TW201903324A - Light source module - Google Patents

Abstract

A light source module including a substrate, a LED package, an optical cover and at least one packing layer is provided. The LED package is disposed on the substrate and has an encapsulation. The optical cover is disposed on the LED package. The at least one packing layer is disposed between the LED package and the optical cover.

Description

Light source module

The invention relates to a light source module, and in particular to a light source module with waterproof and high light efficiency.

Most of the existing LED light source modules are provided with an optical cover outside the LED package, and an air layer exists between the LED package and the optical cover, and the light pattern is adjusted by the difference in refractive index and the curvature of the optical cover. In addition, in order to meet the requirements of waterproofing, an additional layer of waterproof silicone is usually disposed between the substrate and the optical cover.

However, the optical transmittance is limited by the material's own transmittance and the Fresnel loss caused by the interface between the air and the material, so the light extraction efficiency is thus limited. In addition, although the waterproof silicone layer is additionally disposed and assembled by screws, the waterproof effect can be achieved, but the components of the light source module are also added, and the assembly process is complicated.

The invention provides a light source module which can provide high light-emitting efficiency, waterproof effect and is relatively simple to assemble.

A light source module of the present invention includes a substrate, an LED package, an optical cover, and at least one interstitial layer. The LED package comprises an encapsulant and is disposed on the substrate. The optical housing is disposed on the LED package, and the interstitial layer is filled between the LED package and the optical housing.

In an embodiment of the invention, the refractive index of the encapsulant is greater than the refractive index of the at least one interstitial layer, and the refractive index of the at least one interstitial layer is greater than or equal to the refractive index of the optical cover.

In an embodiment of the invention, there is no air gap between the LED package and the optical cover.

In an embodiment of the invention, the at least one interstitial layer comprises a first interstitial layer and a second interstitial layer.

In an embodiment of the invention, the first interstitial layer and the second interstitial layer have a refractive index difference of between 0.05 and 0.5.

In an embodiment of the invention, the refractive index of the first interstitial layer is greater than the refractive index of the second interstitial layer.

In an embodiment of the invention, the refractive index of the first interstitial layer is smaller than the refractive index of the second interstitial layer.

In an embodiment of the invention, the second interstitial layer comprises diffusing particles.

In an embodiment of the invention, the light source module further includes a filter coating on the inner surface of the optical cover.

In an embodiment of the invention, the light source module further includes a reflective coating on the inner surface of the at least one interstitial layer.

Based on the above, the light source module of the present invention provides a similar refractive index by encapsulating the colloid, the interstitial layer and the optical cover by filling the interstitial layer between the LED package and the optical cover to achieve improved optical efficiency. Control the effect of the light type. Since the light source module of the present invention has no air gap between the LED package and the optical cover, the light between the package colloid and the air layer and the air layer and the optical cover can be avoided between the light source module as in the conventional light source module. The loss caused by the interface can improve the light efficiency and improve the lighting quality. In addition, the interstitial layer covers the LED package to provide a waterproof and dustproof effect without additional screw fixing, which saves assembly time and process. In addition, if diffusing particles are added to the interstitial layer, the light emitted from the LED package can be made uniform, providing a user with a comfortable visual effect and reducing glare.

The above described features and advantages of the invention will be apparent from the following description.

1 is a schematic diagram of a light source module in accordance with an embodiment of the invention. Referring to FIG. 1 , in FIG. 1 , a plurality of light source modules 100 are arranged in an array to take an array of light. Of course, in other embodiments, the light source module 100 may have other arrangements. Form is not limited to this. The structure of the light source module 100 will be described in detail below by taking one of the light source modules 100 of FIG. 1 as an example.

Fig. 2 is a schematic cross-sectional view taken along line A-A of Fig. 1. Referring to FIG. 2 , the light source module 100 of the present embodiment includes a substrate 110 , an LED package 120 , an optical cover 140 , and at least one interstitial layer 130 . In this embodiment, the substrate 110 can be any suitable circuit board, such as an aluminum-based circuit board 110, which is provided with a circuit (not shown) and an insulating layer (not shown) for isolating the circuit from the substrate. The LED package 120 is disposed on the substrate 110 and electrically connected to the circuit on the substrate 110. In this embodiment, the LED package 120 includes a board body 122 having a wire, an LED 124 disposed on the board body 122 and electrically connected to the board body 122, and being disposed on the board body 122 and enclosing the LED 124. An encapsulant 126.

