Device and method for pressure-molding anti-overheating CSP fluorescent membrane

Abstract

Disclosed are a device and a method for pressure-molding an anti-overheating CSP fluorescent membrane. The device comprises a frame, a mould pressing device, a force measuring device, a control device and a feeding device; and the mould pressing device comprises an upper pressing mould, an upper clamp, a lower pressing mould, a guide post, an elastic supporting structure, and a lower clamp. As the stage of pressing the elastic supporting structure is added to the course of pressure molding, a mould clamping force of the pressure molding increases in a relatively steady way, and a force impact of a mould clamping device is reduced, thereby easily determining an initial point for maintain temperature of the pressure molding. The present invention effectively prevents overheating caused by long-term and large-area contact between the lower clamp and the heating lower pressing mould, and avoids the process defect of premature melting of the fluorescent membrane due to overheating, thereby greatly improving the product consistency and yield rate of the CSP-package fluorescent membrane in the pressure molding process.

Claims

1. A method of a device for pressure-molding an anti-overheating CSP fluorescent membrane, the device including a lower pressing mould heating device (7), a force measuring device (14), a feeding device (16) and a mould pressing device (13), the mould pressing device (13) having an upper pressing mould, a lower pressing mould and a lower clamp (5), the upper pressing mould having an upper pressing mould body (1) and an upper pressing mould heating device (2), the lower pressing mould having a lower pressing mould body (6), the method comprising the steps of: step 1: starting the upper pressing mould heating device (2) and the lower pressing mould heating device (7) to preheat the upper pressing mould body (1) and the lower pressing mould body (6); step 2: clamping an LED chip into an upper surface of the lower clamp (5) and placing a fluorescent membrane above the LED chip at the same time; step 3: controlling, by the feeding device (16), only the upper pressing mould to move downward or only the lower pressing mould to move upward, so that the upper pressing mould and the lower pressing mould get close to each other, and measuring, by the force measuring device (14), a mould clamping force in real time; step 4: maintaining a mould clamping state, pressurizing the feeding device (16) until the mould clamping force measured in real time has a second inflection point, warming up the upper pressing mould body (1) and the lower pressing mould body (6) simultaneously through the heating devices, and maintaining the temperature and pressure; and step 5: controlling, by the feeding device (16), the upper pressing mould and the lower pressing mould to separate, and taking down the moulded LED chip to complete pressure molding.

2. The method for pressure-molding the anti-overheating CSP fluorescent membrane according to claim 1, wherein in the step 1, the preheating is to preheat and maintain the temperature at 78-82 C.

3. The method for pressure-molding the anti-overheating CSP fluorescent membrane according to claim 1, wherein in the step 3, a feeding speed for only the upper pressing mould to move downward or only the lower pressing mould to move upward is controlled as 5-10 cm/s.

4. The method for pressure-molding the anti-overheating CSP fluorescent membrane according to claim 1, wherein the mould clamping force measured by the force measuring device (14) in real time has two inflection points, and a stage from mould clamping to a first inflection point is an air compressing stage; a stage from the first inflection point to the second inflection point is a stage of pressure-molding an elastic supporting structure; a stage from the second inflection point to the end of pressure molding is a stage of pressure-molding the fluorescent membrane; and the second inflection point is an initial point for warming, and the temperature after warming is a temperature for the fluorescent membrane to melt and flow.

5. The method for pressure-molding the anti-overheating CSP fluorescent membrane according to claim 1, wherein in the step 4, the pressurizing is to pressurize the pressure to 1000-2000 Pa; the warming is to warm the temperature to 118-122 C.; and the maintaining the temperature and pressure lasts for 2-3 minutes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic diagram of a device for pressure-molding an anti-overheating CSP fluorescent membrane of the present invention;

(2) FIG. 2 is a schematic diagram illustrating a mould pressing device clamped with an LED chip and a fluorescent membrane in the device of the present invention;

(3) FIG. 3a is a schematic diagram illustrating that an upper clamp and a lower clamp in the device of the present invention are positioned by inclined planes at two ends of the clamps;

(4) FIG. 3b is a schematic diagram illustrating that the upper clamp and the lower clamp in the device of the present invention are positioned by mounting the two ends of the clamps in minitype guide posts;

(5) FIG. 4a is a schematic diagram illustrating that an elastic supporting structure in the device of the present invention is a spring;

(6) FIG. 4b is a schematic diagram illustrating that the elastic supporting structure in the device of the present invention is a spring slider;

(7) FIG. 4c is a schematic diagram illustrating that the elastic supporting structure in the device of the present invention is a curved plate spring;

(8) FIG. 4d is a schematic diagram illustrating that the elastic supporting structure in the device of the present invention is a folded plate spring;

(9) FIG. 5a is a schematic diagram illustrating an air compressing stage in the course of pressure molding of the device of the present invention;

(10) FIG. 5b is a schematic diagram illustrating a stage of pressure-molding the elastic supporting structure in the course of pressure molding of the device of the present invention; and

(11) FIG. 5c is a schematic diagram illustrating a stage of pressure-molding the fluorescent membrane in the course of pressure molding of the device of the present invention.

