石墨烯導熱材料內(nèi)嵌高壓線性模組一體成型工藝——2018神燈獎申報技術(shù)

項目名稱：石墨烯導熱材料內(nèi)嵌高壓線性模組一體成型工藝 

Integrated molding technology of AC LED in graphene thermal conductive material.

申報單位：中山德誠智造光電有限公司
Declaration Unit :Zhongshan DC Design Photoelectric Co.,LTD

綜合介紹或申報理由：
Consolidated Presentation or Declaration of Reasons:

石墨烯新材料與DOB (Driver-On-Board)光源一體化成型工藝，響應(yīng)國家《中國智造2025》通過高新技術(shù)改造傳統(tǒng)產(chǎn)業(yè)政策，采用機械手改造生產(chǎn)設(shè)備，實現(xiàn)生產(chǎn)制造自動化、標準化、流程化，簡化了工藝，如鋁基板同燈體用螺絲固定的工藝（打螺絲）、鋁基板與散熱器涂導熱膠的工序，相比傳統(tǒng)導熱膠涂抹不均勻?qū)е庐a(chǎn)品壽命下降，新的工藝使鋁基板同燈體無縫結(jié)合，減少了熱阻更好將熱傳導至散熱器，從而提升產(chǎn)品的一致性和可靠性，更適合自動化生產(chǎn)，提升生產(chǎn)效率。

The new graphene material and ODB light source new integrated molding process are in response to the traditional industrial policy of "Made in China 2025" . That is through the reform of the traditional industrial policy of high and new technology, the mechanical hand is used to transform the production equipment to realize the automation, standardization and process of production and manufacturing, and the process is simplified.Such as the process of fixing the aluminum substrate with the same lamp body with screws (screwing, the process of coating heat conductive glue between the aluminum substrate and the radiator), which results in a decrease in product life compared with the traditional thermal conductive adhesive.The new process can make aluminum substrate and lamp body seamlessly combine, reduce thermal resistance to heat transfer to the radiator better, thus improve the consistency and reliability of the product, more suitable for automatic production, improve production efficiency.

主要技術(shù)參數(shù)：
Main Technical Parameters :

1、鋁基板導熱率>2.0 W/m.K

2、鋁基板厚度>1.5mm

3、石墨烯導熱率>2.0 W/m.K

4、石墨烯材料耐壓>10000v

5、鋁基板耐壓>2000v

6、耐高低溫：-40℃~100℃

7、支持最大200w燈具的制造生產(chǎn)

1.Thermal conductivity of aluminum substrate > 2.0 W/m.K
2.Aluminum substrate thickness > 1.5mm
3.Graphene thermal conductivity > 2.0 W/m.K
4.Graphene material, pressure resistance > 10000v
5.Aluminium substrate voltage > 2000v
6.Resistant to high and low temperatures-40 to 100)
7. Support the manufacture and production of 200w lamps

與國內(nèi)外同類產(chǎn)品或同類技術(shù)的比較情況：
Comparison with Similar Products or Technologies at Home and Abroad:

一、前瞻性：
1、人工組裝到設(shè)備自動化，符合國際工業(yè)4.0和智能制造2025，從低端數(shù)量到高效質(zhì)量的國家策略。
2、一體化成型（自動化）：簡化了工藝，如鋁基板同燈體用螺絲固定的工藝（打螺絲）、鋁基板與散熱器涂導熱膠的工序，相比傳統(tǒng)導熱膠涂抹不均勻?qū)е庐a(chǎn)品壽命下降，新的工藝使鋁基板同燈體無縫結(jié)合，減少了熱阻更好將熱傳導至散熱器，從而提升產(chǎn)品的一致性和可靠性，更適合自動化生產(chǎn)，提升生產(chǎn)效率。
3、石墨烯國內(nèi)外積極探索的新材料，它的特性...，以后會有廣泛的社會應(yīng)用。
4、線性方案簡化了結(jié)構(gòu)降低了成本，而且提高了產(chǎn)品的穩(wěn)定性與壽命，最近幾年隨著飛利浦、歐司朗等廠家的改良與應(yīng)用，市場應(yīng)用增長速度非?？?，將是燈具應(yīng)用主流方案之一。

1、Prospective:
1. Manual assembly to equipment automation, in line with international industrial 4.0 and intelligent manufacturing 2025, from low end quantity to efficient quality national strategy.
2. Integrated molding (automation: simplified process, such as the process of fixing the aluminum substrate with the screw of the lamp body (the process of tapping the screw, the process of coating the heat conductive adhesive between the aluminum substrate and the radiator), the uneven application of the heat conductive adhesive to the traditional heat conduction adhesive results in a decrease in the product life.The new process can make aluminum substrate and lamp body seamlessly combine, reduce thermal resistance to heat transfer to the radiator better, thus improve the consistency and reliability of the product, more suitable for automatic production, improve production efficiency.
3. Graphene is a new material which has been actively explored at home and abroad, and its characteristics will be widely used in society in the future.
4. The linear scheme simplifies the structure, reduces the cost, and improves the stability and life of the product. In recent years, with the improvement and application of Philips, Osram and other manufacturers, the market application has grown very fast.Will be one of the mainstream applications of lamps and lanterns.

