EP3782208A1 - Module del comprenant une lentille en silicone appliquée par impression 3d - Google Patents

Module del comprenant une lentille en silicone appliquée par impression 3d

Info

Publication number
EP3782208A1
EP3782208A1 EP19718647.1A EP19718647A EP3782208A1 EP 3782208 A1 EP3782208 A1 EP 3782208A1 EP 19718647 A EP19718647 A EP 19718647A EP 3782208 A1 EP3782208 A1 EP 3782208A1
Authority
EP
European Patent Office
Prior art keywords
lens
led
led module
light
module according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP19718647.1A
Other languages
German (de)
English (en)
Inventor
Katrin Schroll
Konstantin Engeter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siteco GmbH
Original Assignee
Siteco GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siteco GmbH filed Critical Siteco GmbH
Publication of EP3782208A1 publication Critical patent/EP3782208A1/fr
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/58—Optical field-shaping elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/90—Methods of manufacture
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/04—Refractors for light sources of lens shape
    • F21V5/048—Refractors for light sources of lens shape the lens being a simple lens adapted to cooperate with a point-like source for emitting mainly in one direction and having an axis coincident with the main light transmission direction, e.g. convergent or divergent lenses, plano-concave or plano-convex lenses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/08—Refractors for light sources producing an asymmetric light distribution
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • the present invention relates to an LED module which has a plastic lens produced in the 3D printing process, in particular silicone.
  • LEDs light-emitting diodes, by which all forms of semiconductor light sources, including organic light-emitting diodes are understood
  • the optics for the LEDs in the LED modules must be adapted to this. High tool costs for new optics are therefore the result.
  • the optics must be precisely aligned with the LEDs on the respective carrier of the LED. Since the LED acts as a nearly punctiform light source, the optics must be exactly matched to the position of the LED. Precise tuning, adjustment and manufacture of a lens made of injection-molded part must be, because for a faster cost-effective installation usually the largest possible lens array are used, but have a significantly different thermal expansion than the PCB material used. Simple mechanical means for mounting plastic components on a support are often not sufficient to ensure a precise alignment of an art fabric look over the LED.
  • the object of the present invention is to provide an LED module which solves the mentioned disadvantages in terms of high tool costs, the high storage costs for the provision of various optics and the problem of fixing the optics on the support of the LED.
  • the object is achieved by an LED module according to claim 1 and by a manufacturing method of such an LED module according to claim 18.
  • a special feature of the LED module of the present invention is that the plastic lens, in particular made of silicone, is printed directly onto the carrier substance of the LED by means of a 3D printing method.
  • the lens can be adjusted individually for the respective LED and for the purpose of use of the luminaire in which the LED module is to be installed, without having to provide different tools for injection-molded art fabric lenses.
  • the lens material silicone also has a high optical quality and can be well processed in a 3D printer.
  • the carrier substrate is designed as a printed circuit board, PCB.
  • PCB printed circuit board
  • the conductor tracks for contacting the LEDs can already be applied.
  • the PCB can also be designed as part of a luminaire housing.
  • the LED can be easily applied to the PCB, for example, by a pick and place machine.
  • the usual materials of a PCB are suitable for directly printing on it a lens made of silicone or another plastic. The materials enable the necessary mechanical connection to the material of the PCB.
  • the printed optics may be mounted on either the LED or on the PCB material, or both. It can also be printed on an art fabric lens, which are then fastened by means of previously applied adhesion promoter or with retaining pins which surround the LED, for example.
  • the lens is formed of different materials, in particular different silicone materials, which differ in the refractive index, in the color, in the light absorption property and / or in the light reflection property.
  • the 3D printing process makes it easy to combine different materials within the lens. This property can be exploited to form complicated lens structures of different materials. For example, by using materials with different refractive indices, interfaces can be created where total internal reflection takes place in the lens.
  • lens regions can be provided which are designed to absorb light. As a result, certain effects can be achieved in the light distribution of the LED module. For example, a cut-off in the light distribution in a certain solid angle range can be generated in order to allow glare reduction of the luminaire.
  • the lens material may be colored to produce certain color effects.
  • the colorant may comprise a phosphorescent material to effect a conversion of the wavelength of the LED. It is also possible to combine different colors within a lens.
