TW201537106A - Light emitting diode module having optical lens - Google Patents
Light emitting diode module having optical lens Download PDFInfo
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Abstract
Description
本發明係關於一種發光二極體模組,尤指一種具有光學透鏡之發光二極體模組,該發光二極體模組具有金屬基板及前置金屬板,至少一光學透鏡射出成形於該前置金屬板上。 The present invention relates to a light emitting diode module, and more particularly to a light emitting diode module having an optical lens. The light emitting diode module has a metal substrate and a front metal plate, and at least one optical lens is injection molded on the light emitting diode module. Front metal plate.
習知技術如德國專利DE102004062989,其專利家族為歐盟專利EP1828678、ES2342549、中國專利CN101087977、JP2008524816A、中華民國專利TWI388767、美國專利US7806562及WO2006066531,此一習知技術揭露可藉由插銷(52)將初級光學元件(5)固定於載板(2)上,為了將初級光學元件(5)在位於其底下之各發光二極體晶片(3)上方的距離,設定為正確數值,可在初級光學元件(5)與載板(2)或是裝設表面(10)之間,設置一個或更多個間隔層,而該間隔層則限制了插銷(52)於孔洞(22)內的穿透深度。初級光學元件(5)係一種複合式光學聚焦器,這種光學聚焦器(5)的一個終端係結合於鑄造凹槽(4)內,且係藉由例如加拿大膠香脂(Canada balsam)而光學地耦接於各發光二極體晶片(3)上。該光學聚焦器(5)可使由各發光二極體晶片(3)產生之光聚焦,使得光以已減小的發散度自光學聚焦器(5)上遠離各發光二極體晶片(3)的終端側(51)出射。初級光學元件(5)可與車頭燈之光學元件(二階光學 元件)搭配。 Conventional technologies such as the German patent DE102004062989, the patent family of which are the European Union patents EP1828678, ES2342549, Chinese patent CN101087977, JP2008524816A, the Republic of China patent TWI388767, the US patent US7806562 and WO2006066531, this prior art disclosure can be used by the plug (52) The optical element (5) is fixed on the carrier (2), and the primary optical element is set to a correct value in order to set the distance of the primary optical element (5) above each of the light-emitting diode chips (3) underneath. (5) Between the carrier plate (2) or the mounting surface (10), one or more spacer layers are provided, and the spacer layer limits the penetration depth of the pin (52) in the hole (22) . The primary optical element (5) is a composite optical concentrator in which one end of the optical concentrator (5) is incorporated into the casting recess (4) and optically made, for example, by Canadian balsam. The ground is coupled to each of the LED chips (3). The optical focus (5) can focus the light generated by each of the LED chips (3) such that the light is removed from the optical focus (5) away from the respective LED chips with a reduced divergence (3) The terminal side (51) exits. Primary optics (5) can be used with the optics of the headlights (second-order optics) Component).
惟,此一習知技術是以插銷(52)將初級光學元件(5)固定於載板(2)上,初級光學元件(5)與發光二極體晶片(3)中間易存在間隙,當發光二極體晶片(3)所射出之光束經過該間隙時,將因該間隙內的空氣產生折射而影響光學聚焦,並增加光損耗。再者,習知技術實施於車頭燈時,需要許多光學元件(二階光學元件)搭配,例如:一至二個光學透鏡及一至二個反射鏡,因此,車燈所需要的透鏡構件數量較多,車燈所需要的焦距較長,車燈所組成的體積較大及車燈的製造成本較高,而有改良之必要。 However, this prior art is to fix the primary optical component (5) to the carrier (2) with a pin (52), and there is a gap between the primary optical component (5) and the LED (3). When the light beam emitted from the LED chip (3) passes through the gap, it will refract the air in the gap to affect optical focusing and increase optical loss. Furthermore, when the conventional technology is implemented in a headlight, many optical components (second-order optical components) are required, for example, one to two optical lenses and one or two mirrors, and therefore, the number of lens components required for the lamp is large. The required focal length of the lamp is long, the volume of the lamp is large, and the manufacturing cost of the lamp is high, and there is a need for improvement.
本發明之目的在於,提供一種具有光學透鏡之發光二極體模組,包括金屬基板、前置金屬板、複數發光二極體晶片及第一光學透鏡等構成;金屬基板與前置金屬板貼合,且第一光學透鏡射出成形於前置金屬板上;金屬基板具有一電路圖案,且前置金屬板具有複數第一穿孔,複數發光二極體晶片透過複數第一穿孔各別設置於該電路圖案上;其中第一光學透鏡具有複數第一長形齒及複數第二長形齒而導引對應的發光二極體晶片50所發射的光束,各第一長形齒傾斜方向與各第二長形齒之傾斜方向相反。 An object of the present invention is to provide a light emitting diode module having an optical lens, comprising a metal substrate, a front metal plate, a plurality of light emitting diode chips, and a first optical lens; and the metal substrate and the front metal plate And the first optical lens is injection molded on the front metal plate; the metal substrate has a circuit pattern, and the front metal plate has a plurality of first through holes, and the plurality of light emitting diode chips are respectively disposed through the plurality of first through holes a first optical lens having a plurality of first elongate teeth and a plurality of second elongate teeth for guiding a light beam emitted by the corresponding LED body 50, each of the first elongate teeth tilting direction and each of the first The two elongated teeth are inclined in opposite directions.
