阅读说明：本技术 Led灯珠、照明灯及led灯珠的制造方法 (LED lamp bead, illuminating lamp and manufacturing method of LED lamp bead ) 是由 郑朝曦 吴学坚 程寅山 徐钊 郑世鹏 刘富彬 于 2021-07-09 设计创作，主要内容包括：本申请提供一种LED灯珠、照明灯及LED灯珠的制造方法,其中LED灯珠包括LED支架、晶片、封装胶水。LED支架设有正极和负极,LED支架在预定的位置具有聚四氟乙烯分散液涂层。晶片固定于LED支架,LED支架的正极和负极均与晶片电性连接。晶片通过封装胶水封装于LED支架上,封装胶水固化形成弧面,聚四氟乙烯分散液涂层和封装胶水相接以利用聚四氟乙烯分散液涂层的张力作用阻止封装胶水在从注入LED支架的支架杯内到固化的过程中流动。这样的LED灯珠具有更高的光通量取出率和亮度,可以降低灯具的功耗和成本,而且制造工艺简单,生产效率高,良率高。(The application provides an LED lamp bead, a lighting lamp and a manufacturing method of the LED lamp bead, wherein the LED lamp bead comprises an LED support, a wafer and packaging glue. The LED support is provided with an anode and a cathode, and the LED support is provided with a polytetrafluoroethylene dispersion liquid coating at a preset position. The wafer is fixed in the LED support, and the positive pole and the negative pole of LED support all are connected with wafer electric property. The wafer is sealed on the LED support through the packaging glue, the packaging glue is solidified to form a cambered surface, and the polytetrafluoroethylene dispersion liquid coating is connected with the packaging glue so as to prevent the packaging glue from flowing in the process from the inside of the support cup filled into the LED support to solidification by utilizing the tension action of the polytetrafluoroethylene dispersion liquid coating. The LED lamp bead has higher luminous flux extraction rate and brightness, can reduce the power consumption and the cost of the lamp, and is simple in manufacturing process, high in production efficiency and high in yield.)

1. The utility model provides a LED lamp pearl which characterized in that includes:

the LED bracket is provided with a bracket cup for accommodating a wafer, the LED bracket is provided with an anode and a cathode, and the LED bracket is provided with a polytetrafluoroethylene dispersion liquid coating at a preset position;

the wafer is fixed in a support cup of the LED support, and the anode and the cathode of the LED support are both electrically connected with the wafer;

and the wafer is sealed on the LED bracket through the packaging glue, the packaging glue is cured to form a cambered surface, and the polytetrafluoroethylene dispersion liquid coating is connected with the packaging glue so as to prevent the packaging glue from flowing in the process from being injected into a bracket cup of the LED bracket to curing.

2. The LED lamp bead of claim 1, wherein the outer periphery of said support cup forms a containment step, said ptfe dispersion coating being on the surface of said containment step.

3. The LED lamp bead of claim 1, wherein the ptfe dispersion coating is a coating formed from a dispersion of micro-or nano-polytetrafluoroethylene powder;

and/or the polytetrafluoroethylene dispersion liquid coating is a coating formed by a coating comprising polytetrafluoroethylene powder, silicate, alkoxy silane, ethanol, deionized water and an auxiliary agent.

4. The LED lamp bead of claim 1, wherein the encapsulant is cured to form a hemispherical surface.

5. The LED lamp bead of claim 1, wherein the height of the highest point of the arc formed by the encapsulation glue from the top surface of the LED support ranges from 0.5 mm to 2.5 mm.

6. The LED lamp bead of claim 1, wherein the fillet radius at the junction of said encapsulation glue and the rim of the support cup of said LED support is in the range of 0.5-4 mm.

7. The LED lamp bead of any one of claims 1-6, wherein the LED lamp bead has a light angle of 90 ° -120 °.

8. The LED lamp bead of any one of claims 1-6, wherein some or all of the area of said encapsulation glue is mixed with phosphor.

9. An illuminating lamp, characterized in that the illuminating lamp comprises a plurality of LED lamp beads according to any one of claims 1 to 8.

10. The illumination lamp according to claim 9, wherein the illumination lamp is a household illumination lamp, a commercial illumination lamp or a plant illumination lamp.

11. The manufacturing method of the LED lamp bead is characterized by comprising the following steps:

a die bonding step, namely fixing the wafer in a bracket cup of the LED bracket;

a connecting step, electrically connecting the wafer with the anode and the cathode of the LED bracket through bonding wires;

coating, namely coating a polytetrafluoroethylene dispersion liquid coating at a preset position of the LED support;

dispensing, namely dispensing packaging glue into the LED bracket to enable the wafer to be sealed on the LED bracket through the packaging glue, wherein the polytetrafluoroethylene dispersion liquid coating is connected with the packaging glue;

and a curing step, curing the packaging glue to form a cambered surface under the condition of a preset temperature, wherein the polytetrafluoroethylene dispersion liquid coating prevents the packaging glue from flowing in the process from being injected into the bracket cup of the LED bracket to curing.

12. The method for manufacturing the LED lamp bead according to claim 11, wherein in the coating step, the ptfe dispersion is coated on a predetermined position of the LED support by brushing, spot coating, spraying or transfer printing, and then the ptfe dispersion is baked, thereby forming the ptfe dispersion coating on the LED support.

13. The method for manufacturing an LED lamp bead according to claim 12, wherein in the coating step, a plurality of LED supports are arranged in a predetermined manner, then the mesh is placed on the LED supports to block the area of the LED supports where the teflon dispersion coating is not to be formed by coating, then the mesh for brushing the teflon dispersion is placed on the mesh, and the teflon dispersion is brushed on the LED supports by scraping the mesh with a scraper.

14. The method for manufacturing the LED lamp bead according to claim 11, wherein the periphery of the support cup of the LED support forms a surrounding step, and the teflon dispersion coating is located on the surface of the surrounding step.

