CN104303322A - 硅酮涂覆的发光二极管 - Google Patents
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Abstract
用于电子光源的硅酮保护性涂层和将所述涂层施用在电子光源的暴露表面或外表面上的方法,所述电子光源组装为电路板或其它基片的部分或者安装到电路板或其它基片。
Description
发明领域
本发明涉及保护性涂层和将阻挡层或保护性涂层施用到电子光源(例如,发光二极管(LED)或有机发光二极管(OLED))的方法,更特别地涉及将保护性涂层施用在电子光源的暴露表面或外表面上的方法,所述电子光源组装为电路板或其它基片的部分或者安装到电路板或其它基片。
发明背景
有多种固态照明技术,包括电子光源,例如发光二极管(LED)和有机发光二极管(OLED)。LED和OLED比起传统光源具有很多已知优势,包括较小尺寸、较长寿命、较低能耗和较高的效率(通过其每单位功率输入的光输出来测量)。典型LED的平均寿命长度估计为50,000小时至100,000小时。平均寿命长度取决于LED品质、系统设计、工作环境和其它因素。为了在此期间保护包含电子光源(例如,LED或OLED)的发光电路板的电路和电子组件,对于外力的暴露应为考虑因素。然而,至今没有解决方法,以有效针对或解决与发光电路板暴露于环境因素(例如,水分)相关的问题,但仍提供与LED或OLED相关的已知优势和性能特征。
发明概述
本发明涉及涂覆电子光源的方法,所述电子光源包括但不限于发光二极管(LED)和有机发光二极管(OLED),在本文中一般称为LED,本发明还涉及将保护性涂层施用在电子光源的暴露表面或外表面上的方法,所述电子光源组装为电路板或其它基片的部分或者安装到电路板或其它基片。例如,印刷电路板或基片可包括光引擎、阵列或光模块。
很多类型LED市售可得,这些LED安装到电路板上或组装为电路板的部分,并且具有应用于磷光体上的封装或透镜。这些透镜和封装为LED或LED板组件提供很少保护或无保护以避免环境污染物。
在本发明方法的一个方面,该方法包括提供非导电硅酮喷涂,以顺应安装到印刷电路板的连结的LED、其它发光装置和支承电子组件的全部外表面,以在这些所述组件(如果需要,包括透镜)的所有表面上和周围产生密封的保护性阻挡层。
通过以下提供的详述,本发明适用性的其它范围将变得显而易见。应了解,详述和具体实施例虽然说明了本发明的优选实施方案,但仅旨在说明目的,并不是旨在限制本发明的范围。
附图简述
通过详述和附图,本发明将变得被更完全地了解,这些附图不必按比例,其中:
图1图示说明根据本发明的方面安装到电路板或基片的发光二极管(LED),已在板和LED(包括透镜)的外表面上完全涂覆。
图2A图示说明根据本发明的方面安装到电路板或基片的发光二极管(LED),并且LED的透镜的一部分已部分涂覆。
图2B图示说明根据本发明的方面安装到电路板或基片的发光二极管(LED),使得已涂覆电路板或基片,不包括LED和透镜。
图3图示说明根据本发明的方面适合使用的电路板或基片。
图4为图示说明图3的安装到电路板或基片的LED的侧视图,并且根据本发明已在板和LED(包括透镜)的外表面上涂覆。
图5为图示说明根据本发明的方面安装到电路板或基片的多个LED的侧视图,其中某些LED已在外表面上选择性涂覆(包括透镜),而其它未在外表面上涂覆。
发明详述
以下实施方案详述只为示例性质,不以任何方式限制本发明、其应用或用途。
现在参考附图,图1图示说明已安装到印刷电路板或基片(未显示)或者组装为印刷电路板或基片(未显示)部分的固态发光二极管(LED) 1。透镜2连结到LDE 1。如图1所示,根据本发明的方面,LED 1和LED透镜2已在其外表面上完全涂覆(如在位置3所示的涂层),并且板已在其外表面上涂覆(如在位置4所示的涂层)。