The optical housing 140 is disposed on the LED package 120. In the present embodiment, the optical housing 140 is located at the outermost side and completely encloses the LED package 120, and has the effect of protecting the LED package 120. Of course, in other embodiments, the optical housing 140 may also partially encapsulate the LED package 120.

Fig. 3 is a schematic cross-sectional view taken along line B-B of Fig. 1. It should be noted that, in FIG. 3, in order to show the relative relationship between the optical cover 140 and the LED package 120 and the outline of the inner surface 142 of the optical cover 140, the substrate 110 and the interstitial layer 130 are hidden. Referring to FIG. 3 , the center position of the LED 124 of the LED package 120 is taken as the origin on the XY plane, and the axis L of the LED 124 penetrating the LED package 120 is taken as the rotation axis of the Z axis. In the example, the inner surface 142 of the optical housing 140 is a non-axisymmetric curved surface. As can be seen from Figure 3, the inner surface 142 of the optical housing 140 is asymmetrical on the left and right sides of the axis L, and the optical housing 140 provides a preferred optical effect by virtue of this particular curvature and shape.

It is to be explained that the axisymmetric surface is opposite to the non-axisymmetric surface, and the axis is symmetric with respect to the shape of the two sides of the axis, such as a spherical surface, a paraboloid, a hyperboloid or an elliptical surface. Therefore, the non-axisymmetric curved surfaces mentioned in this embodiment can be said to be aspherical, non-parabolic, non-hyperbolic, and non-elliptical. More specifically, a non-axisymmetric surface is a non-axisymmetric optical surface that follows a particular mathematical equation. Of course, in other embodiments, the inner surface 142 of the optical housing 140 can also be other curved surfaces, such as irregular optical curved surfaces that follow a particular mathematical equation. As will be described later, the optical cover 140 can be formed by superposition of a molding process. Alternatively, it is a previously formed hard layer. In this case, the optical cover 140 includes a glue injection hole (not shown) for injecting a material forming the interstitial layer 130.

Referring back to FIG. 2 , in the embodiment, the light source module 100 includes a gap filling layer 130 , and the gap filling layer 130 is filled between the LED package 120 and the optical cover 140 . As can be clearly seen from FIG. 2, the gap between the LED package 120 and the optical cover 140 is filled by the interstitial layer 130. Therefore, there is no air gap between the encapsulant 126 of the LED package 120 and the optical cover 140 ( Air gap). In particular, in the present embodiment, the refractive index of the encapsulant 126, the interstitial layer 130, and the optical cover 140 may be changed in a gradual manner to achieve good penetration efficiency. For example, the refractive index of the encapsulant 126 is greater than the refractive index of the interstitial layer 130, and the refractive index of the interstitial layer 130 is greater than or equal to the refractive index of the optical housing 140. In this embodiment, the material of the interstitial layer 130 may be a glue material such as silicone or any suitable material. The refractive index of the encapsulant 126, the interstitial layer 130, and the optical cover 140 may be between 1.4 and 1.7, and the refractive indices of the encapsulant 126, the interstitial layer 130, and the optical cover 140 have the above-described relationship. In this way, the light source module 100 can avoid Fresnel loss caused by the interface between the encapsulant and the air layer and the interface between the air layer and the optical cover in the light source module as in the conventional light source module. The light-emitting efficiency is improved and the lighting quality is improved. Since the gap-filling layer 130 covers the LED package 120, the waterproof and dust-proof effect can be provided, and no additional screw fixing is needed, thereby saving assembly man-hours and processes.