15. The method for manufacturing an LED lamp bead of claim 11, wherein the teflon dispersion coating is a coating formed from a dispersion of micro-or nano-polytetrafluoroethylene powder;

and/or the polytetrafluoroethylene dispersion liquid coating is a coating formed by a coating comprising polytetrafluoroethylene powder, silicate, alkoxy silane, ethanol, deionized water and an auxiliary agent.

16. The method for manufacturing an LED lamp bead of claim 11, wherein in the curing step, the encapsulation glue is cured to form a hemispherical surface.

17. The method for manufacturing an LED lamp bead according to claim 11, wherein the height of the highest point of the arc surface formed by the encapsulation glue from the top surface of the LED support ranges from 0.5 mm to 2.5 mm.

18. The method of claim 11, wherein the fillet radius at the junction of the encapsulation glue and the rim of the support cup of the LED support is in the range of 0.5-4 mm.

19. The method of manufacturing an LED lamp bead of any one of claims 11-18, wherein the method of manufacturing an LED lamp bead comprises the steps of: mixing the fluorescent powder and the packaging glue.

20. The method of manufacturing an LED lamp bead of claim 19, wherein said mixing step precedes said dispensing step.

21. The method for manufacturing the LED lamp bead according to claim 19, wherein in the dispensing step, a packaging glue not mixed with phosphor is dispensed and injected into the holder cup of the LED holder, and then a packaging glue mixed with phosphor is dispensed and injected onto the LED holder again;

or, dispensing and injecting the packaging glue mixed with the fluorescent powder into the support cup of the LED support, and then dispensing and injecting the packaging glue not mixed with the fluorescent powder onto the LED support again.

Technical Field

The application belongs to the technical field of lighting, and more specifically relates to an LED lamp bead, a lighting lamp and a manufacturing method of the LED lamp bead.

Background

At present, in the field of general illumination such as household illumination and commercial illumination and the field of plant illumination, Light-emitting Diode (LED) lamp beads are more and more widely applied. However, with social development, people have higher and higher requirements on the illumination intensity, the extraction rate of the light quantum flux and the like of the LED lamp, so that a novel LED lamp bead which is different from a conventional TOP mounted LED lamp bead in the extraction rate of the light quantum flux is developed in the industry. The structural biggest difference with conventional TOP paster lamp pearl of this novel LED lamp pearl is: conventional TOP paster LED lamp pearl is planar structure, and novel LED lamp pearl is bulb column structure, and this novel LED lamp pearl has great promotion for the light quantum flux extraction rate of conventional TOP paster lamp pearl.

The novel bulb LED lamp bead on the existing market is usually formed by presetting a forming die through an injection molding machine, then putting an LED support after die bonding and wire bonding into a glue injection die cavity of a die, injecting LED packaging glue into the glue injection die cavity of the die, reheating the die to solidify the LED packaging glue, and forming the bulb LED lamp bead after demolding. However, the ball-head LED lamp bead produced by the process has the defects of complex production equipment, high cost, low efficiency and poor yield.

In addition, the height of the bulb of the novel bulb LED lamp bead formed by the process is low, the process for forming the bulb is complex, the joint of the bulb part and the LED support is not in a real arc shape after the two baking forming processes, actually, the joint is in a partial elliptic arc shape, so that the LED lamp bead is easy to block the suction nozzle on the Surface of the suction nozzle due to the fact that the LED lamp bead is in a clamping track phenomenon in the subsequent use of a light splitter and a braiding machine and the Surface Mount Technology (SMT) process is easy to block the suction nozzle due to the fact that the LED lamp bead is clamped on the Surface of the suction nozzle, and machine faults are caused, and therefore production efficiency is affected.

Disclosure of Invention

An object of the embodiment of the application is to provide an LED lamp bead, a lighting lamp and a manufacturing method of the LED lamp bead, so as to solve the technical problems that in the prior art, ball head lamp bead production equipment is complex, production efficiency is low, and the height of a ball head part is low.

In order to achieve the purpose, the technical scheme adopted by the application is as follows: the LED lamp bead comprises an LED support, a wafer and packaging glue. The LED support is provided with a support cup used for containing the wafer, the LED support is provided with an anode and a cathode, and the LED support is provided with a polytetrafluoroethylene dispersion liquid coating at a preset position. The wafer is fixed in the support cup of LED support, and the positive pole and the negative pole of LED support all are connected with wafer electric property. The wafer is sealed on the LED support through the packaging glue, the packaging glue is solidified to form a cambered surface, and the polytetrafluoroethylene dispersion liquid coating is connected with the packaging glue so that the polytetrafluoroethylene dispersion liquid coating prevents the packaging glue from flowing in the process from being injected into the LED support to solidification.

Optionally, the periphery of the support cup forms a containment step, and the polytetrafluoroethylene dispersion coating is located on the surface of the containment step.

Optionally, the polytetrafluoroethylene dispersion coating is a coating formed by a micron-scale or nanometer-scale polytetrafluoroethylene powder dispersion;

and/or the polytetrafluoroethylene dispersion liquid coating is a coating formed by a coating comprising polytetrafluoroethylene powder, silicate, alkoxy silane, ethanol, deionized water and an auxiliary agent.

Optionally, the encapsulation glue is cured to form a hemispherical surface.

Optionally, the height range of the highest point of the arc surface formed by the packaging glue from the top surface of the LED support is 0.5-2.5 mm.

Optionally, the fillet radius at the junction of the encapsulation glue and the rim of the support cup of the LED support is in the range of 0.5-4 mm.

Optionally, the light-emitting angle of the LED lamp bead is 90-120 degrees.

Optionally, part or all of the area of the encapsulation glue is mixed with the phosphor.

According to another aspect of the present application, the present application further provides a lighting lamp, which includes a plurality of LED lamp beads of any one of the above.

Optionally, the lighting lamp is a household lighting lamp, a commercial lighting lamp or a plant lighting lamp.

