CN1526169A

CN1526169A - Method of producing a lamp

Info

Publication number: CN1526169A
Application number: CNA02812023XA
Authority: CN
Inventors: ��·��Ү��ɵ�; 巴路·耶甘纳丹; A; 约翰·A·蒙塔纳特
Original assignee: Lednium Technology Pty Ltd
Current assignee: Lednium Technology Pty Ltd
Priority date: 2001-06-15
Filing date: 2002-06-14
Publication date: 2004-09-01
Also published as: NZ530066A; WO2002103794A1; AUPR570501A0; TW567617B; KR20040019015A; CA2450156A1; EP1396023A1; EP1396023A4; JP2004532532A; ZA200309547B

Abstract

A method of producing a lamp, including mounting light emitting junctions on a support structure (52) such that the junctions adopt a three-dimensional array. The support structure may be a curved lead frame, which is also claimed. The conductors may be in a part spherical configuration. The light emitting junctions may be mounted in recesses (57) in the curved conductors, the recesses acting as an optical guide controlling the direction of light output from the junction.

Description

Produce the method for lamp

The field of the invention

The present invention relates to produce lamp, particularly LED lamp and for the method for the lead frame that uses in the lamp.

General introduction of the present invention

According to the present invention, a kind of method of producing lamp is provided, be included on the supporting construction light-emitting junction is installed, make knot adopt cubical array.

This method preferably also is included in each depression that forms in the supporting construction and makes the knot location, and the function of this depression is as light guide, is used to control the direction of light from relevant knot output.

This supporting construction preferably includes a plurality of conductors, and this method also is included in the warp architecture and forms conductor, and this crooked structure the pick of is a spherical structure.

Conductor is preferably installed with the form of lead frame.

This method comprises also that preferably making lead frame moves with respect to forming platform, and makes drift and punch die from the engagement of lead frame opposition side, to form depression.These depressions can be in independent on formation, or can sequentially form in addition, makes each be recessed to form that drift and punch die move with respect to lead frame after the action, make for order be recessed to form the action drift and punch die is suitably located.

Framework preferably is supported on the carriage, and this method comprises movable support bracket, makes to be installed to each depression of conductor place towards erecting bed at knot.Carriage preferably can be around the first and second orthogonal axle rotations, so that making each depression aims at erecting bed, and by knot and associated conductor are advanced toward each other along the 3rd, knot is installed in each depression, and the 3rd preferably orthogonal to first and second.

Each knot preferably is electrically connected to two conductors by middle conductor.Middle conductor can be connected, so that cross the electric current that each ties connected associated conductor by control flows, allows the independent control of at least two knots.Knot also can be electrically connected to the conductor that can separately control in groups.

This method preferably includes at least and apply shared phosphorus on two adjacent bonds, and is more preferably sealing supporting construction and knot in spherical part.

In another way, the lead frame that is included in a plurality of conductors that form in the crooked configuration is provided, be used for light-emitting junction is supported on cubical array.Lead frame preferably includes the depression of holding a knot respectively.

In another way, provide the lamp that forms according to the above method.

In another way, provide and handled the above with a kind of method of conductor with the lamp that is connected electrically in light-emitting junction formation therebetween, comprise the electric current of control, so that the independent light of exporting from connected knot of controlling by each conductor.

Brief description of drawings

More describe the present invention with reference to the accompanying drawings in detail, wherein:

Fig. 1 is the end view of a LED lamp;

Fig. 2 is the plan view of the lamp of Fig. 1;

Fig. 3 is the plan view for the lamp of Fig. 1 and 2;

Fig. 4 is the schematic sectional view of second LED lamp;

Fig. 5 is the circuit diagram of the lamp of Fig. 4;

Fig. 6 is the cutaway view of the lamp of Fig. 4;

Fig. 7 is the plan view of the lamp of Fig. 4;

Fig. 8 is the expression of the lamp light illumination mode of Fig. 4 to 7;

Fig. 9 is the plan view of the 3rd lamp;

