KR20040019015A - A Method Of Producing A Lamp - Google Patents

Abstract

Mounting the light emitting junction on the support structure 52 such that the junctions are suitable for a three-dimensional arrangement. The support structure may also be a curved lead frame as claimed in the claims. The conductor may be partly of a spherical arrangement. The light emitting junction can be installed in the tail 57 of the curved conductor, which tail acts as a light guide for controlling the direction of light output from the junction.

Description

A method of producing a lamp

The present invention relates to a lamp, in particular an LED lamp and a method for producing a lead frame for use in the lamp.

1 is a side view of an LED lamp;

2 is a plan view of the lamp of FIG. 1;

3 is a circuit diagram for the lamp of FIGS. 1 and 2;

4 is a schematic cross sectional view of a second LED lamp;

5 is a circuit diagram of the lamp of FIG. 4;

6 is a cross sectional view of the lamp of FIG. 4;

7 is a top view of FIG. 4;

8 shows the illumination pattern of the lamp of FIGS. 4 to 7;

9 is a plan view of a third lamp;

10 is a circuit diagram for the lamp of FIG. 9;

11 is a front view of the lamp of FIG. 9;

12 is a side view of the lamp of FIG. 9;

FIG. 13 is a side view of the lens for fitting onto the lamp of FIG. 9; FIG.

14 is a cross sectional view taken along the line X-X in FIG. 11;

15 is a cross sectional view taken along the line Y-Y in FIG. 12;

FIG. 16 shows the illumination pattern represented by the lamp of FIGS. 9 to 12;

17 is a schematic flowchart illustrating steps for manufacturing a lamp;

18 is a schematic perspective view of a lead frame arranged for a tail forming operation;

19 is a perspective view of a lead frame on a carrier;

20 is a cross sectional view of a lead frame;

21a) is a plan view of a lead frame with attached junctions and intermediate conductors;

FIG. 21B) is a cross sectional view of the lead frame taken along line A-A shown in FIG. 21A);

22 is a top view of another lead frame with an attached junction;

23 is a top view of another lead frame configuration;

24 is a perspective view of a lamp formed from the lead frame of FIG. 23; And

25 is a perspective view of another lamp.

According to the present invention, there is provided a lamp manufacturing method comprising mounting a light emitting junction on a support structure such that the junctions are in a three-dimensional arrangement.

Preferably, the method further comprises positioning a junction at each trailing end formed in the support structure, which trailing end functions as a light guide for controlling the direction of light output from the associated junction.

Preferably, the support structure further comprises the step of forming the conductor, comprising a plurality of conductors, in a curved arrangement, preferably in a partially spherical arrangement.

Preferably, the conductor is provided in the form of a lead frame.

Preferably, the method further comprises moving the lead frame relative to the feature zone and engaging a die with a punch from opposite sides of the lead frame to form a trailing portion. The trailing portion may be formed in one operation, or alternatively, the trailing portion may be sequentially formed by appropriately arranging the punch and die with respect to the lead frame after each tail forming operation and for subsequent tail forming operations.

Preferably, the lead frame comprises moving the carrier so as to introduce each trailing edge into a mount where the lead frame is supported on the carrier and the junctions are mounted to the conductor. The carrier is preferably rotatable around the first and second vertical axes to align the rear end with the mount, the junctions being mounted at their respective rear ends by advancing the conductors associated with the junctions with respect to each other along the third axis, The third axis is preferably perpendicular to the first and second axes.

Each junction is preferably electrically connected to the two conductors via an intermediate conductor. The intermediate conductors can be connected to allow independent control of at least two junctions by controlling the current through the associated conductors to which each junction is connected. The junction can also be electrically connected with the conductors in an individually controllable group.

The method preferably comprises the application of a common phosphor over at least two adjacent junctions, and more preferably, the encapsulation of the support structure and the junction in the bulb.

In another aspect, a lead frame is provided that includes a plurality of conductors formed in a curved arrangement for supporting light emitting junctions in a three-dimensional arrangement. The lead frames preferably comprise a trailing portion for receiving one junction each.

In another aspect, a lamp formed according to the method described above is provided.

In another aspect, electrically coupled luminescence between conductors and the conductors includes controlling current through one of the respective conductors to independently control the light output from junctions connected to the conductors. The lamp operating method described above, which is formed with junctions, is provided.

