CN107112401A - 具有直接安装在散热器上的led的效率提高的照明装置 - Google Patents

具有直接安装在散热器上的led的效率提高的照明装置 Download PDF

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CN107112401A
CN107112401A CN201580069721.0A CN201580069721A CN107112401A CN 107112401 A CN107112401 A CN 107112401A CN 201580069721 A CN201580069721 A CN 201580069721A CN 107112401 A CN107112401 A CN 107112401A
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radiator
led
lighting device
conductive member
heat sink
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CN107112401B (zh
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安东尼·马格利卡
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AMERICAN LIGHT TOOL CORP
Mag Instrument Inc
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Abstract

例如铝制手电筒筒体的照明装置的LED效率通过在不使用PCB的情况下将LED直接安装在散热器上而增加，该散热器与外壳体热接触且电接触从而散热，使得LED的运行更低温并且因此更有效。

Description

具有直接安装在散热器上的LED的效率提高的照明装置
背景技术
LED的效率和光输出随着运行过程中装置的发热而下降。通常，LED安装在层压印刷电路板上。有些LED安装在特殊的金属基或陶瓷的印刷电路板上，从而试图将热量从LED传导出去。
发明内容
本发明大体涉及一种照明装置，其中至少一个LED安装在散热器的顶表面上，散热器被保持在导热和导电的外壳内，该LED具有第一导电构件和第二导电构件，第一导电构件在不使用印刷电路板的情况下被直接热连接且电连接到散热器，第二导电构件通过保持在散热器内的电绝缘材料与散热器电隔离。
LED的第二导电构件可以钎焊到保持在电绝缘材料内的端子上，而LED的第一导电构件也可以钎焊到散热器上，并且所得到的散热器组件可以压配合到管体或筒体(例如，铝制手电筒筒体)内或插入管体或筒体内，然后通过机械装置(例如拧到管体或筒体上的螺母)可拆卸地保持。可替代地，散热器可以与管体或筒体一体形成。
因此，本发明的主要目的是提供一种通过将LED直接安装在散热器上而具有提高的效率的照明装置。
结合附图以及下面给出的本发明的详细描述，上述及另外的目的以及优点对于本领域的技术人员而言将是显而易见的。
附图说明
下文将通过简要参照附图以及之后对附图中标识的用数字表示的元件的描述来描述附图。
图1A至图1D示出了安装在金属管体或手电筒筒体中的散热器和绝缘芯，其中具有下述标出的元件：
1.管体或筒体
2.散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
图1B是图1D中分解示出的内容的剖视图，而图1A和图1C各自是往里观察图1B中以剖面示出的装置的顶视图和底视图。
图2A至图2D示出了散热器和绝缘芯安装在金属管体或手电筒筒体中的图1A至图1D的变型，其中具有下述标出的元件：
1.管体或筒体
2.散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
图2B是图2D中分解示出的内容的剖视图，而图2A和图2C各自是往里观察图2B中以剖面示出的装置的顶视图和底视图。
图3A至图3D示出了与图2A至图2D中所示的散热器类似的单体式散热器，其中具有下述标出的元件：
1.一体式的管体或筒体与散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
图3B是图3D中分解示出的内容的剖视图，而图3A和图3C各自是往里观察图3B中以剖面示出的装置的顶视图和底视图。
图4A至图4D示出了图1A至图1D中散热器和绝缘芯的变型。在这个示例中，在LED与组件的另一端部之间存在印刷电路板，其中具有下述标出的元件：
1.管体或筒体
2.散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
8.印刷电路板
9.绝缘体
10.触头
图4B是图4D中分解示出的内容的剖视图，而图4A和图4C各自是往里观察图4B中以剖面示出的装置的顶视图和底视图。
图5A至图5D示出了图4A至图4D所示的组件的变型，其中具有下述标出的元件：
1.管体或筒体
2.散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
8.印刷电路板
9.绝缘体
10.触头