  • the lens has curved surface sections, whose curvature is step-shaped, and which effect a light diffusion and / or a light mixture when using differently colored LEDs.
  • surface sections with curvature can be produced in a high quality by means of 3D printing, small steps, which are caused by the printing process, can not be avoided. However, this does not have to be disadvantageous for the optical quality of the lenses.
  • the steps can be deliberately designed to purposely effect a diffusion of light and / or color mixing in LEDs of different colors.
  • punk-shaped light sources as they are LEDs
  • the light must be mixed with differently colored LEDs to prevent light of different colors from being perceived from different angles. Light mixing is often beneficial even with white LEDs, as they also have the problem of changing color over the angle. Often luminaires reflect these colors through the angles in the room. Here it often happens that you need a light mixing to prevent yellow stripes on walls.
  • the light mixture also takes place through the steps in the curved surface sections of the lens, which are formed anyway by the 3D printing process.
  • smooth curved surface portions can be done for example by a separate subsequent treatment of the lens surface, for example by applying an additional coating, by local melting of surface areas of the lens or by polishing the lens surface.
  • the lens comprises a black colored material adjacent a transparent portion of the lens.
  • the black-colored material in particular silicone material, has a light-absorbing effect.
  • the black-colored material can be arranged in a region radially to the optical axis of the lens. This is advantageous for lenses which are not intended to emit light sideways, e.g. to create a desired glare of the LED module.
  • the lens has one or more interfaces, which are arranged opposite the LED so that the light of the LED is reflected.
  • the interfaces may be defined by an outer surface of the lens, ie be formed by an optical transition from the lens material to the air, or by an interface within the lens, that is between two lens materials with different refractive index. Both types of interfaces are suitable for reflecting the light of the LED at least partially or even totally. This is a particularly efficient way to direct the light within the lens since no reflection is caused by the reflection and further no additional reflective material such as a metallic coating or the like. , on or in the lens must be introduced.
  • the lens may comprise regions of light-reflecting lens material, in particular white-colored lens material, which adjoin an area with transparent lens material.
  • the reflective lens material may be directed reflective or diffuse reflective.
  • diffuse reflection can be produced by white lens material. By light reflection, larger deflection angles can be generated in comparison to the refraction of light. Therefore, it is possible to produce with this type of lenses light distributions, which are very different from the natural light distribution of an LED (this acts as a Lambert radiator).
  • the reflective lens material may in particular be arranged radially to the optical axis of the lens.
  • light beams of the LED can be deflected in the direction of the optical axis of the lens in order to achieve a focusing of the light.
  • the reflection areas may also have an inclination angle with respect to the optical axis of the lens in order to deflect the light radiation crosswise to the optical axis of the lens.
  • the light distribution can also widen and / or redirect light in a targeted manner at a shallow angle to the light exit surface of the LED module.
  • the reflective lens material can also be arranged only on one side on the transparent portion of the lens.
  • LED modules according to the invention can be designed such that the lens has a light-reflecting or light-absorbing lens material on the side of the optical axis pointing in the direction of the front of the house. As a result, the light can be blocked off to the facade of the building or redirected in the direction of the street side to be illuminated.
  • the lens has a recess on the opposite side of the LED along the optical axis, and interfaces of the recess are arranged opposite to the LED so that light of the LED thereon is totally reflected.
  • This embodiment is suitable for producing a very wide light distribution and / or a light distribution with a minimum along the optical axis, because the light is deflected by the total reflection at the interfaces of the recess along the optical axis.
  • the light can be redirected in the direction of the optical axis by multiple reflection, for example on outer surfaces of the lens or on light-reflecting regions on the outside of the lens.
  • this embodiment is adapted to redirect light, which is emitted along the optical axis without light deflection, in other solid angle ranges.
  • the lens has integral with the optically active components of the lens still holding devices for other components.
  • holders for other optical components can also be printed directly on the carrier substrate of the LED or directly on the LED.
  • holders for further auxiliary lenses or reflectors or mechanical fastening for inserting a cover can be generated during the printing of the lens. 3D printing makes it possible to achieve undercuts, for example by using two or more components.
