WO2013131463A1

WO2013131463A1 - Three-dimensional metal-based pcb circuit board assembly structure, corresponding light-emitting lamp and manufacturing method

Info

Publication number: WO2013131463A1
Application number: PCT/CN2013/072156
Authority: WO
Inventors: 蔡子丰
Original assignee: Cai Zifeng
Priority date: 2012-03-05
Filing date: 2013-03-04
Publication date: 2013-09-12
Also published as: CN102595788B; CN102595788A

Abstract

A three-dimensional metal-based PCB circuit board assembly structure in a light-emitting lamp, a light-emitting lamp having the assembly structure, and manufacturing method thereof, the three-dimensional metal-based PCB circuit board assembly structure consisting of a single continuous metal-based circuit board (1) and a plurality of light-emitting elements (2) disposed on the upper surface of the metal-based circuit board (1); each of the light-emitting elements (2) is connected to the metal-based circuit board (1) via a circuit; the parts on the metal-based circuit board(1) having the light-emitting elements (2) are not on the same plane or curved surface; and the metal-based circuit board (1) has a three-dimensional solid structure. The three-dimensional metal-based PCB circuit board assembly structure, the corresponding light-emitting lamp and the manufacturing method, have a large heat conduction contact surface, a simple and practical single modularized assembly structure, a simplified process, simple and quick processing, large scale mechanical production, low cost, high circuit reliability, stable and reliable performance, firmness and durability, thus improving mounting stability and mechanical strength of the circuit board assembly, being unlikely to deform, and having a wide range of application.

Description

Three-dimensional metal-based PCB circuit board assembly structure, corresponding illuminating luminaire and manufacturing method thereof

The invention relates to the field of illuminating illumination, in particular to the field of illuminating lighting equipment and structure technology, and in particular to a three-dimensional metal-based PCB circuit board assembly structure, a corresponding illuminating luminaire and a manufacturing method thereof. Background technique

With the continuous advancement of human civilization and the continuous development of science and technology, lighting devices have long been widely known. In general, such lighting devices include a housing and a lighting component disposed within the housing.

With the advancement of technology, LEDs have been able to provide enough light energy for lighting purposes. In order to reduce the energy consumption of lighting and reduce carbon dioxide emissions, in order to promote the continuous advancement of the alternative light source market, replacing incandescent and halogen lamps with LED light sources has been It is the trend of the times that consumers need products that can achieve the light output of incandescent or halogen lamps, have lower energy consumption and longer service life, and are cheaper. Although many different LED products are already on the market, most of them are too expensive for the average consumer, and the initiatives and original intentions of reducing energy consumption have not achieved the desired results.

However, LEDs need to work within a certain temperature range in order to have reasonable performance and service life. Due to the compact structure, especially the illuminating device is received in the housing, the following disadvantages exist:

The illuminating equipment itself consumes electric energy, and the efficiency of electro-optical conversion is not 100%. Some of the heat is always generated. Since the inside of the casing is mostly sealed, heat cannot be released in time.

Therefore, the heat dissipation problem of the entire lamp has always been a technical bottleneck. In the prior art, in order to obtain better heat conduction and heat dissipation effects, many LED lamps use a metal base as a substrate for a PCB circuit board, and for many light sources. For luminaire products, LEDs are usually mounted on metal-based PCB (MC-PCB) boards by automated surface mount equipment. Therefore, in the surface mount process, metal-based PCB boards must be the same. A flat (flat), which is why most of the LED luminaires in the prior art must be attached to the surface of a flat PCB board, or a complex method is required to flatten multiple independent flats. The PCB boards are assembled together into a three-dimensional structure to achieve multi-directional or omnidirectional illumination.

