Vacuum laminating equipment for LED lamp beads

Abstract

The utility model provides a kind of LED lamp pearl vacuum laminating equipment: vacuum fence is closed with lower mould base and forms vacuum cavity, upper and lower pressing module is correspondingly provided with convex, concave elastic silica gel surface, self-adapting multidimensional curved surface, vacuum pump air pumping+heating rod activated back glue, laminating no bubble and high strength;Concave silica gel surface is equipped with limit slot, and accurate positioning can be realized without positioning hole;First air cylinder drives lower mould to automatically enter and exit, four air cylinders are synchronously lifted, and double grating and double hand start ensure operation safety, suitable for complex curved surface LED module mass production.The utility model adapts multidimensional curved surface, realizes high-quality lamination, does not need positioning hole, reduces process difficulty and cost.

Description

Technical Field

[0001] This utility model relates to the field of LED equipment technology, specifically to a vacuum bonding equipment for LED beads. Background Technology

[0002] LED modules are increasingly widely used in automobiles, home appliances, and consumer electronics, and their appearance is gradually expanding from traditional flat shapes to complex multi-dimensional curved structures. To improve protection levels and optical performance, it is usually necessary to vacuum bond the LED chips to a transparent or semi-transparent curved protective cover. Currently, the bonding of LED chips to the protective cover generally uses the following two types of equipment: Flatbed vacuum laminator: It uses a flat platen to complete the lamination process in a vacuum chamber, and is mainly used for laminating flat or near-flat display modules; Fixture bonding machine with positioning holes: Positioning holes are pre-set on the LED beads and protective cover, and initial positioning is performed by positioning pins. Then, the bonding is completed under normal pressure or simple vacuum environment.

[0003] The shortcomings of existing technology: 1. It can only handle planar parts and cannot adapt to multi-dimensional curved surfaces. Traditional flat-plate vacuum laminators have a rigid flat surface for pressing. When the LED beads or covers have curved or bent structures, the pressure plate cannot make uniform and sufficient contact with the surface to be laminated, resulting in uneven bonding pressure distribution, inconsistent adhesive thickness, and ultimately defects such as bubbles, wrinkles, and optical distortion.

[0004] 2. Relative positioning must be achieved using positioning holes. Most existing fixture bonding machines drill positioning holes in the LED beads and protective covers, and use positioning pins to mechanically limit their movement. This method has the following problems: Additional positioning holes need to be machined on the LED beads and protective cover, which increases the number of processes, costs, and the potential risk of cracking. When the product has a complex shape or a small size, it is difficult to process the positioning holes and assemble the positioning pins, resulting in a decrease in yield. Once the product design changes, the position of the positioning holes needs to be adjusted accordingly, resulting in poor jig versatility.

[0005] Therefore, existing technologies have shortcomings and need further improvement. Utility Model Content

[0006] In view of the problems existing in the prior art, this utility model provides an LED lamp bead vacuum bonding equipment.

[0007] To achieve the above objectives, the specific solution of this utility model is as follows: This utility model provides an LED lamp bead vacuum bonding device, including: A vacuum enclosure, with a vacuum chamber at its lower end; The upper pressing module is disposed within the vacuum chamber; The lower pressing module has an LED light bead placement module installed on it; The in-and-out displacement module is used to drive the lower pressing module into or away from the bottom of the vacuum chamber; The lifting drive mechanism is used to drive the vacuum enclosure and the upper pressing module to move up and down in the vertical direction, so as to realize the pressing and separation action of the upper pressing module and the lower pressing module; The in-and-out displacement module includes a lower mold base, and the lower pressing module is installed on the lower mold base. When the in-and-out displacement module drives the lower pressing module to enter the lower part of the vacuum chamber, the lifting drive mechanism drives the vacuum enclosure plate to move downward. The vacuum enclosure plate and the lower mold base form a sealed space, in which the upper pressing module, the LED lamp bead placement module, and the lower pressing module are located. Both the lower side of the upper pressing module and the upper side of the lower pressing module are provided with elastic silicone contact surfaces. The elastic silicone contact surface is compliant with curved parts. The LED beads to be bonded and the protective cover body to be bonded are placed between the upper pressing module and the lower pressing module, and are assembled and bonded under the pressure of the upper and lower parts. The vacuum chamber is connected to a vacuum pump for evacuating the air and reducing air bubbles.

