The utility model content
The utility model provides a kind of integrated morphology of diaphragm type high-power LED chip; it mainly is in order to packaged high-power LED electric power system or device take the flexible circuitry film as substrate; the utility model has the characteristic of comprehensive power according to the power supply of LED, adopt brand-new control and protection scheme overcome traditional power supply system somewhat complex design and in conjunction with the advantage of fexible film formed can with the integrated novel power supply system of light source chip., and this is exactly to be main purpose of the present utility model.
The technical scheme that the utility model adopts is: a kind of integrated morphology of integrated diaphragm type high-power LED chip, comprise led light source, power control circuit and substrate, this power control circuit is arranged in this substrate, this power control circuit one end is connected with this led light source, and its other end is connected with external circuit, electric current in this external circuit at first flows in this power control circuit, and after-current makes this led light source can convert electrical energy into luminous energy through flowing to this led light source after the adjustment of this power control circuit.
This external circuit is alternating current circuit, and this substrate is the thin film flexible wiring board.
This power control circuit comprises the power control signal circuit; power control circuit and power factor (PF) are regulated and are lighted protective circuit; wherein; this power control signal circuit is connected with this external circuit; this power control circuit is connected to this power control signal circuit and the adjusting of this power factor (PF) is lighted between the protective circuit; this led light source is connected to this power factor (PF) adjusting and lights in the protective circuit; this power control signal circuit is in order to access the alternating current in this external circuit; and drive this led light source electrified light emitting; the operating state that this power control signal circuit can this led light source of sensing simultaneously; and regulate the angle of flow of this power control circuit; realization is regulated the overall power output of this power control circuit by the variation of the operating state of this led light source of sensing; this power control signal circuit also comprises sensing circuit; this sensing circuit can this led light source of sensing operating state; thereby and carry out dividing potential drop action and adjust current status in this integrating circuit; reach the angle of flow of regulating this power control circuit; realization is regulated the overall power output of this power control circuit by the variation of the operating state of this led light source of sensing; electric current in this power control signal circuit flows into this power control circuit; this power control circuit is processed in order to the electric current that flows into is carried out full-wave rectification; and this power control circuit is carried out overload protection; this power factor (PF) is regulated and is lighted protective circuit in order to the voltage of different LED both sides in this led light source of balance; between different LED, carry out voltage distribution; and realize disconnected string safeguard function; this power control circuit is arranged in this substrate; be provided with some interfaces in this substrate, this led light source is connected in this substrate that is provided with this power control circuit by this interface.
This led light source is led chip or LED crystal grain.
This power control signal circuit comprises circuit junction, integrating circuit and conducting valve module, and this integrating circuit is connected between two these circuit junctions, and this conducting valve module and this integrating circuit are connected in series, and this integrating circuit comprises power distribution circuit and electric capacity.
This sensing circuit comprises photosensitive bleeder circuit, and this photosensitive bleeder circuit comprises photo resistance and divider resistance, and this sensing circuit also comprises the temperature-sensitive bleeder circuit, and this temperature-sensitive bleeder circuit comprises thermistor and divider resistance.
This power control signal circuit accesses the alternating current in this external circuit, and drive this led light source electrified light emitting, this power control signal circuit can pass through respectively the operating state of this photosensitive bleeder circuit and this this led light source of temperature-sensitive bleeder circuit sensing simultaneously, and adjust this integrating circuit and reach adjusting to this power control circuit angle of flow, realize that the variation of light intensity by this led light source of sensing and temperature is to the adjusting of this power control circuit overall power output.
This power control circuit comprises the bidirectional thyristor module; full-wave rectifying circuit and temperature current control module; this temperature current control module can be carried out temperature and Current Control simultaneously; this temperature current control module is connected to this power control circuit and the adjusting of this power factor (PF) is lighted between the protective circuit, is used for realization to the control of this led light source temperature and supply current.
This temperature current control module can limit peak brightness temperature and the maximum operating currenbt of this led light source, this temperature current control module is just blocked the power supply to this led light source automatically when this led light source temperature or electric current are elevated to the limiting value of setting, after this led light source recovered normal operating conditions, this temperature current control module was recovered the power supply to this led light source automatically.
This power factor (PF) adjusting is lighted protective circuit and is comprised some divider resistances and some pressure-sensitive semiconductor devices; this divider resistance and this pressure-sensitive semiconductor device are connected between the different LED of this led light source, and this power factor (PF) is regulated and lighted the protective circuit realization to all pressures and the disconnected string protection of different LED in this led light source.
