Method of mounting self-adhesive substrate on electronic device

A method of mounting a self-adhesive substrate on an electronic device comprising steps of: (S01) providing a base for mounting at least one self-adhesive substrate thereon, wherein each self-adhesive substrate includes a copper circuit layer formed thereon, an insulated adhering layer adhered with the copper circuit layer and made of glue with thermal conductive powders, and a release layer attached with the insulated adhering layer; (S02) forming the at least one self-adhesive substrate on the base based on a profile or a circuit configuration of a fixing portion of an accommodating member of an electronic device; (S03) welding a plurality of electronic elements on the copper circuit layer of each self-adhesive substrate; (S04) removing each self-adhesive substrate; (S05) removing the release layer from each self-adhesive substrate to adhere each self-adhesive substrate on the fixing portion of the accommodating member of the electronic device.

FIELD OF THE INVENTION

The present invention relates to a method of mounting a self-adhesive substrate on an electronic device which is employed to mount the self-adhesive substrate on the electronic device directly so that heat is transmitted to air from a plurality of electronic elements via the self-adhesive substrate and the electronic device.

BACKGROUND OF THE INVENTION

Referring toFIG. 1, a conventional LED bulb1′ contains: a seat11′, a connecting mount12′, a control module13′, a circuit substrate14′, and a shade15′. The circuit substrate14′ includes a plurality of LED elements16′ welded thereon and is manually locked on a fixing portion112′ of the seat11′ by using two screws141′, a first orifice111′, and a second orifice142′. Furthermore, two wires143′ of the circuit substrate14′ are inserted through an aperture113′ of the fixing portion112′ to electrically connect with the control module13′ in the connecting mount12, such that the plurality of LED elements16′ is driven by the control module13′ to illuminate lights.

However, the conventional LED bulb1′ still has disadvantages as follows:

1. The conventional LED bulb1′ cannot be produced easily, because the circuit substrate14′ is manually locked on the fixing portion112′ of the seat11′.

2. The circuit substrate14′ is used to hold the plurality of LED elements16′, the plurality of LED elements16′ is electrically connected with the control module13′ in the connecting mount12via the circuit substrate14′, but the circuit substrate14′ is made of fiberglass, heat from the plurality of LED elements16′ cannot be dissipated easily.

SUMMARY OF THE INVENTION

The primary object of the present invention is to provide a method of mounting a self-adhesive substrate on an electronic device is employed to mount the self-adhesive substrate on the electronic device directly so that heat is transmitted to air from a plurality of electronic elements via the self-adhesive substrate and the electronic device.

To obtain the above objective, a method of mounting a self-adhesive substrate on an electronic device provided by the present invention contains steps of:

(S01) providing a base for mounting at least one self-adhesive substrate thereon, wherein each self-adhesive substrate includes a copper circuit layer formed thereon, an insulated adhering layer adhered with the copper circuit layer and made of glue with thermal conductive powders, and a release layer attached with the insulated adhering layer;

(S02) forming the at least one self-adhesive substrate on the base based on a profile or a circuit configuration of a fixing portion of an accommodating member of an electronic device;

(S03) welding a plurality of electronic elements on the copper circuit layer of each self-adhesive substrate;

(S05) removing the release layer from each self-adhesive substrate to adhere each self-adhesive substrate on the fixing portion of the accommodating member of the electronic device.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A method of mounting a self-adhesive substrate on an electronic device according to a preferred embodiment of the present invention is employed to mount at least self-adhesive substrate in an electronic device, such as a LED bulb, as shown inFIG. 2. The LED bulb comprises an accommodating member11, a connecting seat12, at least one self-adhesive substrate13, and a peripheral shade15.