According to another aspect of the present application, the present application further provides a method for manufacturing an LED lamp bead, comprising the following steps:

a die bonding step, namely fixing the wafer in a bracket cup of the LED bracket;

a connecting step, electrically connecting the wafer with the anode and the cathode of the LED bracket through bonding wires;

coating, namely coating a polytetrafluoroethylene dispersion liquid coating at a preset position of the LED support;

dispensing, namely dispensing packaging glue into the LED bracket to enable the wafer to be sealed on the LED bracket through the packaging glue, wherein the polytetrafluoroethylene dispersion liquid coating is connected with the packaging glue;

and a curing step, curing the packaging glue to form a cambered surface under the condition of a preset temperature, wherein the polytetrafluoroethylene dispersion liquid coating prevents the packaging glue from flowing in the process from being injected into the bracket cup of the LED bracket to curing.

Optionally, in the coating step, the polytetrafluoroethylene dispersion liquid is coated on the predetermined position of the LED support by brushing, spot coating, spraying or transfer printing, and then the polytetrafluoroethylene dispersion liquid is baked, so as to form a polytetrafluoroethylene dispersion liquid coating on the LED support.

Optionally, in the coating step, a plurality of LED supports are arranged according to a predetermined manner, then the mesh is placed on the LED supports to shield a position area on the LED supports where a teflon dispersion coating is not required to be formed by coating, then the mesh for brushing the teflon dispersion is placed on the mesh, and the teflon dispersion is brushed on the LED supports by a scraper that scrapes the mesh.

Optionally, the periphery of the support cup of the LED support forms a surrounding step, and the teflon dispersion liquid coating is located on the surface of the surrounding step.

Optionally, the polytetrafluoroethylene dispersion coating is a coating formed by a micron-scale or nanometer-scale polytetrafluoroethylene powder dispersion;

and/or the polytetrafluoroethylene dispersion liquid coating is a coating formed by a coating comprising polytetrafluoroethylene powder, silicate, alkoxy silane, ethanol, deionized water and an auxiliary agent.

Optionally, in the curing step, the encapsulation glue is cured to form a hemispherical surface.

Optionally, the height range of the highest point of the arc surface formed by the packaging glue from the top surface of the LED support is 0.5-2.5 mm.

Optionally, the fillet radius of the joint between the packaging glue and the edge of the bracket cup of the LED bracket is 0.5-4 mm.

Optionally, the manufacturing method of the LED lamp bead includes a mixing step: mixing the fluorescent powder and the packaging glue.

Optionally, the mixing step precedes the dispensing step.

Optionally, in the dispensing step, dispensing and injecting packaging glue not mixed with the fluorescent powder into the support cup of the LED support, and then dispensing and injecting packaging glue mixed with the fluorescent powder onto the LED support again;

or, dispensing and injecting the packaging glue mixed with the fluorescent powder into the support cup of the LED support, and then dispensing and injecting the packaging glue not mixed with the fluorescent powder onto the LED support again.

The application provides a beneficial effect of LED lamp pearl and light lies in: compared with the prior art, its LED support of LED lamp pearl of this application has polytetrafluoroethylene dispersion coating at predetermined position, and this polytetrafluoroethylene dispersion coating can prevent encapsulation glue to flow all around from pouring into the support cup of LED support in to the in-process of solidification at encapsulation glue to make and form the cambered surface after the solidification of encapsulation glue. The LED lamp bead made in the way is not of a plane structure, but is of a ball head LED lamp bead of an arc-shaped curved surface structure, so that the extraction rate of light quantum flux is improved, the brightness and the lighting effect are improved, the LED lamp bead is less in requirement of the lighting lamp of the LED lamp bead under the condition of the same brightness requirement, and the cost is reduced. Correspondingly, according to the manufacturing method of the LED lamp bead, the polytetrafluoroethylene dispersion liquid coating is formed by coating on the LED support, the polytetrafluoroethylene dispersion liquid coating can prevent the packaging glue from flowing around in the process from the step of injecting the packaging glue into the support cup of the LED support to the step of curing, the packaging glue can form the cambered surface after being cured, and the spherical LED lamp bead is manufactured. By adopting the manufacturing method, complex processes such as presetting a forming die, injecting glue into the die, demoulding and the like through the injection molding machine are not needed, large complex equipment such as the injection molding machine is also not needed, the processes and the equipment are relatively simpler, the production efficiency is higher, and the yield is also higher.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the embodiments or the prior art descriptions will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without inventive exercise.

Fig. 1 is a cross-sectional view of a first LED lamp bead provided in the embodiment of the present application;

fig. 2 is a cross-sectional view of a second LED lamp bead provided in the embodiment of the present application;

fig. 3 is a cross-sectional view of a third LED lamp bead provided in the embodiment of the present application;

fig. 4 is a cross-sectional view of a fourth LED lamp bead provided in the embodiment of the present application.

Wherein, in the figures, the respective reference numerals:

10-an LED support; 11-positive electrode; 12-a negative electrode; 13-enclosing step; 14-coating of a polytetrafluoroethylene dispersion; 20-a wafer; 30-packaging glue; 40-a bond wire; 50-fluorescent powder.

Detailed Description

In order to make the technical problems, technical solutions and advantageous effects to be solved by the present application clearer, the present application is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the present application.

It will be understood that when an element is referred to as being "secured to" or "disposed on" another element, it can be directly on the other element or be indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or be indirectly connected to the other element.

It will be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like, as used herein, refer to an orientation or positional relationship indicated in the drawings that is solely for the purpose of facilitating the description and simplifying the description, and do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus should not be considered as limiting the present application.

Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present application, "a plurality" means two or more unless specifically limited otherwise.

Referring to fig. 1, a description will now be given of an LED lamp bead provided in the present embodiment. The LED lamp bead comprises an LED support 10, a wafer 20 and packaging glue 30.