[0008] Furthermore, the vacuum enclosure is also equipped with a heating rod to heat the vacuum chamber, activate the adhesive backing and improve the bonding strength during the pressing process.

[0009] Furthermore, the infeed / outfeed displacement module also includes a first cylinder and a slide rail; The lower mold base is slidably mounted on two slide rails. The telescopic rod of the first cylinder is fixedly mounted on the lower mold base to drive the lower mold base and the lower pressing module on it into or away from the bottom of the vacuum chamber. A first sensor is also provided next to the first cylinder to detect the position of the cylinder piston rod to determine whether it is in position.

[0010] Furthermore, a first grating is arranged parallel to the slide rail to sense whether the operator puts their hand in, in order to prevent injury.

[0011] Furthermore, the upper pressing module includes a film-applying plate; Several upper templates are installed on the lower side of the film-applying platen. A convex silicone surface is provided on the lower side of the upper template, which constitutes the elastic silicone contact surface on the lower side of the upper pressing module.

[0012] Furthermore, the lifting drive mechanism includes four second cylinders; The telescopic rod of the second cylinder is fixedly connected to the upper template and is used to drive the upper template to move up and down.

[0013] Furthermore, the upper template is installed on top of the vacuum chamber; The vacuum enclosure is also slidably mounted on four guide columns; The second cylinder drives the upper template to move up and down, which in turn drives the vacuum enclosure to move up and down along the guide post; A second sensor is also installed next to the second cylinder to detect the position of the cylinder piston rod to determine whether it is in position.

[0014] Furthermore, a second grating is arranged parallel to the guide post to sense whether the operator puts their hand in, in order to prevent injury.

[0015] Furthermore, the pressing module includes: a lower base plate; The lower base plate is equipped with several lower templates, and the lower templates are provided with concave silicone surfaces; The lower templates and the upper templates are positioned correspondingly, and the convex and concave silicone surfaces are positioned correspondingly to each other. The concave silicone surface forms the elastic silicone contact surface on the upper side of the lower pressing module.

[0016] Furthermore, the concave silicone surface is provided with a limiting groove that matches the shape of the LED bead, which is used to achieve shape positioning without positioning holes. The device has two start buttons, which need to be pressed with both hands simultaneously to start the device.

[0017] The technical solution of this utility model has the following beneficial effects: 1. Adapts to multi-dimensional curved surfaces, achieving high-quality fit. Both the upper and lower laminating modules use elastic silicone contact surfaces (convex + concave combination), which can adapt to different curvatures, bends or irregularly shaped LED beads and covers, ensuring uniform force and consistent adhesive thickness in all areas of the curved surface, significantly reducing bubbles, wrinkles and optical distortion, and breaking through the limitations of traditional flat laminating machines.

[0018] 2. No positioning holes are required, reducing manufacturing difficulty and cost. The concave silicone surface of the lower template is equipped with a limiting groove that matches the shape of the LED bead. Precise positioning can be achieved using the outline, eliminating the need for drilling holes and installing pins on the bead and cover, avoiding the risk of cracking, shortening changeover time, and improving the versatility of the fixture.

[0019] 3. Dual vacuum and heating processes enhance bonding strength. The vacuum chamber can be quickly evacuated before pressing to completely remove air from the interface; the built-in heating rod activates the backing adhesive during the pressing process, allowing the adhesive layer to flow, wet and cure fully, resulting in high bonding strength consistency and no risk of delamination or edge lifting during long-term use. Attached Figure Description

[0020] Figure 1 This is a perspective view of the present invention; Figure 2 This is a perspective view of the present invention after the shell has been removed; Figure 3 This is a perspective view of the upper pressing module, lower pressing module, infeed displacement module, and lifting drive mechanism of this utility model; Figure 4 This is a perspective view of the vacuum enclosure and lower mold base of this utility model; Figure 5 This is a perspective view of the vacuum enclosure and lower mold base of this utility model from another angle. Figure 6 This is a perspective view of the infeed / outfeed displacement module of this utility model; Figure 7 This is a perspective view of the pressing and closing module of this utility model; Figure 8 This is a perspective view of the upper template and the convex silicone surface of this utility model.

