TWM570919U - One-piece forming beam controller with positioning detection function - Google Patents

Abstract

A beam controller includes: a light entrance surface, a light exit surface, a bottom surface, and a positioning view surface. The light incident surface is configured to face a light source substrate and collect at least half of the light flux of the light source substrate; the light emitting surface is configured to emit at least 80% of the light; the bottom surface is provided for facing the light source substrate a positioning layer; and the positioning field of view is disposed at an outer edge of the light-emitting surface, and has at least one total reflection portion at an angle α with the bottom surface. The feature is that all the materials are the same material; when the human eye views the positioning field of view from above, the whole or part of the positioning layer is not visible; and after changing the angle α between the total reflection portion and the bottom surface, See all of the positioning layers in the same location.

Description

One-piece forming beam controller with positioning detection function

The present invention relates to a beam controller, and more particularly to a beam shaping controller that can be inspected and positioned with the naked eye.

A light-emitting diode (LED) is a kind of surface-emitting light source. The distribution angle of light intensity varies with different manufacturers, process methods, and power levels. Therefore, for each beam controller, the assembly position and the scaling curvature after demolding can meet the designed target, which determines the yield of the finished product. As for the large-area illumination device described in Japanese Patent Laid-Open Publication No. 5396606B2, the overall brightness is composed of a plurality of LED light sources and a beam controller, which is quite dependent on the mutual compensation of the light sources between the light sources, like a light building block, once a light source cannot be used. To form a beam at the correct location, it is quite time consuming to remove the entire set of sources. In this regard, the above-mentioned charter design is located on the multi-point stand below the beam controller for corresponding multi-point grooves on the LED substrate, and the alignment confirmation is performed before sealing.

However, the material of the beam controller (lens) is mostly a mold-releasing resin. During the process of inserting the liquid resin into the mold, it is necessary to maintain a certain high temperature to avoid the formation of internal bubbles and affect the effect of beam control. The later flaming procedure is the key to shape curing. The above multi-point stand is easy to deform in this program, often because of the bulging. The part is too large or deformed to be placed on the predetermined LED substrate. In order to solve the elimination rate caused by the demoulding deformation, a convex mold having a slightly smaller size is generally designed, so that the above-mentioned positioning stand and the groove of the light source substrate have some allowable values, but only the beam controller and the light source are thus obtained. There is considerable positioning error between the substrates. As for the final beam control effect, it is necessary to wait until the entire light bar is sealed and the upper diffusion plate is energized before it is known, and it is impossible to know whether the factory light bar conforms to the beam design specification when assembling.

If there is a positioning detection method, the lens positioning confirmation can be performed at the time of assembly, and the curvature integrity of the lens can be instantly verified, which can greatly improve the yield of the lamp and provide the quality that the back end customer can trust.

The main purpose of this creation is to observe the total reflection part provided on the integrated beam controller through the naked eye, and confirm that the positioning pattern on the light source substrate has reached the standard pattern, thereby completing the product yield detection.

To achieve the above objective, the present invention provides a beam controller 10 comprising: a light incident surface 110, a light exit surface 120, a bottom surface 140, and a positioning field of view surface 130. The light incident surface 110 is configured to face the light source 210 on the light source substrate 20 and collect at least half of the light flux of the light source 210, and the light exit surface 120 is configured to emit at least 80% of the light. The bottom surface 140 is disposed to face the layer 230 on the light source substrate, and the positioning field 130 is located at the outer edge of the light exit surface 120, and has at least one total reflection portion 131 at an angle α with the bottom surface. When the human eye 30 views the positioning field of view 130 from above, all or part of the positioning layer 230 is not visible. The beam controller 10 is all of the same material, and the angle α between the total reflection portion 131 and the bottom surface can be designed to be greater than or equal to the total reflection critical angle, which is related to the beam controller 10 It is related to the relative refractive index of the exiting environment.

2 is a schematic diagram of the optical path of the present invention, illustrating that the ambient light 2301 surrounding the reflective portion of the positioning layer 230 is refracted to the field of view 30 of the human eye, and the ambient light 2311 is reflected from the surrounding portion to be reflected by the total reflection portion 131, and then refracted once ( Or multiple reflections and refraction) to the outside of the human eye 30 field of view. Thus, the total reflection pattern 231 on the positioning layer 230 cannot be seen by the human eye 30 as if it disappeared, thereby judging that the beam steering element 10 has been placed at the designed position. The surrounding ambient light is taken from an indoor light source or a natural light source, and does not require additional lighting or an inspection machine.