This power factor (PF) is regulated and is divided into following three kinds of situations when lighting protective circuit work:
The first situation, when the plurality of LEDs series connection is used in this led light source, because plurality of LEDs voltage characteristic and not quite identical, need this divider resistance of arranging and this pressure-sensitive semiconductor device by the magnitude of voltage of its dividing potential drop effect automatic equalization each point by certain connection.
The second situation, it lights the threshold values height when the plurality of LEDs series connection is used in this led light source, this makes the power factor (PF) of this power control circuit be in low state, by the adjusting to this divider resistance and this pressure-sensitive semiconductor device, realization is lighted control to the step of this led light source, thereby reduced the threshold values of lighting of whole this led light source, increased substantially the power factor (PF) of this power control circuit.
The third situation, when the plurality of LEDs series connection is used in this led light source, when certain point in series circuit disconnects, whole this led light source will extinguish, setting by this divider resistance and this pressure-sensitive semiconductor device, when certain point occurs to disconnect, the magnitude of voltage of this divider resistance and this pressure-sensitive semiconductor device respective point will raise and make the automatic conducting of series circuit, make this led light source loop of outage reconnect the recovery illuminating state, meanwhile, this divider resistance and this pressure-sensitive semiconductor device have also kept the automatic adjusting of this led light source power by settings in advance, what the degree that allows at this led light source was recovered this led light source 10 normally lights performance number.
This power factor (PF) adjusting is lighted protective circuit and is also comprised voltage electromagnetic protection module; this voltage electromagnetic protection module is in order to the protection that realizes respectively reverse voltage is impacted and the protection that high-frequency electromagnetic is impacted; this voltage electromagnetic protection module is the electronic module that is made of damper diode and capacitance resistance ware; this voltage electromagnetic protection module and this led light source are connected in parallel; in order to suppress and subdue that reverse voltage impacts and frequency electromagnetic waves to the damaging impact of led light source, cut down simultaneously the electromagnetic interference of self.
This power control circuit comprises the bidirectional thyristor module, full-wave rectifying circuit and temperature current control module, after the external AC of this external circuit is inputted from two these circuit junctions, alternating current will be given this capacitor charging through this power distribution circuit, this moment, this sensing circuit is not worked, when the magnitude of voltage at these electric capacity two ends rises to the conducting threshold values that is higher than this conducting valve module, the G utmost point that electric current will flow to this bidirectional thyristor module triggers its conducting, this moment, alternating current will be through this circuit junction flow through this full-wave rectifying circuit and the D1 by this bidirectional thyristor module, consist of the loop with another this circuit junction behind the D2 electrode, through this full-wave rectifying circuit direct current is powered to this led light source through this temperature current control module simultaneously, make it luminous, at this moment, the power of lighting of this led light source is predefined by this power distribution circuit.
A kind of production method of integrated morphology of integrated diaphragm type high-power LED chip is characterized in that, its production stage is as follows:
The first step, make this power control circuit in this this substrate that is the thin film flexible wiring board, and the electronic devices and components that comprise in this power control circuit are welded in this power control circuit on the corresponding node, form Power Supply Assembly.
Second step, this Power Supply Assembly in the first step is fitted on the chip substrate of this led light source, by some these interfaces of arranging in this substrate with this led light source welding or be crimped on this Power Supply Assembly, thereby form finished product.
When carrying out second step, at first the Power Supply Assembly of this in the first step arranges the AuSn alloy-layer, then this led light source is fixed on this Power Supply Assembly, in this AuSn alloy-layer the mass percent of Au be 30%-70% all the other be Sn.
When the percentage by weight of Au in this AuSn alloy-layer is 70%, be in 200 degrees centigrade the situation this led light source to be fixed on this Power Supply Assembly at baking temperature.
When the percentage by weight of Au in this AuSn alloy-layer is 30%, be in 300 degrees centigrade the situation this led light source to be fixed on this Power Supply Assembly at baking temperature.
When the percentage by weight of Au in this AuSn alloy-layer is between 70% to 30%, be in 200 to 300 degrees centigrade the situation this led light source to be fixed on this Power Supply Assembly at baking temperature.
After being fixed to this led light source on this Power Supply Assembly, between the PN junction chip that forms this led light source, fill inorganic silicon dioxide liquid, the height of the height of liquid and PN junction chip maintains an equal level, then, baking is 30 minutes under the environment of 200 degrees centigrade of temperature, afterwards, clicks and enters silica gel at this led light source top, at last, fluorescent crystal is covered on this led light source, in the environment of 100 degrees centigrade of temperature, toasted 3 hours, take out, obtain finished product after pilot is bright.
