Development of reel-to-reel microchip mounting system for fabrication of meter-long LED lighting tapes

Abstract

We have developed a reel-to-reel microchip mounting system that continuously mounts LED chips and other microchips on meter-long flexible printed circuit board (PCB) tape for 1.2-m-long standard LED light tubes. Mounting microchips on meter-long PCBs is difficult because a large chip mounter is expensive and the chip positioning stage is difficult to move in a meter-wide area with an accuracy of hundreds of micrometers. Hence, we developed a new microchip mounting system that utilizes a small chip mounter and reel winding machines. The system repeatedly moves the long PCB tape by a certain length with the reel winding machines and mounts the chips on it. The PCB tape (which is 5 mm wide) is made by fabricating long PCB tapes which are 25 cm × 26.6 m through a roll-to-roll PCB process and slitting them into meter-long tapes. The reel-to-reel system repeatedly mounts chips by adjusting their positions through image processing of the copper wiring pattern on the PCBs. Our constructed system mounted 24 LED chips with a pitch of 5 cm with an accuracy of 0.082 mm to form a 1.2-m-long LED tape. The luminance of the tape is 12.4 lx at a distance of 1 m, which is the luminance of outdoor corridor lighting. Therefore, this system can be used for meter-long tape lighting.