FIG. 3 is a top plan view of the lower positioning layer 230 in cooperation with the present invention. When the human eye is directly viewed from the top view of FIG. 3, the total reflection pattern 231 is totally reflected by the total reflection portion 131, so that it seems to disappear. same. During design, three or more of the total reflection portions 131 may be disposed along the outer edge of the light-emitting surface 120, or the continuous total reflection portion 131 and the corresponding positioning layers 230, 231 may be disposed. When the total reflection patterns 231 are in a disappearing state under direct vision, it means that the beam controller is already at the center of the lower light source 210. Unlike the conventional technology, it can only be confirmed by the action of inserting the groove during assembly. The positioning detection method of the present invention can even perform the visual inspection repeatedly in the assembly factory or after the factory to improve the yield of the product at the vending end. .

The light exiting surface 120 has a first region 121 with a slowly varying curvature, the periphery of which has a higher height from the bottom surface 140. A light-emitting substrate 20 is disposed on the light source substrate 20 to face the bottom surface 140. A plurality of pattern gaps (between 221 and 222) are distributed on the first inspection layer, corresponding to the curvature distribution of the first region 121. When the human eye 30 looks directly at the first In the area 121, the first area is like a concave lens for the first inspection layer, so that the pattern gap on the first inspection layer is reduced to be invisible, and the assembly person recognizes the curvature standard of the first area. Similarly, the light exiting surface 120 has a second region 122 whose curvature changes slowly, and its periphery is lower in height from the bottom surface 140. A second inspection layer is disposed on the light source substrate 20 in cooperation with the present invention, and faces the bottom surface 140 as well. A plurality of pattern gaps (between 222 and 223) are distributed on the second inspection layer, corresponding to the curvature distribution of the two regions 122. When the human eye 30 looks directly at the second area 122, the second area is like a convex lens for the second inspection layer, which enlarges the pattern gap on the second inspection layer which is not visible to the naked eye, thereby confirming the Whether the curvature of the second zone 122 meets design criteria.

10‧‧‧Integrated beam controller

20‧‧‧Light source substrate

30‧‧‧ human eyes

12‧‧‧ Included space under the integrated beam controller

110‧‧‧Into the glossy surface

120‧‧‧Glossy

130‧‧‧ Positioning field of view

140‧‧‧ bottom

121‧‧‧First District

122‧‧‧First District

131‧‧‧ Total Reflection Department

210‧‧‧Light source

221‧‧‧ first inspection layer

222‧‧‧The pattern between the first inspection layer and the second inspection layer

223‧‧‧Second inspection layer

230‧‧‧Location layer

231‧‧‧ total reflection pattern

2211‧‧‧The first test layer reflects the ambient light to the human eye

2221‧‧‧The first or second inspection layer reflects the ambient light to other places

2231‧‧‧Second inspection layer reflects ambient light to other places

2210‧‧‧ Imaging of the first test layer after refraction in the first zone

2220‧‧‧Imaging after refraction in the first and second zones

2230‧‧‧ Imaging of the second inspection layer after refraction in the second zone

2301‧‧‧ Positioning layer reflects the ambient light to the human eye

2311‧‧‧Location layer reflects the ambient light to other places

FIG. 1 is a schematic cross-sectional view showing the structure of the light source controller in accordance with the first embodiment of the present invention.

Fig. 2 is a schematic view of the total reflection path of the first embodiment of the creation.

Figure 3 is a visual effect of the top positioning layer in the second embodiment of the creation.

Figure 4 is a schematic view of the optical path of the third embodiment of the present invention.

Fig. 5 is a visual effect of a plurality of inspection layers in a third embodiment of the creation.

Figure 6 is a positioning layer and a plurality of detection layers in the fourth embodiment of the present invention.

Figure 7 is one of the top view of the positioning layer and the plurality of detection layers in the fourth embodiment of the creation.

Figure 8 is the second embodiment of the positioning layer and the top view of the plurality of detection layers in the fourth embodiment of the present invention.

