Material: LED holder; the LED chip; the LED die attach adhesive; welding line; the LED package glue; the LED phosphor; mainly over several materials.
Equipment: automatic die bonding machine; plasma cleaning machine; automatic wire bonding machine; automatic dispensing machine; glue mixer; oven; slitting machine; automatic sorting machine; automatic packaging machine;
Production environment: LED packaging factory is generally 100,000 dustproof requirements; in the dispensing room may need higher protection, hope is 10,000-level dustproof; back-end test sorting requirements are lower, million-level dustproof. However, good static protection is required throughout the process because the LED chip is afraid of electrostatic breakdown.
The first step: LED bracket inspection. Main test items: appearance size, thickness of plating layer, and oxidation. Recommended tools: two-dimensional measuring instrument, film thickness tester, metallographic microscope.
The second step: LED bracket baking. The LED bracket is baked using the device, mainly to remove the moisture remaining in the stent during the injection molding process.
The third step: LED bracket plasma cleaning. Arc plasma cleaning is mainly formed from hydrogen and oxygen inside the device, the LED support surface residual organics removal to improve the adhesion of the solid crystal.
The fourth step: solid crystal. The LED chip is bonded to the LED holder by an LED solid crystal glue through an automatic die bonding machine.
Step 5: Bake. The solid crystal glue is baked to make the LED chip and the LED bracket form a good bond. After the baking is completed, the solid crystal thrust test is carried out, and the equipment used is very expensive. The push-pull force tester.
Step 6: Welding wire. The pads on the LED chip and the conductive areas on the LED holder are soldered using metal wires. There are several types of welding: gold wire spherical welding and wedge welding. The metal wires used are: gold wire, aluminum wire, alloy wire, copper wire, etc. LED lamp beads mainly use gold wire, alloy wire and copper wire. After the welding is completed, the size of the solder joint and the welding tension are measured. This is a critical step, and most of the LED dead lights are caused by soldering problems.
Step 7: Sealing the glue. In the cup-shaped area formed by the LED bracket, the LED package glue is used for filling. If the white LED lamp bead is made, an appropriate amount of phosphor needs to be added to the glue. This step is the step of producing white light, and is also the step of determining the color temperature, the index, and the color blocks. The company that produces the white light bead will have a special person to mix the phosphor.
Step 8: Bake. The LED package glue is cured through the oven.
The ninth step: slitting. The LED holder is cut from a plurality of sheets joined together into individual small units of LED beads.
Step 10: Sorting. Each of the cut small lamp beads is sorted by setting various parameters: voltage, color temperature, luminous flux, and the like.
Step 11: Tape the lamp beads with the same parameters.
The main steps are completed. The above is the main production step of an SMD LED. At present, the high power with lens such as CREE and OSRAM is different in the process and equipment used in the phosphor spraying process and the sealing process, and the general process is consistent.
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