, a simpler process, higher production efficiency, can greatly reduce the generation of sewage, and can effectively reduce production costs.

[0022] Preferably, Figure 5 As shown, the distance between the first support bar 133 and the second support bar 134 is greater than the width of the inner hole of the rectangular frame 13, so as to ensure that both ends of the first support bar 133 and the second support bar 134 have sufficient area to support the LED chip 3, and make the middle section width of the first support bar 133 and the second support bar 134 smaller, which can effectively reduce the residual stress generated during stamping.

[0023] Preferably, in step S1, when the base tape is stamped for the first time, Figure 5 As shown, in the same light-emitting unit, one of the opposite ends of a group of adjacent rectangular frames 13 is integrally stamped with a connecting piece 135, and two connecting pieces 135 are arranged at intervals from each other. After adopting this process design, not only a mounting position is provided for the resistor 4, but also Figure 3 The light grey waste shown in the figure forms a continuous strip structure, which is convenient to tear off as a whole, so as to achieve the purpose of facilitating the removal of waste; Step S2, when the upper insulating film is punched, a through hole 23 is formed on the upper insulating film to expose the connecting piece 135; Step S5, when assembling the LED chip 3, assemble the resistor 4 onto the two connecting pieces 135 arranged in pairs, that is, connect the two rectangular frames 13 provided with the connecting pieces 135 through the resistor 4, so that each light-emitting unit is provided with a resistor 4; as a specific connection scheme, the rectangular frame 13 is connected to the resistor 4 through the first support bar 133 or the second support bar 134, and the first support bar 133 or the second support bar 134 connected to the resistor 4 is not provided with a connecting line 14.

[0024] As a preferred structure, the first support bar 133 and the second support bar 134 are parallel or perpendicular to the length direction of the base tape. Figure 4 As shown, when the first support bar 133 and the second support bar 134 are parallel to the length direction of the base strip, the light strip of this structure is a single-row LED light strip. Figure 6 As shown, in step S1, when the base strip is punched for the first time, the first support bar 133 and the second support bar 134 are perpendicular to the length direction of the base strip, so that the light strip is a double-row LED light strip to increase the arrangement density of the LED chips 3 and improve the brightness of the light strip.

[0025] Preferably, the method for manufacturing a flexible LED light strip further includes step S6, laying a lower insulating film on the bottom surface of the base strip; step S5, when assembling the LED chip 3, the LED chip 3 is arranged on the top surface of the upper insulating film, and the LED chip 3 completely covers the through hole 22, so as to achieve the effect of sealing the base strip, so that the base strip is completely enclosed between the upper insulating film, the lower insulating film and the LED chip 3, so as to improve the leakage protection and sealing effect of the light strip. If in step S5, when assembling the LED chip 3, the LED chip 3 is arranged at a position corresponding to the bottom surface of the base strip and the through hole 22, it is necessary to open a receiving hole on the lower insulating film to facilitate the connection of the LED chip 3 with the base strip.

[0026] Further preferably, the method for manufacturing a flexible LED light strip further includes step S7, plastic sealing, in which the base strip, the upper insulating film and the lower insulating film are sealed in a transparent protective cover by injection molding to achieve the purpose of waterproofing and dustproofing.

[0027] Preferably, Figure 2 As shown, both ends of the strip hole 21 on one side of the upper insulating film are marked with a symbol "+", and both ends of the strip hole 21 on the other side are marked with a symbol "-". In the present embodiment, the strip hole 21 corresponding to the symbol "+" is located on the top surface of the first frame 11, and the strip hole 21 corresponding to the symbol "-" is located on the top surface of the second frame 12, indicating that the first frame 11 is used to connect the positive power supply, and the second frame 12 is used to connect the negative power supply; when using the light strip, the light strip can be cut at the interval between adjacent light-emitting units according to the required length. After the light strip is cut, the ends of the first frame 11 and the second frame 12 will be exposed in the strip hole 21 to facilitate the connection of the power supply.

[0028] The above description is only a preferred embodiment of the present invention, and does not represent the only or limit the present invention. Those skilled in the art should understand that various changes or equivalent substitutions made to the present invention without departing from the scope of the present invention are within the scope of protection of the present invention.