Meanwhile, in the prior art, there is a technical solution for using a flexible bendable PCB circuit board in an LED lighting fixture, so that although the characteristics of illumination in multiple directions can be achieved, since the flexible PCB circuit board is mostly flexible and Resilience, but lacks the necessary rigidity and strength, must be given the necessary constraints after bending, so it can not achieve complex free-form shape, and can not provide greater thermal load capacity, which greatly limits the design of illuminating lamps And manufacturing, can not achieve low-cost all-round lighting. Summary of the invention

The object of the present invention is to overcome the above-mentioned shortcomings in the prior art, and to provide a multi-directional illumination on a single metal-based PCB circuit board, effectively increase the heat transfer area, and the structure is simple and convenient to process, and is convenient and quick to process. Large-scale mechanized production, low cost, stable and reliable performance, wide application range of three-dimensional metal-based PCB circuit board assembly structure, corresponding lighting fixtures and manufacturing methods.

In order to achieve the above object, the three-dimensional metal-based PCB circuit board assembly structure, the corresponding illuminating luminaire and the manufacturing method of the present invention are as follows:

The main feature of the three-dimensional metal-based PCB circuit board assembly structure in the illuminating lamp is that the component structure is composed of a single continuous metal-based circuit board and a plurality of illuminating elements disposed on the surface of the metal-based circuit board. Each of the light-emitting elements is electrically connected to the metal-based circuit board, and the portions of the metal-based circuit board having the light-emitting elements are not on the same plane or the same continuous curved surface, and the metal-based circuit board has a three-dimensional shape structure.

The metal-based circuit board in the three-dimensional metal-based PCB circuit board assembly structure of the light-emitting fixture includes:

a metal-based circuit master block, wherein each part having the light-emitting element is on the same plane or the same continuous curved surface; or each part having the light-emitting element is not in the same plane or the same continuous curved surface;

a metal-based circuit sub-block integrally formed with the metal-based circuit master block, and each part of the metal-based circuit sub-block having the light-emitting element is on the same plane or the same continuous curved surface; or the metal-based circuit The portions of the panel having the illuminating elements are not in the same plane or on the same continuous curved surface;

At the same time, the respective portions of the metal-based circuit sub-block having the light-emitting elements are not in the same plane or the same continuous curved surface as the respective portions of the metal-based circuit master block having the light-emitting elements.

The metal-based circuit board in the three-dimensional metal-based PCB circuit board assembly structure of the light-emitting fixture is a three-dimensional structure formed by one or more continuous planes or curved surfaces.

The projection area of the metal-based circuit board in the three-dimensional metal-based PCB circuit board assembly structure of the light-emitting fixture in the mounting direction of the heat sink attached to the lower surface of the metal-based circuit board is smaller than the metal-based circuit board and the heat sink Contact area.

The shape of the three-dimensional structure of the metal-based circuit board in the three-dimensional metal-based PCB circuit board assembly structure in the light-emitting fixture matches the shape of the heat sink to which the lower surface of the metal-based circuit board is attached.

The metal-based circuit board in the three-dimensional metal-based PCB circuit board assembly structure of the light-emitting lamp has a three-dimensional structure of a regular polyhedron, an irregular polyhedron, a concave body, a convex body, a conical body, a composite conical body, and a square cone. , compound square cone, polygonal cone, composite polygonal cone, free plane, symmetrically bent structure, asymmetrically bent structure or a combination of the above various structures. The free facet in the three-dimensional metal-based PCB circuit board assembly structure of the illuminating luminaire is a non-uniform rational B-spline NURBS facet.

The light-emitting element in the three-dimensional metal-based PCB circuit board assembly structure of the light-emitting fixture is a light-emitting diode LED. The light-emitting component in the three-dimensional metal-based PCB circuit board assembly structure of the light-emitting fixture is a patch LED, and the patch LED is attached to the surface of the metal-based circuit board.

Each of the patch LEDs in the three-dimensional metal-based PCB circuit board assembly structure of the illuminating lamp is evenly distributed on the surface of the metal-based circuit board.

The main feature of the illuminating lamp having the above-mentioned component structure is that the illuminating lamp further comprises a heat sink body, and the heat sink body is fixedly provided with one or more metal-based PCB circuit boards. The component structure, the metal-based circuit board in the metal-based PCB circuit board assembly structure is electrically connected to the main body phase, and the metal-based PCB circuit board is matched with the surface of the heat sink main body.