本發明增益之功效(一)在於,所提供之發光二極體模組可利用第一光學透鏡直接修正其光束圖案並使光束照射至指定位置,因此,本發明實施於車燈時,可簡化車燈所需要的透 鏡構件數量,縮短車燈所需要的焦距,減少車燈所組成的體積及降低車燈的製造成本。 The effect of the gain of the present invention is that the provided LED module can directly correct its beam pattern and illuminate the beam to a specified position by using the first optical lens. Therefore, the present invention can be simplified when implemented in a vehicle lamp. Required for the lights The number of mirror members shortens the focal length required for the lamps, reduces the volume of the lamps and reduces the manufacturing cost of the lamps.
本發明增益之功效(二)在於,所提供之發光二極體模組直接利用第一光學透鏡,使複數發光二極體晶片發射的光束在X軸向所形成的半功率角(half-intensity directional angle)可以小於或等於60度,並且複數發光二極體晶片發射的光束在Y軸向所形成的半功率角可以小於或等於30度。 The effect of the gain of the present invention (2) is that the provided light-emitting diode module directly utilizes the first optical lens to make the half-power angle formed by the light beam emitted from the plurality of light-emitting diode chips in the X-axis (half-intensity). The directional angle may be less than or equal to 60 degrees, and the half power angle formed by the beam emitted by the plurality of light emitting diode chips in the Y axis may be less than or equal to 30 degrees.
本發明增益之功效(三)在於,所提供之發光二極體模組採用無空氣間隙之封裝方式將第一光學透鏡射出成形於前置金屬板上,因此,本發明可降低光束的折射及光損耗。 The effect of the gain of the present invention (3) is that the provided LED module is formed by using an air-free package to form the first optical lens on the front metal plate. Therefore, the present invention can reduce the refraction of the beam and Light loss.
本發明增益之功效(四)在於,所提供之發光二極體模組在熱壓合過程及冷卻過程中,前置金屬板與金屬基板因熱能所導致的長度變化量不致於使發光二極體模組產生彎曲(bending),可避免損壞發光二極體模組的封裝結構。 The effect of the gain of the present invention (4) is that during the thermal pressing process and the cooling process of the provided LED module, the length variation caused by the thermal energy of the front metal plate and the metal substrate is not caused by the light-emitting diode. The body module is bent to avoid damage to the package structure of the LED module.
本發明增益之功效(五)在於,所提供之發光二極體模組可利用第一光學透鏡及第二光學透鏡直接修正其光束圖案並使光束照射至指定位置,各第一長形齒及各第三長形齒具有相同之尺寸及傾斜角度,各第二長形齒及各第四長形齒具有相同之尺寸及傾斜角度,或者,各第一長形齒及各第三長形齒可具有不同之尺寸及傾斜角度,各第二長形齒及各第四長形齒可具有不同之尺寸及傾斜角度,以符合各式車燈之需求。 The effect of the gain of the present invention (5) is that the provided LED module can directly correct the beam pattern by using the first optical lens and the second optical lens and illuminate the beam to a specified position, and each of the first elongated teeth and Each of the third elongate teeth has the same size and inclination angle, and each of the second elongate teeth and each of the fourth elongate teeth have the same size and inclination angle, or each of the first elongate teeth and each of the third elongate teeth Different sizes and inclination angles are available, and each of the second elongated teeth and each of the fourth elongated teeth can have different sizes and inclination angles to meet the requirements of various types of lamps.
本發明增益之功效(六)在於,所提供之發光二極 體模組可藉由前置金屬板與金屬基板分散複數發光二極體晶片所產生之熱能,使發光二極體模組可前後散熱,前置金屬板進一步可具有鰭片,以兼具散熱及遮光效果。 The effect of the gain of the present invention (6) is that the provided light-emitting diode The body module can disperse the heat generated by the plurality of light emitting diode chips by the front metal plate and the metal substrate, so that the light emitting diode module can be cooled forward and backward, and the front metal plate can further have fins to simultaneously dissipate heat. And shading effect.
本發明所採取的技術手段(一)為提供一種具有光學透鏡之發光二極體模組,包括:一金屬基板,該金屬基板具有一電路圖案;一前置金屬板,具有複數第一穿孔,且該前置金屬板貼合於該金屬基板;複數發光二極體晶片,透過複數第一穿孔各別設置於該電路圖案上;及一第一光學透鏡,射出成形於該前置金屬板上,且覆蓋複數第一穿孔,該第一光學透鏡具有X軸向之複數第一長形齒及X軸向之複數第二長形齒;其中各第一長形齒之一第一光學面與各第二長形齒之一第二光學面向內側傾斜,各第一光學面之傾斜方向與各第二光學面之傾斜方向相反。 The technical means adopted by the present invention (1) is to provide a light emitting diode module having an optical lens, comprising: a metal substrate having a circuit pattern; and a front metal plate having a plurality of first through holes. And the front metal plate is attached to the metal substrate; the plurality of light emitting diode chips are respectively disposed on the circuit pattern through the plurality of first through holes; and a first optical lens is injection molded on the front metal plate And covering a plurality of first perforations, the first optical lens having a plurality of first elongate teeth in the X-axis direction and a plurality of second elongate teeth in the X-axis; wherein the first optical surface of each of the first elongate teeth One of the second elongated teeth is inclined toward the inner side, and the oblique direction of each of the first optical surfaces is opposite to the oblique direction of each of the second optical surfaces.
