CN102734678B - 一种大功率led光源 - Google Patents
一种大功率led光源 Download PDFInfo
- Publication number
- CN102734678B CN102734678B CN2012102380222A CN201210238022A CN102734678B CN 102734678 B CN102734678 B CN 102734678B CN 2012102380222 A CN2012102380222 A CN 2012102380222A CN 201210238022 A CN201210238022 A CN 201210238022A CN 102734678 B CN102734678 B CN 102734678B
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- red copper
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N copper Chemical compound 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[Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 35
- 229910052802 copper Inorganic materials 0.000 claims abstract description 35
- 239000010949 copper Substances 0.000 claims abstract description 35
- 229910052751 metal Inorganic materials 0.000 claims description 13
- 239000002184 metal Substances 0.000 claims description 13
- 238000004020 luminiscence type Methods 0.000 claims description 12
- 238000010079 rubber tapping Methods 0.000 claims description 6
- 238000002347 injection Methods 0.000 claims description 5
- 239000007924 injection Substances 0.000 claims description 5
- BQCADISMDOOEFD-UHFFFAOYSA-N silver Chemical group 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[Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 5
- 229910052709 silver Inorganic materials 0.000 claims description 5
- 239000004332 silver Substances 0.000 claims description 5
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
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- 238000004519 manufacturing process Methods 0.000 abstract description 8
- DLNKOYKMWOXYQA-APPZFPTMSA-N L-Norpseudoephedrine Chemical compound 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C[C@@H](N)[C@H](O)C1=CC=CC=C1 DLNKOYKMWOXYQA-APPZFPTMSA-N 0.000 abstract 4
- 229960000395 Phenylpropanolamine Drugs 0.000 abstract 4
- 238000005516 engineering process Methods 0.000 description 11
- 238000005538 encapsulation Methods 0.000 description 10
- 230000000694 effects Effects 0.000 description 9
- 238000007598 dipping method Methods 0.000 description 7
- 238000010923 batch production Methods 0.000 description 5
