Step-by-Step Guide: Producing LED Strip Lights

LED strips have gained immense popularity and are an excellent option for lighting in commercial, residential, and industrial settings. They offer remarkable efficiency and effortless installation and demand minimal upkeep. The versatility of LED strips allows for customization in different shapes and sizes, enabling their utilization for illuminating virtually any given space.

What exactly is an LED Strip Light?

An LED strip light, sometimes called LED tape or ribbon light, is a flexible circuit board equipped with surface-mounted light-emitting diodes (SMD LEDs) and additional components. These strips typically include adhesive backing for easy installation.

Key Features of LED Strips:

Wide Color Range: LED strips come in various color options, including monochrome, Tunable White, RGB, RGBW, RGBTW, and Digital color changing. You can choose the perfect color scheme for your needs.

Convenient Size: LED strips can be easily cut to any desired length. You can design your project without worrying about the LED strip’s length, as it can be tailored to fit your requirements.

Easy Installation: The back of the LED strip is equipped with 3M double-sided tape, ensuring hassle-free installation. Stick the LED strip to the desired location with ease.

Dimming Capability: The LED strip supports a range of dimming methods, such as PWM, 0-10V, DALI, DMX512, and TRIAC dimming. This allows you to adjust the brightness according to your preference or desired ambiance.

Long Lifespan: LED strips boast an impressive lifespan of up to 54,000 hours. This ensures long-lasting performance and minimizes the need for frequent replacements.

Customizability: We offer the option of customizing LED strips for your projects. This includes choosing custom colors, CRI (Color Rendering Index), voltage, brightness, width, and lengths. Tailor-made LED strips are available to meet your unique requirements.

The categorization of LED strips is as follows:

1. Static White and Single Color: These LED strips emit a fixed white or single-color light. They are available in red, green, blue, yellow, pink, ultraviolet, infrared, and white, with varying color temperatures ranging from 2100K to 6500K.
2. Tunable White: Tunable White LED strips feature two different color temperature LEDs. Using a controller, the strip’s color can be adjusted, transitioning from warm white to white light.
3. RGB Color Changing: RGB LED strips have three channels that allow you to control and create any desired color.
4. RGB+W Color Changing: Similar to RGB strips, RGB+W LED strips have an additional channel dedicated to producing white light, resulting in a broader color range.
5. RGB+Tunable White Color Changing: These LED strips have five channels, similar to RGBW strips, but with another channel for white or warm white light. This enables the creation of more diverse color combinations.
6. Digital or Pixel Color Changing: Digital LED strips can assign different colors to individual sections of the strip. This allows for creating of varied colors within various segments of a single LED strip.

Manufacturing Process of LED Strip Lights

LED strip lights are produced using a manufacturing process known as the Surface Mount Technology (SMT) Assembly Process. This process involves mounting LEDs, resistors, and other necessary components onto a Flexible Printed Circuit Board (FPCB).

By employing the PCBA process, we can customize LED strips according to your unique lighting requirements at the PCB level. Furthermore, we conduct rigorous quality control testing at every stage to guarantee that our products adhere to the highest standards. Now, let’s delve into the intricacies of this process.

Step 1: LED Lamp Production

The initial stage involves manufacturing LED lamps, also known as LED encapsulation. The LED lamps play a crucial role in determining the quality of the LED strip. Unlike other factories, we do not rely on sourcing LED lamps externally. Instead, we produce our LED lamps to ensure the superior quality of our LED strips. Let’s delve into the process of LED lamp production.

Step 1.1: Die Attachment is a critical process where the chip is bonded to the designated frame area using colloid (typically conductive or insulating glue for LEDs). This bonding forms a thermal or electrical path, facilitating subsequent wire bonding. We utilize high-quality chips from reputable brands such as Epistar and Sanan.

Step 1.2: Wire Bonding involves creating electrical interconnections between the LED frame and LED chips using bonding wires composed of 99.99% gold.