本發明所採取的技術手段(二)為提供一種具有光學透鏡之發光二極體模組,包括:一金屬基板,該金屬基板具有一電路圖案;一前置金屬板,具有複數第一穿孔及複數第二穿孔,該前置金屬板貼合於該金屬基板;複數發光二極體晶片,透過複數第一穿孔及複數第二穿孔各別設置於該電路圖案上;一第一光學透鏡,射出成形於該前置金屬板上,且覆蓋複數第一穿孔,該第一光學透鏡具有X軸向之複數第一長形齒及X軸向之複數第二長形齒;一第二光學透鏡,射出成形於該前置金屬板上,且覆蓋複數第二穿孔,該第二光學透鏡具有X軸向之複數第三長形齒及X軸向之複數第四長形齒;其中各第一長形齒之一第一光學面與各 第二長形齒之一第二光學面向內側傾斜,各第一光學面之傾斜方向與各第二光學面之傾斜方向相反,各第三長形齒之一第三光學面與各第四長形齒之一第四光學面向內側傾斜,各第三光學面之傾斜方向與各第四光學面之傾斜方向相反。 The technical means adopted by the present invention (2) is to provide a light emitting diode module having an optical lens, comprising: a metal substrate having a circuit pattern; and a front metal plate having a plurality of first through holes and a plurality of second through holes, the front metal plate is attached to the metal substrate; the plurality of light emitting diode chips are respectively disposed on the circuit pattern through the plurality of first through holes and the plurality of second through holes; and a first optical lens is emitted Formed on the front metal plate and covering a plurality of first perforations, the first optical lens having a plurality of first elongate teeth in the X-axis direction and a plurality of second elongate teeth in the X-axis; a second optical lens, Injection molding on the front metal plate and covering a plurality of second perforations, the second optical lens having a plurality of third elongate teeth in the X-axis direction and a plurality of fourth elongate teeth in the X-axis; wherein each of the first lengths One of the first optical surfaces of the tooth and each One of the second elongated teeth is inclined toward the inner side, and the oblique direction of each of the first optical surfaces is opposite to the oblique direction of each of the second optical surfaces, and the third optical surface of each of the third elongated teeth is the fourth longest One of the shaped teeth has a fourth optical surface that is inclined toward the inner side, and an oblique direction of each of the third optical surfaces is opposite to an oblique direction of each of the fourth optical surfaces.
本發明所採取的技術手段(三)為提供一種具有光學透鏡之發光二極體模組,包括:一金屬基板,該金屬基板具有一電路圖案;一前置金屬板,具有複數第一穿孔、複數第二穿孔及一第三穿孔,該前置金屬板貼合於該金屬基板;複數發光二極體晶片,透過複數第一穿孔、複數第二穿孔及該第三穿孔各別設置於該電路圖案上;一第一光學透鏡,射出成形於該前置金屬板上,且覆蓋複數第一穿孔,該第一光學透鏡具有X軸向之複數第一長形齒及X軸向之複數第二長形齒;一第二光學透鏡,射出成形於該前置金屬板上,且覆蓋複數第二穿孔,該第二光學透鏡具有X軸向之複數第三長形齒及X軸向之複數第四長形齒;一第三光學透鏡,射出成形於該前置金屬板上,且覆蓋該第三穿孔,該第三光學透鏡具有X軸向之複數第五長形齒及X軸向之複數第六長形齒;其中各第一長形齒之傾斜方向與各第二長形齒之傾斜方向相反,各第三長形齒之傾斜方向與各第四長形齒之傾斜方向相反,且各第五長形齒之傾斜方向與各第六長形齒之傾斜方向相反。 The technical means (3) adopted by the present invention provides a light emitting diode module having an optical lens, comprising: a metal substrate having a circuit pattern; and a front metal plate having a plurality of first perforations, a plurality of second through holes and a third through hole, the front metal plate is attached to the metal substrate; the plurality of light emitting diode chips are respectively disposed on the circuit through the plurality of first through holes, the plurality of second through holes, and the third through holes a first optical lens, which is injection-molded on the front metal plate and covers a plurality of first perforations, the first optical lens having a plurality of first elongate teeth in the X-axis direction and a plurality of second X-axis directions a second optical lens that is injection molded on the front metal plate and covers a plurality of second perforations, the second optical lens having a plurality of third elongated teeth in the X-axis direction and a plurality of X-axis directions a fourth optical lens; a third optical lens is injection molded on the front metal plate and covers the third through hole, the third optical lens having a plurality of fifth elongated teeth in the X-axis direction and a plurality of X-axis directions Sixth long tooth; each of which The oblique direction of the elongated teeth is opposite to the oblique direction of each of the second elongated teeth, and the oblique direction of each of the third elongated teeth is opposite to the oblique direction of each of the fourth elongated teeth, and the oblique direction of each of the fifth elongated teeth is The sixth elongated teeth are inclined in opposite directions.
1a,1b,1c,1d,1e,1f‧‧‧發光二極體模組 1a, 1b, 1c, 1d, 1e, 1f‧‧ ‧ LED modules
10‧‧‧金屬基板 10‧‧‧Metal substrate
12‧‧‧電路圖案 12‧‧‧ circuit pattern
14‧‧‧電路保護漆 14‧‧‧Circuit protection paint
15,16‧‧‧電極部 15,16‧‧‧Electrode
20‧‧‧第一絕緣層 20‧‧‧First insulation
30‧‧‧前置金屬板 30‧‧‧Front metal plate
31‧‧‧第一穿孔 31‧‧‧First perforation
32‧‧‧第二穿孔 32‧‧‧Second perforation
33‧‧‧第三穿孔 33‧‧‧ third perforation
34‧‧‧電鍍壁面 34‧‧‧Electroplating wall
35‧‧‧螢光體 35‧‧‧Fluorite
39‧‧‧鰭片 39‧‧‧Fins
40‧‧‧第二絕緣層 40‧‧‧Second insulation
50‧‧‧發光二極體晶片 50‧‧‧Light Emitter Wafer
51‧‧‧電路保護元件 51‧‧‧ Circuit Protection Components
52‧‧‧中心垂線 52‧‧‧ center vertical line
80‧‧‧第一光學透鏡 80‧‧‧First optical lens
81‧‧‧第一長形齒 81‧‧‧First long tooth
811‧‧‧第一光學面 811‧‧‧First optical surface
82‧‧‧第二長形齒 82‧‧‧Second elongate teeth
821‧‧‧第二光學面 821‧‧‧second optical surface
89‧‧‧中央稜鏡 89‧‧‧Central District
89a‧‧‧中央曲面 89a‧‧‧Central curved surface
90‧‧‧第二光學透鏡 90‧‧‧Second optical lens
91‧‧‧第三長形齒 91‧‧‧3rd long tooth
911‧‧‧第三光學面 911‧‧‧ Third optical surface
92‧‧‧第四長形齒 92‧‧‧4th long tooth
921‧‧‧第四光學面 921‧‧‧Fourth optical surface
99‧‧‧中央稜鏡 99‧‧‧Central District
100‧‧‧第三光學透鏡 100‧‧‧ third optical lens
101‧‧‧第五長形齒 101‧‧‧5th long tooth
102‧‧‧第六長形齒 102‧‧‧6th long tooth
圖1係本發明較佳實施例之立體示意圖。 1 is a perspective view of a preferred embodiment of the present invention.