Claims

1. A method for manufacturing a flexible LED light strip, characterized in that: The following steps are involved: S1: The base strip is punched for the first time. The base strip is a strip-shaped conductive metal. A first frame (11) and a second frame (12) are formed on both sides of the base strip by punching and are parallel to each other. A rectangular frame (13) is formed between the first frame (11) and the second frame (12). N consecutive adjacent rectangular frames (13) form a light-emitting unit. A connecting line (14) is formed integrally between adjacent rectangular frames (13) in the same light-emitting unit. A first connecting portion (131) is formed between the rectangular frame (13) at one end of the light-emitting unit and the first frame (11), and a second connecting portion (132) is formed between the rectangular frame (13) at the other end of the light-emitting unit and the second frame (12). S2: punching the upper insulating film, punching two rows of strip holes (21) on both sides of the upper insulating film, the distance between adjacent strip holes (21) along the length direction of the upper insulating film being consistent with the length of the light-emitting unit, and punching a plurality of through holes (22) on the upper insulating film, the through holes (22) corresponding one-to-one to the ends of the rectangular frame (13); S3: combining, laying the upper insulating film on the top surface of the base tape by hot pressing or bonding, the strip holes (21) are correspondingly arranged between adjacent light-emitting units, and two rows of strip holes (21) are respectively located on the top surfaces of the first frame (11) and the second frame (12), and the tops of the two opposite ends of the rectangular frame (13) are correspondingly provided with through holes (22); S4: the base strip is punched for the second time, and the end of the rectangular frame (13) corresponding to the through hole (22) is cut, so that the rectangular frame (13) forms a first support bar (133) and a second support bar (134) which are parallel to each other and arranged at intervals, and both ends of the first support bar (133) and the second support bar (134) are exposed within the range of the corresponding through hole (22); in the same light-emitting unit, the first support bar (133) of the rectangular frame (13) is connected to the second support bar (134) of the adjacent rectangular frame (13) through the connecting line (14); the first support bar (133) and the second support bar (134) located at both ends of the light-emitting unit and not connected to the connecting line (14) are connected to the first frame (11) or the second frame (12) through the first connecting portion (131) or the second connecting portion (132); S5: Assembling the LED chips (3), wherein the positions corresponding to the through holes (22) on the base band are all provided with LED chips (3), and the LED chips (3) are simultaneously connected to the same end of the first support bar (133) and the second support bar (134).

2. A method for manufacturing a flexible LED light strip according to claim 1, characterized in that: The distance between the first support bar (133) and the second support bar (134) is greater than the width of the inner hole of the rectangular frame (13).

3. The method for manufacturing a flexible LED light strip according to claim 1, characterized in that: Step S1, when the baseband is punched for the first time, in the same light-emitting unit, a group of adjacent rectangular frames (13) are integrally punched at opposite ends to form connecting pieces (135), and two connecting pieces (135) are arranged at intervals from each other; Step S2, when the upper insulating film is punched, a through hole (23) is formed on the upper insulating film to expose the connecting piece (135); Step S5, when assembling the LED chip (3), assembling the resistor (4) onto the two connecting sheets (135) arranged in pairs.

4. A method for manufacturing a flexible LED light strip according to any one of claims 1 to 3, characterized in that: The first support bar (133) and the second support bar (134) are parallel or perpendicular to the length direction of the base tape.

5. A method for manufacturing a flexible LED light strip according to any one of claim 4, characterized in that: The method further comprises step S6 of laying a lower insulating film on the bottom surface of the base tape; and step S5 of assembling the LED chip (3), wherein the LED chip (3) is arranged on the top surface of the upper insulating film, and the LED chip (3) completely covers the through hole (22).

6. A method for manufacturing a flexible LED light strip according to any one of claim 5, characterized in that: The method further includes step S7, plastic sealing, in which the base tape, the upper insulating film and the lower insulating film are sealed in a transparent protective cover by injection molding.

7. A method for manufacturing a flexible LED light strip according to any one of claim 1, characterized in that: The base tape is made of copper or aluminum.

8. A method for manufacturing a flexible LED light strip according to any one of claim 1, characterized in that: Both ends of the strip-shaped hole (21) on one side of the upper insulating film are marked with a symbol "+", and both ends of the strip-shaped hole (21) on the other side are marked with a symbol "-".

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