What are the applications of dispensing in the LED lighting industry?
Glue dispensing machine is widely used and critical in the LED lighting industry, covering multiple links from chip packaging to complete machine assembly. The following are specific application scenarios and technical features:
1.LED chip packaging process
a.Phosphor coating and lens molding
● In LED chip packaging,glue dispenser machine is used to coat the phosphor glue layer, and the color temperature and color rendering of white light LEDs are optimized by precisely controlling the glue amount and uniformity.
● The use of jet dispensing technology (such as piezoelectric valves) to achieve micron-level glue point control is suitable for the high-precision packaging requirements of Mini/Micro LEDs.
b.Chip fixing and electrical connection
● The LED chip is bonded to the substrate (such as PCB or ceramic substrate) by dispensing, and the electrode connection is achieved using conductive glue to ensure long-term stability.
● For high-power LEDs, dispensing also needs to assume the function of heat dissipation, such as filling with high thermal conductivity glue to improve heat conduction efficiency.
Two component Potting Machines SEC-S1500-D Applied in LED light strips
2.LED lamp manufacturing process
a.Structural fixation and sealing protection
● Lamp holder and lampshade bonding: The glue dispensing platform is used for 360-degree glue dispensing on the inner wall of the lamp holder to fix the lampshade and lamp cup and enhance the structural strength.
● Waterproof and dustproof sealing: Waterproof glue is used to seal the joints of outdoor lamps (such as street lights and floodlights) to prevent moisture penetration and improve the IP protection level.
Power module potting: Use two-component organic silicone to conduct thermal potting on the driver power board to enhance heat dissipation and extend life.
b.Solder point protection and insulation treatment
● After the LED lamp beads are welded, the solder feet are covered by glue dispensing to form an insulating protective layer to prevent oxidation or short circuit.
● Epoxy glue or silicone is commonly used for protection, and flexibility and weather resistance must be taken into account.
Dispensing Machine Application Solution-LED Light Bar
3.Application of high-end display technology (such as Mini/Micro LED)
a.Optical design of backlight module
● Dam filling process (DAM + Filling): Form a grid dam by scribing and dispensing glue to prevent cross-lighting, and then fill with transparent optical glue to encapsulate the chip and construct a focusing structure.
● Slit coating process (Slit Coating): Use a slit coating head to apply the glue horizontally to the backlight board to improve uniformity, which is suitable for backlight modules with high-density chips.
b.Pixel gap filling and protection
● In Mini/Micro LED displays, dispensing glue is used to fill the pixel gap to form a transparent protective layer that is anti-glare and anti-moisture, while avoiding the risk of short circuits caused by small spacing.
4.Special scenarios and innovative applications
a.Flexible LED light strip manufacturing
● Soft light strips using FPC (flexible circuit board) are fixed by dispensing glue to the patch LED and covered with a protective glue layer to make it bendable and foldable, suitable for irregular spaces.
b.Intelligent dispensing and process optimization
● AI visual positioning: integrated machine vision system, automatically identifies LED position and dynamically adjusts dispensing path, improving accuracy and efficiency by 45%.
● Multi-valve collaborative operation: equipped with asynchronous dual-valve or multi-head dispensing equipment, it can meet the needs of complex processes such as damming, filling, lens molding, etc., and shorten the production cycle.
5.Technical Challenges and Future Trends
a.High Precision and Miniaturization
● Mini/Micro LED promotes the development of dispensing towards smaller glue dots (diameter as low as 0.33mm) and higher frequency (such as 1000Hz jetting), requiring the equipment to have nano-level positioning capabilities.
b.Intelligence and Automation
● Combined with IoT technology, real-time monitoring and remote debugging of dispensing parameters are achieved to reduce human intervention.
c.Environmental Protection and Material Innovation
● Develop low-VOC glue and recyclable packaging solutions to reduce environmental pollution during production.
Summary
The core role of dispensing processing in the LED lighting industry includes: chip packaging, structural fixation, optical optimization, protective sealing and high-end display technology support. With the iteration of technology, its application is rapidly developing towards high precision, intelligence and environmental protection, becoming a key link in improving the performance and production efficiency of LED products
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Second Intelligent has played an important role in theresearch, development, manufacturing, pre-sales and after-sales services of fluid dispensing robot, potting and coating solutions which range from various types of automatic fluid dispensing, potting, two-component potting machines and coating machines with desktop, free-standing, inline or cobot combined systems, and widely used in global electrical, electronics, home appliances, automobile, telecom, pharmaceutical, automotive electronics, semiconductor, aerospace, LED and more.