圖2係本發明較佳實施例之部份立體分解圖。 Figure 2 is a partially exploded perspective view of a preferred embodiment of the present invention.
圖3係本發明較佳實施例之部份剖面圖。 Figure 3 is a partial cross-sectional view of a preferred embodiment of the present invention.
圖4係本發明較佳實施例之光路徑示意圖。 4 is a schematic diagram of a light path in accordance with a preferred embodiment of the present invention.
圖5係本發明第一光學透鏡之立體示意圖。 Figure 5 is a perspective view of a first optical lens of the present invention.
圖6係本發明另一第一光學透鏡之立體示意圖。 Figure 6 is a perspective view of another first optical lens of the present invention.
圖7係本發明第二實施例之立體示意圖。 Figure 7 is a perspective view of a second embodiment of the present invention.
圖8係本發明第二實施例之部份立體分解圖。 Figure 8 is a partially exploded perspective view of a second embodiment of the present invention.
圖9係本發明第二實施例之部份剖面圖。 Figure 9 is a partial cross-sectional view showing a second embodiment of the present invention.
圖10係本發明第二實施例之光路徑示意圖。 Figure 10 is a schematic illustration of a light path of a second embodiment of the present invention.
圖11係本發明第三實施例之立體示意圖。 Figure 11 is a perspective view of a third embodiment of the present invention.
圖12係本發明第四實施例之立體示意圖。 Figure 12 is a perspective view of a fourth embodiment of the present invention.
圖13係本發明第四實施例之部份剖面圖。 Figure 13 is a partial cross-sectional view showing a fourth embodiment of the present invention.
圖14係本發明第五實施例之立體示意圖。 Figure 14 is a perspective view showing a fifth embodiment of the present invention.
圖15係本發明第五實施例之部份剖面圖。 Figure 15 is a partial cross-sectional view showing a fifth embodiment of the present invention.
圖16係本發明第六實施例之立體示意圖。 Figure 16 is a perspective view of a sixth embodiment of the present invention.
圖17係本發明第六實施例之部份剖面圖。 Figure 17 is a partial cross-sectional view showing a sixth embodiment of the present invention.
為能進一步瞭解本發明之特徵、技術手段以及所達成之具體功能、目的,茲列舉較具體之實施例,繼以圖式圖號詳細說明如後。 For a better understanding of the features, technical means, and specific functions and objects of the present invention, the specific embodiments are illustrated, and the detailed description of the drawings will be followed.
請參閱圖1至圖6所示,在較佳實施例中,本發明之發光二極體模組1a包括金屬基板10、前置金屬板30、複數發光 二極體晶片50及第一光學透鏡80等構成;金屬基板10具有一電路圖案12;前置金屬板30具有複數第一穿孔31,且前置金屬板30貼合於金屬基板10;第一光學透鏡80射出成形於前置金屬板30上,且覆蓋複數第一穿孔31,第一光學透鏡80具有X軸向之複數第一長形齒81及X軸向之複數第二長形齒82而導引對應的發光二極體晶片50所發射的光束;其中各第一長形齒81之一第一光學面811與各第二長形齒82之一第二光學面821向內側傾斜,各第一光學面811之傾斜方向與各第二光學面821之傾斜方向相反,發光二極體模組1a可利用第一光學透鏡80直接修正其光束圖案(Beam Pattern)並使光束照射至指定位置,本發明實施於車燈時,可簡化車燈所需要的透鏡構件數量,縮短車燈所需要的焦距,減少車燈所組成的體積及降低車燈的製造成本。 Referring to FIG. 1 to FIG. 6 , in a preferred embodiment, the LED module 1 a of the present invention comprises a metal substrate 10 , a front metal plate 30 , and a plurality of illuminations The second substrate 50 has a circuit pattern 12; the front metal plate 30 has a plurality of first through holes 31, and the front metal plate 30 is attached to the metal substrate 10; The optical lens 80 is injection molded on the front metal plate 30 and covers a plurality of first through holes 31. The first optical lens 80 has a plurality of first elongated teeth 81 in the X-axis direction and a plurality of second elongated teeth 82 in the X-axis direction. And guiding the light beam emitted by the corresponding LED chip 50; wherein the first optical surface 811 of each of the first elongated teeth 81 and the second optical surface 821 of each of the second elongated teeth 82 are inclined inward. The oblique direction of each of the first optical surfaces 811 is opposite to the oblique direction of each of the second optical surfaces 821, and the LED module 1a can directly correct the Beam pattern by using the first optical lens 80 and irradiate the beam to the designated In the position, when the invention is implemented in a lamp, the number of lens components required for the lamp can be simplified, the focal length required for the lamp can be shortened, the volume of the lamp can be reduced, and the manufacturing cost of the lamp can be reduced.
