项目名称：石墨烯导热材料内嵌高压线性模组一体成型工艺

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

申报单位：中山德诚智造光电有限公司
Declaration Unit :Zhongshan DC Design Photoelectric Co.,LTD

综合介绍或申报理由：
Consolidated Presentation or Declaration of Reasons:

石墨烯新材料与DOB (Driver-On-Board)光源一体化成型工艺，响应国家《中国智造2025》通过高新技术改造传统产业政策，采用机械手改造生产设备，实现生产制造自动化、标准化、流程化，简化了工艺，如铝基板同灯体用螺丝固定的工艺（打螺丝）、铝基板与散热器涂导热胶的工序，相比传统导热胶涂抹不均匀导致产品寿命下降，新的工艺使铝基板同灯体无缝结合，减少了热阻更好将热传导至散热器，从而提升产品的一致性和可靠性，更适合自动化生产，提升生产效率。

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.

主要技术参数：
Main Technical Parameters :

1、铝基板导热率>2.0 W/m.K

2、铝基板厚度>1.5mm

3、石墨烯导热率>2.0 W/m.K

4、石墨烯材料耐压>10000v

5、铝基板耐压>2000v

6、耐高低温：-40℃~100℃

7、支持最大200w灯具的制造生产

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

与国内外同类产品或同类技术的比较情况：
Comparison with Similar Products or Technologies at Home and Abroad:

一、前瞻性：
1、人工组装到设备自动化，符合国际工业4.0和智能制造2025，从低端数量到高效质量的国家策略。
2、一体化成型（自动化）：简化了工艺，如铝基板同灯体用螺丝固定的工艺（打螺丝）、铝基板与散热器涂导热胶的工序，相比传统导热胶涂抹不均匀导致产品寿命下降，新的工艺使铝基板同灯体无缝结合，减少了热阻更好将热传导至散热器，从而提升产品的一致性和可靠性，更适合自动化生产，提升生产效率。
3、石墨烯国内外积极探索的新材料，它的特性...，以后会有广泛的社会应用。
4、线性方案简化了结构降低了成本，而且提高了产品的稳定性与寿命，最近几年随着飞利浦、欧司朗等厂家的改良与应用，市场应用增长速度非常快，将是灯具应用主流方案之一。

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、重大创新、行业领先：
2、Major Inovation, Industry Leading:

石墨烯+高压线性方案+一体制程工艺

Graphene + High-voltage linear scheme+Integrated process technology

经济评价分析：
Economic evaluation analysis:

一、经济性分析：
1. Economic analysis:
1、相比传统灯具压铸工艺提高了50%的生产效率，节省了零配件存储空间，从而减少了中间物流周转成本。
2、整灯更轻薄，运输费节省60%。
3、跟金属散热器相比，电源部分节省成本10%，材料比重轻节省10%，机加工及表面处理节省25%，人工组装节省5%，运输费相比整灯成本节省2%，综合成本节省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、投资回报
2. Return of investment
1、按1万个投光灯计算，传统生产周期35天，一体化工艺周期15天，缩短了60%的生产时间。
2、按1万个投光灯计算，传统制程需1000工时，一体化工艺500工时，节省了50%的工时效率。
3、对比金属灯具外壳整体成本降低40%，很有竞争力。

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、整个产线都符合国家环境评估认证要求，安全无污染。

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

技术及工艺创新要点：
Key points of Technological and Technological Innovation:

一、技术创新点：
Technological Innovation Point
1、简化了工序。
2、灯板焊锡温度240-260°，注塑280-300°，通过超导技术，瞬间降温，通过循环冷却系统保持模具温度恒定，不会伤及灯珠及元器件，解决了注塑高温融化LED灯板上灯珠及IC的问题。
3、模具抗静电技术，生产过程中不会伤及LED灯珠及IC。
4、石墨烯与灯板的无缝衔接，在实用效果上降低了成本及人工，对户外及室内灯具的结构实现了重大的变革。

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、设计创新点
Design Innovation Point
1、基于此工艺，可大范围、高效率的应用在路灯、投光灯、筒灯等室内外产品。
2、设计上可简化电源腔体，使整灯更加轻薄、简洁，造型可以更美观。
3、目前在室内外产品制程过程中，一体成型工艺算行业首家，具有较强的独创性与技术领先优势。
4、相比市场塑包铝工艺，去掉了埋入导热铝件，降低20%左右成本，提高了50%的生产制程效率。

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、其他创新点
Other Innovations
1、新工艺的改良，充当了桥梁，有效的把石墨烯新材料与IC方案整合到了一起，实现成本双降，使整灯成本下降40%。
2、相比金属制成工艺，减化了五金加工、抛光、表面处理、来运运输、焊线、涂散热胶水、打螺丝等低效的人工作业工序，生产效率提升了300%，还有效的避免了各流通环节产品不良率的产生。

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.

实际运用案例和用户评价意见：
Practical Application Cases and User Evaluation

一、技术独立性
Technical Independence

1、解决了280-300°高温瞬间融化灯板和灯珠的问题。
2、解决了灯板10000V以上绝缘问题。
3、铝基板导热率2.0 W/m.K，石墨烯导热率2.0W/m.K，热传导率一致，灯珠的热量能直接传导至散热器，中间没有损耗。
4、工艺设计解决了灯板与外壳分离的问题。

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、技术可行性
Technical Feasibility
1、一体化工艺已成熟，相比市场注塑工艺大幅提升了制程效率，目前已量产了投光灯、筒灯、路灯等系列化产品。

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、应用案例及用户评价
Application Case and User Evaluation
1、惠州西顿照明应用一体成型工艺开发一系列筒灯系列产品。
2、30W-100W石墨烯投光灯量产应用。

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.

获奖、专利情况：
Awards, Patents:

一、专利情况：
Patent Situation

国家发明专利受理通知书
National invention patent

二、获奖情况
Award-winning Situation
质检报告：高低温开裂、热成像->散热（待补充测试报告图片）
Quality inspection report: cracking at high and low temperature, thermal imaging-> heat dissipation (photo of test report to be supplemented)

申报单位介绍：

本公司专业从事LED灯具外壳生产的厂家。业务包括产品设计，模具开发，配件生产和装配等环节 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.

产品图片：