DESCRIPTION OF THE EMBODIMENTS

(12) The invention will be further described in detail hereinafter with reference to the specific embodiments, but the invention is not limited to the following embodiments.

(13) FIG. 1 is a schematic diagram of a device for pressure-molding an anti-overheating CSP fluorescent membrane according to the present invention, comprising a frame 12, a mould pressing device 13, a force measuring device 14, a control device 15 and a feeding device 16. The mould pressing device 13 is disposed in the frame 12, the force measuring device 14 is disposed at a bottom of the mould pressing device 13, and the force measuring device 14 is used to measure a clamping force when the moulds are clamped. The control device 15 and the feeding device 16 are disposed outside the frame 12; the force measuring device 14 is implemented by using a force sensor and a capture card; the feeding device 16 is implemented by a motor screw drive, a pneumatic drive or a hydraulic drive; and the control device 15 is implemented by a closed loop servo-control system and an industrial computer.

(14) The mould pressing device 13 comprises an upper pressing mould, an upper clamp 3, a lower pressing mould, a guide post 4, an elastic supporting structure 10, and a lower clamp 5. FIG. 2 is a schematic diagram illustrating that the mould pressing device 13 is clamped with a LED chip 9 and a fluorescent membrane 8. The LED chip 9 is clamped into an upper surface of the lower clamp 5, and the fluorescent membrane 8 is placed above the LED chip 9.

(15) The upper pressing mould comprises an upper pressing mould body 1 and an upper pressing mould heating device 2. The lower pressing mould comprises a lower pressing mould body 6 and a lower pressing mould heating device 7. The upper pressing mould heating device 2 is disposed in the upper pressing mould body 1, and heats the upper pressing mould body 1 during pressure molding. The lower pressing mould heating device 7 is disposed in the lower pressing mould body 6, and heats the lower pressing mould body 6 during pressure molding.

(16) The upper clamp 3 is fixed in a lateral surface of the upper pressing mould body 1 close to the lower clamp 5. The lower clamp 5 and the lower pressing mould body 6 are connected by the elastic supporting structure 10. When the moulds are not clamped, the elastic supporting structure is not subjected to a mould clamping force, and a bottom surface of the lower clamp is separated from an upper surface of the lower pressing mould body 6. When the moulds are clamped, the elastic supporting structure is subjected to the mould clamping force, and shrinks and deforms, so that the bottom surface of the lower clamp is contacted with the upper surface of the lower pressing mould body 6. The upper surface of the lower clamp 5 is a smooth surface.

(17) The upper pressing mould and the lower pressing mould are mounted at the guide post 4, and by means of controlling the feeding device, the upper pressing mould or the lower pressing mould moves on the guide post 4 and the clamped or separated moulds are precisely positioned. When the moulds are not clamped, the upper pressing mould and the lower pressing mould are in a separated state.

(18) The upper clamp 3 and the lower clamp 5 are precisely positioned by correspondingly complementary inclined planes at two ends of the clamps or by mounting the two ends of the clamps in minitype guide posts. FIG. 3a is a schematic diagram illustrating that the upper clamp and the lower clamp are positioned by the inclined planes at two ends of the clamps. FIG. 3b is a schematic diagram illustrating that the upper clamp and the lower clamp are positioned by mounting the two ends of the clamps in the minitype guide posts.

(19) The bottom surface of the lower clamp 5 is separated from the upper surface of the lower pressing mould body 6 by 1-10 mm when the moulds are not clamped. A contact area of the bottom surface of the lower clamp and the upper surface of the lower pressing mould body 6 is greater than 90% of an area of a lower bottom surface of the lower clamp 5 when the moulds are clamped.

(20) Contact of the elastic supporting structure 10 connected to the lower clamp 5 is point contact or line contact, and a contact area is no more than 5% of an area of the upper surface of the lower pressing mould body 6 lower clamp 5. Contact of the elastic supporting structure 10 connected to the lower pressing mould body 6 is point contact or line contact, and a contact area is no more than 5% of the area of the upper surface of the lower pressing mould body 6.