列舉第一光學透鏡80之實施方式如后:複數第一長形齒81及複數第二長形齒82分佈於對應的發光二極體晶片50之一中心垂線52之兩側,各發光二極體晶片50透過第一光學透鏡80在X軸向所形成的半功率角(half-intensity directional angle)可以小於或等於60度,各發光二極體晶片50透過第一光學透鏡80在Y軸向所形成的半功率角可以小於或等於30度。 The embodiment of the first optical lens 80 is as follows: a plurality of first elongated teeth 81 and a plurality of second elongated teeth 82 are distributed on two sides of a central vertical line 52 of the corresponding light-emitting diode wafer 50, and each of the light-emitting diodes The half-intensity directional angle formed by the bulk wafer 50 through the first optical lens 80 in the X-axis direction may be less than or equal to 60 degrees, and each of the light-emitting diode wafers 50 is transmitted through the first optical lens 80 in the Y-axis direction. The resulting half power angle can be less than or equal to 30 degrees.
列舉第一光學透鏡80之另一實施方式如后:複數第一長形齒及複數第二長形齒分佈於第一光學透鏡80之一中心垂線802之兩側,第一光學透鏡80具有X軸向之一中央稜鏡89(如圖5所示)或中央曲面89a(如圖6所示)而導引對應的發光二極體晶 片50所發射的光束;其中該中央稜鏡89具有兩對稱面,該中央曲面89a可選自非球面(Aspheric Surface)、弧形面(Cambered Surface)、拋物面(Parabolic Surface)、雙曲面(Hyperbolic Surface)或自由曲面(Free-Form Surface)。 Another embodiment of the first optical lens 80 is as follows: a plurality of first elongate teeth and a plurality of second elongate teeth are distributed on either side of a central vertical line 802 of the first optical lens 80, and the first optical lens 80 has an X One of the axial centers 89 (shown in FIG. 5) or the central curved surface 89a (shown in FIG. 6) guides the corresponding light-emitting diode crystal The light beam emitted by the sheet 50; wherein the central ridge 89 has two symmetry planes, and the central curved surface 89a may be selected from the group consisting of an Aspheric Surface, a Cambered Surface, a Parabolic Surface, and a Hyperbolic Surface) or Free-Form Surface.
列舉第一光學透鏡80之封裝方式如后:在需要混光之實施方式中,各第一穿孔31進一步可設有一螢光體35(例如但不限於螢光膠或螢光膠片),各發光二極體晶片50所發射的光束透過螢光體35達成混光。為降低光束的折射及光損耗,第一光學透鏡80與各螢光體35中間採取無空氣間隙之封裝方式,各螢光體35與各發光二極體晶片50中間採取無空氣間隙之封裝方式。 The first optical lens 80 is further provided with a phosphor 35 (such as but not limited to fluorescent glue or fluorescent film), and each of the first through holes 31 is further provided with a phosphor 35 (for example, but not limited to, fluorescent glue or fluorescent film). The light beam emitted from the diode wafer 50 is transmitted through the phosphor 35 to achieve light mixing. In order to reduce the refraction and light loss of the light beam, the first optical lens 80 and each of the phosphors 35 are packaged in an air-free manner, and each of the phosphors 35 and each of the light-emitting diode wafers 50 are sealed in an air-free manner. .
列舉前置金屬板30之封裝方式如后:前置金屬板30與金屬基板10的線性熱膨脹係數(Coefficient of Linear Thermal Expansion,簡稱CLTE)為相同,前置金屬板30與金屬基板10可選自同一材質的鋁材質或銅材質,各第一穿孔31具有一電鍍壁面34。再者,前置金屬板30與金屬基板10的線性熱膨脹係數(CLTE)亦可為接近,前置金屬板與該金屬基板可選自不同材質的鋁材質或銅材質,各第一穿孔31具有一電鍍壁面34。此外,複數發光二極體晶片50所產生之熱能可分散至前置金屬板30與金屬基板10,使發光二極體模組1a可前後散熱,避免複數發光二極體晶片50所產生之熱能積蓄於第一光學透鏡80與複數發光二極體晶片50。 The package of the front metal plate 30 is as follows: the front metal plate 30 and the metal substrate 10 have the same coefficient of linear thermal expansion (CLTE), and the front metal plate 30 and the metal substrate 10 are selected from the same. Each of the first perforations 31 has an electroplated wall surface 34 of aluminum or copper of the same material. Furthermore, the linear thermal expansion coefficient (CLTE) of the front metal plate 30 and the metal substrate 10 may be close, and the front metal plate and the metal substrate may be selected from aluminum materials or copper materials of different materials, and each of the first through holes 31 has A plated wall 34. In addition, the thermal energy generated by the plurality of LED chips 50 can be dispersed to the front metal plate 30 and the metal substrate 10, so that the LED module 1a can be radiated back and forth to avoid heat generated by the plurality of LED chips 50. It is stored in the first optical lens 80 and the complex LED chip 50.
