CN102777776A - 氧化铝陶瓷led球泡灯及其制造方法 - Google Patents
氧化铝陶瓷led球泡灯及其制造方法 Download PDFInfo
- Publication number
- CN102777776A CN102777776A CN2011101227466A CN201110122746A CN102777776A CN 102777776 A CN102777776 A CN 102777776A CN 2011101227466 A CN2011101227466 A CN 2011101227466A CN 201110122746 A CN201110122746 A CN 201110122746A CN 102777776 A CN102777776 A CN 102777776A
- Authority
- CN
- China
- Prior art keywords
- aluminium oxide
- radiator
- ceramic substrate
- cover plate
- oxide ceramics
- Prior art date
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N al2o3 Chemical compound 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[O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 title claims abstract description 153
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 229910052574 oxide ceramics Inorganic materials 0.000 title abstract 15
- 239000011224 oxide ceramics Substances 0.000 title abstract 14
- 239000000758 substrates Substances 0.000 claims abstract description 66
- 240000006028 Sambucus nigra Species 0.000 claims abstract description 11
- 229910003726 AI2O3 Inorganic materials 0.000 claims description 162
- 239000000919 ceramics Substances 0.000 claims description 158
- 239000011957 aluminium oxide Substances 0.000 claims description 138
- 239000000463 materials Substances 0.000 claims description 45
- 238000005516 engineering processes Methods 0.000 claims description 9
- 238000002347 injection Methods 0.000 claims description 6
- 239000007924 injections Substances 0.000 claims description 6
- 230000000694 effects Effects 0.000 abstract description 13
- 238000001816 cooling Methods 0.000 abstract description 3
- 239000004411 aluminium Substances 0.000 description 7
- 229910052782 aluminium Inorganic materials 0.000 description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminum Chemical compound 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- 238000000034 methods Methods 0.000 description 5
