How to make cob-spotlight? What are its applications? ​

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1. COB spotlight production process ​
(I) Chip mounting: Laying a stable foundation ​
Chip mounting is a critical step in the COB-SPOTLIGHT production process. In this link, a layer of solid crystal glue with good thermal conductivity must be carefully applied on the surface of the substrate. This layer of solid crystal glue is not an ordinary glue. It has two important missions: one is to firmly fix the LED chip on the substrate to ensure that the chip will not be displaced during the subsequent production process and long-term use; the other is that it can efficiently conduct the heat generated by the chip during operation, which is crucial to maintaining the stable operation of the chip. Because LED chips generate a lot of heat when working, if the heat cannot be dissipated in time, the performance of the chip will be affected, and even the chip may be damaged. ​
After applying the solid crystal glue, the next step is to accurately place the LED chips that have been strictly screened and tested for multiple rounds at the pre-set position on the substrate. This operation requires extremely high precision, just like dancing on the tip of a needle, it must be accurate. In order to achieve such high-precision operations, in actual production, high-precision chip mounters are usually used. This chip mounter is precisely controlled by a computer program and can quickly and accurately mount the chip on the substrate. After the chip is mounted, it needs to be cured. Generally, heating is used to allow the die-bonding glue to cure quickly at a specific temperature, thereby greatly enhancing the adhesion between the chip and the substrate and ensuring the stability of the entire structure. ​
(II) Wire bonding: achieving electrical connection​
After the chip is mounted and cured, the wire bonding process begins. The core task of this step is to achieve electrical connection between the LED chip and the substrate, so that the current can flow smoothly between the chip and the substrate, so that the chip can work normally and emit light. When wire bonding, metal wires are usually used, and common ones are gold wires, copper wires, etc. Through a specific bonding method, one end of the metal wire is tightly connected to the electrode of the chip, and the other end is connected to the circuit on the substrate. ​
At present, the commonly used wire bonding methods are mainly ultrasonic bonding and hot pressing bonding. Ultrasonic bonding is the clever use of ultrasonic energy to form a strong metallurgical bond between the metal wire and the chip electrode and substrate circuit without applying excessive temperature. This bonding method can not only ensure the stability of the connection, but also minimize thermal damage to the chip and substrate. Thermocompression bonding is to apply a certain amount of heat and pressure to the metal wire at the same time, so that the metal wire can be reliably connected to the chip electrode and substrate circuit under high temperature and high pressure. ​
No matter which bonding method is used, various bonding parameters need to be strictly controlled during the bonding process. These parameters include bonding time, bonding pressure, ultrasonic power (if ultrasonic bonding), etc. Only by accurately controlling these parameters can the quality and reliability of the bonding be ensured. Once the bonding is completed, the leads need to be thoroughly and carefully inspected to carefully check whether there are problems such as breakage and cold soldering. Because even extremely small connection problems may affect the overall performance of the COB spotlight and even cause the lamp to fail to work properly. ​
(III) Packaging: Provide comprehensive protection and optimize optical performance Packaging is the last process in the production of COB spotlights, but it plays a vital role. It has two main purposes: one is to protect the LED chip from interference and damage from external environmental factors; the other is to further improve the light output efficiency and optimize the optical performance of the lamp, so that the COB spotlight can emit better quality light that meets the needs. ​
During the packaging process, a layer of packaging material must first be evenly coated on the surface of the chip and the bonded leads. Common packaging materials are silicone or epoxy resin. When applying this layer of material, it must be ensured that the material can evenly cover every corner of the chip and the leads, and there must be no defects such as bubbles and voids. Because once these defects exist, external impurities such as moisture and dust may invade, affecting the performance and life of the chip, and these defects may also have an adverse effect on the propagation and scattering of light, reducing the optical performance of the lamp. ​
Next, the packaging material containing phosphor should be evenly coated on the surface of the chip. Phosphor plays a vital role in COB spotlights. It can convert the blue light emitted by LED chips into other colors of light. By adjusting the type, thickness and concentration of phosphor, lighting effects of different color temperatures can be achieved to meet the needs of various different scenes. Therefore, when coating the packaging material containing phosphors, the thickness and concentration of the phosphors must be controlled very precisely, and they need to be strictly formulated and coated according to the pre-set color temperature, color rendering index and other parameters. ​
