TW201632786A - LED luminaire - Google Patents

Abstract

The present invention relates to an LED luminaire, wherein the LED luminaire is consisted of a lamp base, a plurality of lamp tubes, a plurality of self-adhesive substrate, and a plurality of LED chips, and the LED luminaire includes the advantages of simple structure, low manufacturing cost, and high color rendering index (CRI). In addition, the method is able to finish the fabrication of the LED luminaire quickly and automatically by using a substrate attaching mechanism to, so as carry out the mass production of the LED luminaire.

Description

LED light fixture

The invention relates to an LED lamp, in particular to an LED lamp used to replace the traditional energy-saving lamp.

A light bulb, that is, an incandescent lamp, is illuminated by heating a tungsten wire disposed in the bulb to an incandescent state. Usually, the bulb of the incandescent lamp is made of glass, and the tungsten wire is placed in a vacuum space surrounded by the glass bulb, and then an inert gas is introduced into the vacuum space to prevent the tungsten filament from being oxidized at a high temperature. Incandescent lamps are a very wasteful source of energy because incandescent lamps convert about 90% of their electrical energy into useless heat, and only a small fraction (about 10%) of the electricity contributes to the light emitted by incandescent lamps. Therefore, incandescent lamps are gradually being phased out, and new lamps used to replace incandescent lamps are called energy-saving lamps.

Please refer to the first figure, which is a perspective view of an energy saving lamp. As shown in the first figure, the energy-saving lamp 1' is also referred to as a compact fluorescent lamp, which is composed of a casing 11', a plurality of lamps 12' and a rotating lamp cap 13', wherein the lamp 12' There is a filament inside, and the filament is coated with some electronic powder; in addition, the tube 12' is filled with mercury (commonly known as mercury), and the tube 12' is coated with a fluorescent material at the same time. quality. Thus, when the filament is electrically heated, the electron powder releases a stream of electrons having a certain velocity and energy, and the electron stream is struck on the mercury, so that the mercury atoms are excited and the ultraviolet light is released, and the phosphor is exposed to ultraviolet light. After the excitation, it will emit light suitable for illumination.

Although the above-mentioned energy-saving lamp 1' has the advantages of energy saving and power saving; however, the inventors of the present invention have found through long-term research that the existing energy-saving lamp 1' exhibits several defects in use:

1. When the energy-saving lamp is used, it will generate some electromagnetic waves and microwaves. Under long-term use, these electromagnetic waves and microwaves may cause harm to the human body.

2. Energy-saving lamps contain mercury and ultraviolet light, which are harmful to the human body; in reality, many Chinese workers are poisoned by mercury because they manufacture energy-saving lamps.

3. Low color rendering: incandescent and halogen lamps have a color rendering of 100, which is perfect, but the color rendering of energy-saving lamps is mostly between 80 and 90.

4. The manufacturing materials based on energy-saving lamps contain various materials such as mercury, electronic powder, filament, and fluorescent materials, so that the manufacturing cost cannot be effectively lowered, and the selling price is high.

Therefore, the inventors of the present invention have invented the invention in view of the fact that the existing energy-saving lamps still have many shortcomings and deficiencies, and finally developed an LED lamp of the present invention.

The main purpose of the present invention is to provide an LED lamp, wherein the LED lamp is mainly composed of a lamp holder, a plurality of lamps, a plurality of self-adhesive substrates, and a plurality of LED elements, and has the advantages of simple structure and low manufacturing cost. And high color rendering and other advantages. In addition, an automated/semi-automated mass production of the LED lamp of the present invention can be accomplished using a substrate bonding tool or a substrate bonding mechanism on the process, further demonstrating the integrity of the present technology.