  • the lens is connected to the carrier substrate in such a way that a moisture-tight and / or gastight seal is formed between the carrier substrate and the LED.
  • the lens can not only be precisely aligned with respect to the carrier substrate, but also be completed fluid-tight.
  • a particularly cost-effective variant for generating an LED module for higher degrees of protection of the lamp, in particular for lights in wet rooms or outdoors, can be produced without additional seal. Furthermore, the ingress of contamination between the LED and the lens is prevented.
  • further light influencing elements in particular reflectors or refractive elements, may be applied in the 3D printing on the carrier substrate at a distance from the lens.
  • a reflection section or a section having an internal or external interface to which total internal reflection takes place may be provided to facilitate the To redirect light in the LED module after exiting the lens.
  • a portion of the lens has a prismatic or wavy surface.
  • the surface can serve for light scattering or light mixing.
  • the surface structures are very easy to apply in the 3D printing process.
  • the dimensions of the structures may also be less than 0.5 mm in the maximum height. Depending on the 3D printing process used, such elevations can arise anyway through the printing process.
  • the surface structure is particularly suitable for
  • Another aspect of the present invention relates to a method of manufacturing an LED module as previously described.
  • the method comprises providing a carrier substrate, in particular a printed circuit board; mechanically attaching and electrically contacting at least one LED on the carrier substrate; and imprinting the lens of a plastic material, in particular of silicone, wherein the lens is printed on the carrier substrate and on the at least one LED.
  • FIG. 1 shows a cross section through an LED module with an associated half side
  • FIG. 2 shows a cross section through an LED module of a further embodiment with a light distribution curve shown on one side.
  • FIG. 3 shows a cross section through a further one
  • Embodiment of an LED module Embodiment of an LED module.
  • FIG. 4 shows a cross section through another one
  • Embodiment of an LED module Embodiment of an LED module.
  • FIG. 5 shows a cross section through another one
  • Embodiment of an LED module Embodiment of an LED module.
  • FIG. 6 shows a cross section through another one
  • Embodiment of an LED module Embodiment of an LED module.
  • FIG. 7 shows a cross section through another one
  • Embodiment of an LED module Embodiment of an LED module.
  • FIG. 8 shows a cross section through a further one
  • Embodiment of an LED module Embodiment of an LED module.
  • Figure 9 shows a cross section through another
  • Embodiment of an LED module Embodiment of an LED module.
  • the LED module of the present invention comprises a carrier substrate 1, which can be designed, in particular, as a printed circuit board (PCB) with already printed-on electrical conductor tracks.
  • a carrier substrate 1 which can be designed, in particular, as a printed circuit board (PCB) with already printed-on electrical conductor tracks.
  • PCB printed circuit board
  • the embodiments shown in the figures differ in particular in the lens shape.
  • the Lens is printed by means of a 3D printing made of silicone or other plastics.
  • a special feature is that the lens is not injected by injection molding on the LED 2 and the carrier substrate 1, but is printed in a 3D printer.
  • a multiplicity of different shapes of lenses can be produced and a material mix of lens materials can be used without the need for different molding tools. This enables mass production of LED modules with high flexibility.
  • FIG. 1 shows a first embodiment in which a silicone lens is formed from a transparent section 4 and an edge section surrounded by a black-colored silicone material 6.
  • the lens is printed on the LED or the carrier substrate in a printing process.
  • the transparent lens material 4 has a relatively strong convex curvature. As a result, the lens has a strong focus.
  • the black-colored silicone material 6 in the edge region further causes light which is emitted laterally from the LED 2 at a shallow angle to be absorbed. Accordingly, the light distribution curve having a corresponding cross section has a strong maximum along the optical axis of the lens. Furthermore, the light distribution curve is cut off at a defined critical angle in the direction of ⁇ 90 °. This effect is produced by the absorbing lens material 6 in the edge region of the lens. This light distribution is particularly suitable for glare control of the lamp.
  • FIG. 2 shows a variant in which the radius of curvature of the transparent section 4 of the lens is smaller. Accordingly, the light distribution curve is made wider. However, this is also Light distribution curve a cut angle to ⁇ 90 ° due to the absorbent lens material. 6
  • FIG. 3 shows a variant in which absorbing lens material 6 is provided on one side only on the lens.
  • reflective lens material can also be provided there.
  • the lens has a LVK (not shown in the figure), which is cut off only on one side.
  • the lens has on the outside an interface 7, which light radiation is deflected by the LED 2 by total internal reflection in the direction of the optical axis.