列舉電路圖案12之絕緣方式如后:金屬基板10與電路圖案12中間設有一第一絕緣層20,使金屬基板10與電路圖案12 達成絕緣,前置金屬板30與金屬基板10中間設有一第二絕緣層40,使前置金屬板30與電路圖案12達成絕緣,且前置金屬板30與金屬基板10達成絕緣;其中第二絕緣層40可選自熱固型之絕緣粘著材質(例如但不限於絕緣導熱膠或環氧樹脂)或非熱固型之絕緣粘著材質。當選用熱固型之第二絕緣層40時,前置金屬板30與金屬基板10在熱壓合過程及冷卻過程中因熱能所導致的長度變化量趨於一致,不致於使發光二極體模組1a產生彎曲,可避免損壞發光二極體模組1a的封裝結構。 The insulation of the circuit pattern 12 is as follows: a first insulating layer 20 is disposed between the metal substrate 10 and the circuit pattern 12 to make the metal substrate 10 and the circuit pattern 12 Insulation is achieved, and a second insulating layer 40 is disposed between the front metal plate 30 and the metal substrate 10 to insulate the front metal plate 30 from the circuit pattern 12, and the front metal plate 30 is insulated from the metal substrate 10; The insulating layer 40 may be selected from a thermosetting insulating adhesive material such as, but not limited to, an insulating thermal conductive adhesive or an epoxy resin or a non-thermosetting insulating adhesive material. When the second insulating layer 40 of the thermosetting type is selected, the length variation of the front metal plate 30 and the metal substrate 10 due to thermal energy during the thermocompression bonding process and the cooling process tends to be uniform, so that the light emitting diode is not caused. The module 1a is bent to avoid damage to the package structure of the LED module 1a.
列舉電路圖案12之電路保護方式如后:電路圖案12可具有複數電極部15,16,電路圖案12上方進一步可塗佈一電路保護漆14,且露出電路圖案12之複數電極部15,16。再者,電路圖案12上進一步可設有一電路保護元件51,且電路保護元件51可選自靜電放電保護二極體(ESD Protection Diode)或突波保護之金屬氧化物變阻器(Metal Oxide Varistor for Surge Protection),以保護複數發光二極體晶片50及電路圖案12,可避免靜電放電或突波之毀損。 The circuit protection mode of the circuit pattern 12 is as follows: The circuit pattern 12 may have a plurality of electrode portions 15, 16, and a circuit protection paint 14 may be further coated on the circuit pattern 12, and the plurality of electrode portions 15, 16 of the circuit pattern 12 are exposed. Furthermore, the circuit pattern 12 may further be provided with a circuit protection component 51, and the circuit protection component 51 may be selected from an ESD Protection Diode or a surge protection metal oxide varistor (Metal Oxide Varistor for Surge) Protection) to protect the complex LED chip 50 and the circuit pattern 12 to avoid electrostatic discharge or surge damage.
請參閱圖5至圖10所示,在第二實施例中,本發明之發光二極體模組1b與較佳實施例者大致相同,兩者之差異處僅在於:前置金屬板30複數第一穿孔31與複數第二穿孔32,複數第一穿孔31之數量大於複數第二穿孔32之數量,複數第一穿孔31與複數第二穿孔32呈兩列分佈於前置金屬板30上,且前置金屬板30貼合於金屬基板10;第一光學透鏡80射出成形於前置金屬板30 上,且覆蓋複數第一穿孔31,第一光學透鏡80具有X軸向之複數第一長形齒81及X軸向之複數第二長形齒82而導引對應的發光二極體晶片50所發射的光束;第二光學透鏡90射出成形於前置金屬板30上,且覆蓋複數第二穿孔32,第二光學透鏡90具有X軸向之複數第三長形齒91及X軸向之複數第四長形齒92而導引對應的發光二極體晶片50所發射的光束;其中各第一長形齒81之一第一光學面811與各第二長形齒82之一第二光學面821向內側傾斜,各第一光學面811之傾斜方向與各第二光學面821之傾斜方向相反,各第三長形齒91之一第三光學面911與各第四長形齒92之一第四光學面921向內側傾斜,各第三光學面911之傾斜方向與各第四光學面921之傾斜方向相反,發光二極體模組1b可利用第一光學透鏡80與第二光學透鏡90直接修正其光束圖案並使光束照射至指定位置。 Referring to FIG. 5 to FIG. 10, in the second embodiment, the LED module 1b of the present invention is substantially the same as the preferred embodiment, and the difference between the two is only that the front metal plate 30 is plural. The first through hole 31 and the plurality of second through holes 32, the number of the plurality of first through holes 31 is greater than the number of the plurality of second through holes 32, and the plurality of first through holes 31 and the plurality of second through holes 32 are distributed in two rows on the front metal plate 30, The front metal plate 30 is attached to the metal substrate 10; the first optical lens 80 is injection molded on the front metal plate 30. And covering a plurality of first through holes 31, the first optical lens 80 has a plurality of first elongated teeth 81 in the X-axis direction and a plurality of second elongated teeth 82 in the X-axis direction to guide the corresponding light-emitting diode wafer 50 The emitted light beam; the second optical lens 90 is injection molded on the front metal plate 30 and covers the plurality of second through holes 32. The second optical lens 90 has a plurality of third elongated teeth 91 and an X-axis in the X-axis direction. The fourth elongate tooth 92 guides the light beam emitted by the corresponding LED chip 50; wherein each of the first elongate teeth 81 has a first optical surface 811 and a second elongate tooth 82 The optical surface 821 is inclined to the inner side, and the oblique direction of each of the first optical surfaces 811 is opposite to the oblique direction of each of the second optical surfaces 821, and one of the third elongated teeth 91 is the third optical surface 911 and each of the fourth elongated teeth 92. One of the fourth optical surfaces 921 is inclined inward, and the oblique direction of each of the third optical surfaces 911 is opposite to the oblique direction of each of the fourth optical surfaces 921. The LED module 1b can utilize the first optical lens 80 and the second optical The lens 90 directly corrects its beam pattern and illuminates the beam to a specified position.