The center of the LED support 10 has a support cup for receiving the wafer 20. The bracket cup is internally provided with a bracket cup cavity. The two ends of the LED support 10 are respectively provided with a positive electrode 11 and a negative electrode 12. The positive electrode 11 and the negative electrode 12 are metal copper sheets. The LED support 10 has a polytetrafluoroethylene dispersion coating 14 formed by coating at a predetermined position. In the manufacturing process, the polytetrafluoroethylene dispersion can be formed on the LED support 10 by brushing, spotting, spraying, transferring, and the like. Illustratively, the polytetrafluoroethylene dispersion coating 14 is a coating formed of a paint including polytetrafluoroethylene powder, silicate, alkoxysilane, ethanol, deionized water, and an auxiliary. During manufacturing, the polytetrafluoroethylene powder resin, the novel nano material, the filler, the functional auxiliary agent and other materials are produced and manufactured through a special process and a nano technology.

It is understood that ptfe is a white, odorless, tasteless, non-toxic powder commonly known as "plastic king". Polytetrafluoroethylene has the following properties: 1) the lubricant has excellent chemical stability, corrosion resistance, sealing property, high lubrication non-adhesiveness, electric insulation property and good ageing resistance; 2) high temperature resistance, and the working temperature reaches 250 ℃; 3) the low temperature resistance is realized, the mechanical toughness is good at low temperature, and the elongation of 5 percent can be kept even if the temperature is reduced to-196 ℃; 4) corrosion resistance, inertia to most chemicals and solvents, strong acid and alkali resistance, water resistance and various organic solvents resistance; 5) the weather resistance is good, and the best aging life in plastics is achieved; 6) high lubrication, which is the lowest coefficient of friction in solid materials; 7) the adhesion is avoided, the surface tension in the solid material is the minimum, and no substance is adhered; 8) it is non-toxic, has physiological inertia, and has no adverse reaction when being implanted into human body for a long time.

When the polytetrafluoroethylene dispersion is applied, the concentration of the polytetrafluoroethylene dispersion used cannot be too low, and it is necessary to make the polytetrafluoroethylene dispersion into a liquid-drop form. After the polytetrafluoroethylene dispersion liquid is coated on the LED support 10, the LED support is baked at a high temperature, so that the liquid substance is volatilized, and polytetrafluoroethylene with a fine particle size in a powder state and a corresponding adhesive are left on the surface of the LED support 10, thereby forming a polytetrafluoroethylene dispersion liquid coating 14 on the surface of the LED support 10.

The polytetrafluoroethylene dispersion liquid coating 14 is a low-surface-energy anti-corrosion anti-sticking coating, and the surface of the polytetrafluoroethylene dispersion liquid coating 14 shows a lotus leaf water repellent effect. The wonderful aspect of the water repellent effect of the lotus leaves is that the leaves of the lotus leaves have very complex multiple nano and micron-sized superfine structures, countless small bags are densely distributed on the leaves of the lotus leaves, air is filled in the concave parts among the small bags, and an extremely thin air layer with the thickness of only nano-scale is formed by clinging to the leaves, so that dust, rainwater and the like far larger than the structure in size fall on the leaves of the lotus leaves, and then a layer of extremely thin air is separated, and the extremely thin air layer can only form a plurality of point contacts with the convex top parts of the small bags on the leaves; the raindrops form a ball under the action of the surface tension of the raindrops, and the water ball adsorbs dust in rolling and rolls out of the leaf surface. The polytetrafluoroethylene dispersion liquid coating 14 prepared by utilizing the lotus leaf water repellent effect is a super hydrophobic coating, the contact angle of the polytetrafluoroethylene dispersion liquid coating 14 and pure water is more than or equal to 150 degrees, and the liquid contacting the polytetrafluoroethylene dispersion liquid coating 14 can be prevented from flowing, so that the liquid forms a spherical shape. The polytetrafluoroethylene dispersion coating 14 has a very wide application prospect, and can be used for preventing ice and snow accumulation, rainwater interference, chemical reagent contamination and the like on building outer walls, roofs, outdoor large-scale steel structures and military facilities. The nano composite latex paint with lotus leaf water repellent effect on the surface of the paint film, high-grade nano waterproof self-cleaning paint and the like have been developed in China.

Table 1 below shows comparative data of surface contact angles of the ptfe dispersion coating 14 and several high performance coating coatings for different liquids. As can be seen from table 1, the teflon dispersion coating 14 of the present application has a larger contact angle for water and castor oil than the other several coating coatings. It can be seen that the polytetrafluoroethylene dispersion coating 14 has an effect of preventing the flow of liquid contacting it, and the liquid can form a spherical shape like a lotus leaf after contacting the polytetrafluoroethylene dispersion coating 14.

TABLE 1 comparison of surface contact angles of several high Performance coating coatings for different liquids

Table 2 below shows the main properties of the polytetrafluoroethylene dispersion coating 14, and it can be seen from table 2 that the polytetrafluoroethylene dispersion coating 14 also has excellent water resistance, alkali resistance, acid resistance, salt water resistance, salt fog resistance, and resistance to weathering, thereby having outstanding corrosion resistance, specific anti-sticking function, good anti-graffiti function, and excellent protection and decoration properties.

TABLE 2 Primary Properties of the Polytetrafluoroethylene Dispersion coating

The wafer 20 is held in the holder cup cavity of the holder cup in the center of the LED holder 10. Specifically, in the manufacturing process, after the LED support 10 is dehumidified at a high temperature, the wafer 20 is fixed in the support cup of the LED support 10 by means of glue bonding for die bonding; and then the bonded glue is cured by means of high-temperature baking, so that the wafer 20 is firmly bonded in the support cup of the LED support 10. The anode 11 and the cathode 12 of the LED support 10 are electrically connected to the wafer 20.