图2A图示说明根据本发明的方面安装到电路板或基片的发光二极管(LED) 10,并且LED 10的透镜12的一部分已被涂层13部分涂覆,并且印刷电路板已在其外表面上涂覆,如在位置14所示。
图2B图示说明根据本发明的方面安装到印刷电路板或基片(未显示)或组装为印刷电路板或基片(未显示)部分的发光二极管(LED) 10,其中板已在其外表面上涂覆(如在位置14所示的涂层),不包括LED 10和透镜12。涂层也施用在LED周围,如在位置13所示。
图3图示说明根据本发明的方面适合使用的印刷电路板或基片15。
图4为图示说明图3的安装到电路板或基片或组装为电路板或基片部分的LED的侧视图,并且根据本发明已在板20和LED 16(包括透镜17)的外表面上涂覆。
图5为图示说明根据本发明的方面安装到电路板或基片40或者组装为电路板或基片40部分的多个LED (30a、34和30b)的侧视图,其中某些LED (30a和30b)已在其外表面上选择性涂覆(包括透镜32a和32b),而其它LED 36未在其外表面上涂覆。图5还图示说明在其外表面上已涂覆(如在位置35所示)的电路板或其它基片40。
本发明涉及涂覆安装到印刷电路板或类似基片上的电子光源(例如,LED)和电子电路的方法。电子光源包括透镜或封装,所述透镜或封装一般由玻璃或另一材料制成,以覆盖磷光体和电子电路。根据本发明的涂覆方法和涂层,涂层施用到电路板上,以形成保护性阻挡层或膜。该涂层增加到并且施用在存在于现有发光电子光源上的任何现有透镜或封装上。本发明的方法提供保护,以避免不利环境条件尤其是水分,其可以腐蚀、加速并导致电子电路板或照明模块的部分或完全失效。因此,本发明的涂层有能力密封整个板,以防止这种腐蚀,避免导致LED板和电路过早失效的环境条件。在施用并涂覆到LED上时,涂层增加现有连结的透镜的物理强度。
出人意料的是,根据本发明的方法,本发明的涂层可施用到可以包括透镜和封装的现有LED装置上,由于变色(可改变LED输出特征的光和显色指数),覆盖在这些组件的顶部上一般是不利的。本发明的涂层任选覆盖透镜,然而不会不利影响LED输出特征的光和显色指数。
另外,施用到电子光源的本发明的涂层组合物也是有利的,因为其在LED寿命内持续的不变黄的性质和光学透明的配方。本发明的施用到LED和电路板的涂层提供与水分控制相关的问题的解决方法,同时使LED的变黄和流明输出损失最小化或消除。已施用到LED板的涂层形成使LED产生的变黄和流明输出损失最小化或消除的清晰或透明膜。
根据本发明,形成的保护性阻挡层减轻或防止水分渗透,因此减小或消除由于水分渗透导致的LED劣化,并因此减小或消除由于水分或其它环境劣化要素(例如但不限于水、灰尘、热和盐雾)导致的LED劣化。
本发明的方法适用于具有要涂覆的暴露表面的多种类型、尺寸和形状的LED板。有许多已知类型和尺寸的LED对于本领域的技术人员市售可得,并且可以很容易根据本发明的方法使用。
本发明的方法包括提供具有要涂覆的暴露表面的LED板。有很多LED的供应商。这些供应商的实例为Seoul Semiconductor、Cree, Inc.、Lumileds和Osram Sylvania。适用于本发明的LED为白色、彩色或多色LED。通常取决于期望的终端用途来选择特定LED。然而,本领域的技术人员将了解哪些LED适用于给定的终端用途。本发明的方法特别适用于任何室外终端用途或任何非调节环境。例如,室外标志和路灯为本发明的涂覆LED的潜在终端用途的非限制实例。
在涂覆LED和LED板之前,通过确定不涂覆的区域,例如如图5中所示的连接焊盘38,来制备LED。根据本发明,可根据本发明的系统和方法选择性程序化要保持为未涂覆区域的区域。掩蔽或避开这些排除区域,保证例如在电源线焊接到印刷电路板上的连接焊盘时,有洁净的铜盘,在上面没有任何涂层。