In the above method for manufacturing a three-dimensional metal-based PCB circuit board assembly structure, the main feature is that the method comprises the following steps:

(1) manufacturing a pre-formed planar metal-based PCB circuit board according to the designed shape;

(2) forming a heat conductive layer on the surface of the planar metal-based PCB circuit board and attaching the light-emitting element to obtain a planar metal-based PCB circuit board assembly;

(3) positioning the planar metal-based PCB circuit board assembly on the heat sink;

(4) deforming the planar metal-based PCB circuit board assembly to form a metal-based PCB circuit board assembly having a three-dimensional structure structure wheel gallery matched with the contact surface of the heat sink.

The method for manufacturing a three-dimensional metal-based PCB circuit board assembly structure in the illuminating lamp performs heat conduction layer formation and illuminating element coating processing on the surface of the planar metal-based PCB circuit board, and includes the following steps:

(21) coating or sandwiching a thermal adhesive layer on a lower surface of the planar metal-based PCB circuit board in contact with the heat sink;

(22) A light-emitting element is attached to the upper surface of the planar metal-based PCB circuit board, and circuit soldering is performed.

The circuit soldering process in the manufacturing method of the three-dimensional metal-based PCB circuit board assembly structure in the illuminating lamp is a planar reflow soldering process.

The manufacturing method of the metal-based PCB circuit board assembly structure in the illuminating lamp further comprises the following steps:

(5) mechanically fixing the metal-based PCB circuit board assembly such that a lower surface of the metal-based PCB circuit board assembly is in close contact with a surface of the heat sink.

The three-dimensional metal-based PCB circuit board assembly structure, the corresponding illuminating luminaire and the manufacturing method thereof are used. Since a single metal-based circuit board is used, the illuminating diode is first attached to the flat pre-prepared by conventional techniques. Molding On the metal-based circuit board, the metal-based circuit board is molded into a desired three-dimensional structure by a suitable deformation process, thereby realizing multi-directional illumination using only a single metal-based PCB circuit board. Provides a larger surface area over the limited projected area of the same heatsink, enabling LED surface mount on a larger PCB area, larger thermal conduction contact surfaces, and a single module assembly for structural simplicity, automated SMT process No one is processing error, the process is completed, the processing is convenient and fast, it is convenient for mass mechanized production, low cost, and can form various complicated three-dimensional structural shapes, such as convex, concave, spherical, irregular shape. Various complex shapes, non-linear overlap, high circuit reliability, small temperature difference between LEDs at various positions, stable and reliable performance, ruggedness, improved assembly stability and mechanical strength of circuit board components , not easy to deform, a wide range of applications, bringing affordable energy-saving lighting to people Decision program. DRAWINGS

1 is a schematic view showing the structure of a metal-based PCB circuit board assembly in the illuminating lamp of the present invention.

2 to 4 are schematic views showing the manufacturing process of the metal-based PCB circuit board assembly structure in the illuminating lamp of the present invention. 5 to 8 are schematic views showing various three-dimensional structures of the metal-based circuit board of the present invention. detailed description

In order to more clearly understand the technical content of the present invention, the following embodiments are specifically described.

Referring to FIG. 1 , a three-dimensional metal-based PCB circuit board assembly structure in the light-emitting fixture, wherein the component structure comprises a single continuous metal-based circuit board 1 and a number disposed on an upper surface of the metal-based circuit board 1 Each of the light-emitting elements 2 is electrically connected to the metal-based circuit board 1 , and the metal-based circuit board 1 has the light-emitting elements 2 not in the same plane or on the same continuous curved surface. And the metal base circuit board 1 has a three-dimensional structure.

