From raw materials to led lights From raw material to LED light process
such as packaging->assembly->inspection->aging. I’ll add some of the process before packaging.
First of all, packaging. First you need LED blue light chip, as large as 60 mil, as small as a few mil can be, how many watts of light need to do how many watts of chip.
Second, you need YAG phosphor, silver glue, silicone, LED bracket and other accessories and auxiliary materials.
Under the microscope with tweezers and other tools to manually complete the solid crystal, that is, a very small LED chip with silver glue fixed in the LED holder (remember to bring anti-static wrist guards), note that the LED chip is very fragile, industrial grade solid crystal are in the clean room
If the manual operation, the environment is not clean enough, then the chip’s performance will be greatly reduced.
After curing, the whole bracket and chip curing in the oven, curing conditions are determined by the performance of the silver glue.
Usually after 1-2 hours of curing, it can be removed for soldering. By solder wire I mean a very thin gold wire to connect the LED electrodes to the electrodes of the holder, then you need a manual soldering machine and spend about three hours to learn how to operate it.
If you are not experienced, then please prepare some spare parts for you to experiment, because the ratio of phosphor and silica gel is needed to DOE to find a better ratio, which is related to the light efficiency color temperature color index of the final product, etc.
Mix the silica gel and YAG phosphor in a certain ratio, usually in a beaker, stir well with a glass rod, and then use a vacuum chamber to remove air bubbles.
The mixed fluorescent glue is spread on the LED chip, note that the amount of glue here is also related to the LED luminous performance. After dispensing into the oven, according to the curing conditions of silica gel, generally 2-3 hours, after the silica gel curing is completed, the production of LED light source is complete.
If in this process, accidentally silver glue to the chip electrode, solder line solder, fill glue accidentally broke the gold line, etc., then congratulations, you have to do it again, otherwise there will be leakage, short circuit or even burned phenomenon.
Chip with actually relatively simple, you need to prepare a DC power supply or in the design of the chip directly in series and parallel, designed to be able to use the 12V DC battery-driven circuit.
Connect the light source in series to the circuit, everything is normal and the LED light source will be lit.
Don’t worry, this is not all, if your light source power is greater than 1W, then you also have to prepare a heat sink, with extruded aluminum, die-cast aluminum or purple copper heat sink can be, in the back of the LED light source coated with some thermal grease, with screws to fix the LED light source on the heat sink can be.
If you want to become a real light, then you also need to match the light, as for how to match the light, different uses of the lamps and lanterns use different ways to match the light, some need to focus on the reflector or spotlight mirror
Some need to level the light, then you need to level the light plate and more
Packaging -> assembly -> led drive -> light distribution, after these steps, an LED lamp is basically complete, the regular factory, then also need to test and aging packaging.
About the process before the package is more complex, first need sapphire wafers
The manufacturing process of sapphire wafers is more complex, requiring the use of MOCVD and other equipment.
Then on the wafer to grow a variety of materials for each layer, such as GaN, Ag/Au and other electrodes ITO layer materials, basically the semiconductor manufacturing process used in the equipment process are involved.