[0021] Attached image captions: 1. Vacuum enclosure; 2. Vacuum chamber; 3. Upper pressing module; 4. Lower pressing module; 5. LED bead placement module; 6. Infeed / outfeed displacement module; 7. Lifting drive mechanism; 8. Lower mold base; 9. Vacuum pump; 10. First cylinder; 11. Slide rail; 12. First grating; 13. Film-applying pressure plate; 14. Upper template; 15. Convex silicone surface; 16. Second cylinder; 17. Guide post; 18. Second grating; 19. Lower base plate; 20. Lower template; 21. Concave silicone surface; 22. Start button. Detailed Implementation

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, not the entire structure.

[0023] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0024] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0025] In the description of this embodiment, the terms "upper," "lower," "front," "rear," "left," and "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0026] Combination Figures 1-8 As shown, this utility model provides an LED lamp bead vacuum bonding device, comprising: Vacuum enclosure 1, with a vacuum chamber 2 at its lower end; The upper pressing module 3 is disposed inside the vacuum chamber 2; The pressing module 4 is equipped with an LED bead placement module 5; The in-and-out displacement module 6 is used to drive the lower pressing module 4 to enter or move away from the bottom of the vacuum chamber 2; The lifting drive mechanism 7 is used to drive the vacuum enclosure 1 and the upper pressing module 3 to move up and down in the vertical direction, so as to realize the pressing and separation action of the upper pressing module 3 and the lower pressing module 4. The in-and-out displacement module 6 includes a lower mold base 8, and a lower pressing module 4 is installed on the lower mold base 8. When the in-and-out displacement module 6 drives the lower pressing module 4 to enter the lower part of the vacuum chamber 2, the lifting drive mechanism 7 drives the vacuum enclosure 1 to move downward. The vacuum enclosure 1 and the lower mold base 8 form a sealed space, and the upper pressing module 3, the LED lamp bead placement module 5, and the lower pressing module 4 are located in the sealed space. Both the lower side of the upper pressing module 3 and the upper side of the lower pressing module 4 are provided with elastic silicone contact surfaces. The elastic silicone contact surface is compliant with curved parts. The LED beads to be bonded and the protective cover body to be bonded are placed between the upper pressing module 3 and the lower pressing module 4, and are assembled and bonded under the upper and lower pressure. The vacuum chamber 2 is connected to a vacuum pump 9 for evacuating the vacuum and reducing air bubbles.

[0027] The vacuum enclosure 1 is also equipped with a heating rod to heat the vacuum chamber 2, which activates the adhesive backing and improves the bonding strength during the pressing process.

[0028] The infeed displacement module 6 also includes a first cylinder 10 and a slide rail 11; The lower mold base 8 is slidably mounted on two slide rails 11. The telescopic rod of the first cylinder 10 is fixedly mounted on the lower mold base 8, which is used to drive the lower mold base 8 and the lower pressing mold assembly 4 on it into or away from the bottom of the vacuum chamber 2. A first sensor is also provided next to the first cylinder 10 to detect the position of the cylinder piston rod to determine whether it is in place.

[0029] A first grating 12 is arranged parallel to the slide rail 11 to sense whether the operator puts their hand in, so as to prevent injury.

[0030] The upper pressing module 3 includes a film-applying pressing plate 13; A plurality of upper templates 14 are installed on the lower side of the film-applying plate 13. A convex silicone surface 15 is provided on the lower side of the upper template 14. The convex silicone surface 15 constitutes the elastic silicone contact surface on the lower side of the upper pressing module 3.