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- 238000006243 chemical reactions Methods 0.000 description 4
- 238000002360 preparation methods Methods 0.000 description 4
- 239000006185 dispersions Substances 0.000 description 3
- 239000011230 binding agents Substances 0.000 description 2
- 230000017525 heat dissipation Effects 0.000 description 2
- 239000011810 insulating materials Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
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Abstract
本发明公开了一种氧化铝陶瓷LED球泡灯及其制造方法，所述球泡灯包括灯罩、氧化铝陶瓷盖板、氧化铝陶瓷基板、LED芯片、散热器和灯头；散热器一端连接所述灯头，其另一端连接所述灯罩；氧化铝陶瓷盖板上开有多个孔，LED芯片固定述氧化铝陶瓷基板上，氧化铝陶瓷盖板与氧化铝陶瓷基板盖合并热接触，LED芯片透过氧化铝陶瓷盖板上开有的孔发出的光线朝向所述灯罩；散热器与灯罩围合成一空间，氧化铝陶瓷盖板与氧化铝陶瓷基板组成的盖合体置于所述空间内；散热器与所述氧化铝陶瓷基板热接触。本发明的氧化铝陶瓷LED球泡灯采用氧化铝陶瓷材料制作散热器、基板和盖板，显著地提高了LED灯的散热效果。
Description
氧化铝陶瓷LED球泡灯及其制造方法
技术领域
[0001] 本发明涉及LED领域，尤其涉及一种氧化铝陶瓷LED球泡灯及其制造方法。
背景技术
[0002] LED (Light Emitting Diode,发光二极管）是一种固态的半导体器件,它可以直接把电转化为光。LED基于上述属性,被广泛应用于光源产品。
[0003] 从上世纪80年代起，LED —直作为小功率光源，其散热一般不存在太大问题。但进A 21世纪后，LED逐渐被应用于大功率光源，由于LED半导体发光的机理,产生大量的热。这些热需要尽快散发出去，否则在LED温度过高时其发光效率将大幅降低，而且寿命也短。
[0004] 近10年来，出于成本考虑，大功率LED产品一般采用铝散热器进行散热，但是，即 使是铝散热器，其成本仍然较高，一是材料成本高，二是加工成本更高，导致目前大功率LED产品的价格仍然相对较高，对市场的普及有一定影响；而且，铝散热器散热性能也并不突出。目前市场上也存在其他散热较好的散热器，比如铜散热器或采用水冷、风扇等辅助工具的散热器。但这些散热器要不成本非常高，要不结构非常复杂，难以普及。
[0005]目前，应对资源紧缺导致发展不可持续的严重状况，国家已经确立节能减排以及低碳目标，并将发展LED产业特别是LED节能灯方面作为突破口之一。
[0006] LED节能灯中，承载LED芯片的基板目前采用陶瓷散热基板，如2008年10月I日公开的中国发明专利申请第200810067069. 0号所描述的一种LED封装用陶瓷散热基板。LED节能灯除基板外的其余结构，如散热器、灯尾等部分仍然采用传统铝材等作为散热结构。在2007年8月8日公开的中国发明专利申请第200710008419. I号所描述的陶瓷散热材料及其用途和制造方法中，公开了技术方案：所述陶瓷散热材料由碳化硅、三氧化二铝、二氧化硅和粘结剂为原材料注射成型而成，它们的重量百分比配方是，碳化硅50%〜90%，三氧化二铝5 %〜35 %，二氧化硅2 %〜15 %，粘结剂3 %〜25 %，其用作电固体器件散热装置的散热鳍片体，射灯的灯罩。据此专利申请描述，所述主要有碳化硅构成的陶瓷散热材料热传导系数介于4〜8w/m-k之间，其主要是利用碳化硅热传导系数高的特点。
[0007] 如前述，LED节能灯在民用市场上能否普及主要取决于三点：第一点是如何解决散热技术；由此引发第二点问题是成本如何控制；第三点是开关电源转换效率过低。其中，采用PCB板的开关电源导热系数差造成转换效率低，因此，关键仍在于散热设计。