(21) The elastic supporting structure 10 is a helical spring, a spring leaf, an element having elasticity or a device having elasticity. FIGS. 4a to 4d are schematic diagrams illustrating that the elastic supporting structure is a spring, a spring slider, a curved plate spring and a folded plate spring respectively. The elastic supporting structure 10 has a stiffness of more than 1000 N/cm perpendicular to a pressure-molding direction, and a stiffness of 10-25 N/cm along the pressure-molding direction, and change values of the stiffness in the two directions do not exceed 5% when a temperature change range is less than 120 C.

Embodiment 1

(22) In the device used in this embodiment, an elastic supporting structure is a spring leaf, and the spring leaf has a stiffness of 10 N/cm along a pressure-molding direction. A contact of the spring leaf connected to a lower clamp 5 is line contact, and a contact area is 3% of an area of an upper surface of the lower clamp 5. A contact of the spring leaf connected to the lower pressing mould body 6 is line contact, and a contact area is 3% of the area of the upper surface of the lower pressing mould body 6. A contact area of the bottom surface of the lower clamp 5 and the upper surface of the lower pressing mould body 6 is greater than 95% of an area of a lower bottom surface of the lower clamp 5 when the moulds are clamped.

(23) The device for pressure-molding an anti-overheating CSP fluorescent membrane described above is adopted to mould a CSP fluorescent membrane.

(24) (1) Upper pressing mould and lower pressing mould heating devices are started to preheat the pressing moulds, and a temperature is maintained at 78 C.

(25) (2) The upper clamp 3 and the lower clamp 5 are controlled to be separated by the feeding device 16, and the lower clamp 5 and the lower pressing mould body 6 are separated by 1 mm through the elastic supporting structure.

(26) (3) A LED chip 9 is clamped into the upper surface of the lower clamp 5 and a fluorescent membrane 8 is placed above the LED chip 9 at the same time.

(27) (4) The feeding device 16 controls only the upper pressing mould to move downward, so that the upper pressing mould and the lower pressing mould get close to each other, wherein a feeding speed for only the upper pressing mould to move downward is controlled as 5 cm/s; and meanwhile, the force measuring device 14 measures a mould clamping force in real time.

(28) (5) The upper clamp 3 gets close to the lower clamp 5, and a process is as shown in FIG. 5a. The upper clamp 3 is contacted with the fluorescent membrane 8, and starts squeezing the lower clamp 5, and a process is as shown in FIG. 5b. The mould clamping force has a first inflection point, the elastic supporting structure 10 is constantly compressed, and the bottom surface of the lower clamp 5 gets constantly close to the upper surface of the heating lower pressing mould body 6.

(29) (6) The bottom surface of the lower clamp 5 is contacted with the upper surface of the heating lower pressing mould body 6, and a process is as shown in FIG. 5c. The mould clamping force has a second inflection point, and the feeding device 16 is pressurized to 1000 Pa.

(30) (7) When the second inflection point of the mould clamping force occurs, temperature of the upper pressing mould and the lower pressing mould is raised to 118 C., and the temperature and pressure are maintained for 2 minutes. The feeding device 16 controls the upper pressing mould and the lower pressing mould to separate and the moulded LED chip is taken down to complete the pressure molding procedure.

(31) The CSP product with the fluorescent membrane obtained by pressure molding has uniform thickness, uniform phosphor concentration distribution, good spatial light color distribution, and no process defects caused by overheating of the fluorescent membrane.

Embodiment 2

(32) In the device used in this embodiment, an elastic supporting structure is a spring leaf, and the spring leaf has a stiffness of 25 N/cm along a pressure-molding direction. A contact of the spring leaf connected to a lower clamp 5 is line contact, and a contact area is 5% of an area of an upper surface of the lower clamp 5. A contact of the spring leaf connected to the lower pressing mould body 6 is line contact, and a contact area is 5% of the area of the upper surface of the lower pressing mould body 6. A contact area of the bottom surface of the lower clamp 5 and the upper surface of the lower pressing mould body 6 is greater than 90% of an area of a lower bottom surface of the lower clamp 5 when the moulds are clamped.

(33) The device for pressure-molding an anti-overheating CSP fluorescent membrane described above is adopted to mould a CSP fluorescent membrane.

(34) (1) Upper pressing mould and lower pressing mould heating devices are started to preheat the pressing moulds, and a temperature is maintained at 82 C.

(35) (2) The upper clamp 3 and the lower clamp 5 are controlled to be separated by the feeding device 16, and the lower clamp 5 and the lower pressing mould body 6 are separated by 10 mm through the elastic supporting structure.

