ED lighting production requires high precision, but many manufacturers make their lights on basic assembly lines. We strictly regulate and monitor all processing steps in our manufacturing system. We also have a full set of equipment designated for production and quality control. Our rigorous standards keep our rejections down to 0.0001%.
To attach an LED chip to the contact pad of the lead frame in the package, we coat a round wafer to create a semiconductor, the “heart” of a blue LED. We then slice the wafer into small rectangles. We only use red copper frames and Taiwan Epistar InGaN wafer chips. Other suppliers may use iron brackets to save money, but those brackets will oxidize, shortening the life of the lamp bead.
This process provides the electrical connection between the LED chip and lead frame. We use industrial gold, 99.9999% pure, for its strength, conductivity, and rust resistance, ensuring a long life for the connection.
3Integrating-Sphere Spectral Measurement
We use integrating-sphere photometers to measure the luminous flux and total spectral parameters of the packaged LED. Our engineers must confirm that the light color matches production requirements before moving to the next step.
4Phosphor Coating And Encapsulation
Once the color matches production requirements, we begin phosphor coating, using American Intematix phosphor for SMD packages. After that, we add a protective layer of glue to prevent contamination of the LED. Myledy’s chemical mixture also eliminates UV damage to extend LED life if used outdoors.
Next the LED goes in an oven at 80 ºC (±5 ºC) with a relative humidity of 10% for two hours to seal the LED’s protective layer. After that, we heat it to 150 ºC to stabilize and shape the package.
We always test our LEDs and sort them into specific color bins to guarantee consistent light quality. Our production line removes all LEDs that fall outside the MacAdam ellipse.
7Moisture Proof Packing
To prevent moisture absorption during transportation and storage, we pack the LEDs in moisture barrier bags, along with desiccants and humidity indicators for secondary protection.
We use double-sided PCBs (printed circuit boards) to produce the electronic circuits where we mount the LEDs. During this process, we print the production date on the back of the PCB for easy reference in case of future issues. This step allows us to provide our 5-year warranty.
Here a solder paste attaches the LED to the PCB. Then we heat the entire assembly to melt the solder and permanently connect the joint.
10Preliminary Product Inspection
Our quality-control department conducts a detailed visual inspection of the ribbon, searching for defects.
We solder our 0.5M PCBs to 5-m strips by machine. However, we can do customized lengths on request. We use flat 2468 20 AWG red/black cable 350 mm long, soldered at both ends. We can do customized cable lengths as well.
All semi-finished strips undergo eight hours of continuous life testing to ensure each LED runs in good condition.
For potentially damp areas such as bathrooms and kitchens, we use silicon glue on all IP62 strips. This glue can withstand temperatures from -50 to 300 degrees and resist hardening and yellowing. It’s odorless and toxin-free, plus it protects against corruption and corrosion. Some suppliers use PU glue and epoxy resin, but these unstable chemicals smell bad and turn yellow.
For damp or outdoor areas with no water immersion, we use silicone sleeves on our IP65 strips. Some suppliers claim their silicone sleeves as IP66, but the actual level should be IP65.
15Life Testing On Waterproof Strips
For all waterproof strips, from IP62 to IP68, we test their life again after adding the silicone.
All of our IP20/IP62/IP65/IP68 strips have 3M tape attached to provide easy installation for the end consumer.
17Complete Product Inspection
Our quality-control department will perform a final check on every strip reel to ensure consistent light color as well as good appearance.