Figure 10 is the circuit diagram of the lamp of Fig. 9;

Figure 11 is the front view of the lamp of Fig. 9;

Figure 12 is the end view of the lamp of Fig. 9;

Figure 13 is the end view that fits in the lens on the lamp of Fig. 9;

Figure 14 is the cutaway view of being got along the X-X of line shown in Figure 11;

Figure 15 is the cutaway view of being got along the Y-Y of line shown in Figure 12;

Figure 16 be the light illumination mode that produces by the lamp of Fig. 9 to 12 expression;

Figure 17 is the flow chart that expression is used to produce the step of lamp;

Figure 18 is a perspective illustration of operating the lead frame of arranging for being recessed to form;

Figure 19 is the perspective view of lead frame on the carriage;

Figure 20 is the cutaway view of lead frame;

Figure 21 is with the plan view of knot with the lead frame of middle conductor a);

Figure 21 b) be along a) cutaway view of the lead frame got of the timberline A-A of institute of Figure 21;

Figure 22 is with the plan view of another lead frame of knot;

Figure 23 is the plan view that another kind of lead frame constitutes;

Figure 24 is the perspective view from the lamp of Figure 23 lead frame formation; And

Figure 25 is the perspective view of another lamp.

DETAILED DESCRIPTION OF THE PREFERRED

As shown in Figure 1, lamp 1 comprises spherical part 2, has cylindrical base 3 and parabola shaped end 4, is configured to improve the brightness in the axial output of lamp.Lamp also comprises first and second terminals, and it is preferably the form that is embedded into the

conductor

5,6 in the spherical part 2.Terminal 5 has support platform 7, and integrated circuit (IC) wafer 8 is installed on it.In the example that provides, wafer comprises two adjacent basically each other knots of arranging, and makes such as the phosphorus layer, to be applied in the fluorescent material shared layer and to tie.9 to 12 knots of middle conductor are electrically connected to respectively holds 5,6, makes as pointed in the circuit diagram 3, and

LED ties

14,15 and arranges with opposite polarity.A resistive element 16 is installed between another conductor 13 (connecting middle conductor 11 and 12) and the terminal 5.

Conductor

5,6, middle conductor 9 to 13 reaches wafer 8 and all is embedded in spherical part 2, makes lamp be rendered as a firm overall structure.The opposite polarity of knot allows lamp to be connected to power supply, compares with traditional LED structure and needn't consider polarity.Use common single phosphorus layer to simplify manufacturing for each knot, and aesthetic advantage is provided, promptly from being from single light source in one of any light perception of two knots.

In a kind of preferred form of LED lamp, use following standard:

Nominal size-9.5mm diameter

Photochromic-white

Spherical color-water is clear

Light intensity-superbright typical light output＞500Cd@20mA

Guarantee life-span-30,000 hour

15 ° of typ. of focusing-half-angle

Pedestal type-interchangeable with the wedge shape type lamp

Outside lead-in wire size-6mm nom. pedestal wedge shape

Supply power voltage-12 volt nom.{＞11.5＜14 volts AC or DC}

Forward current-20+8/-3mA@12 volt

Forward voltage-3.6nim (typ) 4.0max.@20mA

Reverse voltage-5 volt nim.

Power dissipation-LED ties 120Mw

Resistance 170mW

Reverse current-50 * 10 ^-3MA max.@5V

Internal resistance-430ohms nom

Yet the configuration and the running parameter that should be appreciated that any part dimension of lamp can change on demand, and the number of LED knot also can increase to be fit to the illumination needs.

Referring now to second lamp 20 of Fig. 4 to 8 explanation.With regard to installing first and

second terminals

21 and 22 scopes, together to embed the form of the

conductor

23,24 of spherical part 25 with

extra conductor

26,27, lamp 20 structurally is similar to Fig. 1 to 3.Each

conductor

23,26 and 27 has depression 28 separately, and provide the structural support is used to hold by

label

29,30, the relevant knot of 31 indications.Knot is covered by phosphorus 35 shared layers, and is connected between each each

conductor

23,26,27 that they are installed in and the adjacent conductor by

middle conductor

32,33,34.In an example shown, represent that knot is connected as the circuit diagram of Fig. 5.