二、重大創(chuàng)新、行業(yè)領(lǐng)先：
2、Major Inovation, Industry Leading:

石墨烯+高壓線性方案+一體制程工藝

Graphene + High-voltage linear scheme+Integrated process technology

經(jīng)濟評價分析：
Economic evaluation analysis:

一、經(jīng)濟性分析：
1. Economic analysis:
1、相比傳統(tǒng)燈具壓鑄工藝提高了50%的生產(chǎn)效率，節(jié)省了零配件存儲空間，從而減少了中間物流周轉(zhuǎn)成本。
2、整燈更輕薄，運輸費節(jié)省60%。
3、跟金屬散熱器相比，電源部分節(jié)省成本10%，材料比重輕節(jié)省10%，機加工及表面處理節(jié)省25%，人工組裝節(jié)省5%，運輸費相比整燈成本節(jié)省2%，綜合成本節(jié)省40%以上。

1.Compared with the traditional die-casting process, the production efficiency is increased by 50%, the storage space of spare parts is saved, and the turnover cost of intermediate logistics is reduced.
2.The whole light is lighter, transportation cost savings of 60%.
3.Compared with the metal radiator, the power supply part saves 10%, the material proportion is light and 10%, the machining and surface treatment save 25%, the manual assembly saves 5%, the transportation cost saves 2% compared with the whole lamp cost, and the comprehensive cost savings more than 40%.

二、投資回報
2. Return of investment
1、按1萬個投光燈計算，傳統(tǒng)生產(chǎn)周期35天，一體化工藝周期15天，縮短了60%的生產(chǎn)時間。
2、按1萬個投光燈計算，傳統(tǒng)制程需1000工時，一體化工藝500工時，節(jié)省了50%的工時效率。
3、對比金屬燈具外殼整體成本降低40%，很有競爭力。

1.The traditional production cycle is 35 days, the integrated process production period is 15 days, and the production time is reduced by 60%.
2.The traditional process needs 1000 man-hours, and the integrated process only needs 500-man-hour, which saves 50% man-hour efficiency.
3.Compared with the overall cost of metal lamps, reduce the cost of 40 parts, very competitive.

三、其他收益
3. Other Income
1、整個產(chǎn)線都符合國家環(huán)境評估認證要求，安全無污染。

1. The whole production line meets the requirements of national environmental assessment and certification , and is safe and pollution - free .

技術(shù)及工藝創(chuàng)新要點：
Key points of Technological and Technological Innovation:

一、技術(shù)創(chuàng)新點：
Technological Innovation Point
1、簡化了工序。
2、燈板焊錫溫度240-260°，注塑280-300°，通過超導技術(shù)，瞬間降溫，通過循環(huán)冷卻系統(tǒng)保持模具溫度恒定，不會傷及燈珠及元器件，解決了注塑高溫融化LED燈板上燈珠及IC的問題。
3、模具抗靜電技術(shù)，生產(chǎn)過程中不會傷及LED燈珠及IC。
4、石墨烯與燈板的無縫銜接，在實用效果上降低了成本及人工，對戶外及室內(nèi)燈具的結(jié)構(gòu)實現(xiàn)了重大的變革。

1. The working procedure is simplified.
2. The solder temperature of lamp plate is 240-260 °, injection molding 280-300 °, through superconducting technology, instant cooling, through the circulation cooling system to keep the mold temperature constant, will not hurt the lamp bead and components, solved the problem of melting lamp bead and IC on LED lamp board at high temperature.
3. Mold antistatic technology, production process will not hurt the LED lamp beads and IC.
4. The seamless connection between graphene and lamp board reduces the cost and labor in practical effect, and makes great changes to the structure of outdoor and indoor lamps and lanterns.