Wherein, the metal base circuit board comprises:

(1) a metal-based circuit master block 11 in which the respective portions having the light-emitting elements 2 may be on the same plane or the same continuous curved surface; or the respective portions having the light-emitting elements are not on the same plane or the same continuous curved surface;

(2) a metal-based circuit sub-block 12 integrally formed with the metal-based circuit master block 11, and the portions of the metal-based circuit sub-block 12 having the light-emitting elements 2 may be in the same plane or the same continuous curved surface. Or the respective portions of the metal-based circuit sub-block having the light-emitting elements are not on the same plane or the same continuous curved surface; and at the same time, the respective portions of the metal-based circuit sub-block having the light-emitting elements and the metal-based circuit The portions of the master block having the light-emitting elements are not on the same plane or on the same continuous curved surface.

The metal-based circuit board is a three-dimensional structure formed by one or more continuous planes or curved surfaces, the metal The projection area of the base board in the mounting direction of the heat sink attached to the lower surface of the metal base circuit board is smaller than the contact area of the metal base circuit board and the heat sink, that is, the metal base circuit board is in the mounting direction. Any projection size is smaller than the projection size of the planar metal-based circuit board before forming, and the shape of the three-dimensional structure of the metal-based circuit board is matched with the heat sink 3 of the lower surface of the metal-based circuit board. The shapes match.

Wherein, the three-dimensional structure of the metal-based circuit board may be a regular polyhedron, an irregular polyhedron, a concave body, a convex body, a conical body, a composite conical body, a square cone, a compound square cone, a polygonal cone, A composite polygonal cone, a free plane, a symmetrically bent structure, an asymmetrically bent structure or a combination of the above plurality of structures, wherein the free face is a non-uniform rational B-spline NURBS facet.

As a metal-based PCB circuit board assembly structure in the illuminating lamp of the present invention, it has an "S"-shaped undulating line shape which cannot be formed by splicing a plurality of flat PCB boards.

Through the above technical solution, the three-dimensional structure that can be realized by the metal-based circuit board 1 in the metal-based PCB circuit board assembly structure of the light-emitting lamp comprises a linear overlapping structure, a nonlinear overlapping structure, a symmetric bending structure, An asymmetrically bent structure, an irregularly bent structure, or a combination of the above various structures.

At the same time, in the metal-based PCB circuit board assembly structure of the light-emitting lamp, the light-emitting element 2 is generally a light-emitting diode LED, and the light-emitting diode LED is used in order to increase the integration degree of the light-emitting lamp as much as possible, reduce the volume and be easy to install. For the chip light emitting diode LED, the chip light emitting diode LED is attached to the surface of the metal base circuit board.

In order to make the illumination of the illuminating lamp in all directions, the respective splicing LEDs can be evenly distributed on the surface of the metal-based circuit board.

According to another aspect of the present invention, the illuminating lamp having the above-mentioned component structure, wherein the illuminating lamp further includes a heat sink body, and the heat sink body is fixedly provided with one or more of the above-mentioned a metal-based PCB circuit board assembly structure, wherein the metal-based circuit board in the metal-based PCB circuit board assembly structure is electrically connected to the heat sink body, and the metal-based PCB circuit board is matched with the surface of the heat sink body Hehe.

Wherein, the main body of the illuminating lamp is further provided with a transparent casing or a translucent casing, and the transparent casing or the semi-transparent casing surrounds the metal-based PCB circuit board assembly structure.

Referring to FIG. 2 to FIG. 4, the manufacturing method of the three-dimensional metal-based PCB circuit board assembly structure in the above-mentioned illuminating lamp comprises the following steps:

(1) manufacturing a pre-formed planar metal-based PCB circuit board 1 according to the designed shape;

(2) Conducting a heat conductive layer formation and a light emitting element attaching process on the surface of the planar metal-based PCB circuit board 1 to obtain a planar metal-based PCB circuit board assembly, comprising the following steps:

(a) coating or sandwiching the thermal conductive adhesive on the lower surface of the planar metal-based PCB circuit board 1 in contact with the heat sink 3 Floor;

(b) attaching a light-emitting element to the upper surface of the planar metal-based PCB circuit board 1 and performing circuit soldering; the circuit soldering process is a planar reflow soldering process;

(3) positioning the planar metal-based PCB circuit board assembly on the heat sink 3;

(4) deforming the planar metal-based PCB circuit board assembly to form a metal-based PCB circuit board assembly having a three-dimensional structure structure corridor matched with the contact surface of the heat sink 3;

(5) mechanically fixing the metal-based PCB circuit board so that the lower surface of the metal-based PCB circuit board is in close contact with the surface of the heat sink 3.