- 238000010586 diagram Methods 0.000 description 5
- 238000009792 diffusion process Methods 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminum Chemical compound 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- 229910002027 silica gel Inorganic materials 0.000 description 1
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Abstract
本发明涉及一种大功率LED光源，包括外壳（1）和支架（3），所述支架（3）上设置有发光芯片，发光芯片上设置有反光层，其特征在于，所述LED光源还包括紫铜电极，紫铜电极（4）套在支架上，支架和紫铜电极设置注塑成形的PPA，PPA将紫铜电极包覆在其中间，所述注塑成形的PPA外设置有透镜（9）。本发明的技术方案结构简单，设计新颖，成本较低，生产工艺简单，安全可靠，散热性好，出光均匀，密封性好，并且整个外观结构时尚美观。
Description
一种大功率LED光源
技术领域
[0001] 本发明涉及一种LED光源，尤其是涉及到一种大功率的LED光源。
背景技术
[0002] 随着LED技术的不断发展和成熟，LED以其独特的优势在市场中占有越来越重要的地位，不论是路灯，隧道灯、庭院灯、墙壁灯等，LED灯渗透到灯具的各个领域，但是现有技术中也存在着一些一直困扰技术人员的难题。
[0003] LED的核心发光部分是由P型和η型半导体的ρη结管芯，当ρη结通过电流，电子与空穴相当移动并结合时，就会发出可见光、紫外光或近红外光。但是ρη结区发出的光子是非定向的，即向各个方向发射的几率相同。因此并不是管芯产生的所有光都可以释放出来，这主要取决于半导体材料质量、管芯结构及几何形状、封装内部结构与封装材料。LED封装是指发光芯片的封装，相比集成电路封装有较大的不同。LED的封装不仅要求能够保护灯芯，而且还要能够透光，所以LED的封装对封装材料有特殊的要求，LED封装是在完成输出电信号，保护管芯正常工作，输出可见光的功能，既有电参数，又有光参数的设计和技术要求，无法简单地使用普通封装技术。
[0004] 一般情况下，LED的发光 波长随温度变化为O. 2-0. 3nm/°C，光谱宽度随之增加，影响颜色鲜艳度。另外，当正向电流流经Pn结，发热性损耗使ρη结结区温度升高。在室温附近，温度每升高IV，LED的发光强度会相应地减少I %左右，故而封装散热性能，在保持LED工作发光时的色纯度与发光强度显得尤为重要。以往多采用减少其驱动电流的办法，降低ρη结结区温度，来保持发光的色纯度以及光照强度，多数的LED的驱动电流都保持在20mA左右，但是LED的光输出会随着电流的增大而增加，目前很多功率型LED的驱动电流可以达到70mA、IOOmA甚至IA级，需要改进封装结构。
[0005] 进入21世纪后，LED的高效化、超高亮度化、全色化不断发展创新，红、橙LED光效已达到100 lm/ff,绿LED为50 lm/ff,单只LED的光通量也达到数十流明（Im)。LED芯片和封装不再沿袭传统的设计理念和制造生产模式，在增加芯片的光输出方面，研发不仅仅限于改变改变材料内的杂质数量，晶格缺陷和位错来提高内部效率，同时，如何改善管芯及封装内部结构，增强LED内部产生光子出射的几率，提高光效、解决散热、取光和热沉优化设计，改进光学性能成为本领域技术人员关注的难题。
[0006] 目前市场上现已可以生产出O. 5W3W大功率LED产品，例如美国流明(Lumileds)公司的Luxeon LED，其特点是利用较大面积的金属底座，并用铝基板做为散热片，将芯片发光时所产生的热传导于空气中，在金属底座上用单颗大尺寸芯片或多颗小尺寸芯片封装，也能有效的提高LED的功率和亮度，但也是小幅度的提高，因为散热原理不太合理，还是无法解决芯片工作时的高热量问题，导致LED芯片容易衰减、崩溃，且工艺较难、成本高，不易推广。同时传统的LED支架封装结构是整个支架一起镀银，因此成本较高，力口工工艺也比较复杂，不适合批量生产，此外由于现有的应用于道路照明的LED 二次光学处理仅仅是在LED光源前部安装反光罩，因此光分部很不均匀，会大大影响照明效果。因此， 迫切的需要一种改进的大功率LED光源来解决上述技术问题。
发明内容
[0007] 本发明所解决的技术问题正是针对现有技术中大功率LED光源存在的技缺陷，提供一种结构、工艺简单、成本较低，散热快，密封性好，出光均匀的大功率LED光源。