The die 20 is encapsulated on the LED support 10 by means of an encapsulation glue 30. In the manufacturing process, the packaging glue 30 is coated inside and around the support cup of the LED support 10 through a dispenser, the packaging glue 30 covers the wafer 20 and the surface of the LED support 10 at the periphery, then high-temperature baking is carried out, so that the packaging glue 30 is solidified and shaped, the wafer 20 is packaged and fixed with the LED support 10 through the packaging glue 30, and the polytetrafluoroethylene dispersion coating 14 on the surface of the LED support 10 is connected with the packaging glue 30, so that the polytetrafluoroethylene dispersion coating 14 prevents the packaging glue 30 from flowing in the process from the cup cavity of the support cup filled into the LED support 10 to solidification. The polytetrafluoroethylene dispersion coating 14 coated on the LED support 10 can withstand a high temperature of 250 ℃ for a long time without decomposition and yellowing. The polytetrafluoroethylene dispersion coating 14 has small surface tension and does not adhere to the packaging glue 30, and the polytetrafluoroethylene dispersion coating 14 can prevent the packaging glue 30 from flowing in the curing process, so that the packaging glue 30 can maintain the spherical shape just after dispensing to the maximum extent, and an arc surface can be formed on the LED support 10 after the packaging glue 30 is cured, namely the ball-head type lamp bead. Illustratively, encapsulation glue 30 cures to form a hemispherical surface.

Firstly, dehumidifying the LED support 10 at high temperature, and then fixing the wafer 20 in a support cup of the LED support 10 through adhesive glue, namely, a die bonding step; then, the bonding glue between the wafer 20 and the LED support 10 is solidified through high-temperature baking, so that the wafer 20 is firmly bonded in the support cup; then, the wafer 20 is electrically connected with the anode 11 and the cathode 12 respectively by a bonding wire 40 through a wire bonding machine; coating a layer of polytetrafluoroethylene dispersion liquid on the surface of a preset position of the LED support 10 by a brushing machine, a transfer machine and other equipment, and then baking at high temperature to evaporate water in the polytetrafluoroethylene dispersion liquid, so that a layer of polytetrafluoroethylene dispersion liquid coating 14 is formed on the surface of the LED support 10; the dispensing coating of the packaging glue 30 is performed on the LED support 10 through a dispenser, and the polytetrafluoroethylene dispersion coating 14 can prevent the packaging glue 30 from flowing, so that the packaging glue 30 can maintain a spherical shape on the LED support 10 to the maximum extent; and finally, baking at high temperature to cure and shape the packaging glue 30 to obtain the ball-head type LED lamp bead.

In the process of coating the polytetrafluoroethylene dispersion liquid on the LED supports 10, a plurality of LED supports 10 can be arranged and fixed on one metal fixing sheet, then all areas, which do not need to be coated with the polytetrafluoroethylene dispersion liquid, of the LED supports 10 are shielded by another shielding screen plate, then the screen plate for brushing the polytetrafluoroethylene dispersion liquid is placed on the shielding screen plate, slurry of the polytetrafluoroethylene dispersion liquid is scraped through the screen plate by a scraper, and the polytetrafluoroethylene dispersion liquid is brushed on preset positions of the LED supports 10.

Compared with the prior art, the LED lamp bead provided by the application, set up by polytetrafluoroethylene dispersion coating 14 through the preset position at its LED support 10, this polytetrafluoroethylene dispersion coating 14 can prevent encapsulation glue 30 to flow all around in encapsulation glue 30 curing process to make and form the cambered surface after encapsulation glue 30 solidifies. Therefore, the surface of the LED lamp bead is not of a plane structure but of a curved surface structure, and the LED lamp bead with the curved surface structure has higher light quantum flux extraction rate. Specifically, compared with a patch type LED lamp bead produced by the same materials, the extraction rate of the light quantum flux of the LED lamp bead with vertical red light and vertical yellow light can be improved by more than 15%, and the extraction rate of the light quantum flux of the LED lamp bead with white light can be improved by 4%, so that the brightness and the light effect are improved. The number of the LED lamp beads used by the illuminating lamp with the LED lamp beads is less under the condition of the same brightness requirement, so that the cost and the power consumption of the illuminating lamp can be reduced.

On the other hand, the manufacturing process of the LED lamp bead is that a polytetrafluoroethylene dispersion coating 14 for preventing the flow of the packaging glue 30 is coated at a preset position of the LED support, so that the packaging glue 30 is prevented from flowing to the periphery after the packaging glue is dispensed into a spherical shape, the spherical shape of the packaging glue 30 is maintained to the maximum, and finally the spherical-head-shaped LED lamp bead is formed through baking, curing and molding. The manufacturing process does not need an injection molding machine to preset a forming die, inject packaging glue into a die cavity, demould and other complex procedures and complex equipment, relatively speaking, the glue dispensing forming mode is simple and multiple, the cost is lower, and the finally manufactured product has high yield and higher production efficiency.

In another embodiment of the present application, the LED lamp bead further includes a plurality of bonding wires 40, and two ends of the wafer 20 are respectively and correspondingly electrically connected to the anode 11 and the cathode 12 of the LED support 10 through the bonding wires 40. Specifically, the bonding wires 40 may be bonded between the wafer 20 and the anode 11, and between the wafer 20 and the cathode 12 by a wire bonding machine.

In another embodiment of the present application, the outer periphery of the support cup of the LED support 10 forms a surrounding step 13, the height of the surrounding step 13 is higher than that of the wafer 20 in the support cup, the surrounding step 13 is a ring structure surrounding the wafer 20, and the teflon dispersion liquid coating 14 is located on the surface of the surrounding step 13. Thus, when the encapsulation glue 30 is injected into the holder cup by the dispenser, the periphery of the encapsulation glue 30 can be connected with the teflon dispersion coating 14, i.e. the encapsulation glue 30 is surrounded by the teflon dispersion coating 14, so that the encapsulation glue 30 cannot flow around. Thus, the shape of the encapsulation glue 30 after curing is ideal and can be close to a hemisphere.