The invention is explained in more detail with reference to the accompanying drawings in which:

As shown in FIG. 1, the lamp 1 comprises a bulb part 2 having a cylindrical base 3 and an elliptical end 4, arranged to enhance the light output in the axial direction of the lamp. The lamp also has first and second terminals, which are preferably formed of conductors 5, 6 embedded in the bulb 2. The terminal 5 has a support platform 7 on which an integrated circuit wafer 8 is mounted. In the example shown, the wafer includes two junctions, which are arranged substantially adjacent to each other such that a common layer of fluorescent material, such as a fluorescent layer, can be applied to both junctions. The intermediate conductors 9-12 electrically couple the junctions to the respective terminals 5, 6 such that the LED junctions 14, 15 are arranged in opposite polarities, as shown in the circuit diagram of FIG. A resistance element 16 is provided between the other conductor 13 and the terminal 5 (which connects the intermediate conductors 11 and 12).

The conductors 5 and 6, the intermediate conductors 9 to 13, and the wafer 8 are all embedded in the bulb 2, so that the lamp has a strong unitary structure. The opposite polarity of the junction allows the lamp to be connected to the power source irrespective of polarity, as compared to the case of conventional LED arrangements. The use of a single fluorescent layer common to each junction also simplifies manufacturing and provides an aesthetic advantage in that light from either junction is perceived as coming from a single source.

In a preferred form of the LED lamp, the following specifications can be applied:

Nominal size Diameter 9.5mm Light color White Light bulb color Water clear Light intensity Typical light output> 20mCd at super bright average 20mA Guaranteed life 30,000 hours Focus Half angle type 15 ° Base form Compatible with wedge lamps Lead dimension 6 mm nominal. Outer basal wedge Supply voltage Nominal 12V. {> 11.5 <14V AC or DC} Forward current 20 + 8 / -3 mA at 20 mA average Forward voltage 3.6 (typ) maximum 4.0 at 20 mA average. Reverse voltage 5V minimum. Power loss LED Junction 120Mw Resistance 170mW Reverse current Up to 50 × 10 ^-3 mA at 5V Average Internal resistance 430 ohm nominal

However, it should be taken into account that the size arrangement and operating parameters of any part of the lamp may vary as needed and the number of LED junctions may also be increased to meet the lighting needs.

The second lamp 20 is described with reference to FIGS. 4 to 8. The lamp 20 is provided with additional conductors 26, 27 in the form of conductors 23, 24 with the first and second terminals 21, 22 embedded in the bulb 25. The construction is generally similar to the lamp of FIGS. Each conductor 23, 26 and 27 has a respective trailing edge 28 to provide a support structure for receiving associated junctions, denoted by reference numerals 29, 30 and 31. The junction is covered by a common fluorescent layer 35 and is electrically connected through intermediate conductors 32, 33, 34 between each individual conductor 23, 26, 27 on which the junctions are mounted and adjacent conductors. In the illustrated embodiment, as shown in the circuit diagram of FIG. 5, the junctions are connected in series.

All the conductors 23, 24, 26, 27 are preferably formed of the two-dimensional lead frame structure 40 shown in Fig. 6 to apply the fluorescent layer 35 therein and attach the bulb 25 to it. Directly positioning the junctions 29, 30 and 31 facilitates and reliably manufactures. As can be seen in both FIG. 6 and FIG. 7, the junctions 29, 30, 31, together with the conductors 23, 27 before and after the conductors 26, are generally arranged in a linear arrangement to produce the whole generated by the junctions. Illumination is slightly enhanced axially, as indicated by curve A in FIG. 8.

The lamp 20 may also be provided with a lens 41 formed by being fitted to the bulb 25 to change the light generated by the lamp to show, for example, the illumination pattern indicated by curve B in FIG. 8. This results in a slightly more even distribution of the output illumination.

9-16, a third lamp 50 is illustrated. In addition, the lamp 50 has a plurality of conductors 51, 52, 53 and 54 embedded in a single bulb portion 55, mounted to each trailing portion 57, and a common layer of fluorescent material 59 It is generally similar to the previous lamp structure as long as it has covered light emitting junctions 56. Each junction is electrically connected back through an intermediate conductor 58 between each conductor and adjacent conductors mounted in the junction to form the circuit illustrated in FIG. 10. In this case, however, each conductor 51 to 54 carries three junctions 56.

The conductors 51 to 54 are curved in the bulb portion 55 to support the junction on an imaginary curved surface, such as a spheroid, in this way the illumination produced by the lamp 50 It is small and generally has a shape emitted from a spheroidal point light source. Lens 60 is a more uniform distribution pattern, as shown by curve C in FIG. 16, which is the illumination output observed from the top view of lamp 50, ie when the lamp is viewed in the same direction as shown in FIG. 9. It may also be provided to change the output of the junctions to produce.

In addition to altering the light output by using the lens 60, the conductors can also be arranged in any desired arrangement and the structure of the tail 57 helps to control the directional output of the light emitted by the various junctions. May also be used. In particular, the arrangement of each tail may be such that, for example, the tail sidewall acts as optical guides to control the direction and / or divergence angle of the light emitted from the respective junctions.

