Patent ID: 8535959

Claim:
A method for producing a large lighting with a power LED, comprising: (a) a step in which an opening is formed by means of a punching process at part of an upper side in order for a double-sided substrate not to be passed depending on the shape and size of the power LED in the double-sided substrate (FR-4 PCB) in which a Cu thin surface is attached at the upper and lower portions made from a FR-4 material having a solder pad which can fix a lead frame (+pole and −pole) of the power LED; (b) a step in which a plurality of through holes are formed by passing through the remaining parts of the double-sided substrate extended from the opening, so a multi-through hole of a two-tiered structure is formed in such a way that a lower Cu thin surface of a double-sided substrate (FR-4 PCB) is not punched; (c) a step in which a Pb-free cream solder is injected in the multi-through hole of a two-tiered structure as much as the height of the solder pad for the purpose of providing a heat slug function by using a mechanical device; (d) a step in which a PCB assembly (PCB Assy) is finished by soldering a Pb-free cream solder for the purpose of ensuring that the heat radiation point of the heating portion of a backside of the power LED and the Pb-free cream solder and the lower Cu thin surface of the double-sided substrate are integrated, by using a movable high temperature equipment after the power LED is properly positioned at the pole plates following the injection of the Pb-free cream solder; and (e) a step in which the PCB assembly is engaged to an aluminum structure which is a large heat radiation structure, thus maximizing the heat radiation efficiency of the LED lighting.