[0008] 本发明的技术方案如下，一种大功率LED光源,包括外壳和支架,所述支架上设置有发光芯片，发光芯片上设置有反光层，其特征在于，所述LED光源还包括紫铜电极，紫铜电极套在支架上，支架和紫铜电极设置有与其结构配合的注塑成形的PPA，即聚邻苯二酰胺(简称PPA)树脂，PPA将紫铜电极包覆在其中间，这样可以起到保护电极，绝缘耐高温的作用，所述注塑形成的PPA外设置有透镜。此外，上述光源封装硅胶的配方采用添加苯基加油粘度CPS为8000-10000，密封效果好；支架采用高导热材料，散热效果好，该方案中采用主体和外壳相分离的结构设置，相比较于传统的一体化结构，该封装结构降低了生产成本，简化了生产工艺，适合批量生产，所述支架的一侧设置有销口，另一侧设置有单边出线开口，支架通过设置在销口中的定位销卡在外壳上，所述销口设置为半圆形，单边出线开口设置为梯形，该结构在安装中既简单、方便又使得整个结构密封性好。所述紫铜电极的正负电极延伸到支架的单边出线开口处，紫铜电极将芯片的正负极金线与电极相连，靠近的芯片可以就近连接电极，方便打线，提高工作效率，提高产量，其次，紫铜电极的正负电极延伸到圆形支架开口，实现了单边出线，相比较传统的两边出线，该结构简单，使用方便，并且外观时尚美观，而且该结构与灯座配套简单，方便客户使用。该方案中紫铜电极由两个半圆形的冲压件组成，紫铜电极的相比较现有技术中的车铝件，不仅质量可靠，而且由于其是两个半圆形，与支架的接触面积较大。所述LED光源还包括电极盖，所述电极盖通过自攻螺丝固定在支架上。由于该光源采用单边出线的结构，在圆形支架的开口上通过自攻螺丝将电极盖固定在支架上，既方便拆卸又保护电极结构，还具有防尘防水的作用。
[0009] 作为本发明的一种改进，所述透镜为中间厚两边薄的凸透镜，中间厚的区域设置为条纹结构，该条纹结构可以使光进行漫反射，发出的光斑较好，此外该结构可以使光聚集在透镜的中心位置，同时又可以更好的将光均匀的分布在透镜的四周，出光更均匀。
[0010] 作为本发明的一种改进，所述发光芯片在支架上呈直线排列，所述直线与透镜条纹状结构有一定的角度，该角度为45°——90°，优选为60°。芯片的排列方式与透镜的条纹状结构相匹配，利用光的散射原理，主要是为了增加光线散发面积，使光线散发面积的最大化。
[0011] 作为本发明的一种改进，所述透镜曲率半径设置为1. 5 — 2. 5米，优选为1. 8—2. O米，该范围的曲率半径可以更好的对发光芯片进行放大配光，增加灯光的强度。
[0012] 作为本发明的一种改进，所述支架（3)上设置有通气孔，增加透气性，便于散热。
[0013] 作为本发明的一种改进，所述支架下方设有导热性能较强的金属热沉，所述热沉可以是散热片等结构，设置金属热沉便于热量的及时扩散，延长LED灯的使用寿命。
[0014] 作为本发明的一种改进，所述支架设置为三层结构，中间层为纵向、上下两层均为横向设置，每层均为具有一定间隙的热沉层叠而够成散热结构，所述热沉为具导热性能的金属；所述热沉优选为厚度为O. 8mm-1. Omm的铜金属,优选为O. 9mm的铜金属，每层热沉板还设有用于通风散热通孔。[0015] 作为本发明的一种改进，所述支架下方设置有导热管。设置导热管便于热量的及时扩散，延长LED灯的使用寿命。
[0016] 作为本发明的一种改进，所述反光层为镀银层，由于银具有很好的反光效果，本发明采用仅在芯片上面镀银，使光源在出光中有反射，增加了出光效率，同时也解决了 LED的导热问题，相比较现有技术中整个支架一起镀银的结构，该技术方案大大降低了成本，加工工艺比较简单，更适合批量生产。
[0017] 作为本发明的一种改进，所述外壳和支架均设置成圆形。
[0018] 相对于现有技术，本发明的优点如下：结构简单，设计新颖，该大功率LED光源没有借助复杂的部件，仅仅是在现有技术的基础上针对结构做了改变，就解决了现有技术中的难题；成本较低，生产工艺简单，安全可靠，散热性好，出光均匀，密封性好，并且整个外观结构时尚美观。
附图说明
[0019] 图1为本发明整体结构示意图；
[0020] 图2为紫铜电极结构示意图；
[0021] 图3为PPA结构示意图；
[0022] 图4为支架结构示意图；
[0023] 图5为电极盖结构示意图。
[0024] 图中：I为外壳，2为定位销，3为支架，4为紫铜电极，6注塑PPA，7为电极盖，8为自攻螺丝，9透镜，10销口，11为单边出线开口。
具体实施方式
[0025] 为了加深对发明的理解，下面结合附图1一5对大功率LED光源做详细的说明，参见图1。
[0026] 实施例1 :如图1、3所示，一种大功率LED光源，包括外壳（I)和支架（3)，所述外壳和支架可以设置成圆形，所述支架（3)上设置有发光芯片，发光芯片上设置有反光层，所述LED光源还包括紫铜电极（4)，紫铜电极（4)套在支架上，支架和紫铜电极上设置有与其结构配合的注塑成形的PPA，PPA将紫铜电极包覆在其中间，这样可以起到保护电极，绝缘耐高温的作用，所述注塑成形的PPA外设置有透镜（9)。透镜（9)为中间厚两边薄的凸透镜，中间厚的区域设置有条纹结构。该结构可以使光聚集在透镜的中心位置，同时又可以更好的将光均匀的分布在透镜的四周，出光更均匀。该方案采用主体和外壳相分离的结构设置，相比较于传统的一体化结构，该封装结构降低了生产成本，简化了生产工艺，适合批量生产。
[0027] 图2为紫铜电极结构示意图，该紫铜电极（4)由两个半圆形的冲压件组成。紫铜电极的相比较现有技术中的车铝件，不仅质量可靠，而且由于其是两个半圆形，与支架的接触面积较大。
