CN104218138A - A WFCOB light source - Google Patents

Abstract

A WFCOB (trench and fluororubber chip-on-board) light source is a COB light source made with trenches W and FR pipes. The WFCOB light source is characterized in that N trenches are made in a metal substrate along a coordinate axis y by stamping, a plurality of trench cups are formed, electrodes are arranged at two ends of each trench and sleeved with insulating rubber pipes, and other technical structures are provided. The substrate is made with no need for injection molding, an aluminum (copper) substrate bonding process is not required, a substrate slivering process is not required, a glue damming process is not required, the defects of the processes above are thoroughly solved; compared with the integrated light source or aluminum substrate COB light source, the WFCOB light source is simpler in structure, the cost is decreased by about 80%, and fluorescent powder and packaging glue are decreased by about 70%; the COB light source is resistant to high temperature and high in luminous efficiency, and manufacture cost is greatly decreased.

Description

A WFCOB light source

Technical field:

The present invention relates to an LED light source, in particular to a COB integrated light source, to be precise, a COB light source manufactured by using a groove (W) and a fluorine rubber tube (FR) framework, referred to as a WFCOB light source. the

Background technique:

LED packaging technology is the middle link between upstream chips and downstream lamps. The quality and price of LED light sources largely depend on the packaging structure, that is, the design of packaging brackets and the selection of related auxiliary materials play a role in linking the past and the future and leading the overall situation. The industry has strength Many designers in the world are trying to use package brackets to solve the problems of heat dissipation, light efficiency, lifespan and cost of LEDs, so there are various package brackets in the market, from direct plug-in-single-SMD-COB. At present, the research on LED packaging brackets lags behind the rapid development of market needs. There is no standard bracket recognized by everyone at home and abroad. COB integrated light sources have obvious advantages over single and SMD light sources in heat dissipation, light distribution, and cost. The industry generally believes that it is an inevitable trend of future development. The basic technical requirements of COB light sources are: first, to set up a dam structure to block the fluorescent mixed glue from overflowing, and second, to connect the chip electrode and the bracket electrode to the outside world through wire bonding Drive power connection, all bracket design must comply with these two basic requirements. At present, the widely popular integrated light source bracket and aluminum (copper) substrate COB bracket have certain shortcomings: the use of plastic injection molding integrated light source bracket due to the high temperature of plastic PPA It will turn yellow and chalky under ultraviolet light, causing air permeability and water ingress, and the failure rate is very high; while the COB bracket with aluminum or copper substrate must rely on PCB for line connection, it is made of FR4 fiber lamination process, and its interlayer contains insulating glue. This not only increases the thermal resistance of the light source, but also makes it difficult to wire and solder, and the skin will warp and fall off when running at high temperature. The reflective effect of the substrate surface is poor, which is the main reason for affecting the light intensity and the low light efficiency of the system. the

Invention content:

The purpose of the present invention is to provide an LED with simple structure, easy production, low manufacturing cost, and can realize high light efficiency, low light decay, high temperature resistance and long life to overcome the deficiencies of the existing technology. the

The technical scheme that the present invention adopts for realizing the above object is:

A WFCOB light source, including a metal substrate, is characterized in that: the metal substrate is punched with N grooves along the y-coordinate axis to form a plurality of grooved bowl cups, and N LED chips are arranged in the bowl cups by adding glue. The two ends of the groove are equipped with electrode plates and covered with insulating rubber tubes, and the metal substrate is curled to wrap and insulate it. The electrodes of the LED chips are connected in series with gold wires and then connected to the positive and negative ends of the electrode plate to become The parallel circuit is drawn from the four corners of the metal substrate to connect with the external power supply. the

The metal substrate is punched with N grooved bowl cups, the beveled edge of the groove is at an angle of 60-±10 degrees, the width of the groove bottom is 1-5MM, and the groove depth is 0.5-0.8mm. Apply the phosphor powder mixture to the grooved bowl Cover the LED chip and gold wire in the cup, and seal it by heating. The material is copper or aluminum plate with high thermal conductivity. Here, the high-reflective mirror aluminum plate is preferred, with a thickness of 0.3-3mm. Its shape is square, round, and long. Any shape of shape or polygon, with mounting holes around it. the

The material of the insulating rubber hose is silicon or fluorine rubber hose. Here, the high-temperature-resistant Teflon tube is preferred, with a wall thickness of 0.1-0.5mm and an inner diameter of 1-5mm. There is an electrode wiring gap punched in the middle of the corresponding groove bowl and cup, and the LED The electrode of the chip is bonded to the electrode plate in the gap. the

The electrode plate is a copper plate or flat copper wire with a width of 1-5mm and a thickness of 0.1-0.5mm, and the surface is treated with silver plating. the

Description of drawings:

