The Working Principle, Structure, and Production Process of Vape Digital Screens

1- Overview

E - cigarettes with digital - screen are among the trends in the industry. Although LED digital tube is common and the application is mature, it will develop in the direction of large-scale and flexible. Let's take a closer look at the working principle, structure and production process of this kind of screen.

2- Preface and Principle of Operation

2-1 LED digital tubes (LED Segment Displays LED Module) are now very common digital information display devices. They are popular in a wide range of domains like digital products home appliances and industrial digital instruments.

2-2 The LED digital tube, in fact, is made up of 7 light - emitting diodes into an "8" shape. There are a total of eight, adding a decimal point. These segments are denoted using the letters a b c d e f g and dp respectively. If a certain part of the digital tube is connected to the voltagethat part will shine and finally show the content displayed.

2-3 Principle: The operation is based on the behavior of the light - emitting diodes. The process of photon emission occurs when current flow causes electrons and holes to combine in the semiconductor material of the LED releasing energy in the form of photons. Different segment combinations of lit segments display different numbers letters or symbols on an LED digital tube. For example segments a b c d e and f need to be lit in order to display the number "0" and to display "1" only segments b and c are lit. Using multiple LED digital tubes, the information can be conveyed through the ON's and OFF's of a limited number of segments, which is a simple, practical, and effective method. This feature has made LED digital tubes widely used in various applications.

3- Structure Composition

3-1 Basically, the digital tube is made up of PIN Pins (Leads), a plastic shell (Usually PC or PPO), a PCB (Printed Circuit Board), light -emitting diodes (LED lamp beads), a display panel, die -attach adhesive, high - temperature tape epoxy resin and so on. The PIN pins from the tube itself. They are the contact points between the digital tube and the external circuit enabling electrical signals to be fed into the device. It is an outer shell made of plastic that protects the internal components from physical damage and environmental factors such as moisture and dust. The plastic shell is usually made of PC (Polycarbonate) and PPO (Polyphenylene Oxide) plastic, as they have good insulation properties, mechanical strength and heat resistance.

3-2 PCB, which is the carrier of the digital tube electrical components. It is responsible for guiding several electrical connection paths such as LED lamp beads PIN pins and other components. The PCB layout and design are critical for the normal operation of the digital tube, as they determine how the electrical signals are routed and controlled.

3-3 LED lamp beads are the core components that emit the light. Several types of LED lamp beads can produce light of different colors: red, green, blue, yellow, white, etc. Different types of led lamp beads are selected according to the different requirements of the digital tube, such as display color and brightness.

3-4 For panel, the part where the user looks directly at what it displays. The face is the part of the display that is typically made from a transparent material that often contains a specialized layer or coating to improve the appearance of lit areas.

3-5 Die - paste adhesive is used on PCB side to stick LED chips(the core part of LED lamp beads) During production, high - temperature tape is placed to hold components or shield portions of the parts from being influenced by the fabrication activities.

3-6 Encapsulation glue was applied to seal the digital tube to protect the internal parts from air exposure as well as better the optical performance of the device.

3-7 After the raw materials are bought inspections by the quality control department are done. They experiment with the durability and visual of different materials. The materials will only be accepted when they meet the quality standards and only after that can they be entered into the warehouse, and finally laid on the production line, initiating the production process of the digital tube.

4- Manufacturing steps

4-1 The general production process of digital tube: insert PIN die bonding wire bonding semi - finished testing glue filling film pasting, finished products testing and wrapping.

4-2 PIN Insert The first main process is the bonding of PCB and guide pins. Then insert the guide pins into the PCB holes by an automatic pin - inserting machine. Then the guide pins are pressed and rivet well with PCB. This task necessitates high - precision equipment to ensure the pins are correctly inserted and firmly placed. Inserting pins incorrectly may cause issues with electrical connection, or the mechanical stability of the digital tube.

4-3 Die Bonding The second process is die bonding, which includes two sub - processes: LED chip die bonding and aluminum wire bonding. In the LED chip die - bonding is performed using an automatic chip - bonding machine. First, die - Attach adhesive is a dispensed on PCB board and the LED, chip is placed. The die - attach adhesive is cured at elevated temperature to bond the chip tightly. Subsequently, the aluminum wire bonding is done. The LED chip is welded to one end of the aluminum wire (based on the aluminum wire) and a solder to the PCB at the other end. This step is essential to form the circuit connection between the LED chip and the PCB The quality of welding directly affects the performance and stability of the digital tube.

4-4 Semi - completed Testing The third link, that is the testing link. Trained on data between Sep 2020 to Oct 2023- But after the second process was tightened up many manufacturers have shut the testing process down. If the quality control in die - bonding is strict enough the probability of defects of semi - finished products can be effectively reduced. However for some manufacturing that has high requirements for product quality and reliability this kind of testing process is still reserved.