Institute's

conductor

23,24,26,27 to some extent is preferably formed as two-dimentional lead frame structure 40 into as shown in Figure 6, so that before inside applies phosphorus layer 35 and apply before the spherical part 25, allows directly be easy to manufacturing and reliability in the

location knot

29,30,31.As from Fig. 6 and 7 liang figure as seen,

knot

29,30,31 is arranged in the array that is generally straight line, and

conductor

23,27 projectioies make that the whole brightness by the knot generation will axially be reinforced in a way, shown in Fig. 8 curve A on conductor 26.

Lamp 20 also can be installed lens 41, and these lens fit in spherical part 25, and is configured as the light that modification is produced by lamp, so that for example produce the luminance patterns of being represented by the curve B among Fig. 8, thereby the brightness of output is distributed to a certain degree more equably.Referring now to Fig. 9 to 16,, indicates one the 3rd lamp 50.Be embedded in whole spherical part 55 with regard to a plurality of

conductors

51,52,53 and 54, and have the scope that is installed in the light-emitting junction 56 that respectively caves in 57 and covered by shared fluorescent material layer, lamp 50 generally is similar to the structure with headlight.Each knot also is electrically connected to each conductor of its installation and adjacent conductor by middle conductor 58, so that form circuit shown in Figure 10.Yet in this example, each of conductor 51 to 54 has three knots 56.

Conductor 51 to 54 is crooked in spherical part 55, so as knot be supported on dotted line such as on the spherical curve face, and by this way, the illumination that is produced by lamp 50 will be well as if little is generally that the spherical point light source sends from one.The installing of lens 60 is also in order to revise the output of knot, and to produce such as by more uniform distribution pattern shown in Figure 16 curve C, this pattern is to export from the brightness that a plane graph of lamp 50 is observed, promptly when lamp is equidirectional finding observed from Fig. 9.

Except using lens 60 to revise the output of light, can also be with any required assignment of configuration conductor, and 57 the structure of caving in also can be used to help to control the orientation output from the light of respectively binding up one's hair out.Specifically, the configuration of each depression for example can be like this, i.e. the effect of recessed side walls is as direction and/or the angle of light guide control from each light scattering of binding up one's hair out.

More particularly, the shape of each depression is described in more detail and to the effect from the light of knot output now with reference to Figure 14 and 15, these two figure illustrate the cutaway view of the associated conductor of being got along Figure 11 and 12 center line X-X and Y-Y respectively.

The depression 57 that comprises the LED knot is at

conductor

51,52, location and shaping in 53, make the light beam that sends from depression to be combined with predictable pattern at the free space outside the lamp 50, this pattern is by extending the distance that intersects-be labeled as ' r ' to be tied depression side dotted line by the radius of dotted portion sphere ' R ' LED from depression, and the center line 61 of lamp 50 is with definite by the angle ' A ' between the center line of tying perpendicular to any other LED 62.

The radius of dotted line sphere ' R ' is the distance of tying to the LED in the depression from the crosspoint of those center lines.Angle between the depression side has been determined the value of ' r '.

Be equal to or greater than at ' r ' under the situation of ' R ' restriction,, will be configured as Uncrossed light beam by depression from the light of each LED knot no matter the value of angle ' A ' how.Can make the coincident of light beam of tying from each LED and the light beam of tying from adjacent LED for ' r ' all values less than ' R '.Accurate in locating will be determined by the value of ratio R/r and angle ' A ' in this example.

Can see that above-mentioned lamp allows suitable scope to use junction diode to obtain light source, has one of various predetermined output luminance patterns, keeps general simple structure simultaneously.A special advantage is, each knot size is little, and can be configured to and produce naked eyes and can feel the light output of sending from a single point light source.