After completing the above coating steps, the packaged lamps need to be cured to allow the packaging materials to be completely cured and formed. The cured lamps also need to undergo a series of strict quality tests, including optical performance tests, electrical performance tests, reliability tests, etc. Only those products that have passed all the test items and all performance indicators meet the standards can enter the market for sale and be used by consumers. ​
II. Advantages of COB spotlights ​
(I) High brightness and high light efficiency ​
The COB spotlight cleverly integrates multiple LED chips on a substrate through an innovative design. This design greatly improves the power density and luminous intensity. Compared with traditional spotlights, COB spotlights can release brighter light under the same energy consumption conditions, significantly improving lighting efficiency. This advantage makes COB spotlights particularly outstanding in places where high-brightness lighting is urgently needed, such as large shopping malls, stages, outdoor plazas, etc. In large shopping malls, the high brightness of COB spotlights can make the goods more eye-catching and attract customers' attention; on the stage, it can provide sufficient light for the actors, allowing the audience to clearly see every expression and movement of the actors; in outdoor plazas, high-brightness COB spotlights can illuminate the entire area and ensure the safety of people's activities. Moreover, during the propagation process, high-brightness light can better penetrate the air and reduce the loss of light, thereby ensuring the uniformity and stability of lighting and creating a comfortable and bright lighting environment for people. ​
(II) Excellent color rendering index​
The color rendering index (CRI) is an important indicator to measure the ability of a light source to restore the color of an object. The higher the value, the more realistically the light source can restore the original color of the object. COB spotlights usually have a higher color rendering index and can generally reach a higher level. This means that under the illumination of COB spotlights, objects can present their most realistic and brightest colors. In the field of commercial lighting, COB spotlights with high color rendering index can make the display of goods more realistic and attractive. For example, in jewelry stores, COB spotlights can perfectly present the brilliant light and delicate texture of jewelry, making the jewelry more dazzling and stimulating consumers' desire to buy; in clothing stores, it can truly restore the color and texture of clothing, allowing customers to more intuitively feel the charm of clothing. In film and television shooting and stage performances, lighting with high color rendering index is even more indispensable. It can accurately restore the skin color and clothing color of the actors, making the image of the actors more vivid and three-dimensional, enhancing the visual effect of the performance, and bringing more exciting audio-visual enjoyment to the audience. ​
(III) Good heat dissipation performance​
As mentioned above, in the production process of COB spotlights, materials with excellent thermal conductivity such as metal-based printed circuit boards, ceramic substrates or copper substrates are selected as substrates. These high-quality substrate materials can quickly conduct the heat generated by the LED chip, solving the problem of chip heat dissipation from the source. At the same time, in the entire manufacturing process, the heat conduction path between the chip and the substrate is carefully optimized, and efficient packaging materials are used to further improve the overall heat dissipation efficiency of the lamp. Good heat dissipation performance plays a decisive role in extending the service life of LED chips. When the LED chip operates at a lower operating temperature, its luminous efficiency can be effectively maintained, and the light decay phenomenon will be significantly slowed down. This allows COB spotlights to always maintain stable luminous performance during long-term use, reduce the frequency of lamp replacement, and reduce the cost of use. Whether in commercial places or in environments where lighting fixtures are used for a long time, such as homes, good heat dissipation performance provides a strong guarantee for the widespread application of COB spotlights. ​
(IV) Long life ​
Because COB spotlights have good heat dissipation performance and stable electrical performance, their service life has been greatly improved compared to traditional spotlights. Under normal use conditions, COB spotlights can work continuously and stably for a long time. This means that in many lighting scenarios, COB spotlights can be used for years or even decades without replacement. The long life of COB spotlights makes them particularly suitable for special places where it is difficult to replace lamps. For example, in high-altitude lighting, replacing lamps requires professional equipment and personnel, which is difficult and costly. The long life of COB spotlights can avoid the trouble of frequent replacement of lamps; in underwater lighting, lamp replacement is not only difficult, but may also affect the underwater environment. The long life advantage of COB spotlights is also fully reflected here. In addition, for some places with extremely high requirements for lighting stability, such as hospital operating rooms and museums, the long life and stable performance of COB spotlights can ensure that the lighting is always kept in the best condition, providing reliable lighting guarantee for the normal operation of these places. ​