With reference toFIGS. 2 and 3, each self-adhesive substrate13includes a copper circuit layer132formed thereon and welded with a plurality of electronic elements14, an insulated adhering layer131adhered with the copper circuit layer132and made of glue with thermal conductive powders, and a release layer130attached with the insulated adhering layer131. The at least one self-adhesive substrate13is mounted on a fixing portion111of the accommodating member11, and the copper circuit layer132is electrically connected with a driving module16in the connecting seat12. Each self-adhesive substrate13also includes a first insulation layer133adhered on the copper circuit layer132to protect the copper circuit layer132and includes a printing layer134printed on the first insulation layer133, wherein the printing layer134is printed or coated a white paint to reflect lights of the LED bulb. Preferably, the printing layer134is printed or coated a green paint, a yellow paint or other colorful paints to be applicable for other electronic devices.

With reference toFIGS. 4 and 5, a method of mounting a self-adhesive substrate on an electronic device according to a preferred embodiment of the present invention comprises a step of: (S01) providing a base2for mounting at least one self-adhesive substrate13thereon, wherein each self-adhesive substrate13includes a copper circuit layer132formed thereon, an insulated adhering layer131adhered with the copper circuit layer132, and a release layer130attached with the insulated adhering layer131, as shown inFIG. 3. Referring further toFIGS. 3 and 5, a first insulation layer133is covered on the copper circuit layer132and has plural welding orifices1331to expose a plurality of welding bosses on the copper circuit layer132. In addition, a printing layer134is printed on the first insulation layer133.

A method of manufacturing the base2includes steps of: providing and processing the first insulation layer133so that the plural welding orifices1331are formed on the first insulation layer133, as illustrated inFIGS. 6A and 7A(taking the LED bulb for example, the plural welding orifices1331are formed on the first insulation layer of the LED bulb); adhering the first insulation layer133with a copper layer132a, as shown inFIGS. 6B and 7B; processing the copper layer132ato form the copper circuit layer132, as illustrated inFIGS. 6C and 7C; printing the printing layer134on the first insulation layer133as shown inFIG. 6D; adhering the insulated adhering layer131with the copper circuit layer132to form the base2as illustrated inFIGS. 6E and 7C.

Thereafter, the method of mounting the self-adhesive substrate on the electronic device further comprises a step of (S02) forming the at least one self-adhesive substrate13on the base2based on a profile or a circuit configuration of a fixing portion111of an accommodating member11of an electronic device1. For instance, as shown inFIG. 2, the electronic device1is a LED bulb, and the fixing portion111of the accommodating member11is circular, so the at least one self-adhesive substrate13is circular.

With reference toFIG. 8, the electronic device1is an omni-directional LED bulb, and the fixing portion111of the accommodating member11is 360 degrees of a circular column or a polygonal column. Referring toFIG. 9, the self-adhesive substrate13has a central area133b and plural bending zones135, wherein the self-adhesive substrate13is fixed on a top surface of the fixing portion111, the central area133b is formed on a top surface of the self-adhesive substrate13, and the plural bending zones135are arranged around a peripheral side of the self-adhesive substrate13and are bent downwardly to contact with a peripheral wall of the fixing portion111, as shown inFIG. 8.

With reference to aFIG. 10A, the electronic device1is a LED fluorescent lamp, and the fixing portion111of the accommodating member11is elongated, a self-adhesive substrate13includes an elongated insulated adhering layer131, an elongated copper circuit layer132, and an elongated first insulation layer133which are accommodated in the elongated fixing portion111of the accommodating member11.

Referring toFIG. 10B, the electronic device1is a LED grille lamp, and the LED grille light includes a square frame10, a square accommodating members11, and a square diffusion plate1B, wherein the square accommodating member11is a concave lighting housing and has plural elongated fixing portions111to accommodate plural self-adhesive substrates13, and each self-adhesive substrate13includes an elongated insulated adhering layer131, an elongated copper circuit layer132, and an elongated first insulation layer133which are accommodated on each elongated fixing portion111of the square accommodating member11.