二、設(shè)計創(chuàng)新點
Design Innovation Point
1、基于此工藝，可大范圍、高效率的應(yīng)用在路燈、投光燈、筒燈等室內(nèi)外產(chǎn)品。
2、設(shè)計上可簡化電源腔體，使整燈更加輕薄、簡潔，造型可以更美觀。
3、目前在室內(nèi)外產(chǎn)品制程過程中，一體成型工藝算行業(yè)首家，具有較強的獨創(chuàng)性與技術(shù)領(lǐng)先優(yōu)勢。
4、相比市場塑包鋁工藝，去掉了埋入導熱鋁件，降低20%左右成本，提高了50%的生產(chǎn)制程效率。

1.Based on this process, can be used in a wide range of high-efficiency in street lamps, lighting, downlight and other indoor and outdoor products.
2.The design can simplify the power cavity, make the whole light more light, concise, the shape can be more beautiful.
3.At present, in the process of indoor and outdoor products, the integrated molding process calculation industry is the first, with strong originality and technology leading advantage.
4. Compared with the plastic coated aluminum process in the market, the embedded heat conduction aluminum parts are removed, the cost is reduced by about 20%, and the production process efficiency is improved by 50%.

三、其他創(chuàng)新點
Other Innovations
1、新工藝的改良，充當了橋梁，有效的把石墨烯新材料與IC方案整合到了一起，實現(xiàn)成本雙降，使整燈成本下降40%。
2、相比金屬制成工藝，減化了五金加工、拋光、表面處理、來運運輸、焊線、涂散熱膠水、打螺絲等低效的人工作業(yè)工序，生產(chǎn)效率提升了300%，還有效的避免了各流通環(huán)節(jié)產(chǎn)品不良率的產(chǎn)生。

1. The improvement of the new technology acts as a bridge, effectively integrates the new graphene materials with the IC scheme, realizes double cost reduction, and reduces the whole lamp cost by 40%.
2.Compared with the metal-making process, the metal processing, polishing, surface treatment, transportation, welding wire, spreading heat glue, screwing and other inefficient manual working procedures,Production efficiency has been increased by 300, but also effectively to avoid the production of various circulation links of the product defect rate.

實際運用案例和用戶評價意見：
Practical Application Cases and User Evaluation

一、技術(shù)獨立性
Technical Independence

1、解決了280-300°高溫瞬間融化燈板和燈珠的問題。
2、解決了燈板10000V以上絕緣問題。
3、鋁基板導熱率2.0 W/m.K，石墨烯導熱率2.0W/m.K，熱傳導率一致，燈珠的熱量能直接傳導至散熱器，中間沒有損耗。
4、工藝設(shè)計解決了燈板與外殼分離的問題。

1.To solve the 280-300 degree high temperature melted the lamp panel and the lamp beads.
2.The problem of insulation over 10000V of lamp board is solved.
3, Aluminum plate thermal conductivity of 2 W/m.K, 2 W/m.K graphene thermal conductivity, thermal conductivity, heat lamp can directly transfer to the radiator, there is no loss.
4, The process design solves the problem of separation between the lamp plate and the shell.

二、技術(shù)可行性
Technical Feasibility
1、一體化工藝已成熟，相比市場注塑工藝大幅提升了制程效率，目前已量產(chǎn)了投光燈、筒燈、路燈等系列化產(chǎn)品。

1. The integrated technology has matured, compared with the market injection molding technology has greatly improved the efficiency of the process, has produced a series of light, downlight, street lamps and other serialized products.

三、應(yīng)用案例及用戶評價
Application Case and User Evaluation
1、惠州西頓照明應(yīng)用一體成型工藝開發(fā)一系列筒燈系列產(chǎn)品。
2、30W-100W石墨烯投光燈量產(chǎn)應(yīng)用。

1.Huizhou CDN industrial company apply integrated molding process to develop a series of downlight products.
2.Production and application of 30 W-100 W graphene lamp.

獲獎、專利情況：
Awards, Patents:

一、專利情況：
Patent Situation

國家發(fā)明專利受理通知書 
National invention patent

二、獲獎情況
Award-winning Situation
質(zhì)檢報告：高低溫開裂、熱成像->散熱（待補充測試報告圖片）
Quality inspection report: cracking at high and low temperature, thermal imaging-> heat dissipation (photo of test report to be supplemented)

申報單位介紹：

本公司專業(yè)從事LED燈具外殼生產(chǎn)的廠家。業(yè)務(wù)包括產(chǎn)品設(shè)計，模具開發(fā)，配件生產(chǎn)和裝配等環(huán)節(jié) Zhongshan DC Design Photoelectric CO., LTD is a manufacturer engaged in the production of LED lamps shell sets. The business includes product design, mold development, spare parts production and assembly.

產(chǎn)品圖片：