4-5 Glue Filling The fourth process is glue - filling process. Degaasing glue, usually epoxy resin, is degassed with glue filling equipment. Next, the tested products are placed into the glue filled plastic shells. Then they get High Temperature long term curing to become solid structure. Actually, this is due to the importance of the glue - filling process. The glue - filling of the tube not only has the function of protecting the internal digital tube circuit from damage by the environment, but also makes the light illuminated by the LED lamp beads more evenly distributed in the digital tube and can improve the optical performance of the device.

4-6 Finished Products Testing The fifth process is the finished - product testing process. The resulting digital tubes are tested again for performance. So, the performance test is similar as what we did in the 3rd process but the relevant parameters can be reasonably relaxed according to various customer needs. Some special digital tubes need to add processes such as face mask and guide pin shaping. Then, the face mask is to use to protect the display panel or has some special visual effects, the guide - pin shaping for example, use to ensure shaped correctly then facilitate to installed in the final product.

4-7 Wrapping The Final Process The Packaging Process This part is mainly the appearance inspection of the product, code marking printing, packaging work. Every company might edit the respective processes slightly for example by including or skipping some steps or switching the phases around depending on their internal technology. For instance, some companies might perform an extra cleaning process prior to packaging to ensure that the surface of the digital tube is clean and no contaminants are present.

5- Selection

5-1 Font Height or Size The font height or size of the digital tube is an important factor When choosing LED digital tube for e - cigarette or other applications. They come in common sizes like 0.4 inches 0.56 inches 0.8 inches etc. Digital tube size is selected based on the product space and the visibility requirement. For instance, in a mini-vape, a mini digital pipe may be more suitable for space saving, and a larger digital pipe can be used in a larger industrial instrument to ensure better readability.

5-2 Number of DigitsDetermine the number of digits of the digital tube, which decides the maximum amount of the content : a single display component can show. However, if it is a higher-level Content Figuring System or multiple simple numbers or letters need to be displayed, then an electronic tube with a small number of digits is not enough. However when considering to present more sophisticated information for example time date or multi - digit numbers one needs to get a digital tube with more digits.

5-3 Emission Color (Wavelength of Emitted Light) Digital tubes can be single color marshmallow tubes, such as red, yellow, blue, green, white, multicolor RGB (Red - Green - Blue). Color of the product depends on the product design concept and users visual preference. Such as in a medical device the green - colored digital tube can be used to provide a safer feeling and stable feeling to the user or in a decorative e - cigarette the RGB - colored digital tube can be used to create a more beautiful and vivid visual effect.

5-4 Brightness The brightness of the digital tube can be divided into two forms: normal brightness and high - brightness. In strong ambient light environments such as outdoor or brightly lit industrial workshops a high - brightness digital tube shoul be used to ensure that the displayed content is clearly visible. Alternatively, a normal - brightness digital tube may be adequate even in low - light conditions to prevent excessive glare.

5-5 Working Scope Working Voltage And Current The working voltage and current of digital tube. Different digital tube types have different voltage and current requirements. In addition when choosing a digital tube the power supply of the product must reach this level. So as not to cause over - voltage or under - current and other problems damage digital tube or affect its normal work.

5-6 The Silk Screen Color of the Surface (Panel) The color of the surface silk - screening on the panel is generally milky white black gray etc. The color you choose can change the look of the product and contrast of the displayed content. Different The color panel is black - which can provide a high - contrast background for the lit segments in the digital tube so that the display content can be more prominent.

5-7 Internal Connection Method: Common Cathode / Common Anode Digital tubes can be classified into common cathode and common anode based on its internal connection method. A common - cathode digital tube the cathodes of all the LED segments are connected together and the anodes are controlled independently. In the common - anode digital tube all the LED segments anodes are connected together and the cathodes are controlled individually. The design choice of the connection depends on the circuit design of the product.

5-8 Working Life Working life is an important parameter considered for ( digital tube). To increase the life of the product, use a digital Tube that is a longer-life, low maintenance alternative. When selecting a digital tube, it is recommended to consult the manufacturers specifications for the calculated use time under various working states.

5-9 Work temperature and humidity The digital tube needs to work stable in a certain temperature and humidity range. Digital tube performance and lifetime may be affected in a high - temperature or high - humidity environment. So, when selecting a digital tube for such environments, you need to select a type that has heat resistance and moisture resistance.

5-10 Other Performance Other performance requirements include: Waterproof level, dust - proof, anti - ultraviolet, crack - resistant, flame - resistant and super - impact - resistant aging. For example a digital tube with certain waterproof level should be used in e - cigarette that can be used environment humid can ensure that it normally works. Outdoor - used devices require a digital tube with good anti - ultraviolet performance to prevent damage of the display panel from sunlight. Construction requirements: In the aspects of the appearance the LED digital tube must have uniform colors do not have local color changes and do not have bubbles. Although the statistics are not comprehensive, related digital - tube suppliers in e - cigarette industry include Qishunda Guoyexing Yushengxinlong Yongtian Optoelectronics Fengyifang Optoelectronics Chuangyijia Mingcheng Electronics Wanshi Optoelectronics etc. With different specifications and performance, these suppliers provided a wide range of digital tubes for the e - cigarette industry.

Vape User Feedback Reference

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