本发明的方法包括用涂层组合物涂覆LED板的暴露表面或部分暴露表面。涂层充当阻挡层,并顺应LED及其组件的形状。基于本文讨论的喷涂技术,不必掩蔽电极(引线),或者可指定其它区域。喷涂技术具有计算机可编程能力,这些能力允许涂层选择性施用在指定组件周围,并且使液体喷涂完全略过它们,或者在100%板上施加喷涂。
在本发明的另一个方面,涂层组合物包含硅酮。在本发明的另一个方面,涂层组合物为液体形式。
本发明的涂层组合物优选包含至少60重量百分比(重量%)硅酮弹性体,优选至少99%重量硅酮弹性体。用于本发明的适合涂层进一步包含0-40%重量二异丙氧基二(乙氧基乙酰乙酰基)钛酸酯、烷氧基硅烷反应产物、甲醇或它们的组合。
适合的市售可得硅酮的实例包括但不限于可得自Humiseal的硅酮;可得自Dow Corning的硅酮,例如DOW CORNING® 3-1953 Conformal
Coating;和可得自Shin Etsu的硅酮,例如X-832-407、409和424。
在本发明的方法中,通过以下施用涂层组合物:将液体硅酮涂层组合物喷涂到LED板的暴露表面或外表面上或一部分暴露表面或外表面上,以涂覆LED及其透镜。LED优选在环境条件喷涂。可涂覆LED或LED板,而不用除了施用到LED或LED板的涂层本身以外的任何组合物。可涂覆LED和LED板,而不使用粘合助剂。可在喷橱中喷涂LED。
液体涂层组合物优选用空气辅助式无气喷涂系统或珠粒与空气旋流系统(bead and air swirl system)喷涂。珠粒与空气旋流系统施用作为珠粒的硅酮涂料,并用空气产生旋转样式。后面的系统是期望的,因为其提高转移效率,并且因为这种系统提供良好的覆盖率,带有很少的液体喷涂弹回。硅酮涂料可在环境条件喷涂。将LED形状以要涂覆的精确区域和要留下不涂覆的区域程序化到喷涂系统中。由于喷涂时间基于LED的尺寸和形状,喷涂时间变化达到最高约20秒。硅酮涂层的厚度一般为5-8密耳。市售可得喷涂系统的实例包括但不限于Nordson Corporation的Asymtek或可得自PVA的系统。
本发明的系统的其它优势包括但不限于在精确选择的小区域施用少量硅酮的能力。用前述计算机程序化能力选择适当的阀使液体分配进入期望的区域来实现这一点。选择性涂覆能力允许角形透镜(angular
lens)应用于板,而不污染透镜及其流明输出。将LED置于传送带上,并在喷橱中在环境条件下喷涂。LED通过带输送到固化烘箱。
在喷涂后,使经涂覆的LED固化。对于硅酮涂层,固化一般在强制通风烘箱中进行。使LED暴露于200-350℉约10-15分钟。该系统设计为围绕热空气的使用,所述热空气影响LED。在LED离开固化烘箱时,使LED在环境条件冷却。如果选择性过程未程序化,则去除电极(引线)上的掩模。
经涂覆LED的生产速率取决于LED的尺寸和形状及其终端用途而变化。例如,生产速率取决于是否有线性照明或下照明而变化。基于终端用途,典型的生产速度可在90至150件/小时之间变化。
如本文中指明,在LED板上喷涂的硅酮组合物提供一种透明的水分控制系统,所述系统维持LED的寿命长度,此外使变黄和流明输出损失最小化或消除。与另外可利用的其它涂覆方法比较,液体喷涂方法为特别期望的。例如,从实验确定,用粉末喷涂得到均匀涂层和平滑涂层是困难的。例如,用对流烘箱固化的粉末涂层为粒状,并且由于固化温度LED从其底部分开,因此产生美观和性能缺陷。
本发明的硅酮涂层组合物和方法的优势包括但不限于:硅酮组合物不因紫外(UV)光劣化,硅酮保持柔韧,并且能够经受最多400℉的较高温度,而且硅酮组合物消除变黄或与其它涂层组合物比较变黄较少。