发明内容
[0008] 本发明主要解决的技术问题是提供一种导热性能好、价格较低、适合大批量生产的氧化铝陶瓷LED球泡灯及其制造方法。
[0009] 为解决上述技术问题，本发明采用的一个技术方案是：提供一种氧化铝陶瓷LED球泡灯，包括灯罩、氧化铝陶瓷盖板、氧化铝陶瓷基板、LED芯片、散热器和灯头；所述散热器一端连接所述灯头，其另一端连接所述灯罩；所述氧化铝陶瓷盖板上开有多个孔，所述LED芯片固定在所述氧化铝陶瓷基板上，所述氧化铝陶瓷盖板与所述氧化铝陶瓷基板盖合并热接触，所述LED芯片透过所述氧化铝陶瓷盖板上开有的孔发出的光线朝向所述灯罩；所述散热器与所述灯罩围合成一空间，所述氧化铝陶瓷盖板与所述氧化铝陶瓷基板组成的盖合体置于所述空间内；所述散热器与所述氧化铝陶瓷基板热接触。
[0010] 其中，所述氧化铝陶瓷基板的材料中包括75〜95%重量比例的氧化铝。
[0011] 其中，所述氧化铝陶瓷盖板的材料中包括75〜95%重量比例的氧化铝。
[0012] 其中，所述散热器为陶瓷散热器，所述散热器的材料中包括75〜95%重量比例的氧化铝。
[0013] 其中，所述散热器为柱状散热器，柱状散热器外周设置多个放射状散热鳍片。
[0014] 为解决上述技术问题，本发明采用的另一个技术方案是：提供一种氧化铝陶瓷LED球泡灯制作方法，包括以下步骤：
[0015] 准备氧化铝材料及陶瓷辅料，其中所述氧化铝材料占总重量的75〜95%重量比例；
[0016] 采用陶瓷注射成型工艺将所述氧化铝材料及辅料制作成陶瓷散热器和氧化铝陶瓷基板；
[0017] 将LED芯片固定在氧化铝陶瓷基板上，并使得氧化铝陶瓷基板与陶瓷散热器热接触；
[0018] 将灯罩连接于陶瓷散热器的一端，将灯头连接于陶瓷散热器的另一端，且使LED芯片的出光面朝向所述灯罩。
[0019] 其中，在将LED芯片固定在氧化铝陶瓷基板上，并使得氧化铝陶瓷基板与陶瓷散热器热接触的步骤中，还包括以下步骤：
[0020] 准备氧化铝材料及陶瓷辅料，其中所述氧化铝材料占总重量的75〜95%重量比例；
[0021] 采用陶瓷注射成型工艺将所述氧化铝材料及辅料制作成氧化铝陶瓷盖板，并在盖板上开有多个透光孔；
[0022] 将带有透光孔的氧化铝陶瓷盖板盖住所述氧化铝陶瓷基板，使得LED芯片透过所述氧化铝陶瓷盖板上开有的孔发出的光线朝向所述灯罩。
[0023] 其中，在将带有透光孔的氧化铝陶瓷盖板盖住所述氧化铝陶瓷基板的步骤中，所述氧化铝陶瓷盖板与所述氧化铝陶瓷基板盖合并热接触。
[0024] 其中，所述散热器为柱状散热器，柱状散热器外周设置多个放射状散热鳍片。
[0025] 其中，所述氧化铝陶瓷基板内具有驱动所述LED芯片的印刷线路。
[0026] 本发明的有益效果是：区别于现有技术的LED灯散热效果差、成本较高且制作困难的缺陷，本发明的氧化铝陶瓷LED球泡灯采用氧化铝陶瓷材料制作散热器、基板和盖板，显著地提高了 LED灯的散热效果。更加重要的是，在基板上设置绝缘的氧化铝陶瓷盖板，并使得氧化铝陶瓷基板和氧化铝陶瓷盖板贴合，即使在灯罩损坏的情况下，也能起到绝缘作用，提高了 LED球泡灯的安全性。
[0027] 本发明以氧化铝为主，其散热导热率高达27以上，相对于现有碳化硅为主陶瓷材料导热率的6倍左右，本发明的散热性能是其4倍以上，并且恰恰是绝缘体，另一关键的是，本发明散热器由于主要采用氧化铝，成本极低，氧化铝材料价格约为铝的十分之一，因此制作得到的散热器和LED灯价格极为低廉，对LED节能灯的普及是一个关键的突破。本发明散热器加工过程类似于陶瓷工艺，易实现、低成本、适合大批量生产；此外，氧化铝为绝缘材料符合电器使用安全要求。
附图说明
[0028] 图I是本发明氧化铝陶瓷LED球泡灯实施例的结构爆炸图；
[0029] 图2是本发明氧化铝陶瓷LED球泡灯制作方法的步骤流程图；
[0030] 图3是本发明氧化铝陶瓷LED球泡灯制作方法子步骤的步骤流程图。
具体实施方式
[0031] 为详细说明本发明的技术内容、构造特征、所实现目的及效果，以下结合实施方式并配合附图详予说明。
[0032] 热接触，即可以快速热传导的接触。本案中，当氧化铝陶瓷基板的温度升高，通过热接触，氧化铝陶瓷基板的温度通过散热器快速散发出去。当氧化铝陶瓷基板的温度升高，通过热接触，氧化铝陶瓷基板的温度通过氧化铝陶瓷快速散发出去。