Step 1.3: Phosphor Silicone Dispensing. Most LEDs in the market, employ blue-emitting LED chips with added phosphors to achieve a mixed white light output. To attain accurate color temperature, we meticulously adjust the phosphor ratio. The phosphor powder is thoroughly mixed with silica gel, then applied to the LED bracket surface, covering the LED chip. This step is of utmost importance, as many LED lamps encounter issues when the gold wire is disconnected, impeding the current flow between the LED chip and LED bracket, thus causing the LED lamps to malfunction.

Step 1.4: Baking, following the Phosphor Silicone Dispensing, the LED lamps undergo a baking process in an oven to eliminate moisture from the phosphor powder.

Step 1.5: Sorting. Packaged LEDs are subjected to testing and sorting based on wavelength, chromaticity coordinates (x, y), light intensity, light angle, and operating voltage. Consequently, the LEDs are classified into various bins and categories, with a test sorter automatically placing them into different containers according to the predetermined test standards. As demands for LEDs continue to rise, sorting machines have evolved from the initial 32Bin to 64Bin, and now, commercial sorting machines offer 72Bin capability. Despite these advancements, the LED technical indicators of Bin still fail to meet the demands of production and the market. For white color LEDs, our company adheres to the strictest standard, 3-step McAdam, ensuring impeccable color consistency that surpasses human visual detection.

Step 1.6: Taping. Before the LEDs are mounted, they undergo detection, orientation, and packaging in tape format. These taped LEDs can then be efficiently supplied to SMT placement machines for circuit board assembly at high speeds.

Step 1.7: Packaging. After taping, the LED lamps are packaged in rolls. Each roll is placed within a static-discharging aluminum foil bag, which is then evacuated and sealed.

Step 2: Solder Mold Creation and Usage

For each strip light design, molds made of stainless steel are created. These molds consist of holes placed on top of the bare PCB. They aim to ensure the precise distribution of solder paste over the solder points.

Step 3: Application of Lead-free Solder Paste on the Base PCB

The “PCB sheet” is formed by a series of loosely connected strips of bare PCB, each measuring 0.5 meters long. This PCB sheet is positioned beneath the mold, filling the holes with lead-free solder paste. This meticulous process results in defect-free pads.

Quality Test

During the QC step, each solder point is examined to verify the correct amount of solder paste and to prepare it for the placement of components.

Step 4: Component Placement

Next, the PCB sheet is introduced into an SMT placement machine. This machine accurately picks up and positions resistors, LEDs, and other components onto the solder points, applying precise pressure. We utilize high-speed SMT machines of Japanese origin to maintain exceptional quality.

Quality Test

With all its components attached, the PCB undergoes another inspection by the quality control team. If any part is misplaced, it is duly noted, and the PCB sheet is reworked until it passes inspection.

Step 5: Reflow Soldering

The solder paste must solidify before the components are firmly fixed onto the PCB. To accomplish this, the PCB board is secured within a reflow oven. This oven has multiple independently controlled zones, allowing precise temperature regulation as the PCB passes through.

Quality Test

Once the LED sheet emerges from the reflow soldering process, it undergoes a quality inspection. The LED sheet is illuminated to ensure that all the LEDs function correctly. Any LED sheets that do not meet the required standards are reworked or manually soldered until they reach perfection.

Step 6: Segmentation and Welding of 0.5m LED Strip Segments

The 0.5m PCB sheets, consisting of multiple loosely attached LED strips, are separated and soldered together end-to-end until the specified length is achieved. Typically, we fuse the segment PCBs into rolls measuring 5 meters.

Quality Test

During the soldering process of the PCB into a long roll, a thorough inspection of all soldering connections is conducted. This ensures that the entire LED strip can be uniformly illuminated.

Step 7: Aging and Waterproofing

Next, we move on to the aging and waterproofing process for the welded LED strips. These strips will be carefully placed in a designated aging test room, continuously illuminated, and made to function for 12 hours. This phase is commonly referred to as the burn-in test. This test aims to meticulously identify any potential quality issues with the LED strips before they are shipped out to customers.