[0031] The lifting drive mechanism 7 includes four second cylinders 16; The telescopic rod of the second cylinder 16 is fixedly connected to the upper template 14 and is used to drive the upper template 14 to move up and down.

[0032] The upper template 14 is installed on the top of the vacuum chamber 2; The vacuum enclosure 1 is also slidably mounted on four guide posts 17; The second cylinder 16 drives the upper template 14 to move up and down, thereby driving the vacuum enclosure 1 to move up and down along the guide post 17; A second sensor is also provided next to the second cylinder 16 to detect the position of the cylinder piston rod to determine whether it is in position.

[0033] A second grating 18 is arranged parallel to the guide post 17 to sense whether the operator puts their hand in, in order to prevent injury.

[0034] The lower pressing module 4 includes: a lower base plate 19; A plurality of lower templates 20 are installed on the lower base plate 19, and the lower templates 20 are provided with concave silicone surfaces 21; The plurality of lower templates 20 and the plurality of upper templates 14 are positioned correspondingly, and the convex silicone surface 15 and the concave silicone surface 21 are positioned correspondingly to each other. The concave silicone surface 21 forms the elastic silicone contact surface on the upper side of the lower pressing module 4.

[0035] The concave silicone surface 21 is provided with a limiting groove that matches the shape of the LED bead, which is used to achieve shape positioning when there is no positioning hole. The device has two start buttons 22, which need to be pressed with both hands simultaneously to start the device.

[0036] The principle of this utility model is as follows: Preparatory stage Manual or robotic arm inserts the LED beads into the limiting groove of the concave silicone surface 21 of the lower template 20, and then the protective cover body is placed on top of the LED beads.

[0037] Press both start buttons 22 simultaneously with both hands → System self-test → First grating 12 confirms that the lower mold base 8 is in the "safe outer" position.

[0038] Feeding and sealing The first cylinder 10 is activated, pushing the lower mold base 8 along the slide rail 11 into the vacuum chamber 2 directly below; the first grating 12 provides real-time feedback on the displacement and stops when it reaches the desired position.

[0039] The four second cylinders 16 descend synchronously, driving the upper template 14, the film-applying pressure plate 13, and the vacuum enclosure 1 down along the four guide pillars 17 until the lower end face of the vacuum chamber 2 is sealed and fitted with the lower mold base 8, forming a closed vacuum chamber. The second grating 18 monitors the height throughout the process to prevent overshoot.

[0040] Vacuuming + Preheating Vacuum pump 9 starts and draws the cavity to the set negative pressure within a few seconds, expelling the air between the lamp bead and the protective cover interface and suppressing the generation of bubbles.

[0041] The heating rod operates, raising the cavity temperature to the adhesive activation temperature (usually 60-90℃), which reduces the viscosity of the adhesive layer and enhances its wettability.

[0042] Pressing and bonding The second cylinder 16 continues to descend, and the convex silicone surface 15 of the upper template 14 and the concave silicone surface 21 of the lower template 20 gradually close.

[0043] The elastic silicone generates uniform and continuous pressure at various points on the curved surface, allowing the adhesive to flow fully and fill the microscopic gaps; at the same time, the conformability of the silicone ensures that sufficient pressure is obtained at the same level of height difference on the curved surface.

[0044] After the pressure holding time reaches the set value, the heating rod stops or cools down, the adhesive layer begins to cure, and the bonding strength is significantly improved.

[0045] Separation and discharge The second cylinder 16 reverses its movement, causing the upper template 14 and vacuum enclosure 1 to rise as a whole, opening the vacuum chamber; the vacuum pump 9 stops.

[0046] The first cylinder 10 reverses its movement, and the lower mold base 8, carrying the already bonded LED-protective assembly, exits along the slide rail 11 to the outer material picking position; the first grating 12 reconfirms its position.

[0047] The finished product is removed manually or by a robotic arm and enters the next cycle.

