The LED package refers to sealing the light-emitting chip in the package. Although China is already the world's largest producer of lighting appliances and the second largest exporter of lighting appliances, due to the lag in research and development, domestic LED lighting companies are almost following and introducing foreign packaging technologies, lacking independent innovation, and technology is subject to people, resulting in Low product quality, high cost and low profit margin.
Recently, the Haixi Research Institute of the Chinese Academy of Sciences (Fujian Institute of Construction, Chinese Academy of Sciences) announced the successful development of a kilowatt-class high-power LED lighting source. This technology with completely independent intellectual property rights replaces the current LED core material fluorescent glue with fluorescent ceramics and achieves major technology. Breakthrough, which will reconstruct the optoelectronic industry ecology.
In June of this year, at the 2016 Guangzhou International Lighting Exhibition, an LED light source with a power of 1000 watts became the focus of the exhibition: dozens of light source chips were packaged on a ceramic light-emitting surface with a diameter of only 5 cm. Whose masterpiece is this light source packaging technology?
It comes from the Haixi Research Institute of the Chinese Academy of Sciences. In 2013, in order to promote the industrialization of fluorescent ceramics, Fujian Institute of Science and Technology established the Fujian Zhongke Core Source Co., Ltd. with Fujian Capital, and became the only LED technology transfer base and industrialization platform of Haixi Research Institute. In January of this year, the institute used the self-developed fluorescent ceramic white light high-power packaging technology to solve the thermal management difficulties and packaging material failure problems that are common in LED high-power lighting.
It is reported that the current general use in the LED industry is fluorescent plastic packaging technology. When the power exceeds 200W, the LED light source density package will encounter a technical bottleneck - integrating more chips in a small light-emitting area is difficult to solve the problem of light source thermal management, so it is difficult to manufacture high-power LED lights. Even in the well-known Japanese companies with international leading level, the products can only achieve 200W or less, and the limit value does not exceed 500W. Therefore, the current LED lamp application is mainly limited to the general lighting field.
China's LED industry faces patent barriers
"Since 2003, we have begun to consider how to break through foreign patent barriers." Academician Hong Maoyu of the Fujian Institute of Physical Education of the Chinese Academy of Sciences said in an interview.
The patent barriers in Hongmao's mouthwash refer to the current technology and patents in the global LED field, and more than half of them are occupied by developed countries such as the United States, Japan and Germany. The world has formed a technological competition pattern with Japan's Nichia Chemical and Toyota Synthetic, the United States' Kerry and General Electric, and Germany's Osram as the core of the patent. They have deployed patent networks around the world, especially in China. China's LED industry is in a young stage, and the level of industrial technology is low.
Ye Shanghui, executive deputy general manager and technical director of Zhongke Core Source, said that at present, all kinds of light sources used in China's LED lamps use white light chip + fluorescent silicon solution to achieve white light. This technical solution is subject to foreign packaging technology patents. The export market is limited, and light fading is caused by the aging of fluorescent silica gel. "This leads to about 80% of China's LED products concentrated in the application market of landscape lighting, traffic lights, etc., and less involved in high-end products such as automotive lighting and large screens. The conventional product market is turning into the Red Sea. Therefore, China's LED industry needs to achieve long-term. Development must break through the layers of foreign patents." Ye Shanghui said.
In this context, Haixi Research Institute tried to break through the high-power LED light source packaging technology and change the status quo of China's LED industry built on the beach. According to reports, Zhongke Core Source has independent research and development of transparent fluorescent ceramic material sintering equipment, highly confidential formula, unique packaging technology, with complete independent intellectual property rights from equipment, formulation, to packaging technology. At present, this technology has completed 4 PCT applications, and more than 30 domestic invention patents have been granted global patent layout.
Independent research and development of kilowatt-class LED light source
How does the Hercynian Institute think of using ceramics as packaging materials?
"Our solid-state laser materials research has been leading the world. Inspired by laser materials research, we have thought of using laser ceramics as LED packaging materials." Hong Maozhen told reporters that since 2007, researchers have relied on the technical basis of laser ceramics. Process improvement enables transparent fluorescent ceramics to achieve superior thermal and luminescent properties.
