JP2013122827A - Method for manufacturing led illumination lamp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing an LED illumination lamp that can average color temperature or luminance of LED illumination lamps to be manufactured even when individual variations of color temperature or luminance are large at manufacturing as characteristics of an LED.SOLUTION: In the method for manufacturing an LED illumination lamp 10 having a plurality of LEDs 12, the whole LEDs 12 are divided into groups by color temperature as a standard, and a mounting ratio for regulating the number of LEDs 12 to be mounted on each group in one LED illumination lamp 10 in response to a ratio of the number of LEDs 12 included in each group. Then, the LEDs 12 are mounted on the LED illumination lamp 10 according to the mounting ratio.

Description

  The present invention relates to a method for manufacturing an LED lamp, and more particularly, to a method for manufacturing an LED lamp that can average color temperature or luminance.

  In recent years, various LED illumination lamps have been proposed from the viewpoint of energy saving (see, for example, Patent Document 1). Such an LED illumination lamp includes an LED substrate on which a plurality of LEDs are mounted. When LEDs are mounted on the LED substrate, the LEDs provided in a form wound on a reel are picked up for each package, and are sequentially aligned and loaded on the LED substrate.

JP 2011-210729 A

  Here, the individual characteristics of the color temperature and the luminance at the time of manufacture are large as the characteristics of the LED, and generally an error of about 20% (up and down 10% of the reference value) may occur. However, in particular, regarding the color temperature, if there is a difference of 20% (for example, comparing 5000 Kelvin and 6000 Kelvin), it looks as a completely different color, and thus the quality varies to such an extent that the difference can be seen visually. In particular, since a plurality of LED illumination lamps are used side by side in a room, if there are variations in color temperature and luminance, the difference is clearly understood.

  In order to avoid such a problem, the tolerance of the LED to be used may be set small. However, since the LED outside the tolerance range is discarded, an increase in cost is inevitable.

  Therefore, the present invention provides a method for manufacturing an LED lighting device that can average the color temperature or luminance of the manufactured LED lighting device even when the individual differences in color temperature and luminance during manufacturing are large as the characteristics of the LED. The issue is to provide.

  The present invention has been made to solve the above-described problems, and is characterized by the following.

(Claim 1)
The invention described in claim 1 is characterized by the following points.

  That is, the manufacturing method of the LED illuminating lamp according to claim 1 is a manufacturing method of the LED illuminating lamp including a plurality of LEDs, and all the LEDs are grouped based on the color temperature, and are included in each group. According to the ratio of the number of LEDs, a mounting ratio that defines how many LEDs of each group are mounted by one LED lighting is determined, and LEDs are mounted on the LED lighting according to the mounting ratio. And

(Claim 2)
The invention described in claim 2 has the following features in addition to the features of the invention described in claim 1 described above.

  That is, a permutation pattern that defines the order in which the LEDs of each group are mounted is determined, and the LEDs are mounted on the LED illumination lamp according to the permutation pattern.

  The present invention is as described above. All the LEDs are grouped based on the color temperature, and according to the ratio of the number of LEDs included in each group, the number of LEDs in each group by one LED illumination light. Since the mounting ratio that defines whether to mount the LED lighting lamp is determined and the LED is mounted on the LED lighting lamp according to the mounting ratio, the color temperature of the manufactured LED lighting lamp can be averaged.

  In addition, if a permutation pattern that defines the order in which the LEDs of each group are mounted is determined and the LEDs are mounted on the LED lighting according to the permutation pattern, the local deviation of the color temperature in one LED lighting is reduced. Can be resolved.

It is the side view which abbreviate | omitted (a) front view and (b) intermediate part of LED lighting. It is the partially expanded exploded view which looked at the LED illumination light from the bottom. It is the table | surface which grouped LED according to color temperature and a brightness | luminance. It is a table | surface which shows a mounting ratio. It is a figure which shows a permutation pattern.

  As shown in FIG. 1, the LED illumination lamp 10 according to the present embodiment is a straight tube illumination lamp that is structurally compatible with a conventional fluorescent lamp, and can be connected to a conventional lamp body for a fluorescent lamp. It has become.

  As shown in FIG. 2, the LED illumination lamp 10 includes an LED substrate 11 on which a plurality of LEDs 12 are arranged. In the present embodiment, 111 LEDs 12 are mounted on one LED illumination lamp 10.

  Since the LED 12 mounted on the LED illumination lamp 10 has a large individual difference in color temperature and brightness, the tolerance tends to be large. In this embodiment, the color temperature is 5500 to 6500 K (Kelvin), and the voltage value necessary for establishing the reference current value (20 mA × 3 = 60 mA) is 3.1 to 3.3 V (volt). LED12 is used.