Please refer to FIG. 1 for a schematic diagram of the structure of the light source controller of the first embodiment of the present invention. The integrally formed beam controller 10 is formed with a lower space 12 for placing a light source substrate 20, and has a protruding portion for not easily sliding out after the light source substrate 20 is placed, or has a recess. The portion is provided to receive a component protruding from the light source substrate 20, for example, a connecting wire. The light source substrate 20 can be made of a system circuit board, a printed circuit board (PCB), a metal core printed circuit board (MCPCB), a ceramic substrate (Ceramic Printed Circuit Board, DCP), and the like. Substrate composition. Above it is provided a light source 210 facing the light incident surface 110 of the beam controller and at least one layer 230, 211, 222, 223 required to position or verify the curvature. The layers may be developed by blanket development, screen printing, thermal transfer, sand blasting, etching or electroplating onto the substrate, or a pattern of mating may be drilled. Even when the gold wire (wire) mask is made, the layers 230, 211, 222, 223 can be used to complete the necessary pattern with the inactive wires. Alternatively, the separately printed pattern cards display the layers 230, 211, 222, 223 and are sized to fit the dimensions of the lower space 12 for positioning. Although the design can be completely confirmed by ambient light, the layers 230, 211, 222, and 223 can be formed by fluorescent or metallic reflective patches to increase their visibility.

Please refer to FIG. 3 for a schematic diagram of the beam controller of the second embodiment of the present invention in conjunction with the positioning layer 230 below. The positioning layer 230 can be disposed at least three locations on the outer edge of the light-emitting surface (lower figure) for displaying the positioning of the front, rear, left, and right, or It is arranged continuously along the outer edge of the light-emitting surface (above). The positioning layer 230 can be designed to be partially visible and partially invisible 231 (after total reflection), or all invisible (total reflection) patterns, such as concentric circles or graduated patterns. Such a symmetrical arrangement allows the assembler to visually understand the degree of eccentricity of the beam controller 10, and to finely adjust the relative position of the light source substrate 20 before and after, and then seal.

Please refer to FIG. 4, which is a schematic diagram of the light path of the third embodiment of the present invention with the inspection layers 221, 222, and 223 below. As with the large angle scattered beam controller mentioned in the above prior art, the center curvature is important for the combined uniform illumination, however, there is no reliable curvature inspection assembly step in the current assembly method. Using the creative prototype of the present creation, the curvature of the light exit surface 120 of the beam controller 10 after demolding can be further examined. The illuminating surface 120 has a first area 121 and a second area 122. The first area 121 has a concave lens for the first inspection layer (between 221 and 222), and the second area 122 The second inspection layer (between 222 and 223) is like a convex lens. As shown in FIG. 4, the optical path between 2211 and 2221 represents the reduced first inspection layer (between 2210 and 2220), so that the gap existing in the first inspection layer looks like it disappears from above. (Figure 5). Conversely, the optical paths 2221 to 2223 represent the enlarged second inspection layer (between 2220 and 2230), so the gap of the second inspection layer that is not clearly visible is clear from above. 5). The assembler can view the positioning layer 230 first, and confirm that all the total reflection patterns 231 are invisible. Then, by not seeing the gap of the first inspection layer 221 and seeing the gap of the second inspection layer 223, it can be confirmed. The curvature of the light exit surface 120 of the beam controller has reached the set Counting the standard, it is not until the client is found to return the entire light bar.

Please refer to "figure 6", which is a positioning layer and a plurality of detection layers in the fourth embodiment of the present creation. The central quadrangle of the figure is slightly convex outwards, and is used to detect whether the center curvature of the beam controller is qualified. This is an example of the implementation of the plurality of detection layers. The octagonal shape of the outer side of the central quadrilateral or the set of line segments on the left and right sides is used to detect whether the beam controller is symmetric with the center of the lower light source, and is an implementation example of the positioning layer.

Please refer to "Fig. 7", which is one of the positioning layer and the top view of several detection layers in the fourth embodiment of the present creation. When the beam controller is placed above the positioning layer and the plurality of detection layers, and is slightly offset to the right of the center, the assembler can see the black line on the left side of the octagon portion from above, and the central quadrilateral is leftward. protruding.

Please refer to "Fig. 8", which is the second embodiment of the positioning layer and the top view of several detection layers in the fourth embodiment of the present invention. When the beam controller moves to the positioning layer and the center of the plurality of detection layers, the positioning layer is not seen from above, and the positioning layer (that is, the above-mentioned octagon) is not seen, and the slightly convex central quadrilateral is formed. That is, the plurality of detection layers will present a square pattern.