Therefore, in order to achieve the above object of the present invention, the inventor of the present invention provides an LED lamp comprising: a lamp holder having at least one electrical end and a lamp combination end, wherein the lamp assembly end is internally set An LED driving module is coupled to the electrical connecting end; a plurality of lamps are assembled at the lamp assembly end of the lamp holder; a plurality of self-adhesive substrates are respectively disposed on the The inner wall of the plurality of lamps, and each of the surfaces of the self-adhesive substrate is formed with at least one circuit layer, and the circuit layer is electrically connected to the LED driving module; and the plurality of LED components are disposed in the plurality of The LED substrate is electrically connected to the circuit layer, and the LED driving module can control the light emission of the LED elements through the circuit layer.

In addition, in order to achieve the above object of the present invention, the inventor of the present invention proposes a method for manufacturing an LED lamp, which comprises the following steps: (1) providing a plurality of lamps; (2) placing a self-adhesive substrate having a circuit layer and a plurality of LED elements on a substrate bonding tool by using a release paper; (3) removing the release paper, and removing the substrate The bonding tool is placed in the lamp tube; (4) the lamp tube is suspended, and the lamp tube is supported by the substrate bonding tool, so that a glue on the bottom surface of the self-adhesive substrate and the inner wall of the lamp tube (5) operating a roller to roll over the outer wall of the lamp tube, so that the glue on the bottom surface of the self-adhesive substrate can be closely attached to the inner wall of the lamp tube; (6) taking out the substrate bonding (7) repeating the above steps (2) to (6) such that the inner walls of the plurality of tubes are provided with a self-adhesive substrate; and (8) combining the plurality of tubes to a socket A lamp assembly end, wherein the lamp holder has an electric end, and an LED driving module is disposed inside the lamp holder.

Furthermore, in order to achieve the above object of the present invention, the inventors of the present invention have proposed a method of manufacturing an LED lamp comprising the steps of: (1a) providing a plurality of lamps; (2a) using a release paper to set the surface. a self-adhesive substrate having a circuit layer and a plurality of LED elements is disposed on a substrate bonding mechanism, wherein the substrate bonding mechanism has an air bag unit; (3a) removing the release paper and bonding the substrate Inserting a gas into the lamp tube; (4a) charging a gas into the air bag unit to push the self-adhesive substrate by expansion of the air bag unit, thereby making a glue on the bottom surface of the self-adhesive substrate The inner wall of the lamp tube is in full contact; (5a) the substrate bonding mechanism is taken out; (6a) repeating the above steps (2a) to (5a), so that the inner walls of the plurality of lamps are provided with a self-adhesive a substrate; and (7a) combining the plurality of lamps to a lamp assembly end of a lamp holder, wherein the lamp holder further has an electrical end, and an LED driving module is disposed inside the lamp holder.