Ye Shanghui told reporters that the ceramic packaging technology they developed has the characteristics of high thermal conductivity, high temperature resistance, corrosion resistance and good thermal shock resistance. Not only can the light source area be small, but also good heat dissipation. At present, Zhongke Core Source has become the world's first enterprise to produce 1000 watts of light source modules. This research and development has enabled LEDs to enter the high-power lighting market, thereby enabling full replacement of traditional lighting.
In the exhibition hall of Zhongke Core Source, the reporter saw the LED lamp that successfully packaged the 1000W light source. The area of ​​the whole light source chip is only a little larger than the 1 yuan coin. The 600W light source module produced by Zhongke Core Source has been used in Beijing 2018 Beijing Winter Olympics training venue lighting to replace the 2000W metal halide lamp.
Energy saving is a recognized feature of LED lighting products. High-power LED lighting products can also significantly reduce electricity consumption and carbon emissions, with an average power saving rate of about 70%. "Taking 300W transparent fluorescent ceramic package LED high bay light lamp instead of 1000W metal halide lamp as an example: 1000W metal halide lamp is about 2,000 yuan, the service life is about 1 year, and the price of LED lamp is calculated according to 2 times of metal halide lamp, ie 4000 yuan, and the life expectancy is at least 5 years. If you realize the replacement by using 10 hours per day, you can recover the cost in 1 year, and save 12,000 kilowatt hours in 5 years." Ye Shanghui said.
Stringing upstream and downstream to boost industry development
In order to speed up the application and promotion of this technology, Zhongke Core Source has joined the national upstream enterprises such as power supply, heat dissipation and contract energy management to form an industrial technology alliance to carry out collaborative innovation. At present, alliance manufacturers such as power supply and heat dissipation matched with high-power fluorescent ceramic LEDs have developed corresponding products, and the industry alliance has begun to export complete product technology solutions to downstream application enterprises.
"We will develop a series of product solutions based on fluorescent ceramics and its packaging technology based on the requirements of LED downstream luminaire manufacturers, and export technology and technology services." Ye Shanghui said that fluorescent ceramic packaging technology is compared with traditional technology in luminaire manufacturing. The process of simplification of the patch and reflow process can greatly reduce the investment cost in the industrialization process. “For the LED packaging factory that has been put into production, the existing production equipment can be used for technical upgrades without the need to purchase new production equipment.†For example, Zhongke Xinyuan is cooperating with traditional metal halide lamps and high pressure sodium lamps manufacturers. It provides a high-power LED light source module in a fluorescent ceramic package.
Such a convenient technological transformation has enabled Zhongke Core Source's products to begin to go nationwide. Jinan Kunrui Optical Technology Co., Ltd. is a lighting enterprise specializing in the production of LED street lamp lens, mining lamp lens, tunnel lamp lens, etc. It is one of the cooperative members of Zhongke Core Source Technology Strategic Alliance. The company utilizes the new brand of Zhongke core source. Light source packaging technology is developing new lens products. Fujian Province Cross-Strait Lighting Energy-saving Technology Co., Ltd., which is committed to intelligent lighting solutions, is a user of Zhongke Core Source. The company is currently planning to use the products of Zhongke Core Source to create a model of public lighting.
At the beginning of 2015, Zhongke Core Source signed a five-party agreement with the Institute of Semiconductors of the Chinese Academy of Sciences, the Institute of Material Structures of the Chinese Academy of Sciences, the Institute of Engineering Thermophysics of the Chinese Academy of Sciences, and Changchun Xida Electronic Technology Co., Ltd. to achieve cooperation with the development, production and sales. The cooperation of power integrated transparent fluorescent ceramic COB light source and its lamps.
“Fujian LED industry upstream chip enterprises take Sanan as the leader, downstream applications include Hongbo Optoelectronics, Furi Lighting, Xiamen Xinda, etc. If there is a wide application of fluorescent ceramic packaging core technology, the upper, middle and lower reaches can form technical mutual support. The cooperation of the industrial chain will surely bring the development of the LED industry in our province into a new era," said Zhang Yunfeng, director of the Cooperation and Development Division of the Institute of Physical and Cultural Affairs of the Chinese Academy of Sciences.
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