列舉第一光學透鏡80之實施方式如后:複數第一長形齒81及複數第二長形齒82分佈於對應的發光二極體晶片50之一中心垂線52之兩側,複數第三長形齒91及複數第四長形齒92分佈於對應的發光二極體晶片50之一中心垂線52之兩側,第一光學透鏡80在X軸向的長度大於或等於第二光學透鏡90在X軸向的長度,各第一長形齒81及各第三長形齒91具有相同之尺寸及傾斜角度,各第二長形齒82及各第四長形齒92具有相同之尺寸及傾斜角度。再者,各第一長形齒81及各第三長形齒91可具有不同之尺寸及傾斜角度,各第二長形齒82及各第四長形齒92可具有不同之尺寸及傾斜角度。 The embodiment of the first optical lens 80 is as follows: the plurality of first elongated teeth 81 and the plurality of second elongated teeth 82 are distributed on both sides of a central vertical line 52 of the corresponding light-emitting diode wafer 50, and the third long length The shaped teeth 91 and the plurality of fourth elongated teeth 92 are distributed on both sides of a central vertical line 52 of the corresponding light-emitting diode wafer 50. The length of the first optical lens 80 in the X-axis direction is greater than or equal to that of the second optical lens 90. The length of the X-axis, each of the first elongated teeth 81 and each of the third elongated teeth 91 have the same size and inclination angle, and each of the second elongated teeth 82 and each of the fourth elongated teeth 92 have the same size and inclination. angle. Furthermore, each of the first elongated teeth 81 and each of the third elongated teeth 91 may have different sizes and inclination angles, and each of the second elongated teeth 82 and each of the fourth elongated teeth 92 may have different sizes and inclination angles. .
列舉第一光學透鏡80之另一實施方式如后:複數第一長形齒及複數第二長形齒分佈於第一光學透鏡80之一中心垂線802之兩側,第一光學透鏡80具有X軸向之一中央稜鏡89(如圖9所示)或中央曲面(圖未出示)而導引對應的發光二極體晶片50所發射的光束,複數第三長形齒91及複數第四長形齒92分佈於第二光學透鏡90之一中心垂線902之兩側,第二光學透鏡90具有X軸向之一中央稜鏡99(如圖9所示)或中央曲面(圖未出示)而導引對應的發光二極體晶片50所發射的光束;其中該中央稜鏡89具有兩對稱面,該中央曲面可選自非球面、弧形面、拋物面、雙曲面或自由曲面。 Another embodiment of the first optical lens 80 is as follows: a plurality of first elongate teeth and a plurality of second elongate teeth are distributed on either side of a central vertical line 802 of the first optical lens 80, and the first optical lens 80 has an X One of the axial centers 89 (shown in FIG. 9) or a central curved surface (not shown) guides the light beam emitted by the corresponding LED chip 50, the plurality of third elongated teeth 91 and the fourth The elongate teeth 92 are distributed on two sides of a central perpendicular 902 of the second optical lens 90, and the second optical lens 90 has a central axis 99 (shown in FIG. 9) or a central curved surface (not shown). The light beam emitted by the corresponding light-emitting diode wafer 50 is guided; wherein the central surface 89 has two symmetry planes, and the central curved surface may be selected from an aspherical surface, a curved surface, a paraboloid, a hyperboloid or a free curved surface.
請參閱圖11所示,在第三實施例中,本發明之發光二極體模組1c與第二實施例者大致相同,兩者之差異處僅在於:第二光學透鏡90與對應的複數第二穿孔32置左對齊於第一光學透鏡80與複數第一穿孔31,或者第二光學透鏡90與對應的複數第二穿孔32置右對齊於第一光學透鏡80與複數第一穿孔31。 Referring to FIG. 11, in the third embodiment, the LED module 1c of the present invention is substantially the same as the second embodiment, and the difference is only in that the second optical lens 90 and the corresponding plurality The second through hole 32 is left aligned with the first optical lens 80 and the plurality of first through holes 31, or the second optical lens 90 and the corresponding plurality of second through holes 32 are rightly aligned with the first optical lens 80 and the plurality of first through holes 31.