  • This type of lens is suitable, for example, for an LED module in a street lamp, wherein the street lamp generates a light distribution that emits light mainly in the direction of the street side and no light or only a small portion of the light emits towards a whole house facade.
  • Figure 4 shows an alternative embodiment in which two lens materials 4 and 8 are combined, which have a different refractive index. Further, the angle of the interface 7 between the regions of the lens of different refractive index is selected such that the light of the LED 2 is totally internally reflected internally at the interface.
  • This LED module generates a highly focused light distribution by the curvature of the transparent portion 4 of the lens on the one hand, and the reflection at the interfaces to the lower refractive index lens material 8 on the other hand.
  • the lens still has the advantage that no light is absorbed, but only reflected. As a result, the overall efficiency of the LED module is increased.
  • the interface between the two refractive indices may also run along a curve, if for different rays different angles are needed.
  • Figure 5 shows a variant of an LED module similar to Figure 4, wherein an asymmetric light distribution is generated. Internal total reflection also takes place at the interface 7 between the transparent light material 4 with a higher refractive index and the lens material 8 with a lower refractive index. The lens therefore produces an asymmetrical light distribution.
  • Figure 6 illustrates an alternative embodiment in which a recess 10 is disposed on the opposite side of the LED 2 along the optical axis of the lens.
  • the recess 10 forms a conical outer surface 7 of the transparent portion 4 of the lens. In this interface 7, the light of the LED 2 is internally totally reflected.
  • the lens has a lens material 8 with a higher refractive index in an edge region, as well as described in connection with FIG. The light is accordingly redirected twice, first at the interface 11 and a second time at the interface between the lens regions 4 and 8.
  • This lens is suitable for producing a light distribution which has a minimum along the optical axis and the symmetrical maxima in the edge regions having.
  • the recess also serves to reduce the luminous density of the LED and distribute it over a larger area.
  • the lens region 8 may also comprise a specularly reflective material.
  • Figure 7 shows a variant in which the lens is formed only of a material 4 with the same refractive index.
  • another light-influencing element 12 applied in 3D printing is provided, which is designed to be light-reflecting. Leave it Light rays, which leave the lens at a shallow angle, deflect in the direction of the optical axis.
  • a body of lens material with two different refractive indices may also be provided which internally defines an interface between the higher and lower refractive index materials. Such a deflection body acts in a similar way to the reflective element 12.
  • Figure 8 shows a variant in which the lens material 14 comprises a colored silicone or other plastic material to produce a color conversion or simply absorption of certain parts of the spectrum.
  • the optical efficiency is reduced in order to adjust the spectrum of the light. It may also be provided to introduce white color or scattering particles into the lens material to produce a scattering or color mixing of the light. This makes it possible to prevent the light emitted by the lens having a different color in different spatial directions.
  • the color temperature of the LED module can therefore be adjusted easily without requiring storage costs for the modules or the LEDs in different color temperatures.
  • Another advantage of phosphorus in the lens material is that LEDs with less phosphorus or no phosphor can be used which have a longer life.
  • FIG. 9 shows a further embodiment in which the surface of the lens has a prismatic or wavy structure 16.
  • the prismatic structure 16 provides for a Reflection of the light radiation of the LED in some solid angle ranges.
  • the interface between the lens material 4 and the support substrate 1 may be formed to be reflective so that light deflected from the prism structure 16 toward the support is reflected back to the light exit side of the lens.
  • a scattering and / or mixing of the light can be produced.
  • the embodiment of Figure 9 further comprises an absorbent lens material 6 described in connection with Figures 1 and 2 which produces a cut-off angle in the light distribution curve at a defined critical angle in the ⁇ 90 ° direction.
  • the lens in particular the lenses of different lens material 4, 6, 8, 14 can be produced comparatively easily by a 3D printing method.
  • various lens materials can be combined with one another without any effort, which can differ in the refractive index or in the reflection properties and in the color.
  • This is a significant advantage to lens materials made by injection molding.
  • the injection molding process is more complicated because a different tool is needed for each mold.
  • a material mix can only be produced with a multi-component injection molding process, which is technically very complicated compared to a 3D printing.
  • Brackets can be used to hold other reflectors or other attachment optics.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Computer Hardware Design (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