<present invention>

1‧‧‧LED lamps

11‧‧‧ lamp holder

12‧‧‧Light tube

13‧‧‧ Self-adhesive substrate

14‧‧‧LED components

111‧‧‧Electrical end

112‧‧‧ lamp combination end

15‧‧‧LED driver module

15a‧‧‧Sensor unit

131‧‧‧Line layer

132‧‧‧Glue

12C‧‧‧ end cap

121‧‧‧Double-opening tube

122‧‧‧U-shaped end cap

S01~S08‧‧‧ method steps

2‧‧‧Substrate bonding tool

21‧‧‧Rigid support

22‧‧‧Soft joints

221‧‧‧LED groove

S01a~S07a‧‧‧ method steps

3‧‧‧Substrate bonding mechanism

31‧‧‧Airbag housing

31‧‧‧ Self-adhesive substrate insertion hole

311‧‧‧Airbag unit

<知知>

1'‧‧‧ energy saving lamp

11’‧‧‧Shell

12’‧‧‧ lamp

13’‧‧‧Rotating lamp holder

The first figure is a perspective view of an energy-saving lamp; the second picture is a perspective view of an LED lamp of the present invention; the third picture is an exploded view of the LED lamp; and the fourth picture is a self-adhesive substrate and a plurality of LED elements of the LED lamp A perspective view; a fifth embodiment is a second embodiment of a plurality of LED lamps; a fifth embodiment is a third embodiment of a plurality of LED lamps; and a fifth C is a plurality of LED lamps The fourth embodiment of the lamp tube; the fifth embodiment is a fifth embodiment of the lamp tube of the LED lamp; the sixth embodiment is the second embodiment of the lamp holder of the LED lamp; The third embodiment of the lamp socket of the LED lamp; the seventh figure is a side cross-sectional view of the lamp tube, the self-adhesive substrate and the LED component; Please refer to FIG. 8 is a flow chart of a method for manufacturing an LED lamp tube according to the present invention; and FIGS. 9A to 9E are diagrams showing a process of manufacturing the LED lamp tube; A flow chart of a second manufacturing method of the LED tube; and a process diagram of the second manufacturing method of the LED tube of the eleventh to eleventh D.

In order to more clearly describe an LED luminaire proposed by the present invention, a preferred embodiment of the present invention will be described in detail below with reference to the drawings.

Please refer to the second and third figures, which are perspective views and exploded views of an LED lamp of the present invention. As shown in the second and third figures, the LED lamp 1 of the present invention comprises: a lamp holder 11, a plurality of lamps 12, a plurality of self-adhesive substrates 13, and a plurality of LED elements 14; wherein the lamp holder 11 The LED drive module 15 is coupled to the electrical connection end 111. The LED drive module 15 is coupled to the electrical connection end 111. The LED drive module 15 is coupled to the electrical connection end 111. .

Please continue to refer to the second and third figures, and also refer to the fourth figure, which is a self-adhesive substrate 13 and a plurality of LED elements 14 of the LED lamp. Stereogram. As shown in the figure, the plurality of bulbs 12 are assembled to the bulb assembly end 112 of the socket 11, and the plurality of self-adhesive substrates 13 are respectively disposed on the inner walls of the plurality of bulbs 12. In the present invention, at least one circuit layer 131 is formed on the surface of each self-adhesive substrate 13, and the circuit layer 131 is electrically connected to the LED driving module 15. The plurality of LED elements 14 are disposed on the plurality of self-adhesive substrates 13 and electrically connected to the circuit layers 131. The LED driving module 15 can control the LED elements 14 through the circuit layer 131. Glowing. In addition, the LED driving module 15 is internally provided with a sensing unit 15a. When the LED lamp receives an impact force, the sensing unit 15a detects the impact force and simultaneously cuts off the LED driving module 15 to continue supplying power. The plurality of LED elements 14.

Please refer to the fifth embodiment A, the fifth B diagram, the fifth C diagram, and the fifth diagram D. The second embodiment of the plurality of lamps 12, the third embodiment, and the fourth embodiment are A perspective view of a fifth embodiment. Although the number of the lamps 12 shown in the second and third figures is four, as shown in FIG. 5A, in some applications of the energy-saving lamps, the number of the lamps 12 may be three. The lamp tube 12 shown in the second, third and fifth A diagrams is a test tube tube (ie, a single-open tube), the inner wall or the outer wall of which is sprayed with an optical diffusion coating; The tube 12 may also be a glass tube type lamp (ie, a double-open tube) as shown in FIG. 5B, wherein the inner wall or the outer wall of the double-open tube 12 is sprayed with an optical diffusion coating, and one end thereof The opening is combined to the lamp assembly end 112, and the other end of the opening is assembled with one end Cover 12C. In addition, the tube 12 may also be a U-shaped tube 12 as shown in FIG. 5C, and is not necessarily limited to an elongated tube; and, as shown in FIG. 5D, each U-shaped tube 12 It can be composed of two double-opened lamps 121 and one U-shaped end cover 122.