A kind of method referring now to Figure 17 to 24 explanation production lamp.This method comprises three Main Stage: the stage 100 forms suitable lead frame; Stage 101 is that knot is appended to lead frame; Stage 102 is final encapsulated phases.

Stage 100 is included in step 103 a flat lead frame is provided, and forms spherical calotte at the conductor of step 104 lead frame, and forms depression in step 105 in conductor, does the surface in step 106 subsequently and handles.

Figure 18 is illustrated in the lead frame 110 between step 104 and 105.Lead frame 110 is installed in the band 111 of general elongation, and this band is divided into and finally is separated and forms the part 112 of each lamp.Each part 112 comprises a plurality of conductors 113,114,115 that form the curved configuration that is preferably the part sphere.Conductor can form with such configuration by any suitable process such as by band 111 is inserted forcing press etc.

In order to form depression, the part spherical part of lead frame fits on the instrument 116 of the correspondingly-shaped that forms the platform place, wherein the drift (not shown) is from opposition side and the conductor 113 of lead frame to the punch die side, 114,115 engagements, effect by drift is deformed into the relevant punch die 117 that provides in the instrument 116 to conductor, so that form depression in conductor.Depression can sequentially form, and for this reason, and instrument preferably moves with respect to lead frame is rotatable, makes punch die can be turned any desired position at the place that requires to cave in.Like this, coordinated single drift that turns and punch die 117 can be used to form all depressions in any required array.In addition, instrument 116 can have the punch die 117 of a suitable configuration of being scheduled to and the array of drift, makes all be recessed in the on formation of single.Because as above at Fig. 9 to 16 discussion, the effect of depression is as light guide, can select cave in specific location and configuration, so that optimize output on demand, exports so that regulation is directed, Ao Xian number will be determined maximum output intensity simultaneously.

In any case, as shown in figure 19, can be installed on the carriage 119 for stages 101 lead frame 110, wherein light-emitting junction is installed in the depression 120.Carriage 119 itself can rotate around rotating shaft 121, is pivotable to center on the x-axle, and 122 rotates around the shaft, to be pivotable around the y-axle.Like this, lead frame can be in place at erecting bed (not shown) place, and center on x with respect to erecting bed, and the y axle rotates, so that each depression 120 order presents to receive relevant knot.Figure 20 illustrates the section of one of platform 112, and the part ball formation of conductor 114 particularly.The possible path of sphere conversion of curve 123 expression conductors 114, this conductor can be by obtaining around axle 121,122 rotating lead frames 110.Line 124 representational tools 116 leave the rotation of z-axle equivalence, this rotation 120 work angles that can be formed within it 125 of having stipulated again to cave in.

When each depression when suitably being presented on erecting bed, relevant light-emitting device or punch die as shown in Figure 21 in order simply to be called knot 130, is inserted into depression along being preferably in axial the 3rd of z-, and according to the processing stage 101 step 107 bonding in place.At this moment, or subsequently, can be in the additional middle conductor 131 of step 108, so that knot is electrically connected to adjacent conductor.Knot shown in Figure 21 is with the assignment of configuration of electric parallel, yet the location of knot can be any required configuration with being connected, shown in Figure 22, wherein each knot is connected to a shared center conductor 114 and reaches the conductor 132 of radially separately arranging, and can be separated control so that allow by the electric energy that independent control offers conductor from the light intensity of each knot.The another kind of possible configuration of depression 120 shown in Figure 23.In any configuration, various knots can be electrically connected in groups, and making can be by independent control from the light intensity of each group.

In case LED ties installation in position and connected middle conductor, then the treatment step 109 in the stage 101 applies phosphorus to knot.At least two adjacent LED knots of the best paint of phosphorus.

Lead frame 110 is transferred to the terminal stage 102 of processing then, so that form lamp shown in Figure 24 140.Stage 102 comprises separate section 112, removes unnecessary lead frame material, and or at step 135 pressing mold, or in step 136 around the conductor molded spherical parts 137 of 112,114,115 epoxies (referring to Figure 24).The free end of conductor can be bent into terminal or pin 138 then, is inserted into general printed circuit board (PCB) associated through-holes such as (PCB).Test the lamp 140 of gained then in step 139, and pack if desired.