Furthermore, if specific LED strips are intended for outdoor or underwater use, it becomes necessary to ensure their waterproof and dustproof properties. To achieve this, we offer various levels of waterproofing and dust proofing, allowing customers to select the most suitable option based on their specific requirements:

1. IP20: This grade denotes a bare, non-waterproof LED strip suitable for indoor use in dry environments.
2. IP52: We provide LED strips with a silicone coating for slightly damp environments, making them suitable for indoor use.
3. IP65: In semi-outdoor settings where exposure to rain is expected, we offer LED strips with a protective layer of either a silicone tube or a heat shrink tube.
4. IP67: To ensure outdoor durability, our LED strips come with a silicone tube and silicone filling or solid silicone extrusion.
5. IP68: We provide LED strips with a PU (Polyurethane) coating for underwater applications, allowing them to function effectively even when submerged.

Step 8: Application of 3M Tape and Packaging

Upon passing the inspection, the LED strip applies 3M double-sided tape on its back. This facilitates convenient installation for customers, as they can remove the backing and affix the LED strip wherever desired.

It is essential to utilize top-notch 3M double-sided tape, as it guarantees enhanced adhesion, promotes heat dissipation, and extends the lifespan of the LED strip.

Subsequently, each LED strip is carefully rolled onto a reel and placed into an anti-static aluminum foil bag. A label is affixed to the bag, and approximately 50 bags are packed into a single box.

Quality Test:

To ensure a consistently high level of quality, we conduct a random inspection of the LED strips before packaging. This step helps us maintain our stringent quality standards.

Factors influencing the quality of LED strip lights

FPCB (Flexible Printed Circuit Board) Quality

To ensure optimal performance, it is crucial to use high-quality, double-layer pure copper FPCBs weighing 2-4 oz. These superior FPCBs facilitate the smooth flow of high currents, minimize heat generation, and expedite heat dissipation. Since excessive heat can reduce the lifespan of LEDs, it is essential to employ methods that effectively dissipate heat. One such process involves attaching the LED strip to an aluminum profile, maximizing heat dissipation, and lowering the operating temperature.

SMD LED (Surface-Mount Device Light-Emitting Diode) Quality

Choosing SMD LEDs from reputable brands guarantees high-quality packaging, including top-notch thermal pads, die-bond materials, phosphors, and gold bond wires, with a purity of 99.99%. These LEDs undergo rigorous testing, adhering to LM-80 and TM-21 reporting standards.

Additionally, they exhibit exceptional characteristics such as high brightness, high Color Rendering Index (CRI), Gamut Index, Fidelity Index, and Saturation. According to the MacAdam ellipse, it is crucial to ensure good color consistency by using BINs that maintain color uniformity within three steps.

Resistor Quality

To maintain the intended brightness of the LEDs, resistors are employed to regulate the forward current. It is important to note that the value of resistors might vary across different batches. Therefore, it is advisable to acquire resistors from a reputable company.

Use only high-quality resistors to prevent potential harm to the LED strip or its longevity. Inferior resistors can cause a decrease in the lifespan of the LEDs or even lead to damage.

Avoid overpowering your LEDs, as this may initially result in a brighter appearance but ultimately lead to premature failure. Some competitors employ this tactic, but excessive heat generated can pose a risk, especially if installed on flammable materials.

Wire and Connector Quality

Always opt for components that have undergone safety and durability testing.

Quality of 3M Tape

We recommend using 3M brand 300LSE or VHB tape for long-lasting installations and optimal thermal conductivity. Beware of suppliers offering generic or counterfeit adhesive products under well-known brand names. The quality of the tape plays a crucial role in the overall performance and reliability of the installation.

Component Placement

Ensuring proper and secure soldering of all components onto the PCB is paramount. Faulty soldering can sometimes result in LED strips malfunctioning.

Conclusion

While high-quality LED strips may have a higher price tag, their low failure rate significantly reduces maintenance costs. Considering that labor costs outweigh product costs, opting for high-quality LED strips is more cost-effective. It’s always wise to conduct thorough research before making a purchase decision. Please don’t hesitate to reach out if you have any inquiries about LED strips or other topics. We aim to provide durable LED lighting solutions that stand the test of time.

MyLiKeLED specializes in the production of top-notch LED strips and LED neon flex. Our products undergo rigorous testing in state-of-the-art laboratories to ensure unmatched quality. Furthermore, we offer customizable options for our LED strips and neon flex. To acquire premium LED strips and LED neon flex, contact MyLiKeLED immediately!