(36) (3) A LED chip 9 is clamped into the upper surface of the lower clamp 5 and a fluorescent membrane 8 is placed above the LED chip 9 at the same time.

(37) (4) The feeding device 16 controls only the upper pressing mould to move downward, so that the upper pressing mould and the lower pressing mould get close to each other, wherein a feeding speed for only the upper pressing mould is controlled as 10 cm/s; and meanwhile, the force measuring device 14 measures a mould clamping force in real time.

(38) (5) The upper clamp 3 is close to the lower clamp 5, and a process is as shown in FIG. 5a. The upper clamp 3 is contacted with the fluorescent membrane 8, and starts squeezing the lower clamp 5, and a process is as shown in FIG. 5b. The mould clamping force has a first inflection point, the elastic supporting structure 10 is constantly compressed, and the bottom surface of the lower clamp 5 is constantly close to the upper surface of the heating lower pressing mould body 6.

(39) (6) The bottom surface of the lower clamp 5 is contacted with the upper surface of the heating lower pressing mould body 6, and a process is as shown in FIG. 5c. The mould clamping force has a second inflection point, and the feeding device 16 is pressurized to 2000 Pa.

(40) (7) When the second inflection point of the mould clamping force occurs, temperature of the upper pressing mould and the lower pressing mould is raised to 122 C., and the temperature and pressure are maintained for 3 minutes. The feeding device 16 controls the upper pressing mould and the lower pressing mould to separate and the moulded LED chip is taken down to complete the pressure molding procedure.

(41) The CSP product with the fluorescent membrane obtained by pressure molding has uniform thickness, uniform phosphor concentration distribution, good spatial light color distribution, and no process defects caused by overheating of the fluorescent membrane.

Embodiment 3

(42) In the device used in this embodiment, an elastic supporting structure is a spring leaf, and the spring leaf has a stiffness of 20 N/cm along a pressure-molding direction. A contact of the spring leaf connected to a lower clamp 5 is line contact, and a contact area is 5% of an area of an upper surface of the lower clamp 5. A contact of the spring leaf connected to the lower pressing mould body 6 is line contact, and a contact area is 5% of the area of the upper surface of the lower pressing mould body 6. A contact area of the bottom surface of the lower clamp 5 and the upper surface of the lower pressing mould body 6 is greater than 93% of an area of a lower bottom surface of the lower clamp 5 when the moulds are clamped.

(43) The device for pressure-molding an anti-overheating CSP fluorescent membrane described above is adopted to mould a CSP fluorescent membrane.

(44) (1) Upper pressing mould and lower pressing mould heating devices are started to preheat the pressing moulds, and a temperature is maintained at 80 C.

(45) (2) The upper clamp 3 and the lower clamp 5 are controlled to be separated by the feeding device 16, and the lower clamp 5 and the lower pressing mould body 6 are separated by 8 mm through the elastic supporting structure.

(46) (3) A LED chip 9 is clamped into the upper surface of the lower clamp 5 and a fluorescent membrane 8 is placed above the LED chip 9 at the same time.

(47) (4) The feeding device 16 controls only the lower pressing mould to move upward, so that the upper pressing mould and the lower pressing mould get close to each other, wherein a feeding speed for only the lower pressing mould is controlled as 8 cm/s; and meanwhile, the force measuring device 14 measures a mould clamping force in real time.

(48) (5) The upper clamp 3 is close to the lower clamp 5, and a process is as shown in FIG. 5a. The upper clamp 3 is contacted with the fluorescent membrane 8, and starts squeezing the lower clamp 5, and a process is as shown in FIG. 5b. The mould clamping force has a first inflection point, the elastic supporting structure 10 is constantly compressed, and the bottom surface of the lower clamp 5 is constantly close to the upper surface of the heating lower pressing mould body 6.

(49) (6) The bottom surface of the lower clamp 5 is contacted with the upper surface of the heating lower pressing mould body 6, and a process is as shown in FIG. 5c. The mould clamping force has a second inflection point, and the feeding device 16 is pressurized to 1800 Pa.

(50) (7) When the second inflection point of the mould clamping force occurs, temperature of the upper pressing mould and the lower pressing mould is raised to 120 C., and the temperature and pressure are maintained for 3 minutes. The feeding device 16 controls the upper pressing mould and the lower pressing mould to separate and the moulded LED chip is taken down to complete the pressure molding procedure.

(51) The CSP product with the fluorescent membrane obtained by pressure molding has uniform thickness, uniform phosphor concentration distribution, good spatial light color distribution, and no process defects caused by overheating of the fluorescent membrane.

(52) The present invention can be preferably implemented as described above.