[0033] 请参阅图1，本发明实施例的氧化铝陶瓷LED球泡灯，包括灯罩5、氧化铝陶瓷盖板3、氧化铝陶瓷基板2、LED芯片4、散热器I和灯头6 ;所述散热器I 一端连接所述灯头6，其另一端连接所述灯罩5 ;所述氧化铝陶瓷盖板3上开有多个孔，所述LED芯片4固定在所述氧化铝陶瓷基板2上，所述氧化铝陶瓷盖板3与所述氧化铝陶瓷基板2盖合并热接触，所述LED芯片4透过所述氧化铝陶瓷盖板3上开有的孔发出的光线朝向所述灯罩5 ;所述散热器I与所述灯罩5围合成一空间，所述氧化铝陶瓷盖板3与所述氧化铝陶瓷基板2组成的盖合体置于所述空间内；所述散热器I与所述氧化铝陶瓷基板2热接触。
[0034] 本发明的氧化铝陶瓷LED球泡灯采用氧化铝陶瓷材料制作散热器、基板和盖板，显著地提高了 LED灯的散热效果。更加重要的是，在基板上设置绝缘的氧化铝陶瓷盖板，并使得氧化铝陶瓷基板和氧化铝陶瓷盖板贴合，即使在灯罩损坏的情况下，也能起到绝缘作用，提高了 LED球泡灯的安全性。
[0035] 本发明以氧化铝为主，其散热导热率高达27以上，相对于现有碳化硅为主陶瓷材料导热率的6左右，本发明的散热性能是其4倍以上，并且恰恰是绝缘体，另一关键的是，本发明散热器由于主要采用氧化铝，成本极低，氧化铝材料价格约为铝的十分之一，因此制作得到的散热器和LED灯价格极为低廉，对LED节能灯的普及是一个关键的突破。本发明散热器加工过程类似于陶瓷工艺，易实现、低成本、适合大批量生产；此外，氧化铝为绝缘材料符合电器使用安全要求。
[0036] 在一具体实施例中，所述氧化铝陶瓷基板的材料中包括75〜95%重量比例的氧化招。
[0037] 在一具体实施例中，所述氧化铝陶瓷盖板的材料中包括75〜95%重量比例的氧化铝。
[0038] 在一具体实施例中，所述散热器为陶瓷散热器，所述散热器的材料中包括75〜95%重量比例的氧化铝。
[0039] 其中，氧化铝与铝合金6061的参数对比表如下表所示：
[0040]项目 单位乳化铭
铝合金6061
(Item) Unit A1203
密度
g/cm3 3.9 2.7
(Sintered density)
[0041]
热膨账系数 °C-1 8 x 10-6 23.6
(Thermal expansion coefficient)
介电强度
kV/mm >14 —
(Dielectric strength)
体阻抗
C. cm >1014 —
(Volume Resistivity)
热传导率
W/m. K30 170
(Thermal conductivity)
[0042] 在一具体实施例中，所述散热器为柱状散热器，柱状散热器外周设置多个放射状散热鳍片。贴合热接触的作用是提高散热接触面积，有效地提高散热效率，增强散热效果。
[0043] 参见图2，本发明实施例的氧化铝陶瓷LED球泡灯制作方法，包括以下步骤：
[0044] 步骤101 :准备氧化铝材料及陶瓷辅料，其中所述氧化铝材料占总重量的75〜95%重量比例；
[0045] 步骤102 :采用陶瓷注射成型工艺将所述氧化铝材料及辅料制作成陶瓷散热器和氧化铝陶瓷基板；
[0046] 步骤103 :将LED芯片固定在氧化铝陶瓷基板上，并使得氧化铝陶瓷基板与陶瓷散热器热接触；
[0047] 步骤104 :将灯罩连接于陶瓷散热器的一端，将灯头连接于陶瓷散热器的另一端，且使LED芯片的出光面朝向所述灯罩。
[0048] 参见图3，在一具体实施例中，在步骤103中，还包括以下步骤：
[0049] 步骤1031 :准备氧化铝材料及陶瓷辅料，其中所述氧化铝材料占总重量的75〜95%重量比例；
[0050] 步骤1032 :采用陶瓷注射成型工艺将所述氧化铝材料及辅料制作成氧化铝陶瓷盖板，并在盖板上开有多个透光孔；
[0051] 步骤1033 :将带有透光孔的氧化铝陶瓷盖板盖住所述氧化铝陶瓷基板，使得LED芯片透过所述氧化铝陶瓷盖板上开有的孔发出的光线朝向所述灯罩。
[0052] 本发明的灯珠封装方法包括以下步骤：
[0053] I)在氧化铝陶瓷基板的正面印刷导热氧环树脂层，并将氧化铝陶瓷基板与氧化铝陶瓷盖板拼装，加热至120度使导热氧环树脂固化；
[0054] 2)通过固晶机将多个LED晶片安装至氧化铝陶瓷盖板的透光孔的位置，通过邦定机连接LED芯片与氧化铝陶瓷基板上印刷线路的电极；[0055] 3)使用点胶机将荧光胶灌封在氧化铝陶瓷盖板的直径为2. 6毫米圆孔里。