图5B是图5D中分解示出的内容的剖视图，而图5A和图5C各自是往里观察图5B中以示出所示的装置的顶视图和底视图。
图6A至图6D示出了与图3A至图3D类似但是包含印刷电路板的散热器，其中具有下述标出的元件：
1.一体式的管体或筒体与散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
8.印刷电路板
9.绝缘体
10.触头
图6B是图6D中分解示出的内容的剖视图，而图6A和图6C各自是往里观察图6B中以剖面示出的装置的顶视图和底视图。
图7A至图7D示出了安装在常见的散热器上的LED的圆形阵列。在此示出了4个LED，但是可以存在任何数量的LED。图7A至图7D具有下述标出的元件：
1.管体或筒体
2.散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
图7B是图7D中分解示出的内容的剖视图，而图7A和图7C各自是往里观察图7B中以剖面示出的装置的顶视图和底视图。
图8A至图8D示出了安装在常见的散热器上的LED的圆形阵列，其中印刷电路板在绝缘构件中。在此示出4个LED，但可以存在任何数量的LED。图8A至图8D具有下述标出的元件：
1.管体或筒体
2.散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
8.印刷电路板
9.绝缘体
10.触头
图8B是图8D中分解示出的内容的剖视图，而图8A和图8C各自是往里观察图8B中以剖面所示的装置的顶视图和底视图。
图9A至图9C示出了在常见散热器上的LED的线性阵列。在此示出4个LED，但是可以存在任何数量的LED。图9A至图9C具有下述标出的元件：
2.散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
图9B是单个LED的剖视图，图9A和图9C各自是4个LED的线性阵列的顶视图和底视图。
图10A至图10C示出了与图9A和图9C类似但是包含印刷电路板的LED的线性阵列。在此示出4个LED，但是可以存在任何数量的LED。图10A至图10C具有下述标出的元件：
2.散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
8.印刷电路板
9.绝缘体
10.触头
图10B是单个LED的剖视图，图10A和图10C各自是4个LED的线性阵列的顶视图和底视图。
图11是来自图1B的放大的剖视图，其示出了没有放置LED的散热器5的顶部，其中具有下述标出的元件：
6.LED与散热器之间的热接合部和第一电连接部
7.第二电连接部
图12A至图12E示出了典型的现有技术的LED组件，示出了钎焊到PC板上的LED以及将热量传导到环境空气中所需的多个热接合部，其中具有下述标出的元件：
101.管体或筒体
102.散热器
103.绝缘体
104.用于将电力施加给印刷电路板的触头
105.LED
106.壳体
107.绝缘体
108.用于将印刷电路板111连接到PCB 109的触头
109.多层印刷电路板
110.环形触头
111.印刷电路板
图12B是图12E中分解示出的内容的剖视图，而图12A和图12C各自是往里观察图12B中以剖面示出的装置的顶视图和底视图，并且图12D是图12B的放大的局部视图。
图13A至图13D示出了广泛使用的、现有技术的安装有LED的星形、金属和陶瓷底板的PC板以及将热量传导到环境空气中所需的多个热接合部，其中具有下述标出的元件：
101.管体或筒体
102.散热器
105.LED
106.第一电力连接部
107.第二电力连接部
108.星形PC板
图13B是图13D中分解示出的内容的剖视图，而图13A和图13C各自是往里观察图13B中以剖面示出的装置的顶视图和底视图。
图14是具有正极性散热器的、典型的安装有散热器的LED的框图。
图15是具有负极性散热器的、典型的安装有散热器的LED的框图。
图16是具有正极性散热器的、典型的安装有散热器的LED的框图，其包括具有LED驱动电子器件的PC板。
图17是具有负极性散热器的、典型的安装有散热器的LED的框图，其包括具有LED驱动电子器件的PC板。
图18是4种不同的散热方法或系统的性能的比较。图2曲线用于本发明，并且证实了流明输出随时间推移下降最小的优越性能。
1.标注为图1的曲线是图1A至图1D的系统的流明输出随时间推移的图形表示，其示出了当LED发热并且效率下降时性能的下降。
2.标注为图2的曲线是图2A至图2D的系统的流明输出随时间推移的图形表示，其示出了当LED发热并且效率下降时极小的性能下降。
3.标注为图13的曲线是图13A至图13D的系统的流明输出随时间推移的图形表示，其示出了当LED发热并且效率下降时性能的下降。
4.标注为图12的曲线是图12A至图12E的系统的流明输出随时间推移的图形表示，其示出了当LED发热并且效率下降时性能的下降。
图19A至图19B示出了用于制造根据本发明的散热器组件的工序，其中焊料S1和S2用于将LED5的垫钎焊到散热器2的顶表面上，以形成散热器组件200。图19C至图19D示出了将散热组件200插入管体或筒体1中的压配合步骤。
图20A和图20B示出了图19C至图19D的变型，其中散热器和绝缘芯安装在金属管体或手电筒筒体中，其中具有下述标出的元件：
1.管体或筒体
1A.管体或筒体1的肩部
1AT.肩部1A的顶表面
