LED Tube of packaging innovation

First, the conventional method and the existing packaging applications
Packaging methods are currently LED Tube: bracket row package, SMD package, module packaging types, these are our common and encapsulation method used.

Package is the first row of the use of stents, used to produce a single LED Tube device, this is our common lead-type LED Tube emitting diodes, it is suitable for the instrument LED Tube s, city LED Tube engineering, advertisement screens, guardrail tube, traffic LED Tube s, and our country application of some of the more common products and fields.

Mount package (SMD) is a leadless package, small, thin, very suitable for mobile phone keyboard and display LED Tube, television LED Tube, and the need for LED Tube or direct electronic products in recent years has to a large patch package size and high power of direction, a chip package within three to four LED Tube chips, LED Tube can be used to assemble products module package is a multi-chip package, the alumina or aluminum nitride to the smaller size of the board high packaging density packaging dozens or hundreds of LED Tube chip, the internal line is the hybrid type, that is, multiple chips in series, there are several parallel road. This package is mainly to expand the power, used LED Tube products module package due to package high density, the application of heat generated when a large, heat is applied to solve the primary problem.

Using the above method of production of the device package, for the production of LED Tube fixtures have a common characteristic: the number of thermal resistance of the channel more difficult to produce high-quality LED Tube and radiator module itself and the connection processing requirements are relatively high present method is to encapsulate all of the yellow phosphor (YAG) and epoxy resin by mixing different than the column, directly points to the blue LED Tube of the LED Tube chip, and then heat cured. This is common practice to the advantage of saving material the disadvantage is not conducive to heat, the phosphor will be aging, because the thermal conductivity of epoxy and phosphor are not good material, and the heat will affect the entire chip package for manufacturing LED Tube this approach is clearly not the best program.

At present foreign produce high-power chips, 0.5 watt white chips are coated with a layer of blue chip uniform YAG phosphor slurry, the appearance is a yellow cube looked, (except for the welding of two gold pad no phosphor, this method than the previous method can be used to improve LED Tube efficiency, so widely used in foreign countries) in the package as long as this kind of white chips soldered on the circuit board can be designed, eliminating the need for coating phosphor process. to bring the convenience of LED Tube manufacturers, but domestic production can not chip suppliers such mass-produced white LED Tube chips.

China is the early development of LED Light countries, is currently used in China is also good, because the national emphasis on "low-carbon economy", in 2009 China launched city of ten million LED Tube, many cities have a road test to test LED Tube feasibility, China is a street LED Tube to break through, and (MrayLED Tube) is based on a breakthrough in indoor LED Tube, these two lines about who has more advantages, has yet to see the outcome. For our part to start the application of LED Tube street LED Tube direction is due to conditions, because of China's national income is low, and LED Tube interior LED Tube of the high cost, people can not accept, while the use of LED Tube is the Government out of money, LED Lights manufacturer took a fancy to this In fact the working conditions of LED Tube interior LED Tube is more than harsh, demanding, if they can do the quality of clearance (heat, life, color, reliability, etc.), then come back to do the interior LED Tube is more easy.

The LED Tube current foreign giants are rolling out hundreds or even thousands of models of LED Tube interior LED Tube models, the price of 20-75 dollars, and power from a few watts to twenty watts, but they are used in packaging methods are referred to earlier and, the only Philips, the phosphor coating on the LED Lights , was named 2009's most innovative LED Tube products.

I think: all of its manufacturing led fluorescent tube replacement should be multi-chip package and module packaging, and preferably LED Tube LED Tube chip is encapsulated in the subject directly, so the number of thermal resistance of said at least can get a better cooling effect, or deposited in a lamp made of a copper foil on the main line body, its thermal resistance is lower, LED Tube power at least a few watts or more, so more chips are used in the past the packaging process does not apply, must adopt new methods and processes. using more than one packaged LED Tube devices to assemble LED Tube, high-quality and high reliability is difficult to create the LED Tube, LED Tube want to engage in manufacturing and technical personnel can understand this.

Second, the phosphor coating process of innovation

Module encapsulated phosphor coating, will now see the phosphor slurry is applied directly above the chip, phosphor module or with a more consistent, but mass production may occur in different modules with eyes to see color, the better approach is to use LED Lights phosphor film or membrane, membrane and diaphragm can be large-scale production, consistency, LED Tube are multi-chip package, the LED Tube mixed with each other, after fluorescent powder into a white membrane or diaphragm, and its color can be eliminated. the requirements of the film and the diaphragm is:

1. through the LED Tube , between 0.1-0.5mm thickness, phosphor uniform, smooth appearance.

2. LED Tube conversion efficiency is higher, better stability, long life, good aging resistance.

3. can be made into a film-based and non-film-based, sheets can also be made to see the implementation of the conditions and costs. Of colorless and transparent film base requirement is aging well.

4. Molding process easy, any size cut, low cost.

Another method is to phosphor and transparent plastic mixed in proportion, by injection molding machine and mold, with a phosphor to produce directly to the shade by shade the blue into white, so that even more trouble and more convenient, because shade conversion is a mixture of blue, white LED T8 Tube output so there is no color, and softer LED Tube does not produce glare.

Third, in order better to solve the problem of LED Bulbs heat, LED Light design and packaging should be considered together, the packaging and LED Tube heat sink made of a whole, effectively reduce the thermal resistance of the channel number, which is a very effective and improve heat lamps way.

LED Tube fluorescent T8 LED Tube is not currently available with a heat sink, such lamps can not do high-power and high-quality and long life. The right heat sink design should be taken into account, industrial production is the led lights for home heat sink, extruded semi-circular mold with aluminum fins, according to the size of the power cut out the desired length, then the system out of aluminum foil line, the chip fixed on the copper foil, gold wire or play to help set machines to help set so the LED Tube cooling effect, only two thermal resistance, less than the commonly used method of packaging one to two thermal resistance, reduce the temperature of the chip, to improve the quality and life LED Lights can play a role.

Another approach is to design a conflict of aluminum, many milling rectangle as needed, in an ordinary (0.8-1.0mm thick) pcb circuit board according to aluminum rectangular open rectangular hole, the paste or circuit board pcb Riveting on the aluminum, LED Tube chip is fixed to the aluminum rectangular protrusion on the stage, and then gold will be the PCB lines and chips. This production process is best, only a thermal resistance, heat dissipation is the most Well, the production of LED Tube manufacturers such programs should be given priority, followed by another line of aluminum foil on the way to do the only way of innovation, in order to effectively solve the LED Tube strip LED Tube s heat issues, but also to improve the led bulbs lamps the quality and longevity.

Related Reading:
http://leviathan1007.blogspot.com/2011/08/led-tube-investment-wave-hit-rational.html
http://boush1007.wordpress.com/2011/08/23/show-how-the-worlds-largest-led-tube-illuminates-the-road/
http://trikey1007.wordpress.com/2011/08/23/mraylighting-the-industrys-first-led-tube/