本发明的另外益处是,独特的抗变黄性质允许在现有LED或电子光源表面上涂覆保护性涂层材料,并且提供显著的热强度和机械强度,而对照明颜色和输出没有不利的长期影响。
本发明的方法可进一步包括向保护性涂层加入着色剂,为最终组装的照明模块或固定装置提供美观优势。这种着色的涂层将分配在所有不产生光的表面周围,并且与在LED或产生光的区域上分配的光学透明保形涂层融合。
实施例
用液体硅酮喷涂不同形状和尺寸的样品LED板。进行两个试验。一个试验使用Asymtek SL-940E喷涂系统。另一个试验使用PVA 2000 Selective Coating System。各试验检验用Dow Corning制造的硅酮产品(DOW CORNING® 3-1953 Commercial Conformal Coating)喷涂的LED板,和用得自Shin Etsu,
X-832-407的液体硅酮涂覆的LED板。
针对环境和电试验及流明保持独立试验LED板。流明保持是指由于涂覆过程损失的光量。所有试验通过独立的第三方实验室进行。试验结果如下所列:
表1
试验 | 试验方法 | 详细说明 | 功能性能 | 变色 | 破裂 |
湿气暴露 | UL 8750 | 第8.12节 | 通过 | 否 | 否 |
介电1 | UL 8750 | 第8.12节 | 通过 | 否 | 否 |
腐蚀试验/盐雾 | UL 50E | 第8.7节 | 通过 | 否 | 否 |
水浸渍(IP-68) | IEC 60529 | 第14.2.7节 | 通过 | 否 | 否 |
热冲击 | 非标准 | 用户指定 | 通过 | 是 | 否 |
流明损失 | 6-7% | ||||
CRI(显色指数) | 72 | 74 | |||
CCT(相关色温) | 4200 K | 4600 K |
所有试验结果表明,涂层对湿气暴露和腐蚀及盐雾稳定。也显示硅酮涂覆的LED通过IP-68试验。虽然CRI和CCT显示改进和良好控制,但平均流明损失为6-7%。
表2
试验设备
所用设备 | 型号 | 对照编号 |
Envirotronics | SSH32-c | H190 |
Thermotron | SM-32C | H147 |
Despatch | LAC1-67 | H138 |
Omega | 650-TF-DDS | T036 |
Singleton Corp | SCCH22 | H168 |
Atago Co | ES-421 | M185 |
Oakton | WD-25624-86 | I027 |
Pyrex | 3062-100 | B046 |
Biddle | 230425 | V178S |
Fisher Scientific | 14-649-9 | N1132 |
Fluke | 87V | M207 |
Stanley | 33-428 | U011 |
Water Tank | N/A | N/A |
表3
LED样品板:
样品编号 | 说明 | 型号 |
203303-1 | PCB 6 LED’S | CREE 5 |
203303-2 | PCB 102 LED’S | Sylvania 102-2 |
203303-3 | PCB 4 LED’S | Philips 1 |
203303-4 | PCB 6 LED’S | CREE 4 |
203303-5 | PCB 102 LED’S | Sylvania 102-3 |
203303-6 | PCB 4 LED’S | Philips 3 |
203303-7 | PCB 6 LED’S | CREE 6 |
203303-8 | PCB 54 LED’S | Sylvania 54-3 |
203303-9 | PCB 4 LED’S | Philips 4 |