1B.螺母
2.散热器
3.绝缘体
4.用于将电力连接到LED的端子
5.LED
具体实施方式
本发明利用导热和导电的金属外构件，即散热器。散热器的内部或芯是电绝缘材料，其定位和电隔离第二导电构件，该第二导电构件从与LED相对的端部伸出以提供电连接点。该组件的顶表面提供LED的安装表面。通过钎焊或一些其他的导热和导电的方法或材料将LED的阳极侧或阴极侧并且在某些情况下将专用的导热垫结合到散热器的顶表面上。LED组组的电相对侧结合到隔离的第二构件上。来自合适的电路的电力被施加到散热器和隔离的端子，以打开LED。由LED产生的热量通过与散热器的对接而传导到环境空气中。与安装在印刷电路板上的那些的可能情况相比，LED在所述系统中的运行更低温且更有效。图1A至图11描绘了有关上述设计的变型。如所示，散热器可以根据应用具有不同形状。散热器还可以支撑多个不同构造的LED，圆形阵列和线性阵列只是多种可能性中的两种。具有合适的互连方法的电子器件也可以悬在绝缘芯中。在所有情况下也可以提供定位和电隔离两个导电构件的电绝缘材料，这两个导电构件从与LED相对的端部伸出以提供电连接点。在这些情况下，阴极和阳极LED垫被结合到对应的隔离垫上，并且LED导热垫被结合到本发明的散热器表面上。
图1A至图11描绘的改进的散热方法不使用PC板来安装LED，相反，LED直接安装在散热器的金属表面上。与安装LED的PC板设计相比，这种方法产生大大改善的热传递以及更低温运行的更高流明的LED。
本发明提供将热量从LED传导到手电筒或任何其他照明装置(例如，头灯、挂灯或聚光灯)以及使用大功率LED作为光源的所有类型的区域照明装置外部的环境空气中的直接有效的路径。其他散热方法产生被大量热接合部中断的导热路径，其中一些具有差的导热性或高的热阻。现有技术的散热方法的示例在图12A至图13D中示出。本发明的独特之处在于能够将端子和散热器直接钎焊到LED的导电和导热垫上。不需要导热膏或粘合剂。在其他设计中，等同的散热和电接触垫在PC板上，这产生更多不太有效的热接合部以及到环境空气的更长、截面更小的导热路径。在这些不太有效的设计中使用导热膏和粘合剂在一定程度上有助于热传递，但是没有达到将LED直接附接于散热器的程度。能够使用本发明大大改善的热传递的结果是LED运行起来更低温并且因此更有效。与传统系统相比，能够在不增加功率的情况下具有更高的流明。还可以将流明保持在与其他不太有效的系统相同的水平，但是消耗远远更少的功率。在电池供电的照明系统中这一点特别重要，因为在不降低流明的情况下延长了工作时间。通过向LED施加恒定的4安培电流之后60秒的流明输出证实了本发明的优越性能。本发明与其他系统相比的优点如下：
本发明(图2A至图2D)比图13A至图13D中的系统(典型的安装有星形金属底板的PC板的LED)多产生19％的流明；并且
本发明(图2A至图2D)比图12A至图12D中的系统(具有额外的铜迹线和导通孔以试图将热量从LED传导出去的多层传统PC板)多产生93％的流明。
值得注意的是，通过增加或最大化散热器与导热和导电外壳体之间的暴露表面积同时还将散热器设计为在散热器和外壳体之间具有有效地且高效地导热的足够物质，可以借助于本公开而增大或优化本发明的效率。因此，例如，图2A至图2D的散热器2将比图1A至图1D的散热器2具有更好的效果，而图3A至图3D示出了散热器与外壳体一体形成的实施方式，其应该比图2A-2D的散热器产生更好的效果。
还值得注意的是，在图1至图11中描绘的示例性实施方式中作为管体或筒体示出的外壳体不必在其整个外表面上导热和导电，尽管在其整个外表面上导热和导电的外壳体可以实现更好的效果。
还值得注意的是，通过更有效地冷却一个或多个通过本发明得到的LED得到的优点可以用于产生使用增大流明的手电筒模式，或具有增加的工作时间的手电筒模式，或这样的模式之间交替的一种或多种模式，或这样的两种模式的组合元件。
本发明本身适合于更有效、花费更少的、可以通过自动装置经济地制造的照明装置。在图19C至图19D和图20A至图20B所示的说明性实施方式中，通过将LED5的两个导电构件钎焊到散热器2的顶表面上产生散热器组件200。商业上可获得的LED通常具有三个垫(例如参见图11D，其中第二电连接部7具有一个矩形垫，而LED5与散热器2之间的热接合部和第一点连接部具有两个矩形垫)，这三个垫都可用于钎焊(图19A中的焊料S1用于一个垫，而图19A中的焊料S2用于两个垫)。在产生散热器组件200之后，其可以如图19C和图19D中所示压配合到管体或筒体1内或者其可以可拆卸地插入管体或筒体1内然后通过可拆卸的保持机构保持到位，该保持机构的示例是图20A和图20B所示的螺母1B。在图20A和图20B所示的实施方式中，在特别优选的实施方式中，管体或筒体1与散热器2由铝制成，散热器2涂覆有有助于促进焊接工序的金属镀膜(例如，镍)，并且表皮切口由铝制成，在此处散热器2与形成在管体或筒体1中的肩部1A的顶表面1AT接触(以促进更有效的热传递)。
尽管体本文已经参照某些优选的实施方式描述了本发明，但是这些实施方式仅仅是通过举例的方式给出，并不用于限制本发明的范围。对于本领域技术人员而言显而易见的是本发明的另外的实施方式具有所述详细说明的益处。
因此，对于本领域技术人员显而易见的是，在不背离本发明的主旨和范围的情况下仍然可以容易地对本文描述的实际构思作进一步的修改和变型。