[0028] 图4为支架结构示意图，所述支架的一侧设置有销口（10)，另一侧设置有单边出线开口（11)，支架通过设置在销口中的定位销（2)卡在外壳上，所述紫铜电极（4)的正负电极延伸到支架的单边出线开口（11)处，紫铜电极将芯片的正负极金线与电极相连，靠近的芯片可以就近连接电极，方便打线，提高工作效率，提高产量，其次，紫铜电极的正负电极延伸至帽形支架开口，实现了单边出现，相比较传统的两边出线，该结构简单，使用方便，并且外观时尚美观。
[0029] 图5为电极盖结构示意图，结合图1可以看到，电极盖（7)通过自攻螺丝（8)固定在支架（3)上。由于该光源采用单边出线的结构，在圆形支架的开口上通过自攻螺丝（8)将电极盖固定在支架上，既方便拆卸又保护电极结构，还具有防尘防水的作用。
[0030] 实施例2 :将反光层设置为镀银层，其他结构与实施例1相同；由于银具有很好的反光效果，本发明采用仅在芯片上面镀银，使光源在出光中有反射，增加了出光效率，同时也解决了 LED的导热问题，相比较现有技术中整个支架一起镀银的结构，该技术方案大大降低了成本，加工工艺比较简单，更适合批量生产。
[0031] 实施例3 :将销口（ 10)设置为半圆形，单边出线开口（ 11)设置为梯形，其他结构与实施例1相同；该结构在安装中既简单、方便又使得整个结构密封性好。
[0032] 实施例4:发光芯片在支架上呈直线排列，所述直线与透镜条纹状结构有一定的角度，该角度为45° —90°，优选为60°。芯片的排列方式与透镜的条纹状结构相匹配，利用光的散射原理，主要是为了增加光线散发面积，使光线散发面积的最大化。
[0033] 实施例5 :透镜曲率半径设置为1.5—2. 5米，优选为1. 8—2. O米，该范围的曲率半径可以更好的对发光芯片进行放大配光，增加灯光的强度。
[0034] 实施例6 :支架（3)下方设有导热性能较强的金属热沉，所述热沉可以是散热片等结构，设置金属热沉便于热量的及时扩散，延长LED灯的使用寿命。
[0035] 实施例7 :支架（3)设置为三层结构，中间层为纵向、上下两层均为横向设置，每层均为具有一定间隙的热沉层叠而够成散热结构，所述热沉为具导热性能的金属；所述热沉优选为厚度为O. 8mm-1. Omm的铜金属,优选为O. 9mm的铜金属，每层热沉板还设有用于通风散热通孔。
[0036] 实施例8 :支架下方设置有导热管，设置导热管便于热量的及时扩散，延长LED灯的使用寿命。
[0037] 本发明的技术方案结构简单，设计新颖，成本较低，生产工艺简单，安全可靠，散热性好,出光均匀,密封性好,并且整个外观结构时尚美观。
[0038] 需要说明的是，上述实施例仅是本发明的较佳实施例，并没有限定本发明的保护范围，在上述结构上所做的等同替换或者改变均落入本发明的保护范围，本发明的保护范围以权利要求书为准。
Claims (10)
1. 一种大功率LED光源，包括外壳（I)和支架（3)，所述支架（3)上设置有发光芯片， 发光芯片上设置有反光层，其特征在于，所述LED光源还包括紫铜电极，紫铜电极（4)套在支架上，支架和紫铜电极上设置有与其结构配合的注塑成形的PPA，PPA将紫铜电极包覆在其中间，所述注塑成形的PPA外设置有透镜（9);所述支架（3)的一侧设置有销口（10)，另一侧设置有单边出线开口（11)，所述销口（10)设置为半圆形，单边出现开口（11)设置为梯形，支架通过设置在销口中的定位销（2)卡在外壳（I)上；所述紫铜电极（4)由两个半圆形的冲压件组成，其正负电极延伸到支架的单边出线开口（11)处，单边出线开口处通过电极盖（7 )进行密封，所述电极盖通过自攻螺丝（8 )固定在支架（3 )上。
2.根据权利要求1所述的大功率LED光源，其特征在于：所述透镜（9)为中间厚两边薄的凸透镜，中间厚的区域设置为条纹状结构。
3.根据权利要求2所述的大功率LED光源，其特征在于：所述发光芯片呈直线排列，所述直线与透镜条纹状结构有一定的角度，该角度为45°——90°。
4.根据权利要求1或2或3所述的大功率LED光源，其特征在于：所述透镜曲率半径设置为1. 5—2. 5米。
5.根据权利要求1或2或3所述的大功率LED光源，其特征在于：所述支架（3)上设置有通气孔。
6.根据权利要求1或2或3所述的大功率LED光源，其特征在于：所述支架下方设有导热性能较强的金属热沉。
7.根据权利要求6所述的大功率LED光源，其特征在于：所述支架设置为三层结构，中间层为纵向、上下两层均为横向设置，每层均为具有一定间隙的热沉层叠而够成散热结构， 所述热沉为具导热性能的金属；所述热沉优选为厚度为O. 8mm-l. Omm的铜金属，每层热沉板还设有用于通风散热通孔。
8.根据权利要求1或2或3所述的大功率LED光源，其特征在于：所述支架下方设置有导热管。
9.根据权利要求1或2或3所述的大功率LED光源，其特征在于：所述反光层为镀银层。
10.根据权利要求1或2或3所述的大功率LED光源，其特征在于：所述外壳（I)和支架（3)均设置成圆形。
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