203303-10 | PCB 6 LED’S | CREE 7 |
203303-11 | PCB 54 LED’S | Sylvania 54-5 |
203303-12 | PCB 4 LED’S | Philips 2 |
203303-13 | PCB 102 LED’S | Sylvania 102-5 |
进行以下试验,以确定硅酮涂覆的LED的功能性和流明性能。所有试验通过第三方独立实验室进行。Intertek,位于Cortland, New York,进行了环境和电试验。ITL,位于Boulder, Colorado,进行了流明保持试验。
Intertek进行了以下试验:
表4
湿气暴露 | UL 8750 | 第8.12节 |
腐蚀试验/盐雾 | UL 50E | 第8.7节 |
水浸渍 | IEC 60529 | 第14.2.7节 |
热冲击 | 非标准 | 用户指定 |
湿气暴露
UL 8750
第
8.12
节:
用于潮或湿的场所的装置在32.0±2.0℃(89.6±3.6℉)的温度下暴露于具有88±2%相对湿度的湿空气经历168小时。在该试验后,所有样品均有功能。施加500V dc经历一(1)分钟以试验样品上的涂层,进行介电试验。试验以试验引线直接放在PCB涂层上的方式进行。在该试验后,所有样品均有功能。还进行目视检查。样品的涂层未劣化,并且没有颜色变化或破裂。
腐蚀试验
/
盐雾
UL 50E
第
8.7
节:
使试验样品在以下所述气氛经受腐蚀试验24小时,然后进行功能试验。
表5
盐度 | pH | 沉降 | 温度 |
5.5% | 6.6 | 1.4-1.5ml/小时 | 95℉ |
在功能试验后,使样品在以下所述气氛经受腐蚀试验144小时,然后进行功能试验。
表6
盐度 | pH | 沉降 | 温度 |
5.5% | 6.6 | 1.4-1.5ml/小时 | 95℉ |
在试验后,所有样品均有功能。进行目视检查。样品的涂层未劣化,并且没有颜色变化或破裂。
水浸渍
IEC 60529
第
14.2.7
节:
使样品完全浸没于水中达到850mm-1000mm的深度,经历30分钟。在试验后进行功能试验。在试验后,所有样品均有功能。进行目视检查。样品的涂层未劣化,并且没有颜色变化或破裂。
热冲击,非标准,用户指定:
样品应在从-40℃到150℃快速变化的温度之后工作。使样品经受5个循环。一个循环由以下组成:在150℃一(1)小时,然后在-40℃一(1)小时,并且转换速率小于一(1)分钟。在试验后,所有样品均有功能。进行目视检查。样品的涂层未劣化,而对于所有样品,颜色从透明变成棕褐色。没有涂层破裂。
因此,本领域的技术人员应容易理解,本发明可接受广泛的功用和应用。通过本发明及其前文描述,在不脱离本发明的实质或范围下,本文所述以外的本发明的很多实施方案和更改,以及很多变化、修改和等价安排将变得显而易见或得到相当启发。因此,虽然本文已就优选的实施方案详细描述了本发明,但应理解,该公开内容仅为本发明的说明和示例,并且只为了提供本发明的完整和可实现的公开内容而作出。前文公开内容不旨在或者不应解释为限制本发明或者排除任何这样的其他实施方案、更改、变化、修改和等价安排。
Claims (30)
1. 一种制造经涂覆电子光源的方法,所述方法包括:
提供安装到印刷电路板上的电子光源,其中该电子光源包括具有外表面的透镜;和
将包含硅酮的涂层施用到在其上安装有所述电子光源的所述印刷电路板,以形成密封的保护性阻挡层。
2. 权利要求1的方法,其中所述电子光源为发光二极管或有机发光二极管。
3. 权利要求1的方法,其中所述涂层通过喷涂施用。
4. 权利要求3的方法,其中所述喷涂顺应所述发光二极管的表面。
5. 权利要求1的方法,其中所述涂层覆盖透镜。