As shown inFIG. 11, the electronic device1is a LED desk lamp, and the LED desk lamp includes a holder17, a support rack18, and an illumination module19; wherein the illumination module19includes an accommodating member11, and the accommodating member11has a square fixing portion111; a self-adhesive substrate13includes a square insulated adhering layer131, a square copper circuit layer132, and a square first insulation layer133which are accommodated on the square fixing portion111of the accommodating member11.

As illustrated inFIG. 12, the electronic device1is an automobile LED light, and the automobile LED light includes an accommodating member11which has a fixing portion111formed in a column shape and extending outwardly form the accommodating member11; a self-adhesive substrate13includes an insulated adhering layer131, a copper circuit layer132, and a first insulation layer133which are accommodated on the fixing portion111of the accommodating member11.

With reference toFIG. 13, the electronic device1is a LED ring light, and the LED ring light includes an accommodating member11, a light guiding plate1A, and a diffusion plate1B; wherein the accommodating member11has an annular fixing portion111; a self-adhesive substrate13includes an annular insulated adhering layer131, an annular copper circuit layer132, and an annular first insulation layer133which are accommodated in the fixing portion111of the accommodating member11.

Referring toFIG. 14A, the electronic device1is a LED backlight, and the LED backlight includes an accommodating member11adapted for a back holder of a Tablet PC; wherein the accommodating member11has a flat fixing portion111. The electronic device1also includes a plurality of elongated self-adhesive substrates13, and each elongated self-adhesive substrate13includes an elongated insulated adhering layer131, an elongated copper circuit layer132, and an elongated first insulation layer133which are accommodated in the fixing portion111of the accommodating member11in an array manner. Preferably, as shown inFIG. 14A, each elongated self-adhesive substrate13is connected with each of the plurality of electronic elements14to form a LED light bar. In addition, the method of mounting the self-adhesive substrate on the electronic device is employed to other LED illumination devices, such as LED streetlights, LED cylinder lights, LED ceiling lights, LED candle bulbs, LED bulbs, LED lighting tubes, LED energy-saving lamps, LED art lamps, or LED accessory lights. Preferably, the self-adhesive substrate on the electronic device is also applied to other electronic devices, such as a LED display or a cell phone. In addition, each electronic element is any one of a LED chip, an integrated circuit chip, a capacitor, a resistor, an inductor, a transformer, an oscillator, and a sensor.

As illustrated inFIG. 14B, the electronic device1is a LED backlight, and the LED backlight includes a C-shaped accommodating member11, wherein the accommodating member11has a flat fixing portion111. The electronic device1also includes an elongated self-adhesive substrate13, and the elongated self-adhesive substrate13includes an elongated insulated adhering layer131, an elongated copper circuit layer132, and an elongated first insulation layer133which are accommodated on the flat fixing portion111of the accommodating member11.

With reference toFIGS. 4, 6F, and 7E, the method of mounting the self-adhesive substrate on the electronic device further comprises a step of (S03) welding the plurality of electronic elements14on the copper circuit layer132of each self-adhesive substrate13, and delivering the base2to a testing area so as to test each electronic element. For example, when each electronic element14is a LED element, each self-adhesive substrate13is tested to illuminate the LED lamp.

With reference toFIGS. 4 and 7F, the method of mounting the self-adhesive substrate on the electronic device further comprises steps of (SO4) removing each self-adhesive substrate13, (S05) removing the release layer130from each self-adhesive substrate13to adhere each self-adhesive substrate13on the fixing portion111of the accommodating member11of the electronic device1, as shown inFIGS. 8 to 14.

After removing the release layer130from each self-adhesive substrate13in a step of (505), adhering each self-adhesive substrate13on the fixing portion111of the accommodating member11of the electronic device1by ways of a mounting fixture3, as illustrated inFIGS. 15 and 16. The mounting fixture3includes a body31and plural holes32defined on the body31. Thereafter, each self-adhesive substrate13is placed on the body31, and the plurality of electronic elements14, welded with each self-adhesive substrate13, are retained in the plural holes32.