L'invention concerne un module DEL présentant au moins une DEL (2) qui est fixée et mise en contact électrique sur un substrat support (1), ainsi qu'une lentille en matière synthétique, en particulier en silicone, qui est appliquée sur le substrat support (1) et par-dessus la ou les DEL (2) par impression 3D afin d'influer sur la répartition de la lumière de la DEL, l'impression 3D étant réalisée de telle sorte que la lentille soit directement reliée au substrat support par le processus d'impression de façon à être maintenue mécaniquement sur le substrat.
EP19718647.1A 2018-04-19 2019-04-12 Module del comprenant une lentille en silicone appliquée par impression 3d Pending EP3782208A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102018109408.6A DE102018109408A1 (de) 2018-04-19 2018-04-19 Led-modul mit silikonlinse in 3d druck
PCT/EP2019/059514 WO2019201794A1 (fr) 2018-04-19 2019-04-12 Module del comprenant une lentille en silicone appliquée par impression 3d

Publications (1)

Publication Number Publication Date
EP3782208A1 true EP3782208A1 (fr) 2021-02-24

Family

ID=66240105

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19718647.1A Pending EP3782208A1 (fr) 2018-04-19 2019-04-12 Module del comprenant une lentille en silicone appliquée par impression 3d

Country Status (3)

Country Link
EP (1) EP3782208A1 (fr)
DE (1) DE102018109408A1 (fr)
WO (1) WO2019201794A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102019109509A1 (de) 2019-04-10 2020-10-15 Siteco Gmbh LED-Modul mit Silikon-Leiterbahn

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9099575B2 (en) * 2013-07-16 2015-08-04 Cree, Inc. Solid state lighting devices and fabrication methods including deposited light-affecting elements
US20150167926A1 (en) * 2013-12-16 2015-06-18 Vode Lighting Llc Lighting optics for luminaires
TWI587546B (zh) * 2015-03-31 2017-06-11 點金石股份有限公司 具有多層透鏡之發光結構及其製造方法
DE202015103290U1 (de) * 2015-04-29 2016-08-01 Tridonic Jennersdorf Gmbh LED-Linse mit integrierter Verbindungstechnik
DE102016103288A1 (de) * 2016-02-24 2017-08-24 Siteco Beleuchtungstechnik Gmbh Leuchtenmodul insbesondere für Straßenleuchten
DE102016104546A1 (de) * 2016-03-11 2017-09-14 Siteco Beleuchtungstechnik Gmbh LED-Modul mit Silikonlinse
DE102016209460B4 (de) * 2016-05-31 2022-12-29 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. An einem textil anbringbare elektronische vorrichtung sowie ein textil mit einer solchen elektronischen vorrichtung
WO2018014948A1 (fr) * 2016-07-20 2018-01-25 Wacker Chemie Ag Dispositif d'impression 3d et procédé pour produire des objets
CN206921858U (zh) * 2017-04-21 2018-01-23 上海威廉照明电气有限公司 发光装置

Also Published As

Publication number Publication date
WO2019201794A1 (fr) 2019-10-24
DE102018109408A1 (de) 2019-10-24

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