  When the LEDs 12 are mounted on the LED illumination lamp 10, first, all the LEDs 12 are grouped based on the color temperature and the voltage value necessary for the reference current value.

  In this embodiment, as shown in FIG. 3, the color temperature is 5500 K or more and less than 6000 K and the voltage value required for the reference current value is 3.1 V or more and less than 3.2, and the color temperature is 5500 K or more and less than 6000 K. In addition, a group B in which the voltage value required for the reference current value is 3.2 V or more and 3.3 or less, and a group in which the color temperature is 6000 K or more and 6500 K or less and the voltage value required for the reference current value is 3.1 V or more and less than 3.2. C and a group D having a color temperature of 6000K to 6500K and a voltage value required for a reference current value of 3.2V to 3.3V are grouped into four groups. In the present embodiment, it is assumed that, by this grouping, there are 6500 LEDs 12 in Group A, 3200 LEDs in Group B, 2500 LEDs in Group C, and 1800 LEDs in Group D.

  Next, the mounting ratio is determined according to the ratio of the number of LEDs 12 included in each group. The mounting ratio is a value that defines how many LEDs 12 of each group are mounted by one LED lighting lamp 10.

  In this embodiment, there are 6500 groups A, 3200 groups B, 2500 groups C, and 1800 groups D, so that this ratio can be approximated as much as possible to eliminate waste of the LEDs 12. Of 111 LEDs 12 mounted on one LED illuminating lamp 10, 50 groups A, 26 groups B, 20 groups C, and 15 groups D may be used. Therefore, a mounting ratio of “group A: group B: group C: group D = 50: 26: 20: 15” is determined.

  According to this mounting ratio, as shown in FIG. 4, the difference between the number of LEDs 12 of each group and the number of mounted LEDs is set as small as possible, and as many LED lighting lamps 10 as possible. It can be seen that the LED 12 can be used without waste.

  The surplus LED 12 may be sent to the next manufacturing process. That is, the surplus LED 12 may be incorporated when determining the mounting ratio in the next manufacturing process.

  As described above, by determining the mounting ratio, it is determined how many LEDs 12 of each group are mounted by one LED lighting lamp 10.

  Next, a permutation pattern that defines the order in which the LEDs 12 of each group are mounted is determined. At this time, if the LEDs 12 of each group are mounted on one place on the LED substrate 11, a local color temperature deviation in one LED illumination lamp 10 occurs, so that such a deviation does not occur as much as possible. Determine the permutation pattern.

  For example, a permutation pattern as shown in FIG. 5 is desirable. In this permutation pattern, the LEDs 12 of each group are arranged at equal intervals as much as possible, and the order in which the LEDs 12 of each group appear is arranged with a certain regularity. For example, the LEDs 12 in group A are arranged with two or three other groups of LEDs 12 sandwiched between two sets of LEDs 12. The group B LEDs 12 are arranged with three or four other groups of LEDs 12 in between.

  When the mounting ratio and the permutation pattern are determined as described above, an LED loading program is created based on the mounting ratio and the permutation pattern. The mounting of the LEDs 12 is executed by this program, and all the LED lighting lamps 10 are manufactured with the same mounting ratio and permutation pattern.

  The present embodiment is as described above, and all the LEDs 12 are grouped based on the color temperature, and the LED 12 of each group is set by one LED illuminating lamp 10 according to the ratio of the number of LEDs 12 included in each group. Since the mounting ratio that defines how many are mounted is determined and the LEDs 12 are mounted on the LED lighting 10 according to the mounting ratio, the color temperature of the manufactured LED lighting 10 can be averaged.

  In addition, a permutation pattern that defines the order in which the LEDs 12 of each group are mounted is determined, and the LEDs 12 are mounted on the LED illumination lamps 10 according to the permutation pattern, thereby eliminating local color temperature bias in one LED illumination lamp 10. can do.

  In the above-described embodiment, when the mounting ratio is determined, the color temperature and the voltage value necessary for the reference current value are used as a reference. However, the present invention is not limited to this. For example, the mounting ratio may be determined based on only the color temperature. Further, instead of the color temperature or in combination with the color temperature, the mounting ratio may be determined based on the luminance (candela value).

10 LED lighting 11 LED substrate 12 LED

Claims (2)

A method for manufacturing an LED illumination lamp comprising a plurality of LEDs,
Group all LEDs based on color temperature,
According to the ratio of the number of LEDs included in each group, determine the mounting ratio that defines how many LEDs of each group are mounted with one LED lighting,
A method of manufacturing an LED illumination lamp, comprising mounting an LED on the LED illumination lamp in accordance with the mounting ratio. Determine a permutation pattern that defines the order in which each group of LEDs is mounted;
2. The method of manufacturing an LED illumination lamp according to claim 1, wherein LEDs are mounted on the LED illumination lamp according to the permutation pattern.

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