In addition, in terms of the material of the lamp tube 12, the lamp tube 12 may be a full transparent glass tube or a fully transparent plastic tube; and, in order to increase light scattering, the tube 12 may be a light diffusing glass tube or a light diffusing plastic. Light tube. Therefore, it can be inferred that when the lamp tube 12 is a fully transparent glass tube, the light diffusion explosion-proof protective film can be used to cover the full transparent glass tube; conversely, if the tube 12 is a light diffusing glass lamp When used, it is used with a fully transparent explosion-proof protective film and cover protection. Furthermore, if the lamp tube 12 is a heat-conductive plastic and a light-diffusing plastic composite lamp tube, a fully transparent plastic lamp tube, or a light-diffusing plastic lamp tube, since the plastic lamp tube does not suddenly burst, the explosion-proof can be omitted. Use of protective film. In addition, in addition to the attached protective film, the explosion-proof protective film may also be a heat-shrinkable film, such as a light-diffusing heat-shrinkable film and a transparent heat-shrinkable film; in addition, the explosion-proof protective film may also be formed by spraying. Above the tube 12, for example, a spray-molded light-diffusing protective film and a spray-molded transparent protective film; finally, the tube 12 can also be immersed in a glue to form a protective film on the tube 12, for example An impregnated light diffusing protective film or an impregnated transparent protective film.

In addition, please refer to the second embodiment and the third embodiment of the lamp socket 11 of the LED lamp 1 in FIGS. 6A and 6B. although The lamp holder 11 shown in the second and third figures has an electrical connection end 111 which is a rotating base, but does not limit the implementation of the socket 11 by this. As shown in FIG. 6A, the electrical connection end 111 of the socket 11 can be connected to an external power source through two electrical connection terminals; further, as shown in FIG. 6B, the shape of the socket 11 is not limited to a circle. The barrel, which can also be a cube design.

Please refer to the fourth figure again, and also refer to the seventh figure, which is a side cross-sectional view of the lamp tube 12, the self-adhesive substrate 13 and the LED element 15. As shown in the seventh figure, the self-adhesive substrate 13 having the circuit layer 131 formed on the surface of the present invention may be any of the following: a thermally conductive self-adhesive substrate, a glass fiber plate with a glue, and an aluminum substrate with a glue. , a copper substrate with a glue, a FPC soft board with a glue, a ceramic substrate with a glue, or a printed circuit board with a glue. The adhesive 132 is located on the back surface of the self-adhesive substrate 13. The type or form of the adhesive 132 is not particularly limited. Therefore, the adhesive 132 can be any of the following: thermal adhesive, silicone, and acrylic. A glue, glue, paste, adhesive, or any other adhesive substance. Thus, the self-adhesive substrate 13 is adhered to the inner wall of the lamp tube 12 through a glue 132 on the back surface thereof, and the self-adhesive substrate 13 is formed with at least one circuit layer 131. The circuit layer 131 may be copper. The circuit layer; or the circuit layer 131 can also be presented through the circuit board.

Thus, through the above, the structure and technical features of the LED lamp 1 of the present invention are clearly and completely described; then, the manufacturer of the LED lamp 1 will be further described below with the aid of the method flow chart. law. Please refer to FIG. 8 , which is a flow chart of a method for manufacturing an LED lamp tube according to the present invention; and, referring to FIG. 9A to FIG. 9E , a process schematic diagram of a method for manufacturing the LED lamp tube. The manufacturing method of the present invention mainly comprises the following steps. First, as shown in the eighth figure and the ninth A, the step (S01) is performed to provide a plurality of lamps 12; and then, as shown in the ninth B, the system performs In step (S02), a self-adhesive substrate 13 having a wiring layer 131 and a plurality of LED elements 14 disposed on the surface is placed on a substrate bonding tool 2 by using a release paper. The substrate bonding tool 2 is composed of a rigid supporting member 21 and a soft bonding member 22. The rigid support member 21 is configured to support the lamp tube 12 so that the lamp tube 12 is suspended. The soft joint member 22 is disposed on the rigid support member 21 and has a plurality of LED recesses 221 for self-adhesive. When the substrate 13 is placed on the substrate bonding tool 2, the LED elements 14 are housed.