In another embodiment of the present application, the polytetrafluoroethylene dispersion coating 14 is a micro-or nano-scale polytetrafluoroethylene powder dispersion coating. The dispersion liquid formed by the polytetrafluoroethylene powder with the micron-scale or nanometer-scale is brushed or transferred on the LED support 10, and the polytetrafluoroethylene dispersion liquid coating 14 is formed on the surface of the LED support 10 after water in the dispersion liquid is evaporated. The smaller the particle size of the polytetrafluoroethylene powder, for example, the micron-sized or nano-sized particle size, the larger the total contact surface of the polytetrafluoroethylene powder to the encapsulating glue 30 after the coating is formed, the better the effect of blocking the flow of the encapsulating glue 30 is, thereby facilitating the encapsulating glue 30 to maintain the initial shape during the dispensing, and the closer the shape of the encapsulating glue 30 after curing is to the ideal hemisphere shape.

In another embodiment of the present application, referring to fig. 1, the height H from the highest point of the arc surface formed by the encapsulation glue 30 to the top surface of the LED support 10 is in the range of 0.5-2.5 mm. The height from the highest point of an arc surface formed by packaging glue of the conventional ball-head LED lamp bead formed by injection molding through a mold cavity to the top surface of the LED support 10 is generally 0.95-0.98 mm. And this application is owing to adopted polytetrafluoroethylene dispersion coating 14, can prevent the flow of encapsulation glue 30 to furthest maintains the shape when just gluing, and the shape after encapsulation glue 30 solidification is more close the hemisphere shape, and the height value H of the peak distance LED support 10 top surface of the cambered surface that encapsulation glue 30 formed can reach the corresponding height value level that is far higher than prior art bulb lamp pearl.

In another embodiment of the present application, the diameter of the junction of the encapsulation glue 30 and the holder cup rim of the LED holder 10 is in the range of 2.0-3.0 mm. In other embodiments, the amount of the encapsulation glue 30 may also be different according to the size of the LED beads and the size of the LED support 10, so that the diameter of the joint between the cured encapsulation glue 30 and the edge of the support cup of the LED support 10 may also be different accordingly.

In another embodiment of the present application, the fillet radius at the junction of the encapsulation glue 30 and the holder cup rim of the LED holder 10 is in the range of 0.5-4 mm. The shape of the solidified packaging glue 30 of the LED lamp bead can be close to the shape of a hemisphere to the maximum extent, so that compared with the prior art, the joint of the packaging glue 30 and the edge of the support cup of the LED support 10 has a larger fillet. The prior ball head LED lamp bead formed by an injection molding machine die is flat in shape because the fillet of the joint between the solidified packaging glue and the edge of a support cup is not large enough, and the packaging glue is excessively overflowed to the periphery, so that the LED lamp bead is split by a splitting machine and a braiding machine in the follow-up process, the track clamping phenomenon of the LED lamp bead is easily caused in the braiding process, and the suction nozzle is easily blocked by the LED lamp bead clamp on the Surface of the suction nozzle after the SMT (Surface Mounted Technology) process, thereby causing machine faults, and further influencing the production efficiency. And this application provides the shape after the encapsulation glue 30 solidification of LED lamp pearl can be close the hemisphere shape furthest, encapsulation glue 30 and LED support 10's support cup border junction has bigger fillet, consequently LED lamp pearl is difficult to appear LED lamp pearl card track phenomenon at subsequent beam split, braid in-process to and be difficult to lead to LED lamp pearl card suction nozzle phenomenon after SMT (Surface Mounted Technology) process, reduce machine fault probability, improve production efficiency.

In another embodiment of the present application, some or all of the area of the encapsulation glue 30 is mixed with the phosphor 50. According to different requirements of the required LED lamp bead on the light-emitting color, the color temperature and the like, the fluorescent powder 50 with different types, colors and proportions can be correspondingly mixed and doped in the packaging glue 30. For example, the encapsulation glue 30 of a partial region of the LED lamp bead shown in fig. 2 and 3 is mixed with the phosphor 50. Specifically, the encapsulation glue 30 of the partial region of the LED lamp bead in fig. 2, which is located in the cup cavity of the support cup of the LED support 10, is mixed with the phosphor 50, and the encapsulation glue 30 of the partial region of the LED lamp bead in fig. 3, which is located outside the cup cavity of the support cup of the LED support 10, is mixed with the phosphor 50. All the areas of the LED lamp bead shown in FIG. 4, which are encapsulated with the glue 30, are mixed with the fluorescent powder 50.

In other embodiments, the encapsulation glue 30 may also be not doped with phosphor, for example, the encapsulation glue 30 of the LED light bead shown in fig. 1 is not doped with phosphor.

In another embodiment of the present application, the light emitting angle of the LED lamp bead is 90 ° -120 °. The light-emitting angle of the surface-mounted lamp bead with the common plane structure is 110-120 degrees once, and the light-emitting angle of the LED lamp bead provided by the application can be in a wider range of 90-120 degrees. Because the LED lamp bead is coated with the polytetrafluoroethylene dispersion liquid coating 14 on the LED support 10, the polytetrafluoroethylene dispersion liquid coating 14 can prevent the flow of the packaging glue 30, so that the shape of the cured packaging glue 30 is close to the shape of a hemisphere to the maximum extent, the LED lamp bead in the shape of the bulb can have a smaller light-emitting angle, particularly the LED lamp bead with the light-emitting angle of 90-110 degrees can be manufactured, the emitted light rays have gathering performance, and the LED lamp bead is very suitable for a lamp with high focusing strength requirement.

Through the test, this application provides LED lamp pearl and ordinary SMD LED lamp pearl's optical property contrast data as follows:

table 3 general surface mount type LED lamp bead optical performance test data

Table 4 the LED lamp bead optical performance test data of the present application

The luminance ratio (IV%) was recorded as 100% in table 3 with the average of 6 sets of luminous flux values as 28.78. The average of the 6 sets of luminous flux values in table 4 was 34.95, so the equal proportion of the calculated luminance ratio (IV%) was 121.45%. By the data, the brightness ratio (IV%) of the LED lamp bead is higher than that of the LED lamp bead in the prior art, and therefore the LED lamp bead has higher brightness and light effect.