Table 1 compares three light source modules, including the light source module of number 1, which has only the LED package 120; the light source module of number 2, which has the LED package 120 and the optical cover 140, and is in the LED package 120 and There is an air gap between the optical enclosures 140; the light source module of the number 3 is the light source module 100 of FIG. 2, which is filled with the interstitial layer 130 between the LED package 120 and the optical enclosure 140 without an air gap. As can be clearly seen from Table 1, it can be seen that comparing the light source modules of Nos. 1 and 2, only when the optical cover 140 is disposed outside the LED package 120, that is, when there is an air gap, the lumen value will be significantly decreased, however, At the same time, comparing the light source modules of Nos. 2 and 3, it can be seen that after filling the interstitial layer 130, the lumen value and the lens efficiency are improved when there is an air gap. Table I

Of course, the form of the light source module is not limited to the above, and other light source modules are listed below. 4 to 8 are schematic cross-sectional views of various light source modules in accordance with other embodiments of the present invention. It is to be noted that, in the following embodiments, the same or similar elements as those of the previous embodiment are denoted by the same or similar symbols and will not be described again.

Referring to FIG. 4, the main difference between the light source module 100a of FIG. 4 and the light source module 100 of FIG. 2 is that, in the present embodiment, the interstitial layer 130a is doped with particles 131 to provide a special optical effect. For example, the particles 131 doped in the interstitial layer 130 may include diffusing particles for homogenizing the light emitted by the LED package 120 to provide a user's comfortable visual effect, reduce glare, and control the light type. .

It is worth mentioning that because the concentration of the diffusion particles in the interstitial layer 130a will affect the visual effect of the light, for example, the low concentration of the diffusion particles in the interstitial layer 130a will have a higher light penetration efficiency, but the diffusion effect. Insufficient; the high concentration of the diffusing particles in the interstitial layer 130a has a high diffusion effect, but the light penetration efficiency is not good. In the present embodiment, the concentration percentage of the diffusing particles is between 0.1% and 20% to achieve a better balance between the penetration efficiency and the diffusion effect. In addition, in the embodiment, the diffusion particles may include an organic diffusion material, such as an acrylic type, an organic germanium type or a polyethylene type, and the diffusion particles may also include an inorganic diffusion material such as nanometer barium sulfate or cerium oxide. Or calcium carbonate. Of course, the type and concentration percentage of the diffusing particles are not limited to the above.

Of course, the kind of the particles 131 doped in the interstitial layer 130 is not limited to the diffusion particles, and the particles 131 may also include a phosphor powder, which is a photoluminescence mechanism material for wavelength conversion of light. Similarly, the weight percentage of the phosphor powder will be between 0.1% and 30% to achieve a better balance between penetration efficiency and wavelength conversion. In addition, in the present embodiment, the type of the phosphor powder is not particularly limited, and may be, for example, aluminate phosphor powder, tantalate phosphor powder, nitride phosphor powder, oxynitride phosphor powder or fluoride. Fluorescent powder and a mixture of the foregoing.

In the present invention, an embodiment having a plurality of layers of interstitial layers may also be included. In this case, the refractive index of the encapsulant 126, the interstitial layer 130 and the optical cover 140 are still changed gradually, but the refractive index relationship between the interstitial layers can be adjusted as needed. The following examples are given.

Referring to FIG. 5 , the main difference between the light source module 100 b of FIG. 5 and the light source module 100 of FIG. 2 is that, in this embodiment, at least one interstitial layer 130 b includes a first interstitial layer 132 and a second fill. The gap layer 134, the first interstitial layer 132 covers the LED package 120, and the second interstitial layer 134 covers the first interstitial layer 132. In this embodiment, the refractive index of the first interstitial layer 132 may be greater than the refractive index of the second interstitial layer 134, and the refractive index difference between the first interstitial layer 132 and the second interstitial layer 134 is between 0.05 and Between 0.5. In addition, in the present embodiment, the refractive index of the encapsulant 126 is greater than the refractive index of the first interstitial layer 132 and the refractive index of the second interstitial layer 134, and the refractive index of the first interstitial layer 132 and the second interstitial The refractive index of layer 134 is greater than or equal to the refractive index of optical housing 140.

Referring to FIG. 6, the main difference between the light source module 100c of FIG. 6 and the light source module 100b of FIG. 5 is that the refractive index of the first interstitial layer 132 is higher than the refractive index of the second interstitial layer 134c, and the second filling The gap layer 134c is mixed with the particles 131. The particles are exemplified by the diffusing particles, and the light emitted from the LED package 120 can be made uniform, thereby providing a user with a comfortable visual effect, reducing glare, and controlling the light type. Of course, the particles can also be fluorescent powders that are capable of converting the wavelength of light.