The beneficial effects of the utility model are: at first, power control section of the present utility model is divided by a small amount of ordinary electronic element and is formed.So because it is little to have removed various rapid wear electronic component energy consumptions, the life-span is long.Secondly, the utlity model has auto brightness, temperature control and Feedback of Power function.Guarantee that the high-power LED chip endure in predefined temperature range, satisfies the requirement of overtemperature protection.Again, product of the present utility model self is frivolous, soft, fits to easily on the unlike material, and is less demanding to the evenness of binding face.In addition, heat resistance of the present utility model and good heat-transfer.It is after heat transfer substrate is combined, and the heat that components and parts produce is transmitted to substrate and gets on, and guarantees the reliable and safety of circuit working.Be exactly good insulation preformance of the present utility model in addition, be conducive to the combination with the LED chip of high pressure encapsulation mode.Its resistance to acid attack, salt spray resistance, ageing resistace is high.In addition, oneself power consumption of the present utility model is little, the power wide accommodation, same device can only be used for comparatively narrow power bracket to the existing LED charger of several thousand W(for tens watts).The utility model also has accessible interface and the platform that comprises light-operated, temperature control, voltage, electric current and other analog-and digital-control system.With respect to other power control power supply circuits, the utility model can reach 90% or higher power factor (PF).Effectively reduce the larger electromagnetic interference phenomenon that general power controller exists.Compare with the constant pressure and flow charger with the conventional power controller, the utlity model has stronger power supply adaptive capacity to environment and forceful electric power and attack protective capacities.
Embodiment
As shown in Figures 1 to 3, a kind of integrated morphology of integrated diaphragm type high-power LED chip, it comprises led light source 10, power control circuit 20 and substrate 30.
This power control circuit 20 is arranged in this substrate 30, and these power control circuit 20 1 ends are connected with this led light source 10, and its other end is connected with external circuit.
Electric current in this external circuit at first flows in this power control circuit 20, and after-current makes this led light source 10 can convert electrical energy into luminous energy through flowing to this led light source 10 after the adjustment of this power control circuit 20.
This external circuit is alternating current circuit, and in implementation, this led light source 10 can be led chip or LED crystal grain, and this substrate 30 is the thin film flexible wiring board.
This power control circuit 20 comprises that power control signal circuit 40, power control circuit 50 and power factor (PF) are regulated and lights protective circuit 60.
Wherein, this power control signal circuit 40 is connected with this external circuit; this power control circuit 50 is connected to this power control signal circuit 40 and the adjusting of this power factor (PF) is lighted between the protective circuit 60, and this led light source 10 is connected to this power factor (PF) adjusting and lights in the protective circuit 60.
This power control signal circuit 40 is in order to access the alternating current in this external circuit, and drive this led light source 10 electrified light emittings, the operating state that this power control signal circuit 40 can this led light source 10 of sensing simultaneously, and regulate the angle of flow of this power control circuit 20, realize that the variation of the operating state by this led light source 10 of sensing is regulated the overall power output of this power control circuit 20.
This power control signal circuit 40 comprises circuit junction L, N, integrating circuit and conducting valve module D9, and this integrating circuit is connected between two these circuit junctions.
This conducting valve module D9 and this integrating circuit are connected in series.
This power control signal circuit 40 also comprises sensing circuit 41, this sensing circuit can this led light source 10 of sensing operating state, thereby and carry out dividing potential drop action and adjust current status in this integrating circuit, reach the angle of flow of regulating this power control circuit 20, realization is regulated the overall power output of this power control circuit 20 by the variation of the operating state of this led light source 10 of sensing.
In implementation, this sensing circuit comprises photosensitive bleeder circuit 42, and this photosensitive bleeder circuit comprises photo resistance R7 and divider resistance R10.
This sensing circuit also comprises the temperature-sensitive bleeder circuit, and this temperature-sensitive bleeder circuit 43 comprises thermistor R6 and divider resistance R9.
Alternating current in these power control signal circuit 40 these external circuits of access, and drive this led light source 10 electrified light emittings, this power control signal circuit 40 can pass through respectively the operating state of this photosensitive bleeder circuit and this this led light source 10 of temperature-sensitive bleeder circuit sensing simultaneously, and adjust this integrating circuit and reach adjusting to this power control circuit 20 angles of flow, realize that the variation of light intensity by this led light source 10 of sensing and temperature is to the adjusting of this power control circuit 20 overall power output.