More specifically, the effect of the tail on the light output from the shape junctions of each tail will be described in more detail with reference to FIGS. 14 and 15, with FIGS. 14 and 15 being the lines XX shown in FIGS. 11 and 12, respectively. And the cross section of the relevant conductor taken along line YY.

A trailing portion 57 including an LED junction is located and formed in the conductors 51, 52 and 53, so that the light beam emitted from the trailing portion is spherical radius of the virtual image denoted by 'R', the LED in the trailing portion. By the distance indicated by 'r' from the junction to the virtual extension junction of one trailing sidewalls, and by the angle 'A' between the centerline 61 of the lamp 50 and the centerline 62 perpendicular to another LED junction. The determined predictable pattern can be combined in free space outside the ramp 50.

The virtual spherical radius 'R' is the distance from the intersection of the centerline of the trailing edges to the LED junction inside the hobby. The angle between the trailing side walls determines the value of 'r'.

In the extreme case where 'r' is equal to or greater than "R", light from each LED junction is formed by the trailing edge with a beam that does not intersect, regardless of the angle value 'A'. For all values of 'r' less than 'R', the light beam from each LED junction can match the edge of the light beam from the adjacent LED junction. In this case the exact position is determined by the value of the R / r ratio and the angle 'A'.

As will be appreciated, the lamps described above generally consider a significant range of obtaining light sources using junction diodes having a predetermined one of a variety of output lighting patterns while maintaining a simple configuration. A particular advantage is that several junctions are small in size and can be configured to produce light output that can be perceived as being emitted from a single point light source when viewed with the naked eye.

With reference to FIGS. 17-24, the lamp manufacturing method is demonstrated. The lamp manufacturing method includes three main processes: process 100 is to form a suitable lead frame, process 101 is to attach a junction to the lead frame, and process 102 is final packaging.

The process 100 provides, in step 103, a flat lead frame, and in step 104, the conductor of the lead frame is partially spherical, and in step 105, the trailing portion of the conductor is formed. After formation, the surface treatment is then performed in step 106.

18 shows the lead frame 110 between steps 104 and 105. The lead frame 110 is generally provided in an elongated strip 111, which is divided into sections 112, which are ultimately separated to form individual lamps. Each section 112 includes a plurality of conductors 113, 114, 115 formed in a curved shape that is preferably partially spherical. The conductors may be formed in a curved form by any suitable process such as inserting the strip 111 on a press or the like.

To form the tail, some spherical portion of the lead frame is fitted over the corresponding shaped tool 116 at the forming station, where a punch (not shown) is opposite the lead frame. Engaging with the conductors 113, 114, 115 from to the opposite side of the die, the tail is formed in the conductor by the action of a punch that deforms the conductor to the associated die 117 provided in the tool 116. The tail may be formed sequentially and for this purpose, the tool is preferably rotatable relative to the lead frame so that the die may be rotated about any desired position where the tail requires. In this way, one punch and die 117, which are rotated coincidentally, can be used to form all trailing edges in any desired arrangement. Alternatively, the tool 116 may have a predefined arrangement of the die 117 and a punch properly arranged so that all trailing edges are formed in one operation. The special position and arrangement of the trailing part is, if necessary, since the trailing part operates as a light guide as specifically described above with respect to FIGS. 9 to 16 to define the output direction while the number of trailing parts determines the maximum output intensity. Can be selected to optimize the output.

In some cases, the lead frame 110 may be installed on the carrier 119 with respect to the process 101, as shown in FIG. 19, in which the light emitting junction is installed on the trailing portion 120. do. The carrier 119 is itself rotatable on an axis rotation shaft 121 about the x axis and an axis rotation shaft 122 about the y axis. As such, the lead frames are placed in a mounting station (not shown) so that each tail 120 is sequentially arranged to accommodate the associated junction and rotated about the x, y axis relative to the mount. Can be. FIG. 20 shows a cross section of some spherical arrangement of one of the stations 112, in particular the conductor 114. Curve 123 represents a spherically deformable path of conductor 114 that can be obtained by rotating lead frame 110 around axes 121 and 122. Line 124 represents the equivalent rotation of the tool 116 away from the z axis, which in turn defines an operating angle 125 at which the tail 120 can be formed.