Below in conjunction with accompanying drawing and specific embodiment the present invention is described in further detail:

Fig. 1 is a schematic diagram of the planar structure of a WFCOB light source according to the present invention. the

Fig. 2 is a left sectional view of a WFCOB light source of the present invention. the

Fig. 3 is a right sectional view of a WFCOB light source of the present invention. the

Fig. 4 is a schematic diagram of a WFCOB light source connected in series according to the present invention. the

Fig. 5 is a schematic diagram of parallel connection of WFCOB light sources according to the present invention. the

Fig. 6 is a schematic diagram of a WFCOB light source of the present invention equipped with a strip of soft rubber lens. the

Among them: metal substrate 1, LED chip 2, silver glue 3, insulating rubber tube 4, electrode plate 5, metal wire 6, fluorescent powder mixing glue 7, soft rubber lens 8. the

Detailed ways:

In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described below in conjunction with the accompanying drawings and embodiments. It should be understood that the embodiments described below are only for explaining the present invention and not limiting the present invention. the

Embodiment 1: see accompanying drawing 1-3,

A WFCOB light source, comprising a metal substrate 1, characterized in that: the metal substrate 1 is punched with N grooves along the y-coordinate axis to form a plurality of grooved bowl cups, and N LED chips 2 are arranged in the bowl cups to pass through The viscose 3 is heated and sealed, electrode plates 5 are provided at both ends of the groove and insulating rubber tubes 4 are put on, the metal substrate 1 is wrapped and insulated by crimping, and the electrodes of the LED chips 2 are connected in series through gold wires 6 Lead to the positive and negative ends of the electrode plate 5 to form a parallel circuit from the four corners of the metal substrate 1 to connect with the external power supply, and finally put fluorescent glue 7 in the groove bowl cup to wrap the LED chip 2 and heat it to cure. the

The material of the metal base plate 1 is a copper or aluminum plate with high thermal conductivity, and there are mounting holes around it. Here, a mirror-faced aluminum plate with a high reflectivity is preferred, and the reflectivity is as high as 98%, which not only improves the light extraction efficiency, but also completely eliminates the metal silver plating process. There are many disadvantages such as high cost and easy vulcanization. The thickness of the mirror aluminum material is 0.3-3mm, and its shape is any one of square, round, long strip or polygon. the

The metal substrate 1 is punched with N grooves, the beveled sides of the grooves are at an angle of 60-±10 degrees, and are in the shape of a reflective ring. Due to the high reflectivity, the reflective ring gathers light and can increase the light efficiency of the LED by 5-10%. the

The mirror aluminum plate with high reflectivity not only completely eliminates the plastic integrated light source bracket because the plastic PPA will turn yellow and powder under high temperature and ultraviolet radiation, resulting in air permeability and water ingress, but also eliminates the pressure of the aluminum (copper) substrate COB on the FR4 fiber. Relying on the combination process, it completely solves the technical problems that the aluminum substrate is not easy to wire and weld, and the skin will peel off when it is operated at high temperature. the

The metal substrate 1 is punched with N grooved cups with a depth of 0.5-0.8mm, preferably 0.6mm, which is about 60% lower than the depth of conventional integrated light source cups, which can greatly save the cost of phosphor powder and packaging glue. the

The electrode plate 5 is placed on the bottom side of the cup and covered with a fluorine rubber tube 6 to insulate it from the metal plate 1. The material is a copper plate or flat copper wire with a width of 1-5mm and a thickness of 0.1-0.5mm, and is electroplated. the

The insulating rubber tube 4 is made of silicon or fluorine, preferably Teflon rubber tube, whose temperature resistance is above 200 degrees, which ensures that the light source will not age at high temperature for a long time, and improves the temperature resistance of the light source. the

The fluorescent powder mixed silica gel 7 is made by mixing silica gel with high light transmittance and high refractive index and fluorescent powder in a certain proportion and then filling it into the base bowl cup, covering the LED chip 2 and the gold wire 6, and curing by high temperature baking . the

Embodiment 2: see accompanying drawing 3

This embodiment is an arrangement of long series modules on the basis of Embodiment 1. In Figure 3 and Figure 4, the positive and negative electrodes of multiple light sources are connected in series end to end, which can form a series of modules with different powers and different voltages. Groups, such as LED fluorescent tube lights, wall washers, etc. the

Embodiment 3: see accompanying drawing 4:

This embodiment is another arrangement of long parallel modules on the basis of Embodiment 2. In Figure 4, the positive and negative electrodes of multiple light sources are connected in parallel to form a series of modules with different powers, which can realize larger The combination module of power is mainly used in high-power lighting occasions, such as high-power ceiling lamps, spotlights, etc. the

Example 4:

In this embodiment, a set of long strip soft rubber lenses 8 is added on the basis of Embodiment 1. The soft rubber lenses 8 are made by injecting a double group of silica gel with high light transmittance and high refractive index into the strip groove mould. Warm molding, cut into the required length, and glued with fluorescent powder mixed with silica gel 7, because the soft rubber lens 8 has the functions of light concentrating and light refraction, it not only improves the light efficiency of the light source, but also eliminates the fluorescent glue mixing process, completely getting rid of It eliminates the cumbersome manufacturing processes such as powder mixing, mixing, vacuuming, glue pouring, dispensing, and testing, which greatly reduces labor costs. This will undoubtedly be a technological revolution that changes the packaging pattern. the

Compared with the existing COB integrated light source, the obvious advantages of a WFCOB light source of the present invention are:

1. The metal integrated structure is adopted, and the injection molding process of the integrated light source is eliminated, which completely solves the product failure caused by PPA's yellowing, pulverization, and air permeability due to high temperature and ultraviolet radiation, and improves the temperature resistance of the light source. the

2. The technology of tightly wrapping the electrode plate with high temperature-resistant insulating material eliminates the dependence of the COB light source on the lamination process of the aluminum (copper) substrate, and completely solves the problem of high thermal resistance of the aluminum (copper) substrate, difficulty in wiring and welding, and warped skin during high-temperature operation There are many disadvantages such as falling off, which improves the temperature resistance of the light source. the

3. The use of high-reflective mirror aluminum material eliminates the silver-plating process of the substrate, and completely overcomes the disadvantages of high cost and easy vulcanization caused by the silver-plating process. the

4. The use of rubber column lenses not only improves the light efficiency of the light source, but also eliminates the mixing process of fluorescent glue, completely getting rid of the tedious manufacturing processes such as powder mixing, mixing, vacuuming, glue filling, dispensing, and testing, which greatly reduces Labor costs, this will undoubtedly be a technological revolution that changes the packaging pattern. the

5. Using groove technology, not only reduces the amount of fluorescent glue by 60%, but also improves the light efficiency by 10%. the

6. Adopting row-by-row structure technology, it is convenient to intercept brackets with different lengths, widths, and narrows to change the arrangement and combination, which is conducive to the realization of system modularization and arbitrary power. the

7. Compared with the integrated light source or aluminum substrate COB light source, the structure is simple, the bracket cost is reduced by about 80%, and the phosphor and packaging glue are also reduced by about 70%. Significantly reduced manufacturing costs. the

Based on the above-mentioned principle features, the embodiment of a WFCOB light source of the present invention is only a preferred embodiment, and the practical application can also be extended to more structural details and wider application examples. Modifications, equivalents or replacements should all fall within the scope of the claims of the present invention. the

Claims (5)

1. A WFCOB light source, comprising a metal substrate (1), is characterized in that: the metal substrate (1) is punched with N grooves along the y coordinate axis to form a plurality of grooved bowl cups, in which there are N LED chips (2) are heated and sealed by glue (3), electrode plates (5) are provided at both ends of the groove and insulating rubber tubes (4) are put on, and the metal substrate (1) is curled It is wrapped and insulated, and the electrodes of the LED chip (2) are connected in series through gold wires (6) to the positive and negative ends of the electrode plate (5) to form a parallel circuit. Dot the fluorescent glue (7) in the bowl and cup to wrap the LED chip (2) and heat it to cure. 2. A WFCOB light source according to claim 1, characterized in that: the metal substrate (1) is punched with N grooved cups, the beveled edge of the groove is at an angle of 60±10 degrees, and the width of the bottom of the groove is 1- 5MM, the depth of the groove is 0.5-0.8mm, apply the phosphor powder mixture (7) in the bowl of the groove, cover the LED chip (2) and the gold wire (6), and seal it by heating. 3. A kind of WFCOB light source according to claim 1 or 2 is characterized in that the metal plate (1) has mounting holes around it, and the material is copper or aluminum plate with high thermal conductivity, preferably a highly reflective mirror aluminum plate with a thickness of 0.3 -3mm, its shape is any one of square, round, strip or polygon. 4. A WFCOB light source according to claim 1, characterized in that: the material of the insulating rubber tube (4) is silicon or fluorine rubber tube, here preferably a high temperature resistant Teflon tube with a wall thickness of 0.1-0.5 mm and an inner diameter of 1 -5mm, wherein an electrode bonding gap is punched in the corresponding groove bowl cup part, and the electrode of the LED chip (2) and the electrode plate (5) are bonded in the gap. 5. A WFCOB light source according to claim 1 or 4, characterized in that: the electrode plate (5) is a copper plate or flat copper wire with a width of 1-5mm and a thickness of 0.1-0.5mm, and the surface is treated with silver plating.