Other various three-dimensional three-dimensional structure wheel corridors that can be formed by this method are shown in Figs. 5 to 8.

In practical use, the PCB circuit board of the present invention may be a single layer or a plurality of layers, and at the same time, there is no limitation on the wiring of the circuit, and the dent and the elongated through hole may be provided at the deformed bending connection portion of the circuit board. Thus, it is advantageous to produce a high degree of deformation.

The present invention enables a three-dimensional configuration using only a single metal-based PCB circuit board, thereby enabling multi-directional illumination without any additional optical aids. Moreover, the corresponding metal-based PCB circuit board is sufficient as a key element of multi-directional illumination. In the assembly process, no additional assembly process is required, and only the light-emitting lamp is installed and then locked.

As a more complicated lighting environment requirement, two or more metal-based PCB circuit board assembly structures of the present invention can also be assembled and assembled to further meet the requirements of multi-directional illumination. The three-dimensional structure formed by each metal PCB circuit board may be a linear overlap, a nonlinear overlap, a symmetric bend structure, an asymmetric bend structure, a complicated irregular random fold type or a combination of the above forms, and the specific examples are as follows :

>Regular polyhedron, irregular polyhedron

> concave, convex

>symmetric, asymmetric

>Axisymmetric, non-axisymmetric

Conical, compound conical

>Free face, for example: Non-uniform rational B-spline (NURBS, Non Uniform Rational B-Spline) surface

>All of the above composite forms

The manufacturing process of the metal PCB circuit board assembly structure of the present invention is as follows:

(1) First, a preformed metal-based PCB circuit board is manufactured according to the designed shape;

(2) then performing LED coating on the surface of the metal-based PCB circuit board according to a preset process; (3) Three-dimensional forming of the metal-based PCB circuit board by a suitable process to obtain a predetermined three-dimensional structure, such a process does not affect the insulation, circuit traces and circuit elements of the metal-based PCB circuit board. Device.

The above process has no special requirements for the material of the metal-based PCB circuit board, and the known bending method for the metal-based PCB circuit board can be applied to the deformation bending process in the step (3). As well as various new processes that may be used in the future due to technical improvements, the specific process for how to bend the metal-based PCB circuit board is not necessarily described in detail in the present invention.

The above three-dimensional metal-based PCB circuit board assembly structure, corresponding illuminating luminaire and manufacturing method are used. Since a single metal-based circuit board is used, the illuminating diode is first attached to a flat preform by conventional techniques. The metal-based circuit board, and then using a suitable deformation process to form the metal-based circuit board into a desired three-dimensional structure, thereby achieving multi-directional illumination using only a single metal-based PCB circuit board, not only in The same heat sink provides a larger surface area on the limited projected area, enabling LED surface mount on a larger PCB area, larger thermal conduction contact surfaces, and a single module assembly for a single-use, automated SMT process. No one is processing error, the process is finished, the processing is convenient and fast, it is convenient for mass mechanized production, low cost, and can form various complicated three-dimensional structural shapes, such as convex, concave, spherical, irregular shape. , nonlinear overlap, and other complex shapes, circuit reliability High, the temperature difference between the LEDs in each position is small, the performance is stable and reliable, the sturdy and durable, the assembly stability and mechanical strength of the circuit board assembly are improved, the deformation is not easy, and the application range is wide, which brings benefits and energy saving to people. Lighting solutions.