In implementation, this integrating circuit comprises power distribution circuit 44(R0, R1, R2, R3, R11) and capacitor C 1.
Electric current in this power control signal circuit 40 flows into this power control circuit 50.
This power control circuit 50 is processed in order to the electric current that flows into is carried out full-wave rectification, and this power control circuit 20 is carried out overload protection.
This power control circuit 50 comprises bidirectional thyristor module Q1, full-wave rectifying circuit 51(D10, D11, D12, D13), and temperature current control module R8.
This temperature current control module R8 can carry out temperature and Current Control simultaneously.
This temperature current control module R8 is connected to this power control circuit 50 and the adjusting of this power factor (PF) is lighted between the protective circuit 60, is used for realization to the control of these led light source 10 temperature and supply current.
This temperature current control module R8 can limit peak brightness temperature and the maximum operating currenbt of this led light source 10.
This temperature current control module R8 just blocks the power supply to this led light source 10 automatically when these led light source 10 temperature or electric current are elevated to the limiting value of setting.
After this led light source 10 recovered normal operating conditions, this temperature current control module R8 recovered the power supply to this led light source 10 automatically.
This power factor (PF) is regulated and is lighted protective circuit 60 in order to the voltage of different LED both sides in this led light source 10 of balance, carries out voltage distribution between different LED, and realizes disconnected string safeguard function.
This power factor (PF) adjusting is lighted protective circuit 60 and is comprised some divider resistances and some pressure-sensitive semiconductor device D1-D8.
This divider resistance and this pressure-sensitive semiconductor device D1-D8 are connected between the different LED of this led light source 10.
This power factor (PF) adjusting is lighted protective circuit 60 and is realized all pressures (electric voltage equalization) of different LED in this led light source 10 and the string that breaks (series LED causes a certain built-up section disconnection to cause whole this led light source 10 current supply circuits disconnection because certain tie point burns out) protection.
This power factor (PF) is regulated the operation principle of lighting protective circuit 60 and is divided into following three kinds of situations.
The first situation, when the plurality of LEDs series connection is used in this led light source 10, because plurality of LEDs voltage characteristic and not quite identical, need this divider resistance of arranging and this pressure-sensitive semiconductor device D1-D8 by the magnitude of voltage of its dividing potential drop effect automatic equalization each point by certain connection.
The second situation, it lights the threshold values height when the plurality of LEDs series connection is used in this led light source 10, this makes the power factor (PF) of this power control circuit 20 be in low state, by the adjusting to this divider resistance and this pressure-sensitive semiconductor device D1-D8, realization is lighted control to the step of this led light source 10, thereby reduced the threshold values of lighting of whole this led light source 10, increased substantially the power factor (PF) of this power control circuit 20.
The third situation, when the plurality of LEDs series connection is used in this led light source 10, when certain point in series circuit disconnects, whole this led light source 10 will extinguish, setting by this divider resistance and this pressure-sensitive semiconductor device D1-D8, when certain point occurs to disconnect, the magnitude of voltage of this divider resistance and this pressure-sensitive semiconductor device respective point will raise and make the automatic conducting of series circuit, make these led light source 10 loops of outage reconnect the recovery illuminating state, meanwhile, this divider resistance and this pressure-sensitive semiconductor device have also kept the automatic adjusting of these led light source 10 power by settings in advance, what the degree that allows at this led light source 10 was recovered this led light source 10 normally lights performance number.
This power factor (PF) adjusting is lighted protective circuit 60 and is also comprised voltage electromagnetic protection module D14.
This voltage electromagnetic protection module D14 is in order to the protection that realizes respectively reverse voltage is impacted and the protection that high-frequency electromagnetic is impacted.
This voltage electromagnetic protection module D14 is the electronic module that is made of damper diode and capacitance resistance ware.
This voltage electromagnetic protection module D14 and this led light source 10 are connected in parallel, in order to suppress and subdue that reverse voltage impacts and frequency electromagnetic waves to the damaging impact of led light source 10, cut down simultaneously the electromagnetic interference of self.
The utility model is in specific works, after the external AC of this external circuit is inputted from two this circuit junction L, N, alternating current will pass through this power distribution circuit R0, R1, R2, R3, R11 to this capacitor C 1 charging, this moment, this sensing circuit is not worked, (R6, R7, R9, R10 do not work at this moment).