Fig. 9 is a view showing the relationship between the position and the illuminance of the light source modules 100b and 100c of Figs. 5 and 6 as an example. Referring to FIG. 9, the X-axis of FIG. 9 can be regarded as the position where the light source modules 100b and 100c of FIG. 5 and FIG. 6 are arranged along the CC line segment of FIG. 1, and the Y-axis is the light source module of FIGS. 5 and 6. The brightness of the light emitted by 100b, 100c. The light source module 100b of FIG. 5 is indicated by a broken line, and the light source module 100c of FIG. 6 is indicated by a solid line. Since the light source module 100c of FIG. 6 is doped with diffusion particles in the second interstitial layer 134c, it can be clearly seen from FIG. 9 that the light source module 100c of FIG. 6 has a difference in luminance (about 700,000). It is significantly smaller than the illuminance difference (about 1.500000) of this row of light source modules 100b of FIG. Since the luminance difference of the row of light source modules 100c doped with the diffusion particles in the second interstitial layer 134c is significantly smaller, it can provide better visual comfort.

It is to be noted that, since the second interstitial layer 134c of the light source module 100c of FIG. 6 is mixed with the particles 131, the light may scatter in the direction of the first interstitial layer 132 when passing through the second interstitial layer 134c. The light extraction efficiency of the second interstitial layer 134c is affected. In order to avoid the above problem, in the light source module 100c of FIG. 6, the refractive index of the second interstitial layer 134c is greater than the refractive index of the first interstitial layer 132. If a portion of the light in the second interstitial layer 134c is reflected by the particles 131 and is directed toward the first interstitial layer 132, the interfacial organic ratio between the first interstitial layer 132 and the second interstitial layer 134 is totally reflected. Returning to the second interstitial layer 134. Therefore, the design of the second interstitial layer 134c having a refractive index greater than that of the first interstitial layer 132 may cause more light in the second interstitial layer 134 to be directed toward the optical housing 140, and the second interstitial layer may be lifted. 134's light output efficiency.

Table 2 compares four light source modules, including the number 1 light source module, which has an air gap between the package gel and the optical cover, which is also a conventional light source module; the number 2 light source module is in the package colloid A first interstitial layer 132 and a second interstitial layer 134 are filled between the 126 and the optical cover 140, and the refractive index of the first interstitial layer 132 is greater than the refractive index of the second interstitial layer 134, and the light source of FIG. The module 100b; the light source module of No. 3 is a second interstitial layer 134 that mixes 10% of the diffusion particles into the light source module 100b of FIG. 5; the refractive index of the first interstitial layer 132 of the light source module of No. 4 is less than The refractive index of the second interstitial layer 134c is mixed with 10% of the diffusion particles into the second interstitial layer 134c, like the light source module 100c of FIG. Comparing the light source modules of Nos. 1 and 2, it can be seen that the light source module 100b of No. 2 has a gap increase of 6% after filling the interstitial layer 130b between the encapsulant 126 and the optical cover 140. Comparing the light source modules of No. 3 and 4, when the diffusion particles are added to the second interstitial layer 134, the refractive index of the second interstitial layer 134c is designed to be larger than the refractive index of the first interstitial layer 132, and the light extraction efficiency is obtained. Can be increased by 2%. Table II

The main difference between the light source module 100d of FIG. 7 and the light source module 100c of FIG. 6 is that, in the embodiment, the light source module 100d further includes a filter coating 150, preferably located in the optical cover. The inner surface of 140 (ie, the outer surface of the interstitial layer 130c) filters blue/UV light (eg, light having a wavelength of less than 460 nm), so that the blue/UV light does not pass through the interstitial layer 130c to lower the light source module 100d. Blue light/UV light is emitted to affect the health of the user's eyes. In other embodiments, the filter coating 150 may also be located on the outer surface of the LED package 120 (ie, the inner surface of the interstitial layer 130c), or in the first interstitial layer 132 and the second interstitial layer 134c. between.