When each trailing edge is properly in the mount, the associated light emitting device or die, referred to as junction 130 for simplicity, as shown in FIG. 21, is located at the trailing edge along the third axis, preferably in the z-axis direction. It is inserted and bonded in place according to step 107 of the machining process 101. At this time, or following this, an intermediate conductor 131 is attached in step 108 to electrically connect the junction to the adjacent conductor. The junctions shown in FIG. 21 are arranged in an electrically parallel arrangement, but the positions and couplings of the junctions can be in any desired arrangement, as shown in FIG. 22, in which each junction is a common central conductor ( 114 and each radially arranged conductor 132 such that the light intensity from each junction is individually controlled by independently controlling the power supplied to the conductor. Another possible arrangement of the tail 120 is shown in FIG. In any arrangement, several arrangements of junctions can be electrically connected in groups so that the light intensity from each group can be controlled independently.

After the LED junction is installed in place and the intermediate conductors are connected, the phosphor is applied over the junction in the processing step 109 of process 101. The phosphor is preferably applied to at least two adjacent LED junctions.

The lead frame 110 is then conveyed to the final process 102 of processing to form the lamp 140 shown in FIG. The process 102 includes the steps of separating the section 112, removing excess lead frame material, and compression molding the bulb 137 (see FIG. 24) relative to the conductors 112, 114, 115, in step 135. Or, in step 136, one of the steps of epoxy molding. The free end of the conductor can then be bent into a terminal or pin 138 and inserted into an associated through hole, such as a typical printed circuit board (PCB). The final lamp 140 can then be inspected in step 139 and packaged if necessary.

Another completed lamp 150 is shown in FIG. 25 with an additional molded body 151 formed below the bulb 137. In this case, the conductors in the bulb are not shown for the sake of simplicity, but the conductors may have an arrangement similar to that shown in FIG. Specifically, each of the eighteen wire junctions is provided with eighteen associated fins 138 and another fin 152 for supplying current to a common conductor in bulb 137. As such, eighteen different circuits are formed in the lamp 150, which can be individually addressed and controlled via pins 138 suitable for fitting to a PCB or the like.

As described above, the present invention provides an LED lamp manufacturing method in which the LED junction optimizes the output by arranging the junctions in a three-dimensional array and using the tail portion for the light guide. Moreover, the present structure allows the output of each junction or junction group to be controlled to vary independently the intensity of the emitted light. Finally, the three-dimensional arrangement of the junctions and the arrangement of the curved conductors themselves allows the light from the lamp to be emitted mostly from a single point light source or from a small spherical light source, which has a light emitting junction rather than a conventional individual junction. It can be considered beneficial to the device.

The methods and LED lamps described above have been described by way of non-limiting example only, and many variations and modifications may be made without departing from the spirit and scope of the invention as described above.

Claims (20)

And mounting the light emitting junction on the support structure such that the junctions are in a three dimensional arrangement. The method of claim 1, And said support structure comprises a plurality of conductors, further comprising forming the conductors in a curved arrangement. The method of claim 2, And the conductors are formed in a spherical array. The method of claim 1, Positioning a junction at each trailing end formed in said support structure, said trailing end functioning as a light guide for controlling the direction of light output from the associated junction. The method of claim 4, wherein And the support structure is provided in the form of a lead frame to include a plurality of conductors. The method of claim 5, wherein And the conductors are formed in a spherical array. The method according to claim 5 or 6, Engaging a punch and a die with the lead frame to form a trailing portion. The method of claim 7, wherein The rear end portion is a lamp manufacturing method is formed in one operation. The method of claim 7, wherein Wherein the trailing portion is formed sequentially and the punch and die are moved relative to the lead frame after each trailing portion forming operation and are suitably positioned for subsequent trailing portion forming operations. The method according to any one of claims 7 to 9, Supporting the lead frame on the carrier and moving the carrier to introduce each trailing edge into a mount where the junctions are mounted to the conductor. The method of claim 10, The carrier is rotatable about a first and a second vertical axis to align each trailing portion and the mount and advances the conductors associated with the junctions with respect to each other along a third axis such that the junctions are at each trailing edge. Method of manufacturing the mounted lamp. The method according to any one of claims 5 to 11, Wherein each junction is electrically connected to the two conductors via an intermediate conductor. The method of claim 12, And the intermediate conductor is connected to allow independent control of at least two junctions by controlling the current through the associated conductors to which each junction is connected. The method of claim 13, And the junctions are electrically connected with the conductors in an individually controllable group. The method according to any one of claims 1 to 14, And applying a common phosphor over at least two adjacent junctions. The method according to any one of claims 1 to 15, And encapsulating the support structure and the junction in the bulb portion. A lead frame comprising a plurality of conductors formed in a curved arrangement for supporting light emitting junctions in a three-dimensional arrangement. The method of claim 17, A lead frame further comprising a tail portion for accommodating one junction each. A lamp formed according to the method of claim 1. Formed of electrically connected light emitting junctions between the conductors and the conductors, comprising controlling a current through one of the respective conductors to independently control the light output from the junctions connected to the conductors, 20. The lamp operating method of claim 19.