請參閱圖12至圖13所示,在第四實施例中,本發明之發光二極體模組1d與第二實施例者大致相同,兩者之差異處僅在於:前置金屬板30進一步具有複數第二穿孔32及至少一第三穿孔33,複數第一穿孔31、複數第二穿孔32及第三穿孔33呈三列設置於前置金屬板30,複數第一穿孔31之數量大於複數第二穿孔32之數量,且前置金屬板30貼合於金屬基板10;第一光學透鏡80射出成形於前置金屬板30上,且覆蓋複數第一穿孔31,第一光 學透鏡80具有X軸向之複數第一長形齒81及X軸向之複數第二長形齒82而導引對應的發光二極體晶片50所發射的光束;第二光學透鏡90射出成形於前置金屬板30上,且覆蓋複數第二穿孔32,第二光學透鏡90具有X軸向之複數第三長形齒91及X軸向之複數第四長形齒92而導引對應的發光二極體晶片50所發射的光束;第三光學透鏡100射出成形於前置金屬板30上,且覆蓋第三穿孔33,第三光學透鏡100具有X軸向之複數第五長形齒101及X軸向之複數第六長形齒102;其中各第一長形齒81之傾斜方向與各第二長形齒82之傾斜方向相反,各第三長形齒91之傾斜方向與各第四長形齒92之傾斜方向相反,且各第五長形齒101之傾斜方向與各第六長形齒102之傾斜方向相反,發光二極體模組1d可利用第一光學透鏡80、第二光學透鏡90及第三光學透鏡100直接修正其光束圖案並使光束照射至指定位置。 Referring to FIG. 12 to FIG. 13 , in the fourth embodiment, the LED module 1 d of the present invention is substantially the same as the second embodiment, and the difference is only in the front metal plate 30 further. The plurality of second through holes 32 and the at least one third through hole 33, the plurality of first through holes 31, the plurality of second through holes 32 and the third through holes 33 are arranged in three rows on the front metal plate 30, and the number of the plurality of first through holes 31 is greater than the plurality The number of the second through holes 32, and the front metal plate 30 is attached to the metal substrate 10; the first optical lens 80 is injection molded on the front metal plate 30, and covers the plurality of first through holes 31, the first light The learning lens 80 has a plurality of first elongated teeth 81 in the X-axis direction and a plurality of second elongated teeth 82 in the X-axis direction to guide the light beams emitted by the corresponding light-emitting diode wafer 50; the second optical lens 90 is injection molded On the front metal plate 30, and covering a plurality of second through holes 32, the second optical lens 90 has a plurality of third elongated teeth 91 in the X-axis direction and a plurality of fourth elongated teeth 92 in the X-axis direction to guide the corresponding a light beam emitted from the LED wafer 50; the third optical lens 100 is injection molded on the front metal plate 30 and covers the third through hole 33, and the third optical lens 100 has a plurality of fifth elongated teeth 101 in the X-axis direction. And a plurality of sixth elongated teeth 102 in the X-axis direction; wherein the inclination direction of each of the first elongated teeth 81 is opposite to the inclination direction of each of the second elongated teeth 82, and the inclination direction of each of the third elongated teeth 91 and each The inclined directions of the four elongated teeth 92 are opposite, and the oblique directions of the fifth elongated teeth 101 are opposite to the oblique directions of the sixth elongated teeth 102. The LED module 1d can utilize the first optical lens 80, The two optical lenses 90 and the third optical lens 100 directly correct their beam patterns and illuminate the light beam to a specified position.
列舉第一光學透鏡80、第二光學透鏡90及第三光學透鏡100之排列方式如后:第二光學透鏡90與對應的複數第二穿孔32置左對齊於第一光學透鏡80與複數第一穿孔31,第三光學透鏡100與第三穿孔33置左對齊於第二光學透鏡90與複數第二穿孔32。再者,第一光學透鏡80、第二光學透鏡90及第三光學透鏡100之另一排列方式例如:第二光學透鏡90與對應的複數第二穿孔32置右對齊於第一光學透鏡80與複數第一穿孔31,第三光學透鏡100與第三穿孔33置右對齊於第二光學透鏡90與複數第二穿孔32。 The arrangement of the first optical lens 80, the second optical lens 90, and the third optical lens 100 is as follows: the second optical lens 90 and the corresponding plurality of second through holes 32 are left-aligned to the first optical lens 80 and the first plurality The through hole 31, the third optical lens 100 and the third through hole 33 are left-aligned to the second optical lens 90 and the plurality of second through holes 32. Furthermore, another arrangement of the first optical lens 80, the second optical lens 90 and the third optical lens 100 is, for example, that the second optical lens 90 and the corresponding plurality of second through holes 32 are right-aligned with the first optical lens 80 and The plurality of first through holes 31, the third optical lens 100 and the third through holes 33 are rightly aligned with the second optical lens 90 and the plurality of second through holes 32.
請參閱圖14至圖15所示,在第五實施例中,本 發明之發光二極體模組1e與第二實施例者大致相同,兩者之差異處僅在於:前置金屬板30至少具有一可散熱及遮光的鰭片39,複數發光二極體晶片50所產生之熱能可分散至金屬基板10及前置金屬板30之鰭片39,避免熱能集中,鰭片30可位於任一光學透鏡80,90之一側邊,以兼具遮光效果。 Referring to FIG. 14 to FIG. 15, in the fifth embodiment, The LED module 1e of the present invention is substantially the same as that of the second embodiment. The difference between the two is that the front metal plate 30 has at least one heat dissipating and light blocking fin 39, and the plurality of LED chips 50. The generated thermal energy can be dispersed to the metal substrate 10 and the fins 39 of the front metal plate 30 to avoid concentration of heat. The fins 30 can be located on one side of either of the optical lenses 80, 90 to have a light blocking effect.
列舉複數發光二極體晶片50之設置方式如后:複數發光二極體晶片50可採取倒裝晶片(Flip Chip)之方式各別設置於電路圖案12上,或者,如圖16及圖17所示,在第六實施例中,發光二極體模組1i之複數發光二極體晶片50可採取固晶打線(Die bonding and Wire bonding)之方式各別設置於電路圖案12上,但本發明之實施方式不限於此。 The arrangement of the plurality of LED chips 50 is as follows: the plurality of LED chips 50 can be respectively disposed on the circuit pattern 12 by means of a Flip Chip, or as shown in FIGS. 16 and 17 In the sixth embodiment, the plurality of LED chips 50 of the LED module 1i can be separately disposed on the circuit pattern 12 by means of Die bonding and Wire bonding, but the present invention The embodiment is not limited to this.
1a‧‧‧發光二極體模組 1a‧‧‧Lighting diode module
10‧‧‧金屬基板 10‧‧‧Metal substrate
15,16‧‧‧電極部 15,16‧‧‧Electrode
20‧‧‧第一絕緣層 20‧‧‧First insulation
30‧‧‧前置金屬板 30‧‧‧Front metal plate
31‧‧‧第一穿孔 31‧‧‧First perforation
35‧‧‧螢光體 35‧‧‧Fluorite
51‧‧‧電路保護元件 51‧‧‧ Circuit Protection Components
80‧‧‧第一光學透鏡 80‧‧‧First optical lens
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