6. 权利要求1的方法,其中所述涂层包含至少60%重量硅酮。
7. 权利要求1的方法,其中所述涂层包含至少99%重量硅酮。
8. 权利要求6的方法,其中所述涂层进一步包含0-40%重量二异丙氧基二(乙氧基乙酰乙酰基)钛酸酯、烷氧基硅烷反应产物、甲醇或它们的组合。
9. 权利要求7的方法,其中所述涂层进一步包含0-1%重量二异丙氧基二(乙氧基乙酰乙酰基)钛酸酯、烷氧基硅烷反应产物、甲醇或它们的组合。
10. 权利要求1的方法,所述方法进一步包括使所述硅酮涂覆的发光二极管固化。
11. 权利要求10的方法,其中固化利用辐射热。
12. 权利要求10的方法,其中固化在强制通风烘箱中进行。
13. 权利要求1的方法,其中所述涂层透明。
14. 权利要求3的方法,所述方法进一步包括用空气辅助式无气系统或珠粒与空气旋流系统喷涂所述涂层。
15. 一种包括经涂覆表面的发光二极管,其中所述发光二极管的经涂覆表面的涂层包含硅酮。
16. 权利要求15的发光二极管,其中所述涂层被喷涂在所述发光二极管的表面上。
17. 权利要求14的发光二极管,其中所述涂层作为液体施用。
18. 权利要求15的发光二极管,其中所述硅酮涂层包含至少60%重量硅酮。
19. 权利要求15的发光二极管,其中所述硅酮涂层包含至少99%重量硅酮。
20. 权利要求18的发光二极管,其中所述硅酮涂层进一步包含0-40%重量二异丙氧基二(乙氧基乙酰乙酰基)钛酸酯、烷氧基硅烷反应产物、甲醇或它们的组合。
21. 权利要求19的发光二极管,其中所述硅酮涂层进一步包含0-1%重量二异丙氧基二(乙氧基乙酰乙酰基)钛酸酯、烷氧基硅烷反应产物、甲醇或它们的组合。
22. 权利要求15的发光二极管,其中使所述经喷涂的发光二极管固化。
23. 权利要求22的发光二极管,其中使所述经涂覆的发光二极管辐射热固化。
24. 权利要求22的发光二极管,其中所述固化在强制通风烘箱中进行。
25. 权利要求15的发光二极管,其中所述硅酮涂层透明。
26. 权利要求16的发光二极管,其中用空气辅助式无气系统或珠粒与空气旋流系统施用所述喷涂。
27. 权利要求15的发光二极管,其中所述硅酮涂层顺应所述发光二极管的表面。
28. 权利要求15的发光二极管,其中所述喷涂涂层在所述发光二极管的部分表面上或在所述发光二极管的整个表面上。
29. 权利要求15的发光二极管,其中所述涂层不变黄。
30. 权利要求15的发光二极管,其中所述涂层进一步包含着色剂。
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Also Published As
Publication number | Publication date |
---|---|
JP2014527280A (ja) | 2014-10-09 |
KR20140024384A (ko) | 2014-02-28 |
EP2707910A2 (en) | 2014-03-19 |
US20140054632A1 (en) | 2014-02-27 |
WO2012154815A3 (en) | 2014-05-01 |
BR112013028710A2 (pt) | 2017-01-24 |
EP2707910A4 (en) | 2015-06-24 |
WO2012154815A2 (en) | 2012-11-15 |
US8697458B2 (en) | 2014-04-15 |
US9236536B2 (en) | 2016-01-12 |
US20110210364A1 (en) | 2011-09-01 |
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