Referring to FIG. 8, the main difference between the light source module 100e of FIG. 8 and the light source module 100c of FIG. 6 is that, in the embodiment, the particles of the second interstitial layer 134c of the interstitial layer 130c are exemplified by phosphor powder. The light source module 100e further includes a reflective coating 160, and the additive system comprises a reflective coating having a wavelength greater than 500 nm. The reflective coating 160 is located on the inner surface of the at least one interstitial layer 130. More specifically, the reflective coating 160 is positioned on the inner surface of the first interstitial layer 132 to reflect the yellow light outward to adjust the light source module 100e. The color temperature of the light.

Of course, in other embodiments not shown, the filter coating 150 or/and the reflective coating 160 can also be applied to the light source modules 100, 100a, 100b of FIG. 2, FIG. 4, FIG. 5 or other not shown. The light source module is not limited to the above.

A method of manufacturing the light source module 100 is provided below. 10 to 13 are schematic flow charts of a method of manufacturing a light source module 100 according to an embodiment of the invention. In this embodiment, a light source module 100 of FIG. 2 will be taken as an example to describe one of the ways in which the interstitial layer 130 is formed on the LED package 120. Of course, in other embodiments, the method of manufacturing the interstitial layer 130 is not limited thereto.

Referring first to Figure 10, first, a mold 10 is provided in which the mold 10 includes a first portion 12 and a second portion 14 that are separated. The LED package 120 is secured to the first portion 12 of the mold 10 along with the substrate 110. The second portion 14 includes a cavity 17 which, in the present embodiment, includes a fastener 15 and a movable member 16 movable relative to the fixture 15, the cavity 17 being formed on the movable member 16. Of course, this embodiment exemplifies only one of the molds 10, and the aspect of the mold 10 to which the method can be applied is not limited thereto. In addition, it can be seen in FIG. 10 that a release layer 18 is covered in the cavity 17 before the first portion 12 is bonded to the second portion 14 to facilitate subsequent film removal. Of course, in other embodiments, The light source module 100 is easily separated from the mold 10, and the peeling layer 18 may be omitted.

Next, as shown in FIG. 11, the first portion 12 is bonded to the second portion 14, and the LED package 120 positioned on the first portion 12 projects into the cavity 17 of the second portion 14. In the present embodiment, the first portion 12 is joined to the second portion 14 in such a manner as to apply a negative pressure to the cavity 17 and the first portion 12 to the second portion 14 as shown in FIG. As the pressure within the cavity 17 decreases, the movable member 16 moves up relative to the fixture 15 until the movable member 16 is blocked by the substrate 110 and cannot continue to move up. The operator can inject a glue 20 to the space between the peeling layer 18 and the substrate 110 to cover the LED package 120 before or after the movable member 16 is positioned. In this embodiment, the material of the rubber material 20 is, for example, silicone or any material having a refractive index of between 1.4 and 1.7. Of course, in other embodiments, if the first portion 12 can be directly coupled to the second portion 14, the step of applying a negative pressure to the cavity 17 can be omitted. Moreover, in other embodiments, the movable member 16 of the second portion 14 may also be a design that is not movable relative to the fixed member 15, that is, the second portion 14 may also be a single member that does not deform.

Next, as shown in FIG. 13, the adhesive 20 is cured to form a glue layer (that is, the interstitial layer 130) that is coated on the LED package 120. In the present embodiment, the rubber material 20 is exemplified by a material which is cured after being heated, so that the rubber material 20 can be cured by heating the second portion 14 of the mold 10 to form the interstitial layer 130. However, in other embodiments, the glue 20 may also be a photocurable material, such as a material that cures after UV light. When the glue 20 is a photocurable material, the second portion 14 of the mold 10 allows light to penetrate. For example, it is transparent to cure the glue 20 by illuminating the second portion 14 of the mold 10 to form the interstitial layer 130, and completing the formation of the interstitial layer 130 on the substrate 110 and coating the LED package 120 A step of. Then, the substrate 110 is removed from the first portion 12, and the peeling layer 18 is removed to separate the interstitial layer 130 from the second portion 14 to be detached from the mold 10. A semi-finished product having a gap-filling layer 130 is formed. It should be noted that in the case of having a plurality of interstitial layers 130, molding may be repeated to form a semi-finished product of the multi-layer interstitial layer 130. Finally, the semi-finished product having the interstitial layer 130 is molded to form the optical cover 140, and finally the light source module of the present invention is formed.

