The production process of LED lamp beads is a complex and delicate process, which mainly includes the following steps:
Preliminary preparation
1. Material preparation:
- Prepare the required materials such as LED chips, packaging materials (such as epoxy resin, silicone, etc.), leads, brackets, circuit boards, etc.
2. Cleaning and drying:
- Use ultrasonic cleaning technology to clean the PCB or LED bracket, remove impurities and dirt on the surface, and dry it to ensure the quality of subsequent processes.
LED core process
1. Crystal expansion:
- Use an expansion machine to evenly expand the entire LED chip film provided by the manufacturer, so that the LED grains closely arranged on the surface of the film are pulled apart for subsequent operations.
2. Back glue:
- Place the expanded crystal expansion ring on the back glue machine surface with the silver paste layer scraped, and apply silver paste on the back. For bulk LED chips, a dispensing machine can also be used to apply an appropriate amount of silver paste on the PCB printed circuit board.
3. Solidification:
- Place the expanded crystal ring with silver paste in the crystal piercing rack, and the operator will pierce the LED chip accurately on the PCB printed circuit board with a crystal piercing pen under a microscope, and sinter to solidify the silver glue.
4. Wire bonding:
- Use aluminum wire or gold wire welding machine to connect the electrode to the LED tube core to complete the connection of the internal and external leads. This step is the key to ensure that the current can be smoothly injected into the LED chip.
LED packaging and curing
1. Glue dispensing:
- Use a glue dispensing machine to apply an appropriate amount of prepared AB glue or epoxy resin to the bonded LED crystal to protect and fix the welding wire, and perform appearance packaging according to customer requirements.
2. Curing:
- Put the PCB printed circuit board or lamp holder with glue sealed in a thermal cycle oven and keep it at a constant temperature to fully solidify the colloid. The curing time and temperature need to be set according to the specific process requirements.
LED testing and spectrophotometry
1. Initial test:
- Use special testing tools to conduct preliminary tests on packaged LED lamp beads to check whether their photoelectric parameters meet the standards, and return or eliminate unqualified products.
2. Overall test:
- Perform more comprehensive electrical performance tests on LED lamp beads that have passed the initial test to ensure that their performance is stable and reliable.
3. Spectrophotometry:
- Use a spectrometer to distinguish different brightness and light colors of LED lamp beads according to requirements, and classify and package them. This step is to ensure that customers can get products that meet their needs.
Warehousing and delivery
1. Inspection and warehousing:
- Count and package the LED lamp beads that have passed the test, and manage them in warehousing according to the specified standards.
2. Delivery:
- According to customer order requirements, LED lamp beads are shipped in batches and supplied to downstream manufacturers or end users.
The above is the main production process of LED lamp beads. It should be noted that each step requires strict control of process parameters and operating procedures to ensure that the quality and performance of the final product meet the standard requirements. At the same time, with the continuous advancement and innovation of technology, the production process of LED lamp beads is also constantly being optimized and improved.