According to another aspect of this application, this application still provides a light, the light includes a plurality of foretell LED lamp pearls. The illuminating lamp can be provided with all the LED lamp beads or only part of the LED lamp beads. Illustratively, the illumination lamp is a household illumination lamp, a commercial illumination lamp, or a plant illumination lamp. Because the brightness and the light effect of the single LED lamp bead are higher than those of the existing patch type LED lamp bead, the quantity of the LED lamp beads required by the illuminating lamp adopting the LED lamp bead can be less under the condition of requiring the same illumination brightness and light effect, and therefore the cost is reduced.

According to another aspect of the present application, the present application further provides a method for manufacturing an LED lamp bead, comprising the following steps:

a die bonding step, namely fixing the wafer 20 in a bracket cup of the LED bracket 10;

a connecting step, electrically connecting the wafer 20 with the anode 11 and the cathode 12 of the LED support 10 through the bonding wire 40;

a coating step of coating a predetermined position of the LED support 10 to form a polytetrafluoroethylene dispersion coating 14;

dispensing, namely dispensing and injecting the packaging glue 30 into the LED support 10, so that the wafer 20 is packaged on the LED support 10 through the packaging glue 30, and the polytetrafluoroethylene dispersion coating 14 is connected with the packaging glue 30;

and a curing step, curing the packaging glue 30 to form a cambered surface under the condition of a preset temperature, wherein the polytetrafluoroethylene dispersion coating 14 prevents the packaging glue 30 from flowing in the process from being injected into the bracket cup of the LED bracket 10 to curing.

Specifically, the center of the LED support 10 has a support cup for receiving the wafer 20. The bracket cup is internally provided with a bracket cup cavity. The two ends of the LED support 10 are respectively provided with a positive electrode 11 and a negative electrode 12. The positive electrode 11 and the negative electrode 12 may be a metallic copper sheet. In the die bonding step, the wafer 20 is fixed in the holder cup cavity of the holder cup by the adhesive. In the connection step, the bonding wires 40 are bonded between the wafer 20 and the anode 11 and between the wafer 20 and the cathode 12 by a wire bonding machine, so that the electrodes on the two sides of the wafer 20 are electrically connected with the anode 11 and the cathode 12 of the LED support 10 respectively. In the coating step, a polytetrafluoroethylene dispersion is coated at a predetermined position of the LED support 10, and after a liquid substance in the polytetrafluoroethylene dispersion is volatilized, a layer of polytetrafluoroethylene dispersion coating 14 is formed on the surface of the LED support 10. The concentration of the polytetrafluoroethylene dispersion used in the coating process cannot be too low, and it is necessary to be able to make the polytetrafluoroethylene dispersion into a liquid-drop form. In the dispensing step, the packaging glue 30 is dispensed and injected onto the LED support 10, and after the packaging glue 30 is cured, the packaging glue 30 can well cover and package the wafer 20 on the LED support 10. The teflon dispersion coating 14 is attached to the encapsulation glue 30. In the curing step, the encapsulation glue 30 is cured under high temperature conditions, and since the teflon dispersion coating 14 can prevent the encapsulation glue 30 from flowing from the inside of the bracket cup of the LED bracket 10 to the curing process, the encapsulation glue 30 can maximally maintain the shape of a ball drop just after dispensing, so that the surface of the encapsulation glue 30 forms an arc-shaped curved surface after curing. Thus, the LED lamp bead in a spherical shape is manufactured.

In another embodiment of the present invention, in the die bonding step, the LED frame 10 is first dehumidified at a high temperature to remove moisture from the LED frame 10, which may facilitate the subsequent bonding of the wafer 20 in the frame cup of the LED frame 10. Then the wafer 20 is fixed in the cavity of the bracket cup through the bonding glue, and then the high-temperature baking is carried out to solidify the bonding glue, so that the wafer 20 is firmly fixed in the bracket cup.

In another embodiment of the present application, in the coating step, after the ptfe dispersion is coated on the LED support 10, the LED support 10 is baked at a high temperature, so that the liquid material is volatilized, and the ptfe with a fine particle size in a powder state and a corresponding adhesive are left on the surface of the LED support 10, thereby forming a ptfe dispersion coating 14 on the surface of the LED support 10.

In another embodiment of the present application, in the coating step, the ptfe dispersion is coated on the predetermined position of the LED support 10 by brushing, spotting, spraying or transferring, and then the ptfe dispersion is baked at a high temperature to volatilize the liquid substance, so as to form the ptfe dispersion coating 14 on the LED support 10.

In another embodiment of the present application, the outer circumference of the holder cup of the LED holder 10 forms a surrounding step 13, and the teflon dispersion coating 14 is located on the surface of the surrounding step 13. Thus, when dispensing the encapsulating glue 30 into the support cup of the LED support 10 during the dispensing step, the ptfe dispersion coating 14 on the surface of the surrounding step 13 at the periphery of the support cup can surround the encapsulating glue 30 and contact the encapsulating glue 30, so that the ptfe dispersion coating 14 can prevent the encapsulating glue 30 from flowing from dispensing to curing.

In another embodiment of the present application, in the coating step, a layer of the polytetrafluoroethylene dispersion is applied to the surface of the predetermined position of the LED support 10 by a brush coating machine. Specifically, a plurality of LED supports 10 are arranged in a predetermined manner, then a mesh (for example, a metal mesh) is placed on the LED supports 10 to shield the position areas of the LED supports 10 where the teflon dispersion coating 14 is not required to be applied, for example, all the LED supports 10 except the surrounding steps 13 can be shielded by the metal mesh, so that only the surrounding steps 13 of the LED supports 10 are exposed, then a mesh plate for brushing the teflon dispersion is placed on the mesh plate, and the teflon dispersion is brushed on the LED supports 10 through the mesh plate and the mesh plate by a scraper in a manner of scraping the teflon dispersion through the mesh plate. By adopting the mode, the polytetrafluoroethylene dispersion liquid can be coated on the plurality of LED supports 10 at one time, so that the production efficiency is improved.

