Abstract : This paper analyzes the application market environment of high-power LED and the status quo of packaging industry, reviews the development process of high-power LED packaging technology, points out the problems that need to be solved in the industrialization of high-power LED packaging, and discusses the evaluation criteria of industrialization of high-power LED packaging. And the solution to the problem of packaging industrialization.
First, the power LED application market environment
1. High-power LEDs are widely optimistic as a new generation of alternative light sources. The application market has broad prospects and great potential. (Special lighting, auxiliary lighting, general lighting)
2. The size of the existing market is not as large as imagined. The actual domestic consumption does not exceed 5 KK/month, and the growth of market demand is not as fast as imagined.
3, mature application products are not many, engineering applications are mostly, the variety is complex, the market demand is unstable.
4, the application technology is uneven, heat dissipation, drive, light distribution and system reliability technology need to be improved and mature, and application technology needs to be standardized.
5. The lack of professional and technical talents in semiconductor lighting applications, designing application products and using high-power LEDs with the understanding of traditional light sources.
6. The adverse effects caused by the early non-standard application need to be eliminated.
Second, the status quo of high-power LED packaging industry
1. Short development time. From research and development to production, most manufacturers only have one to two years, and the longest is no more than five years.
2. Many manufacturers, small scale, low automation and low technical level. Most manufacturers stay below 50K, mainly in manual/semi-automatic operation; there are only a handful of domestic factories with high degree of automation, relatively mature technology and actual output of 500K/month.
3, product variety blooms, there is no standardized, recognized mainstream products.
4. Lack of professional and technical talents, slow progress in research and development, product design and technology flow in imitation plagiarism, lack of independent research and development and core patent technology.
5, product quality is uneven, low cost performance, there is no uniform inspection standard.
6. The market competition is extremely fierce. In addition to the mutual killing between domestic factories, they have been repeatedly suppressed by powerful foreign brands and foreign-funded factories.
Third, review of high-power LED packaging technology
1. Product form:
2. Input power: 0.5W→1W→3W→5W→10W→20W→30W→100W→200W......
3, chip combination: single chip → multi-chip combination integration
4, lens package:
5, solid crystal process: silver glue baking → metal eutectic
6. Production and testing equipment:
Manual operation→Semi-automatic operation→Full-automatic operation At present, the equipment for automatic solid crystal and wire bonding is relatively mature, and the automation equipment for phosphor coating, flexible optical silicone potting, soft optical silicone molding, inspection and binning and packaging To be developed and mature.
four. Urgent problems in the industrialization of high-power LED packaging
1. Establish product technology and testing standards;
2. Improve product design and form mainstream products;
3. Strengthen technology research and development to form core patents;
4. Improve process technology and stabilize product quality;
5. Develop special automation equipment for high-power LED packaging to improve efficiency and stable quality;
6. Rapid assessment of reliability and light decay life;
7, application technical support.
Fives. Judging the industrialization of high-power LED packaging
1. Product standardization
2. Technology patenting
3, equipment automation
4, production scale
5, the process is simplified
6, management standardization
7, the highest efficiency
8, quality stabilization
9, performance optimization
10, the cost is minimized
Stabilization of quality, optimization of performance and minimization of cost are the ultimate goal of industrialized production of high-power LED packaging; product standardization and equipment automation are the basis for achieving this goal; production scale and process simplification are means to achieve the goal; Patentization, standardized management and maximum efficiency are the fundamental guarantees for achieving the goal.
six. Solution to the problem of industrialization of high-power LED packaging
1. Work together to establish a unified and perfect product technology and testing standards.
1. Basis for standards: application requirements, technical level, and international standards
2. Formulation of standards: government promotion, institutional leadership, and industry participation
3. Implementation of standards: government promotion, agency supervision, and industry implementation
4. Improvement of standards: industry feedback, institutional evaluation, and timely update
2. Do product design, evade patents, and build mainstream products.
1. Design basis: application requirements, technical standards, and technical level
2. Evaluation of design: standardization, patenting, reliability, mainstreaming, practicalization, and simplification
3, the design is perfect: to meet the application needs, convenient mass production, cost-effective
3. Carefully select materials to provide the best material security for industrial production.
1. Basis for selection: design requirements
2. Evaluation of selection: performance quality, reliability, applicability, cost performance, patent avoidance, procurement difficulty 3. Selection of selection: meeting design requirements and applicable mass production
4. Purchase appropriate equipment and equipment to equip the necessary hardware conditions for high-quality, efficient and smooth industrial production.
1. Determination of requirements: process requirements, product performance requirements
2, selection and development: first select the general, re-development
3. Evaluation of equipment: applicability, accuracy, stability, versatility, productivity, cost performance
5, constantly improve the process technology, simplify the process, and strictly control the process conditions.
1. Process technology: maturity and simplification 2. Simplified process: shortest, anti-sluggish 3. Process effect: stable, reproducible
6. Strengthen the online control of key parameters of products and improve the yield of products.
The value of high-power LED is high, and the distribution range of key parameters (such as color temperature, color coordinates, etc.) directly affects the batch yield and cost of the product. When designing products, making process arrangements, and purchasing equipment, you must consider how to implement online control of key parameters of the product.
7. Rigorously and systematically do a good job in product reliability engineering.
1. Carefully plan the reliability engineering of the product, from product design to product application, each stage and every link must be considered in accordance with the requirements of product reliability;
2. Strictly implement each key point of the product reliability project, and carry out continuous improvement and improvement based on the test results and application feedback;
3, the main considerations of product reliability engineering: anti-attenuation, anti-radiation, anti-shock, anti-aging, anti-corrosion, anti-static, temperature resistance, stress resistance, firmness, sealing (product design, material selection, manufacturing Process, product application) ......
8. Do a good job in testing and screening products to ensure that the performance and quality of the products meet the requirements of customers.
1. Formulate standards for product testing and screening: product technical standards and customer requirements;
2. Control, calibration, use and maintenance of instruments and equipment;
3. Continuous monitoring, strengthen communication, pay attention to feedback, and constantly improve.
9. Do a good job in the planning and implementation of quality engineering so that the products are in an effective quality management state from beginning to end.
10. Improve production efficiency and strengthen cost management.
Seven. Conclusion
In China, the industrialization of high-power LED packaging is still in its infancy, and there are many problems to be studied. There are many difficulties waiting for us to overcome. In my opinion, the establishment of standards, the formation of mainstream products, the possession of core intellectual property rights, the development of specialized automation equipment and the maturity of process technology are issues that need to be solved before us. As an industrial person, I have raised these issues today to explore and aim to attract more attention from relevant parties, so as to overcome difficulties together, to truly realize the industrial production of high-power LED packaging, and to work hard for the bright future of semiconductor lighting. Win-win!
About the author :
Yan Xiaoming graduated from the Physics Department of Wuhan University in 1987. He was the general manager of Zhuhai Guohua Electronics Factory Co., Ltd., the general manager of Zhuhai Lifeng Optoelectronic Industry Co., Ltd., and the technical director of Shenzhen Quantum Optoelectronics Co., Ltd. The current Guangzhou Hongli Opto-electronic Technology Co., Ltd. Director, National Semiconductor Lighting Project 863 experts storehouse. Engaged in the research and development and technical management of LED packaging for nearly 20 years, with solid theoretical foundation and rich practical experience. In recent years, he has published many technical papers on LED packaging.
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