LED filament lamps are like the traditional incandescent lamps when their slender LED filaments shine, and they are loved and sought after by nostalgic people. The brightness, efficiency and shape of the LED filament lamp are equivalent to ordinary incandescent lamps, and people use it to retrieve the incandescent lighting environment that is about to be lost.
LED filament lamp adopts innovative technology of HVLEDs
LED filament lamp adopts high voltage, low current HVLEDs innovation technology. When the filament lamp is lit, it can only emit light with a small current of 10-15mA. It can drive 300-700mA with traditional low voltage and high current LED bulb. In comparison, the instantaneous heat generation of the LED die of the same unit area is greatly reduced, and the illumination source designed by the HVLEDs technology can be made bright and not hot. When the traditional 5W LED bulb is lit, the temperature of the bottle neck can reach 75-95 ° C, while the LED filament lamp of the same power is illuminated for 8 hours, and the temperature of the A60 glass bulb is below 36 ° C. LED filament lamps are truly safe to use. The derating design of electronic products is an effective means of extending the life of electronic products.
At present, the technical design and production of 4W LED filament lamp lumens up to 400LM-520LM, equivalent to 40W-50W incandescent lamp brightness, light efficiency up to 100-130 LM / W.
LED filament lamp products are used in A60 bulbs and C35 candle bulbs and tail-blown bulbs. The space inside them is very small. It needs heat and heat dissipation of special gas and glass bulb with limited capacity. The current frame structure and glass bubble space are only It is suitable to make a low-power bulb below 5W to ensure that the LED filament lamp will illuminate for a long time without being hot. Its products are shown in Figure 1. If you want to increase the power, you need to use A80 and A100 glass bubbles with more space.
Key technology for LED filament design
The key technologies of LED filament lamps are: LED filament design and manufacturing technology, filament lamp glass bubble sealing technology, and stroboscopic constant current driving power technology. These key design and manufacturing technologies are of the concern and concern of filament manufacturers.
The key technologies of LED filament design involve the following:
â— Filament shape design (thin and long);
â— Filament operating voltage design (considering the efficiency of the whole lamp system);
â— Filament working current design (A60 4W whole lamp lights up for 8 hours, glass bubbles are not hot);
â— area and power of LED chip (small area, low power);
◠LED chip illumination angle (can achieve 360 ​​degree illumination without back plating);
â— Filament working state design (HVLEDs, VF high voltage, small current, full string);
â— Substrate material (transparent and rigid, such as sapphire, transparent ceramic, glass);
â— Color temperature adjustment (yellow phosphorescent powder + red powder);
â— Blu-ray discharge (all yellow phosphor powder);
â— Pin design (to prevent soldering, the pin uses occlusion technology);
â— Meet the technical needs of glass bulb sealing (suitable for instant high temperature).
LED filament is one of the core technologies of filament lamp. The technical parameters and quality of LED filament involve the brightness, color temperature, index and service life of LED filament lamp, and the lumen ratio of cold and hot.
LED filament manufacturing technology currently has "solid crystal technology" for traditional packaging and "cladding technology". The solid crystal technology needs to be used for gold wire. The flip chip technology uses flip chip LED chips, which are like the ordinary electronic components, and can be reflow soldered. The production process is different and the production cost is different. This article takes the solid crystal technology as an example.
Blu-ray discharge
LED lighting sources and luminaires are not allowed to bleed out. Blu-ray is harmful to human eye health and is especially harmful to children's retina. Therefore, ensuring that LED light sources and lamps do not emit blue light is the responsibility and responsibility of every conscience entrepreneur and engineer; eliminating the LED light source and the blue light leakage of the lamps is also the basic guarantee for product quality.
The cross section of the LED filament is shown in Figure 2. 1 is a sapphire base strip, 2 is a blue LED chip without back plating, 5 is a gold wire, and 6 is a yellow phosphor phosphor. From Fig. 2, the yellow phosphor phosphor has been used to remove the entire sapphire. The base strip is coated and the blue light of the LED does not leak out.
If the LED filament is coated with yellow phosphor phosphor only on the upper and lower sides, there will be blue light leakage from the left and right sides. Some filaments are produced by spraying yellow phosphor powder in a row and then cutting the base strip by laser. The yellow strip phosphor is not coated on both sides of the transparent strip, and the blue light will leak out along the edge of the transparent strip. Figure 3 shows. This unreasonable production process needs to be corrected.
The LED filament with blue light leakage is normally observed and identified by the naked eye. As shown in Figure 4, the LED filament is covered with yellow phosphor powder on both the upper and lower sides of the sapphire strip, and the sapphire strip is visible on both sides. When the LED filament is lit, the blue light will leak out and can be detected by optical instruments.
Pin using occlusion technology
In view of the fact that the process of glass bulb sealing of LED filament lamps has a secondary high temperature (800-1000 ° C) process (Fig. 5), the pins of the LED filaments cannot be soldered, and the pins of the occlusion technology must be used. Yield in the process of glass bubble sealing.