In another embodiment of the present application, the polytetrafluoroethylene dispersion coating 14 is a coating formed from a dispersion of micro-or nano-sized polytetrafluoroethylene powder. The dispersion liquid formed by the micron-sized or nano-sized polytetrafluoroethylene powder with the small particle size is coated on the LED support 10, the larger the sum of the contact surface of the polytetrafluoroethylene powder to the packaging glue 30 after the coating is formed is, the better the effect of blocking the flowing of the packaging glue 30 is, so that the packaging glue 30 is favorable for maintaining the initial shape during glue dispensing, and the shape of the packaging glue 30 after being cured is closer to the ideal hemisphere shape.

In another embodiment of the present application, in the curing step, the encapsulation glue 30 is cured to form a hemisphere.

In another embodiment of the present application, the height H from the highest point of the arc surface formed by the encapsulation glue 30 to the top surface of the LED support 10 is in the range of 0.5-2.5 mm. Because the polytetrafluoroethylene dispersion coating 14 is coated on the LED support 10, the flow of the packaging glue 30 can be prevented, so that the shape of the packaging glue 30 just glued can be maintained to the maximum extent, the shape of the packaging glue 30 after being cured is closer to the shape of a hemisphere, and the height value H of the highest point of the arc surface formed by the packaging glue 30 from the top surface of the LED support 10 can be far higher than the corresponding height value level of the bulb bead in the prior art.

In another embodiment of the present application, the fillet radius at the junction of the encapsulation glue 30 and the bracket cup rim of the LED bracket 10 is in the range of 0.5-4 mm. Because the polytetrafluoroethylene dispersion coating 14 is coated on the LED support 10, the flowing of the packaging glue 30 can be prevented, and the shape of the cured packaging glue 30 can be close to the shape of a hemisphere to the maximum extent, so that compared with the prior art, the joint of the edge of the support cup of the packaging glue 30 and the LED support 10 has a larger fillet, so that the prepared LED lamp bead is not easy to have the phenomenon of clamping tracks of the LED lamp bead in the subsequent light splitting and braiding processes, and the phenomenon of clamping suction nozzles of the LED lamp bead is not easy to cause after the SMT (Surface Mounted Technology) process, the machine failure probability is reduced, and the production efficiency is improved.

In another embodiment of the present application, the method for manufacturing the LED lamp bead includes a mixing step: the phosphor 50 and the encapsulation glue 30 are mixed. Specifically, the fluorescent powder 50 with different types, colors and proportions can be mixed and doped in the packaging glue 30, so that the packaging glue 30 mixed with the fluorescent powder 50 can be dispensed and injected on the LED support 10, and the prepared LED lamp bead has different light-emitting effects.

In another embodiment of the present application, the mixing step precedes the dispensing step. Mixing the fluorescent powder 50 and the packaging glue 30 before the dispensing step; then, in the dispensing step, the packaging glue 30 mixed with the phosphor powder 50 is dispensed and injected into the holder cup of the LED holder 10. As shown in fig. 4, all the encapsulation glue 30 of the manufactured LED lamp bead is uniformly mixed with the fluorescent powder 50.

It is understood that, in another embodiment of the present application, only a portion of the encapsulating glue 30 may be mixed with the phosphor 50, and the rest of the encapsulating glue 30 is not mixed with the phosphor, and the encapsulating glue 30 mixed with the phosphor 50 and the encapsulating glue 30 not mixed with the phosphor are dispensed and injected onto the LED support 10.

Specifically, in the dispensing step, the packaging glue 30 mixed with the phosphor powder 50 is dispensed and injected into the holder cup of the LED holder 10, then the packaging glue 30 not mixed with the phosphor powder is dispensed and injected onto the LED holder 10 again, and the packaging glue 30 not mixed with the phosphor powder is cured to form an arc shape. The LED lamp bead prepared in the way is shown in figure 2, the bottom of the LED lamp bead is provided with fluorescent powder, and the top bulb part of the LED lamp bead is transparent.

Or, in the dispensing step, dispensing and injecting the packaging glue 30 without mixing the phosphor powder into the holder cup of the LED holder 10, and then dispensing and injecting the packaging glue 30 mixed with the phosphor powder 50 onto the LED holder 10 again. The LED lamp bead manufactured in this way is shown in fig. 3, the bottom of the LED lamp bead is transparent, and the top bulb part of the LED lamp bead is provided with fluorescent powder.

The application provides LED lamp pearl and the light that includes this LED lamp pearl have higher luminous flux and take out rate and luminance, can reduce the consumption and the cost of lamps and lanterns, and manufacturing process is simple moreover, and production efficiency is high, and the yield is high. Correspondingly, according to the manufacturing method of the LED lamp bead provided by the application, the polytetrafluoroethylene dispersion coating 14 is formed by coating on the LED support 10, the polytetrafluoroethylene dispersion coating 14 can prevent the packaging glue 30 from flowing around in the process from the inside of the support cup filled into the LED support 10 to the curing process of the packaging glue 30, and the packaging glue 30 can form an arc surface after being cured to manufacture the bulb-shaped LED lamp bead. By adopting the manufacturing method, complex processes such as presetting a forming die, injecting glue into the die, demoulding and the like through the injection molding machine are not needed, large complex equipment such as the injection molding machine is also not needed, the processes and the equipment are relatively simpler, the production efficiency is higher, and the yield is also higher.

The above description is only exemplary of the present application and should not be taken as limiting the present application, as any modification, equivalent replacement, or improvement made within the spirit and principle of the present application should be included in the protection scope of the present application.