In addition to the above method of directly molding the optical cover 140, the present invention may also use a rigid optical cover 140. That is, an optical cover 140 having a glue injection hole is provided, and the substrate 110 having the LED package 120 is directly aligned with the optical cover 140, and then the glue material 20 is injected from the glue injection hole to form a single layer. The light source module of the gap layer 130. Alternatively, after the semi-finished product of the N-layer interstitial layer 130 is aligned with the optical cover 140, the adhesive material 20 is injected from the rubber injection hole to be cured to form a light source module having the N+1 layer interstitial layer 130. .

In summary, the light source module of the present invention fills the gap between the LED package and the optical cover, and provides a similar refractive index by the encapsulant, the interstitial layer and the optical cover to achieve the lifting optics. Efficiency and the effect of controlling light patterns. Since the light source module of the present invention has no air gap between the LED package and the optical cover, the light between the package colloid and the air layer and the air layer and the optical cover can be avoided between the light source module as in the conventional light source module. The Fresnel loss caused by the interface can improve the light efficiency and improve the lighting quality. In addition, the interstitial layer covers the LED package to provide a waterproof and dustproof effect without additional screw fixing, which saves assembly time and process. In addition, if diffusing particles are added to the interstitial layer, the light emitted from the LED package can be made uniform, providing a user with a comfortable visual effect and reducing glare.

Although the present invention has been disclosed in the above embodiments, it is not intended to limit the present invention, and any one of ordinary skill in the art can make some changes and refinements without departing from the spirit and scope of the present invention. The scope of the invention is defined by the scope of the appended claims.

L‧‧‧ axis

 10‧‧‧Mold

12‧‧‧Part 1

14‧‧‧Part II

15‧‧‧Fixed parts

16‧‧‧Activities

17‧‧‧ cavity

18‧‧‧ peeling layer

20‧‧‧Stained materials

100, 100a, 100b, 100c, 100d, 100e‧‧‧ light source module

110‧‧‧Substrate

120‧‧‧LED package

122‧‧‧ board

124‧‧‧LED

126‧‧‧Package colloid

130, 130a, 130b, 130c‧‧‧ gap layer

131‧‧‧ particles

132‧‧‧First gap layer

134, 134c‧‧‧Second interstitial layer

140‧‧‧Optical cover

142‧‧‧ inner surface

150‧‧‧Filter coating

160‧‧‧reflective coating

1 is a schematic diagram of a light source module in accordance with an embodiment of the invention. Fig. 2 is a schematic cross-sectional view taken along line A-A of Fig. 1. Fig. 3 is a schematic cross-sectional view taken along line B-B of Fig. 1. 4 to 8 are schematic cross-sectional views of various light source modules in accordance with other embodiments of the present invention. FIG. 9 is a diagram showing the relationship between the position and the luminance of the light source module of FIGS. 5 and 6. 10 to 13 are schematic flow charts of a method of manufacturing a light source module according to an embodiment of the invention.

Claims (10)

A light source module includes: a substrate; an LED package disposed on the substrate, the LED package includes an encapsulant; an optical cover disposed on the LED package; and at least one interstitial layer, filled Between the LED package and the optical housing. The light source module of claim 1, wherein a refractive index of the encapsulant is greater than a refractive index of the at least one interstitial layer, and a refractive index of the at least one interstitial layer is greater than or equal to a refractive index of the optical cover. . The light source module of claim 1, wherein there is no air gap between the LED package and the optical cover. The light source module of claim 1, wherein the at least one interstitial layer comprises a first interstitial layer and a second interstitial layer. The light source module of claim 4, wherein a refractive index difference between the refractive index of the first interstitial layer and the second interstitial layer is between 0.05 and 0.5. The light source module of claim 4, wherein the first interstitial layer has a refractive index greater than a refractive index of the second interstitial layer. The light source module of claim 4, wherein the first interstitial layer has a refractive index smaller than a refractive index of the second interstitial layer. The light source module of claim 7, wherein the second interstitial layer comprises diffusion particles. The light source module of claim 1, further comprising: a filter coating on an inner surface of the optical cover. The light source module of claim 1, further comprising: a reflective coating on an inner surface of the at least one interstitial layer.