III. Wide application of COB spotlights ​
(I) Commercial lighting field ​
Shopping malls and supermarkets: In the bustling shopping malls and supermarkets, COB spotlights can be seen everywhere, especially in the product display area, where it plays an irreplaceable and important role. Its high brightness and excellent color rendering index can accurately highlight the color and details of the goods, just like a magical magician, instantly attracting the attention of consumers and stimulating their inner desire to buy. In jewelry counters, COB spotlights perfectly present the brilliant light of jewelry without reservation, making each piece of jewelry seem to exude a unique charm, more dazzling and eye-catching, making consumers love it; in the food area, it can truly restore the color of the food, allowing consumers to intuitively feel the freshness of the food at a glance and buy it with confidence. ​
Specialty stores: In order to create a unique store atmosphere and display the brand image, various brand specialty stores often cleverly use COB spotlights. Through the carefully designed lighting layout, COB spotlights can accurately illuminate key products and make them instantly become the visual focus. At the same time, it can complement the overall decoration style and create a comfortable and fashionable shopping environment together. In clothing specialty stores, COB spotlights can flexibly select the appropriate color temperature for illumination according to the color and style of clothing. For bright and colorful clothing, choosing light with a higher color temperature can make it more lively; for calm and atmospheric clothing, light with a lower color temperature can highlight its texture, enhance the customer's trial experience, and let customers feel the unique charm of the brand during the shopping process. ​
Window display: As an important window for merchants to display goods, COB spotlights play a key role here. Its powerful focusing effect can accurately focus the light on specific goods or display areas, forming a strong visual impact, like a huge magnet, firmly attracting the attention of passers-by. Moreover, the adjustability of COB spotlights provides unlimited possibilities for window design. Designers can freely adjust the angle, brightness and color temperature of the light according to different display themes and product characteristics to create a variety of display effects and fully highlight the characteristics and advantages of the products. Whether it is fashionable clothing, exquisite accessories or novel electronic products, COB spotlights can make them shine in the window and attract more potential customers.​
(II) Stage lighting field​
Theater performances: On the stage of the theater, COB spotlights are a powerful assistant in providing high-quality lighting for actors and stage scenery. Its high brightness and stable light output are like a "guardian" on the stage, ensuring that every action and expression of the actors on the stage are clearly presented to the audience. At the same time, it can accurately restore the color and details of the stage scenery, presenting a wonderful and beautiful visual feast for the audience. In opera performances, COB spotlights can flexibly adjust the brightness, color and angle of the lights as the plot develops and the scene changes. When the plot reaches its climax, the lights become bright and warm, enhancing the artistic appeal of the performance; when the scene switches to a quiet night, the lights become soft and dim, creating a corresponding atmosphere and emotional tone, making the audience feel as if they are on the scene and immersed in the ocean of art. ​
Concerts: Concerts are a stage where lighting art and music performances are perfectly integrated, and COB spotlights play a pivotal role in them. Its powerful power and rich color expression can create colorful and stunning lighting effects. At the concert, COB spotlights work closely with the rhythm of the music, and achieve fast and accurate switching and changes through the computer lighting control system. When the music is exciting, the lights shine brightly, creating all kinds of fantastic light and shadow effects, pushing the atmosphere of the concert to a climax; when the music is soothing, the lights become soft and warm, creating a romantic atmosphere together with the music. While enjoying the music, the audience can also enjoy a visual carnival and immerse themselves in the unique charm of the concert in all aspects. ​
Dance performance: Dance performances have extremely demanding requirements on lighting, requiring the lights to follow the dancers' movements as accurately as shadows, highlighting the dancers' body lines and graceful postures. COB spotlights have become the only choice for dance performance lighting with their high color rendering index and good dimming performance. It can truly restore the color and texture of the dancers' costumes, making the costumes more colorful under the lights. At the same time, through soft and uniform light, a comfortable and beautiful stage environment is created, allowing dancers to show their dancing postures more confidently on the stage. Whether it is passionate modern dance or elegant classical ballet, COB spotlights can add brilliance to dance performances and allow audiences to better appreciate the charm of dance art.