The solder is an alloy composed of tin (melting point 232 ° C) and lead (melting point 327 ° C). A solder consisting of 63% tin and 37% lead is called eutectic solder, and the melting point of this solder is 183 °C. Therefore, the LED filament spot welded on the filament lamp post encounters an instantaneous high temperature environment during the packaging process, and the solder will undergo secondary melting, resulting in the collapse of the solder joint and the false soldering, and the filament lamp may be normally lit after being sealed into a lamp. However, after the shipment of the shipment is shaken, the solder joint is disengaged and may not light up to the client. The occlusal technology pin adopts a special pin design, and the combination of the pin and the transparent base strip is not a silver paste resin or a solder joint, but a physical three-sided clamped connection, which is not affected by high temperature. Production practice has proven to be the most scientific and effective connection method.
The LED filament with the occlusion technology pin is unlikely to be soldered due to the high temperature LED filament pin during the glass bubble sealing process. Figure 6 shows the LED filament with the occlusion technology pin. The yellow phosphor phosphor has been wrapped all over, which is the basic requirement for good quality LED filament.
LED lights should be strobed
No stroboscopic is a basic requirement for good LED light sources and luminaires. A stroboscopic light source will cause rapid fatigue of the human eye and affect the health of the human eye.
The strobe of LED light sources and lamps is mainly derived from inferior driving power sources, such as switching capacitors with high resistance and step-down power supply and high ripple. Check and discriminate whether the LED light source and the luminaire have strobe? The simple method can use the simple tools that everyone has to open the camera and camera function of the mobile phone. The electronic viewfinder is the lens to observe the LED light source. The viewfinder screen accounts for more than 2/3 of the area of ​​the mobile phone screen, especially against the LED. The light source is observed at a close distance. If the light source on the mobile phone screen sees a clear black-striped scroll or a change in light and dark (Fig. 7), it can be determined that there is stroboscopic. Strobe, the frequency of flicker, is a periodic, repetitive flash that includes visible strobes and undetectable strobes. The low frequency flashing of 50Hz-200Hz is visible to the human eye and may be very sensitive to children and young people. The strobe is easy to fatigue the eyes.
For strobes of LED light sources and luminaires, the United States interprets the dangers of stroboscopic effects in IEEE PAR1789, "The Potential Health Effects of LED Lighting Flashing." Therefore, LED light sources and lamps should not have stroboscopic.
Do a good job of power supply
The switch constant current driving power supply of the LED filament lamp can remove the early filament lamp to cover the white plastic parts of the power supply in the lamp cap. The foreign market customers are required to remove the plastic parts, so that the filament lamp is more like an incandescent lamp.
A new generation of LED filament lamp dedicated switch constant current drive power chip, integrated more LED filament lamp needs to switch a variety of electrical performance and protection functions required for constant current drive power, has a very good cost performance. Figure 8 is a new generation of LED filament lamps without stroboscopic, de-plasticized parts, using a low-height, non-isolated switch constant current drive power supply.
To automation to productivity
LED filament lamp will be a cheap LED lighting source that all people in the world can afford. LED filament lamp will be a blue ocean product that can be used and sold all over the world. LED filament lamp should be a good cost-effective consumer electronic product. Therefore, automated production is a key means of reducing product costs, and productivity is required for automated production. For this innovation, we have successfully developed automated production equipment such as “LED filament automatic spot welding machineâ€, “filament lamp sealing and sorting machineâ€, “automatic glue machine†and “automatic head welding machine†(Fig. 9). The most expensive cost in the production process of all products should be labor, so the LED lighting industry will inevitably go to automation, to produce productivity to automation, and to rely on automation to save production costs.
LED filament light new development
The original intention of designing A6 0 and C3 5 LED filament lamps is to save the incandescent lamp factory, and to use the high light transmittance glass resources of the incandescent lamp factory and the mature glass bulb production process technology to innovate and develop a new generation of LED filament bulbs for the benefit of the public. In the limited space of A60, the new technology of driving LED lamp bead with high voltage and small current, designing four 1W filament string LED bulbs, the illumination can reach 400LM-520LM, which is equivalent to 40W incandescent lamp brightness, and continuously lighting At 8 hours, the peripheral temperature of the glass bulb can be below 35 °C. Produce a new light source for non-scaling, safe and durable LED bulbs.
For example, in the A60 bulb, increase the brightness by increasing the number of filaments, such as 6 or 8. Since the effective heat dissipation space is not increased, the filament heat dissipation is not smooth, the heat in the bulb is accumulated, and the temperature of the glass bulb rises rapidly, so the LED light The decline will occur early. The original intention of the æ‚– filament lamp.
With the continuous innovation of LED lighting technology, the technology of LED filament lamp will have a leap forward. The innovative products of LED filament lamp will emerge in an endless stream. LED filament lamp is more and more popular in the world market. The output of LED filament lamp will inevitably turn to the blue ocean.
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