Continuing, as shown in FIG. C, the step (S03) is performed to remove the release paper, and the substrate bonding tool 2 is placed inside the tube 12. Then, in step (S04), the lamp tube 12 is suspended by the rigid support member 21, and the lamp tube 12 is supported by the substrate bonding tool 2, so that the glue 132 of the bottom surface of the self-adhesive substrate 13 is made. It is in full contact with the inner wall of the tube 12. Then, as shown in the ninth D, the step (S05) is performed to operate a roller to roll over the outer wall of the tube 12, so that the glue 132 on the bottom surface of the self-adhesive substrate 13 can be closely attached to the tube. The inner wall of 12; then, Step (S06) is performed to take out the substrate bonding tool 2. Continuing, in step (S07), the above steps (S02) to (S06) are repeated such that the inner walls of the plurality of tubes 12 are provided with a self-adhesive substrate 13; finally, as shown in FIG. The step (S08) is performed to couple the plurality of tubes 12 to a lamp assembly end 112 of a socket 11. The socket 11 further has an electrical end 111, and the socket 11 is internally provided with a LED drive module 15.

Furthermore, the present invention further provides a second method of manufacturing the LED lamp 1 . Please refer to the tenth figure, which is a flow chart of a second manufacturing method of an LED lamp tube of the present invention; and, please refer to FIG. 11A to FIG. 11E at the same time, which is a schematic diagram of a manufacturing process of the manufacturing method. The manufacturing method of the present invention mainly comprises the following steps. First, as shown in FIG. 11 and FIG. 11A, the step (S01a) is performed to provide a plurality of lamps 12; then, as shown in FIG. Step (S02a) is performed to place a self-adhesive substrate 13 having a wiring layer 131 and a plurality of LED elements 14 on the surface of the substrate bonding mechanism 3 through the use of a release paper. The substrate bonding mechanism 3 further includes an air bag accommodating body 31 having a self-adhesive substrate insertion hole 312 formed on the surface thereof and an air bag unit 311 disposed therein.

Continuing, as shown in FIG. 11C, the step (S03a) is performed to remove the release paper, and the substrate bonding mechanism 3 is placed inside the tube 12. Then, in the step (S04a), the gas can be charged into the airbag unit 311 to push the self-adhesive substrate 13 by the expansion of the airbag unit 311. In this way, a glue 132 on the bottom surface of the self-adhesive substrate 13 is brought into full contact with the inner wall of the tube 12. Then, the step (S05a) is performed to take out the substrate bonding mechanism 3. Continuing, in the step (S06a), repeating the above steps (S02a) to (S05a), so that the inner walls of the plurality of tubes 12 are provided with a self-adhesive substrate 13; finally, as shown in FIG. As shown, the step (S07a) is performed to couple the plurality of tubes 12 to a lamp assembly end 112 of a socket 11. The socket 11 further has an electrical end 111, and the socket 11 is internally provided with a LED drive module 15.

Thus, the above-mentioned series has completely and clearly explained the LED lamp tube of the present invention and its two sets of manufacturing methods, and, through the above, we can know that the present invention has the following advantages:

1. Compared with the conventional energy-saving lamp, the LED lamp of the present invention is composed of a lamp holder 11, a plurality of lamps 12, a plurality of self-adhesive substrates 13, and a plurality of LED elements 14, and has a simple structure and a manufacturing cost. Low, and high color rendering.

2. According to the above first point, since the LED lamp of the present invention does not contain materials such as mercury and ultraviolet rays which cause harm to the human body, mercury gas, ultraviolet rays, electromagnetic waves and the like are not emitted, and the human body is not damaged.

3. Furthermore, unlike the conventional energy-saving lamps, the LED lamp of the present invention can complete the automatic/semi-automatic mass production of the LED lamp 1 of the present invention by using a substrate bonding tool 2 or a substrate bonding mechanism 3. The integrity of the techniques of the present invention is shown.