In this specification, the invention has been described with reference to specific embodiments thereof. However, it will be apparent that various modifications and changes can be made without departing from the spirit and scope of the invention. Accordingly, the specification and figures are to be regarded as illustrative and not limiting.

Claims

Rights request

A three-dimensional metal-based PCB circuit board assembly structure in an illuminating lamp, characterized in that: the component structure is composed of a single continuous metal-based circuit board and a plurality of light-emitting elements disposed on a surface of the metal-based circuit board Each of the light-emitting elements is electrically connected to the metal-based circuit board, and the portions of the metal-based circuit board having the light-emitting elements are not on the same plane or the same continuous curved surface, and the metal-based circuit board has three-dimensional Three-dimensional structure.

2. The three-dimensional metal-based PCB circuit board assembly structure of the illuminating lamp of claim 1, wherein the metal-based circuit board comprises:

3. The three-dimensional metal-based PCB circuit board assembly structure in an illuminating lamp according to claim 1, wherein the metal-based circuit board is a three-dimensional structure formed by one or more continuous planes or curved surfaces. .

The three-dimensional metal-based PCB circuit board assembly structure of the light-emitting lamp according to claim 1, wherein the metal-based circuit board is attached to the heat sink of the lower surface of the metal-based circuit board. The projected area of the mounting direction is smaller than the contact area of the metal base circuit board and the heat sink.

The three-dimensional metal-based PCB circuit board assembly structure of the light-emitting lamp according to claim 1, wherein the shape of the three-dimensional structure of the metal-based circuit board and the lower surface of the metal-based circuit board are The fitted heat sinks are shaped to match.

The three-dimensional metal-based PCB circuit board assembly structure according to any one of claims 1 to 5, wherein the metal-based circuit board has a three-dimensional structure of a regular polyhedron, Regular polyhedron, concave body, convex body, conical body, composite cone, square cone, compound square cone, polygonal cone, composite polygonal cone, free plane, symmetrically bent structure, asymmetrically bent structure or A combination of the above various structures.

The three-dimensional metal-based PCB circuit board assembly structure of the illuminating lamp according to claim 6, wherein the free face body is a non-uniform rational Β spline NURBS face body.

The three-dimensional metal-based PCB circuit board assembly structure in the light-emitting fixture according to any one of claims 1 to 5, The light emitting element is a light emitting diode LED.

The three-dimensional metal-based PCB circuit board assembly structure of the illuminating lamp according to claim 8, wherein the illuminating element is a chip light emitting diode LED, and the splicing light emitting diode LED is attached to the The surface of the metal-based circuit board.

The three-dimensional metal-based PCB circuit board assembly structure of the illuminating lamp according to claim 8, wherein each of the patch LEDs is uniformly distributed on a surface of the metal-based circuit board.

11. The illuminating luminaire having the component structure of claim 1, wherein the illuminating luminaire further comprises a heat sink body, wherein the heat sink body is fixedly disposed with one or more of the a metal-based PCB circuit board assembly structure, the metal-based circuit board in the metal-based PCB circuit board assembly structure is electrically connected to the heat sink body, and the metal-based PCB circuit board is matched with the surface of the heat sink body Hehe.

12. A method of fabricating a three-dimensional metal-based PCB circuit board assembly structure in a light-emitting fixture according to claim 1, wherein the method comprises the steps of:

The method of manufacturing a three-dimensional metal-based PCB circuit board assembly structure according to claim 12, wherein the surface of the planar metal-based PCB circuit board is formed by a heat conductive layer and the light-emitting element is pasted. Processing, including the following steps:

14. A method of fabricating a three-dimensional metal-based PCB circuit board assembly structure in a light-emitting fixture according to claim 13, wherein said circuit soldering process is a planar reflow soldering process.

The method of manufacturing a three-dimensional metal-based PCB circuit board assembly structure according to claim 12, wherein the method further comprises the following steps:

(5) mechanically fixing the metal-based PCB circuit board assembly such that the lower surface of the metal-based PCB circuit board assembly is in close contact with the surface of the heat sink.