[0056] 在一具体实施例中，在将带有透光孔的氧化铝陶瓷盖板盖住所述氧化铝陶瓷基板的步骤中，所述氧化铝陶瓷盖板与所述氧化铝陶瓷基板盖合并热接触。贴合热接触的作用是提高散热接触面积，有效地提高散热效率，增强散热效果。
[0057] 在一具体实施例中，所述散热器为柱状散热器，柱状散热器外周设置多个放射状散热鳍片。放射状的散热鳍片由于散热面积大，可有效地提高散热效率，增强散热效果。
[0058] 在一具体实施例中，所述氧化铝陶瓷基板内具有驱动所述LED芯片的印刷线路。采用75〜95%氧化铝陶瓷散热器；采用75〜95%氧化铝陶瓷线路板；采 用离线式开关电源。
[0059] 本发明至少具有以下优点：
[0060] I)氧化铝陶瓷热交换率高于铝，可有效减少散热面积；
[0061] 2)氧化铝陶瓷绝缘高耐压特性更符合安规要求；
[0062] 3)氧化铝陶瓷线路板具有高散热性及高气密性的特质，可提高LED发光效率及寿命;
[0063] 4)本发明可采用离线式开关电源为LED球泡灯供电，且离线式开关电源的能源转换效率高于90%、性能价格比高；
[0064] 5)氧化铝陶瓷线路板高散热性及高耐压特性，通过LED光源与电源一体化双面板设计有效提高性能及可靠性；
[0065] 6)氧化铝陶瓷良好的气密性，使其具有高度的耐候性优点，可运用于各种不同环境;
[0066] 7)电路全封蔽式安全设计，即使在灯罩破损的情况下也不会接触到带电部分。
[0067] 以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。
Claims (10)
1. 一种氧化铝陶瓷LED球泡灯，其特征在于：包括灯罩、氧化铝陶瓷盖板、氧化铝陶瓷基板、LED芯片、散热器和灯头；所述散热器一端连接所述灯头，其另一端连接所述灯罩；所述氧化铝陶瓷盖板上开有多个孔，所述LED芯片固定在所述氧化铝陶瓷基板上，所述氧化铝陶瓷盖板与所述氧化铝陶瓷基板盖合并热接触，所述LED芯片透过所述氧化铝陶瓷盖板上开有的孔发出的光线朝向所述灯罩；所述散热器与所述灯罩围合成一空间，所述氧化铝陶瓷盖板与所述氧化铝陶瓷基板组成的盖合体置于所述空间内；所述散热器与所述氧化铝陶瓷基板热接触。
2.根据权利要求I所述的氧化铝陶瓷LED球泡灯，其特征在于：所述氧化铝陶瓷基板的材料中包括75〜95%重量比例的氧化铝。
3.根据权利要求I所述的氧化铝陶瓷LED球泡灯，其特征在于：所述氧化铝陶瓷盖板的材料中包括75〜95%重量比例的氧化铝。
4.根据权利要求I〜3任一项所述的氧化铝陶瓷LED球泡灯，其特征在于：所述散热器为陶瓷散热器，所述散热器的材料中包括75〜95%重量比例的氧化铝。
5.根据权利要求4所述的氧化铝陶瓷LED球泡灯，其特征在于：所述散热器为柱状散热器，柱状散热器外周设置多个放射状散热鳍片。
6. 一种氧化铝陶瓷LED球泡灯制造方法，其特征在于，包括以下步骤： 准备氧化铝材料及陶瓷辅料，其中所述氧化铝材料占总重量的75〜95%重量比例； 采用陶瓷注射成型工艺将所述氧化铝材料及辅料制作成陶瓷散热器和氧化铝陶瓷基板； 将LED芯片固定在氧化铝陶瓷基板上，并使得氧化铝陶瓷基板与陶瓷散热器热接触； 将灯罩连接于陶瓷散热器的一端，将灯头连接于陶瓷散热器的另一端，且使LED芯片的出光面朝向所述灯罩。
7.根据权利要求6所述的氧化铝陶瓷LED球泡灯制造方法，其特征在于：在将LED芯片固定在氧化铝陶瓷基板上，并使得氧化铝陶瓷基板与陶瓷散热器热接触的步骤中，还包括以下步骤： 准备氧化铝材料及陶瓷辅料，其中所述氧化铝材料占总重量的75〜95%重量比例； 采用陶瓷注射成型工艺将所述氧化铝材料及辅料制作成氧化铝陶瓷盖板，并在盖板上开有多个透光孔； 将带有透光孔的氧化铝陶瓷盖板盖住所述氧化铝陶瓷基板，使得LED芯片透过所述氧化铝陶瓷盖板上开有的孔发出的光线朝向所述灯罩。
8.根据权利要求7所述的氧化铝陶瓷LED球泡灯制造方法，其特征在于：在将带有透光孔的氧化铝陶瓷盖板盖住所述氧化铝陶瓷基板的步骤中，所述氧化铝陶瓷盖板与所述氧化铝陶瓷基板盖合并热接触。
9.根据权利要求6〜8任一项所述的氧化铝陶瓷LED球泡灯制造方法，其特征在于：所述散热器为柱状散热器，柱状散热器外周设置多个放射状散热鳍片。
10.根据权利要求9所述的氧化铝陶瓷LED球泡灯制造方法，其特征在于：所述氧化铝陶瓷基板内具有驱动所述LED芯片的印刷线路。
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