4. According to the first point above, since the LED lamp 1 of the present invention does not use any aluminum base, the all-glass lamp 12 or the all-plastic lamp 12 can effectively achieve the insulation effect and the insulation effect thereof. It complies with the relevant safety regulations of LED lamps 1.

5. In addition to the advantages listed above, the LED driving module 15 of the LED lamp 1 is further provided with a sensing unit 15a; thus, when the LED lamp receives an impact force, the sensing unit 15a detects Measuring the impact force and simultaneously cutting off the LED driving module 15 to continue supplying power to the plurality of LED elements 14 further provides safety in use of the LED lamp 1.

It is to be understood that the foregoing detailed description of the embodiments of the present invention is not intended to Both should be included in the scope of the patent in this case.

1‧‧‧LED lamps

11‧‧‧ lamp holder

12‧‧‧Light tube

13‧‧‧ Self-adhesive substrate

14‧‧‧LED components

111‧‧‧Electrical end

112‧‧‧ lamp combination end

15‧‧‧LED driver module

Claims (14)

An LED lamp includes: a lamp holder having at least one electrical end and a lamp combination end, wherein the lamp assembly end is internally provided with an LED driving module, and the LED driving module is coupled The electrical connection end; the plurality of lamps are assembled at the lamp assembly end of the lamp holder; the plurality of self-adhesive substrates are respectively a heat-conductive adhesive soft board, and the circuit layer is formed on the surface thereof. The self-adhesive substrate is respectively disposed on the inner wall of the plurality of lamps through the adhesive and is in close contact with each other, and the circuit layer on the surface of each self-adhesive substrate is electrically connected to the LED The driving module; the plurality of LED components are disposed on the plurality of self-adhesive substrates and electrically connected to the circuit layers, wherein the LED driving module can control the illumination of the LED components through the circuit layer. The LED lamp of claim 1, wherein the LED driving module has a sensing unit, and when the LED lamp receives an impact force, the sensing unit detects the impact force and simultaneously cuts off The LED driver module continues to supply power to the plurality of LED components. The LED lamp of claim 1, wherein one end of the lamp tube is formed with an opening, and the inner wall or the outer wall is sprayed with one Optical diffusion coating. The LED lamp of claim 1, wherein the two ends of the lamp tube are respectively formed with an opening, wherein one opening is combined with the lamp assembly end, and the other opening is assembled with an end cover. The LED lamp of claim 4, wherein the lamp tube is formed with the opening at both ends, and the inner wall or the outer wall is sprayed with an optical diffusion coating. The LED lamp of claim 3, wherein the lamp can be any of the following: an all-glass tube or an all-plastic tube. The LED lamp of claim 6, wherein the all-glass lamp tube can be any one of the following: a light diffusing glass tube or a transparent glass tube. The LED lamp of claim 6, wherein the all-plastic lamp tube can be any one of the following: a heat conductive plastic and a light diffusing plastic composite lamp, a light diffusing plastic lamp, or a transparent plastic lamp. The LED lamp of claim 4, further comprising a plurality of explosion-proof protective films respectively attached to the outer surface of the plurality of lamps, Covering and protecting the plurality of lamps. The LED lamp of claim 9, wherein the explosion-proof protective film can be any of the following: a light diffusion explosion-proof protective film, a transparent explosion-proof protective film, a light diffusion heat shrinkable film, a transparent heat shrinkable film, and a spray coating. A molded light diffusion protective film, a spray-molded transparent protective film, an impregnated light diffusion protective film, or an impregnated transparent protective film. The LED lamp of claim 1, wherein the self-adhesive substrate on which the circuit layer is formed is an FPC soft board having a glue. The LED lamp of claim 11, wherein the adhesive can be any one of the following: a thermal conductive adhesive, a silicone rubber, an acrylic adhesive, a viscose, a paste, or an adhesive. The LED lamp of claim 1, wherein the electrical end is a rotating lamp cap. The LED lamp of claim 1, wherein the electrical end has two electrical terminals for electrically connecting to an external power source.