Another lamp of finishing is shown in Figure 25, and additional molding 151 forms under spherical part 137.In this example, for the conductor of simplifying in the spherical part does not illustrate, yet conductor can have and similar configuration shown in Figure 22, though more knot and relevant depression are provided.Specifically, provide the knot of 18 lines that separate, had 18 relevant pins 138 and also have pin 152, so that the common conductor in spherical part 137 provides electric current.Like this, in lamp 150, form 18 different circuit, and can be by pin 138 addressing and control these circuit respectively, they are fitted to PCB etc. again.

Then just as is understood, the invention provides a kind of method of producing the LED lamp, this method is optimized the output that LED ties by making knot with the cubical array location and be used for the depression of optics guiding.And then this structure allows the different output of the group of each knot or knot by independent control, to change radiative intensity.At last, mention once more that the configuration of the conductor of the cubical array of knot and bending itself allows more to manifest from a single point or pellet shapes light emitted from the light of lamp, this can think to surpass the light emitter junction device of traditional discrete knot.

Just the mode with non-limitative example has illustrated above method and LED lamp, and is not deviating under the above the spirit and scope of the present invention, can make many remodeling and distortion to it.

Claims

1. produce a kind of method of lamp, be included on the supporting construction light-emitting junction is installed, make knot adopt cubical array.

2. the method described in claim 1, wherein supporting construction comprises a plurality of conductors, and this method also is included in the warp architecture and forms conductor.

3. the method described in claim 2, wherein conductor forms with the part ball formation.

4. the method described in claim 1 comprises also making to tie being positioned in each depression that forms in the supporting construction that the function of this depression is as light guide, is used to control the direction of light of exporting from relevant knot.

5. the method described in claim 4, wherein the supporting construction conductor is with the form installing of lead frame, to comprise a plurality of conductors.

6. the method described in claim 5, wherein conductor forms with the part ball formation.

7. the method described in claim 5 or 6 also comprises making drift and punch die and lead frame engagement, to form depression.

8. the method described in claim 5 wherein is recessed in independent on formation.

9. the method described in claim 5, wherein depression sequentially forms, and drift and punch die move with respect to lead frame after each is recessed to form action, make for order be recessed to form the action drift and punch die is suitably located.

10. the method described in one of any as claim 7 to 9 also comprises frame supported on a carriage, and movable support bracket, makes each depression appear at erecting bed, is installed on the conductor at this erecting bed knot.

11. the method described in claim 10, wherein carriage can be around the first and second orthogonal axle rotations so that each depression is aimed at erecting bed, and by make knot and associated conductor along the 3rd relative each advance, tie to be installed in and respectively cave in.

12. the method described in one of any as claim 5 to 11, wherein each knot is electrically connected to two conductors by middle conductor.

13. the method described in claim 12, wherein middle conductor can be connected, so that cross the electric current that each ties connected associated conductor by control flows, allows the independent control of at least two knots.

14. the method described in claim 13, wherein knot also can be electrically connected to the conductor that can separately control in groups.

15. the method described in one of any also comprises at least applying shared phosphorus on two adjacent bonds as claim 1 to 14.

16. the method described in one of any also is included in sealing supporting construction and knot in the spherical part as claim 1 to 15.

17. a lead frame comprises with a plurality of conductors of the configuration formation of bending, is used for light-emitting junction is supported on cubical array.

18. the lead frame described in claim 17 also comprises the depression of holding a knot respectively.

19. the lamp that forms according to one of any method of claim 1 to 16.

20. handle a kind of method of the lamp described in claim 19, described lamp forms with conductor and the light-emitting junction that is connected electrically in therebetween, this method comprises the electric current of control by each conductor, so that independent control from the light of connected knot output.