When the magnitude of voltage at these capacitor C 1 two ends rose to the conducting threshold values that is higher than this conducting valve module D9, the G utmost point that electric current will flow to this bidirectional thyristor module Q1 triggered its conducting.
This moment, alternating current will be flowed through through this circuit junction L and be consisted of the loop with another this circuit junction N behind this full-wave rectifying circuit and the D1 by this bidirectional thyristor module Q1, the D2 electrode.
Through this full-wave rectifying circuit direct current is powered to this led light source 10 through this temperature current control module R8 simultaneously, make it luminous, at this moment, the power of lighting of this led light source 10 is predefined by this power distribution circuit.
P1 to P16 is the plurality of LEDs in this led light source 10 shown in Fig. 2,3.
As mentioned above, the defective that the utility model exists for traditional LED powering mode no matter on the line design and on the version, has all broken through original design concept, has accomplished that the technology of essence changes.Especially at the circuit design aspect, be to have used a kind of multi-function power controller to substitute traditional stabilized voltage power supply.
Power control section in implementation in the utility model is divided and high voltage led chip coupling, has saved transformer, electrochemical capacitor, IC(switching circuit) assembly, the current/voltage control element.Do not have the light current device, do not have self-destruction protection components and parts.Only have a small amount of energy to resist high-tension electronic component, and have auto brightness, temperature control and Feedback of Power function.All components and parts all have very long useful life in theory, and oneself power consumption is little.
Aspect version, the power control section that will have a various control function is divided and is produced on the FPC film, consist of the flexible LED power supply device, stay the Interface design integrated with various led chips according to concrete application needs, in order to be attached on the led chip substrate, thereby form integrated light source device with the led chip of various encapsulation.This integrated film LED power supply device, frivolous, softness, shared volume is very little, conducts heat and good insulation preformance, is easy to combine with various LED packing forms.
Corresponding to technology of the present utility model, this power control circuit 20 is arranged in this substrate 30, is provided with some interfaces in this substrate 30, and this led light source 10 is connected in this substrate 30 that is provided with this power control circuit 20 by this interface.
The utility model carries out according to following production method in concrete production.
A kind of production method of integrated morphology of integrated diaphragm type high-power LED chip is characterized in that, its production stage is as follows:
The first step, make these power control circuits 20 in this this substrate 30 that is the thin film flexible wiring board, and the electronic devices and components that comprise in this power control circuit 20 are welded in this power control circuit 20 on the corresponding node, form Power Supply Assembly.
Second step, this Power Supply Assembly in the first step is fitted on the chip substrate of this led light source 10, by some these interfaces of arranging in this substrate 30 with these led light source 10 welding or be crimped on this Power Supply Assembly, thereby form finished product.
When this led light source 10 is LED crystal grain, can directly LED crystal grain be fixed or be encapsulated on this Power Supply Assembly, form finished product.
In the implementation second step, also at first the Power Supply Assembly of this in the first step arranges the AuSn alloy-layer, then this led light source 10 is fixed on this Power Supply Assembly.
In this AuSn alloy-layer the mass percent of Au be 30%-70% all the other be Sn.
When the percentage by weight of Au in this AuSn alloy-layer is 70%, be in 200 degrees centigrade the situation this led light source 10 to be fixed on this Power Supply Assembly at baking temperature.
When the percentage by weight of Au in this AuSn alloy-layer is 30%, be in 300 degrees centigrade the situation this led light source 10 to be fixed on this Power Supply Assembly at baking temperature.
When the percentage by weight of Au in this AuSn alloy-layer is between 70% to 30%, be in 200 to 300 degrees centigrade the situation this led light source 10 to be fixed on this Power Supply Assembly at baking temperature.
After being fixed to this led light source 10 on this Power Supply Assembly, between the PN junction chip that forms this led light source 10, fill inorganic silicon dioxide liquid, the height of the height of liquid and PN junction chip maintains an equal level, and is generally 0.4mm to 0.6mm.
Then, baking is 30 minutes under the environment of 200 degrees centigrade of temperature, afterwards, clicks and enters silica gel at these led light source 10 tops, the silica gel of clicking and entering filling gel in the situation that these led light source 10 light-emitting areas are 10mm is 1 gram, and along with the ratio that is varied to of area increases or reduces.
At last, fluorescent crystal is covered on this led light source 10, in the environment of 100 degrees centigrade of temperature, toasted 3 hours, take out, obtain finished product after pilot is bright.