Finally, the assembler can use a double-sided tape, a gel-like adhesive, a liquid adhesive, a clip, or a thread to secure the relative position of the beam controller 10 to the light source substrate 20. This creation not only provides the assembly personnel with positioning and curvature inspection, but also can continuously and randomly test the assembly pattern in subsequent accessory combinations and even after shipment, and effectively improve the product yield to avoid misassembly.

The present invention can also perform non-human eye detection. After completing the assembly with the light source substrate 20, the beam controller 10 is sequentially sent to an inspection platform, and the inspection platform includes a hood, an automatic scanning light source or a A large angle uniform light source and a photometric sensor located adjacent to the light source. The positioning layer 230 is made of a high reflectivity material in addition to the total reflection pattern 231 or the total reflection pattern is made of a high absorptivity material. Then, when the beam controller 10 is not assembled in the correct position, the portion of the high-reflectivity positioning layer 230 is covered by the total reflection portion 131, and the automatic scanning light source cannot be reflected. In this case, the photosensor has a low detection value, so that the assembly of the beam controller 10 and the light source substrate 20 can be determined to be unacceptable, and the unqualified assembly is excluded from leaving the inspection platform. The high-reflection material can also be replaced with a special photoreactive material, and the photometric sensor can be equipped with a filter or a grating for selective photometric measurement of the special light.

This creation is to create a beam controller with visual positioning function in a simple process, and to utilize the existing surface layer of the light source substrate to simplify the assembly process and cost, and to provide a positioning and curvature inspection method synchronized with the assembly to improve the product yield. The concept of environmental protection with beauty and energy saving and carbon reduction has indeed met the requirements for the creation of patent applications, and patent applications have been filed according to law.

However, the above is only a preferred embodiment of the present invention, and the scope of the present invention cannot be limited by this; therefore, the simple equivalent changes and modifications made by the scope of the patent application and the content of the creation specification are All should remain within the scope of this creation patent.

Claims (10)

A light beam controller comprising: a light incident surface for supplying light to a light source substrate and collecting more than half of the light flux of the light source substrate; a light emitting surface for emitting at least 80% of the light; and a bottom surface for facing the light source a positioning layer on the substrate; and a positioning field of view disposed on the outer edge of the light-emitting surface, and having at least one total reflection portion at an angle α with the bottom surface, wherein all components are formed of the same light-transmitting material; When the positioning field of view is barely viewed, all or part of the positioning layer is not visible; and after changing the angle α between the total reflection portion and the bottom surface, all of the positioning layers below the positioning field of view are visible at the same position. The beam controller of claim 1, wherein the beam controller is shaped to form a cavity, and the cavity is substantially the same size as the light source substrate for receiving the light source substrate. The beam controller of claim 2, further comprising: at least one protruding portion facing the cavity, and the slopes of the upper and lower sides of the protruding portion are different, so that the light source substrate is not slipped after being placed in the light source substrate Out of the cavity. The beam controller of claim 1, wherein an angle α between the total reflection portion and the bottom surface is related to a relative refractive index of the beam controller to an exit environment. The beam controller of claim 1, wherein the total reflection portions are uniformly distributed or symmetrically distributed on an outer edge of the light exit surface. The beam controller of claim 1, wherein the light-emitting surface is connected to the total reflection portion at an angle β with the bottom surface, and β is greater than or equal to α. The light beam controller of claim 1, wherein the light-emitting mask has a first region having a slowly varying curvature, and a height of the periphery of the light-emitting mask is higher from the bottom surface; the bottom surface is further provided to face the light source substrate a first detection layer, and the first inspection layer is distributed with a plurality of pattern gaps corresponding to the curvature distribution of the first region; when the human eye is naked to the first region, the pattern gaps are not visible; and the After the first zone is separated from the bottom surface by the height difference, the pattern gaps are seen at the same position. The light beam controller of claim 1, wherein the light-emitting mask has a second region whose curvature changes slowly, and a periphery of the light-emitting mask has a lower height; the bottom surface is further provided with a second detection on the substrate facing the light source. a layer, and the second inspection layer is distributed with a plurality of pattern voids corresponding to the curvature distribution of the second region; when the human eye is naked to view the second region, the pattern gaps are clearly seen; and the distance in the second region is reduced After the height difference of the bottom surface, the pattern gaps are not visible at the same position. The beam controller of claim 1, further comprising: at least one through hole for locking the beam controller on the light source substrate by inserting a screw. The beam controller of claim 1, further comprising: at least one internal thread for introducing a screw from the through hole in the light source substrate to lock the light source substrate on the beam controller.