[0048] Safety Chain If any grating signal is abnormal during operation or any start button 22 is released, the system will immediately cut off the cylinder air supply and sound an alarm to prevent crushing or collision.

[0049] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. All equivalent structural transformations made under the inventive concept of the present utility model using the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the protection scope of the present utility model.

Claims

1. An LED lamp bead vacuum bonding equipment, characterized in that, include: A vacuum enclosure, with a vacuum chamber at its lower end; The upper pressing module is disposed within the vacuum chamber; The lower pressing module has an LED light bead placement module installed on it; The in-and-out displacement module is used to drive the lower pressing module into or away from the bottom of the vacuum chamber; The lifting drive mechanism is used to drive the vacuum enclosure and the upper pressing module to move up and down in the vertical direction, so as to realize the pressing and separation action of the upper pressing module and the lower pressing module; The in-and-out displacement module includes a lower mold base, and the lower pressing module is installed on the lower mold base. When the in-and-out displacement module drives the lower pressing module to enter the lower part of the vacuum chamber, the lifting drive mechanism drives the vacuum enclosure plate to move downward. The vacuum enclosure plate and the lower mold base form a sealed space, in which the upper pressing module, the LED lamp bead placement module, and the lower pressing module are located. Both the lower side of the upper pressing module and the upper side of the lower pressing module are provided with elastic silicone contact surfaces. The elastic silicone contact surface is compliant with curved parts. The LED beads to be bonded and the protective cover body to be bonded are placed between the upper pressing module and the lower pressing module, and are assembled and bonded under the pressure of the upper and lower parts. The vacuum chamber is connected to a vacuum pump for evacuating the air and reducing air bubbles.

2. The device according to claim 1, characterized in that: The vacuum enclosure is also equipped with a heating rod to heat the vacuum chamber, activate the adhesive backing and improve the bonding strength during the pressing process.

3. The device according to claim 1, characterized in that: The infeed / outfeed displacement module also includes a first cylinder and a slide rail; The lower mold base is slidably mounted on two slide rails. The telescopic rod of the first cylinder is fixedly mounted on the lower mold base to drive the lower mold base and the lower pressing module on it into or away from the bottom of the vacuum chamber. A first sensor is also provided next to the first cylinder to detect the position of the cylinder piston rod to determine whether it is in position.

4. The device according to claim 3, characterized in that: A first optical grating is installed parallel to the slide rail to sense whether the operator puts their hand in, in order to prevent injury.

5. The device according to claim 1, characterized in that: The upper pressing module includes a film-applying pressing plate; Several upper templates are installed on the lower side of the film-applying platen. A convex silicone surface is provided on the lower side of the upper template, which constitutes the elastic silicone contact surface on the lower side of the upper pressing module.

6. The device according to claim 5, characterized in that: The lifting drive mechanism includes four second cylinders; The telescopic rod of the second cylinder is fixedly connected to the upper template and is used to drive the upper template to move up and down.

7. The device according to claim 6, characterized in that: The upper template is installed on top of the vacuum chamber; The vacuum enclosure is also slidably mounted on four guide columns; The second cylinder drives the upper template to move up and down, which in turn drives the vacuum enclosure to move up and down along the guide post; A second sensor is also installed next to the second cylinder to detect the position of the cylinder piston rod to determine whether it is in position.

8. The device according to claim 7, characterized in that: A second grating is installed parallel to the guide post to sense whether the operator puts their hand in, in order to prevent injury.

9. The device according to claim 5, characterized in that: The pressing module includes: a lower base plate; The lower base plate is equipped with several lower templates, and the lower templates are provided with concave silicone surfaces; The lower templates and the upper templates are positioned correspondingly, and the convex and concave silicone surfaces are positioned correspondingly to each other. The concave silicone surface forms the elastic silicone contact surface on the upper side of the lower pressing module.

10. The device according to claim 9, characterized in that: The concave silicone surface is provided with a limiting groove that matches the shape of the LED bead, which is used to achieve shape positioning when there is no positioning hole. The device has two start buttons, which need to be pressed with both hands simultaneously to start the device.

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