Referring toFIG. 17A, the insulated adhering layer131is adhered on the fixing portion111of the accommodating member11. As shown inFIG. 17B, the mounting fixture3is removed from each self-adhesive substrate13, thus mounting each self-adhesive substrate13on the fixing portion111of the accommodating member11of the electronic device1, such as a LED bulb.

As illustrated inFIG. 18A, in another preferred embodiment, a mounting fixture3includes a central affixing portion31a, plural flexible tabs32aconnecting with the central affixing portion31a, and a plurality of apertures33adefined on the central affixing portion31aand the plural flexible tabs32a. Each self-adhesive substrate13and the plurality of electronic elements14are placed on the central affixing portion31a and the plural flexible tabs32aso that the plurality of electronic elements14are retained in the plurality of apertures33. With reference toFIG. 18B, after removing the release layer130from each self-adhesive substrate13, the accommodating member11is turned upside down and then is placed on each self-adhesive substrate13so that the insulated adhering layer131is adhered on the fixing portion111of the accommodating member1. Thereafter, the mounting fixture3is removed from each self-adhesive substrate13, thus mounting each self-adhesive substrate13on the fixing portion111of the accommodating member11of the electronic device1. Referring toFIG. 18C, the accommodating member11is a fixing mount of the omni-directional LED bulb.

As illustrated inFIG. 19, in another embodiment, each self-adhesive substrate13includes a copper circuit layer132formed thereon, an insulated adhering layer131adhered with the copper circuit layer132, a release layer130attached with the insulated adhering layer131, a first insulation layer133aseparating the copper circuit layer132from the insulated adhering layer131, and a printing layer134printed on the copper circuit layer132.

To mount the self-adhesive substrate13ofFIG. 19, a method of mounting the self-adhesive substrate on the electronic device in another preferred embodiment comprises a step of (S01) providing a second insulation layer133aand a copper layer132aand adhering the second insulation layer133aand the copper layer132atogether, as shown inFIG. 20A. Referring further toFIG. 20B, the copper layer132ais processed to form a copper circuit layer132. As shown inFIG. 20C, the printing layer134is printed on the copper circuit layer132. As illustrated inFIG. 20D, the second insulation layer133ais adhered with the insulated adhering layer131.

With reference toFIG. 21, in another embodiment, each self-adhesive substrate13at least includes a printing layer134, a first insulation layer133, a copper circuit layer132, a second insulation layer133a, and an insulated adhering layer131.

To mount the self-adhesive substrate13ofFIG. 21, a method of mounting the self-adhesive substrate on the electronic device in another preferred embodiment comprises a step of (S01) providing a second insulation layer133aand a copper layer132aand adhering the second insulation layer133aand the copper layer132atogether, as shown inFIG. 22A. Referring further toFIG. 22B, the copper layer132ais processed to form a copper circuit layer132. As shown inFIG. 22C, a first insulation layer133is processed and adhered with the copper layer132a. As illustrated inFIG. 20D, the printing layer134is printed on first insulation layer133, and the second insulation layer133ais adhered with the insulated adhering layer131.

With reference toFIG. 23, the electronic device1is a smart phone, and a plurality of electronic elements14are welded with a self-adhesive substrate13. The self-adhesive substrate13at least one includes an insulated adhering layer131, a copper circuit layer132, and a first insulation layer133which are adhered on a fixing portion111of an accommodating member11of the electronic device1.

With reference toFIG. 24, the electronic device1is a tablet PC, and a plurality of electronic elements14are welded with a self-adhesive substrate13. The self-adhesive substrate13at least one includes an insulated adhering layer131, a copper circuit layer132, and a first insulation layer133which are adhered on a fixing portion111of an accommodating member11of the electronic device1.

Thereby, the method of mounting the self-adhesive substrate on the electronic device is employed to mount the self-adhesive substrate13on the electronic device1directly so that heat is transmitted to air from the plurality of electronic elements14via the self-adhesive substrate13and the electronic device1.