Claims (10)

1.一种照明装置，包括：
导热且导电的外壳体；
导热且导电的散热器，其具有顶表面，所述散热器被保持在外壳体内并且与外壳体热接触和电接触；
电绝缘材料，其被保持在散热器内；以及
发光二极管(“LED”)，其具有第一导电构件和第二导电构件，
其中，LED安装于顶表面，同时第一导电构件在不使用印刷电路板的情况下直接电连接和热连接到散热器并且第二导电构件通过电绝缘材料与散热器电隔离；并且
其中，当来自电路的电力被施加到散热器和第二导电构件时，LED被打开。
2.根据权利要求1所述的照明装置，其中，外壳体与散热器一体形成。
3.根据权利要求1所述的照明装置，其中，散热器通过过盈配合被保持在外壳体内。
4.根据权利要求1所述的照明装置，其还包括被保持在电绝缘材料内的端子，所述端子电连接到第二导电构件。
5.根据权利要求4所述的照明装置，其中，外壳体是手电筒筒体。
6.根据权利要求5所述的照明装置，其中，手电筒筒体由铝制成。
7.根据权利要求6所述的照明装置，其中，照明装置通过下述工序制造：
通过将第一导电构件钎焊到散热器的顶表面上并且将第二导电构件钎焊到端子上而形成散热器组件；以及
将散热器组件插入手电筒筒体。
8.根据权利要求7所述的照明装置，其中，散热器组件压配合到手电筒筒体内。
9.根据权利要求7所述的照明装置，其中，散热器组件通过机械装置可拆卸地固定在手电筒筒体内。
10.根据权利要求9所述的照明装置，其中，机械装置是拧到手电筒筒体中的螺母。
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