WO2014206165A1 - 一种低光衰大功率led路灯及其制作方法 - Google Patents

一种低光衰大功率led路灯及其制作方法 Download PDF

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Publication number
WO2014206165A1
WO2014206165A1 PCT/CN2014/078442 CN2014078442W WO2014206165A1 WO 2014206165 A1 WO2014206165 A1 WO 2014206165A1 CN 2014078442 W CN2014078442 W CN 2014078442W WO 2014206165 A1 WO2014206165 A1 WO 2014206165A1
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WO
WIPO (PCT)
Prior art keywords
type semiconductor
semiconductor element
semiconductor elements
oxide ceramic
circuit board
Prior art date
Application number
PCT/CN2014/078442
Other languages
English (en)
French (fr)
Inventor
陈志明
顾伟
Original Assignee
苏州伟源新材料科技有限公司
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Filing date
Publication date
Application filed by 苏州伟源新材料科技有限公司 filed Critical 苏州伟源新材料科技有限公司
Priority to EP14816753.9A priority Critical patent/EP3015764B1/en
Priority to AU2014301911A priority patent/AU2014301911B2/en
Priority to JP2016522204A priority patent/JP6151448B2/ja
Priority to DK14816753.9T priority patent/DK3015764T3/en
Publication of WO2014206165A1 publication Critical patent/WO2014206165A1/zh
Priority to US14/998,285 priority patent/US9989238B2/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
    • F21V29/76—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S8/00—Lighting devices intended for fixed installation
    • F21S8/08—Lighting devices intended for fixed installation with a standard
    • F21S8/085—Lighting devices intended for fixed installation with a standard of high-built type, e.g. street light
    • F21S8/086—Lighting devices intended for fixed installation with a standard of high-built type, e.g. street light with lighting device attached sideways of the standard, e.g. for roads and highways
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/51—Cooling arrangements using condensation or evaporation of a fluid, e.g. heat pipes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/54—Cooling arrangements using thermoelectric means, e.g. Peltier elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/71—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks using a combination of separate elements interconnected by heat-conducting means, e.g. with heat pipes or thermally conductive bars between separate heat-sink elements
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N10/00—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects
    • H10N10/01—Manufacture or treatment
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N10/00—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects
    • H10N10/10—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects operating with only the Peltier or Seebeck effects
    • H10N10/17—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects operating with only the Peltier or Seebeck effects characterised by the structure or configuration of the cell or thermocouple forming the device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2131/00—Use or application of lighting devices or systems not provided for in codes F21W2102/00-F21W2121/00
    • F21W2131/10—Outdoor lighting
    • F21W2131/103—Outdoor lighting of streets or roads
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • the invention relates to a low light decay high power LED street lamp and a manufacturing method thereof, and belongs to the technical field of high power LED street lamps.
  • LED light-emitting diodes have been widely used as light sources for illumination because of their advantages of energy saving, high brightness, and small size.
  • the heat dissipation structure of the LED light source in the prior art generally uses a heat sink of an aluminum alloy structure or an aluminum injection part with a weight to dissipate heat.
  • the surface has a simple structure, it has a poor heat dissipation effect and is manufactured.
  • the cost is high, and it can not effectively reduce the temperature of the LED lamp during operation.
  • the use effect is not ideal. It is not suitable for use on high-power LED lamps with a power of 150 watts or more.
  • due to the heat dissipation of the profile aluminum it will be larger.
  • the step temperature often causes the LED light-emitting diode as a light source to work under high temperature conditions.
  • the LED light-emitting diode can even work at a temperature higher than 70 ° C, so that the LED light-emitting diode is prematurely aged. A large amount of light decay occurs, and its luminous efficiency is greatly reduced, which not only increases the energy consumption of the LED light-emitting diode, but also greatly shortens its service life and increases the use cost; and the existing high-power LED street light is For the need of heat dissipation, the heat sink must be made large, so there are problems such as large volume and heavy weight. Therefore, the existing LED street light using LED light-emitting diodes as a light source is not ideally constructed, and the energy-saving advantages of existing LED light sources cannot be fully utilized.
  • the object of the present invention is to provide a low-light-fat high-power LED street lamp with simple structure, small volume, light weight, high luminous efficiency, long service life and low energy consumption, and a manufacturing method thereof, to overcome the prior art. insufficient.
  • the present invention is achieved by: a method for fabricating a low-light-loss high-power LED street lamp according to the present invention, the method comprising: dissipating a circuit board on which an LED bulb is mounted by using an N-type semiconductor element and a P-type semiconductor element as a cooling element; When the N-type semiconductor element and the P-type semiconductor element are used as the cooling element, the semiconductor ingot for forming the N-type semiconductor element or the P-type semiconductor element is previously formed into a cone-shaped ingot having a large diameter and a small diameter at the other end.
  • the cone-shaped semiconductor ingot is then sliced to produce a wafer of the same thickness, each wafer
  • the small diameter end serves as the head end
  • the large diameter end serves as the tail end
  • the color mark number is marked on the tail end surface of each wafer; then the conical surface of each wafer is cut and granulated, and each wafer is cut and granulated.
  • the semiconductor of the polygonal cylinder shape is an N-type semiconductor element or a P-type semiconductor element provided with a head end and a tail end, and then the N-type semiconductor element and the P-type semiconductor element are arranged in a matrix
  • the method is arranged between the upper yttrium oxide ceramic piece and the lower yttria ceramic piece provided with the conductive circuit, so that the N-type semiconductor element and the P-type semiconductor element of each column are connected in series, and the head of the N-type semiconductor element of each column is connected in series.
  • the end is connected to the tail end of the P-type semiconductor element or the tail end of the N-type semiconductor element is connected to the head end of the P-type semiconductor element, and then the lower yttria ceramic piece is pasted through the graphene thermal grease layer to be mounted on the LED bulb
  • a heat sink is mounted on the upper yttrium oxide ceramic piece, and then the circuit board and the heat sink are all installed in the street lamp cover.
  • a low-light-loss high-power LED street lamp of the present invention constructed according to the above method, comprising a street lamp cover and a circuit board mounted with an LED bulb and a DC power supply device, wherein the circuit board is connected to the DC power supply device through a wire, and the circuit board and the DC
  • the power supply device is installed in the street lamp cover, and a transparent cover is arranged at the bottom of the street lamp cover, and at least one piece of lower yttria ceramic piece is connected on the back side of the circuit board through the graphene thermal grease layer, and is disposed on the lower yttria ceramic piece.
  • an N-type semiconductor element and a P-type semiconductor element arranged in a matrix shape are connected between the lower yttria ceramic sheet and the upper yttria ceramic sheet, and are formed on one end surface of the N-type semiconductor element and the P-type semiconductor element
  • a conductive color mark is provided, and the end face provided with the color mark is the tail end of the N-type semiconductor element or the P-type semiconductor element, and the other end of the N-type semiconductor element or the P-type semiconductor element without the color mark is the head end
  • Each of the N-type semiconductor elements and the P-type semiconductor elements respectively pass through the upper conductive sheets disposed on the upper yttrium oxide ceramic sheets
  • the lower conductive sheets disposed on the lower yttria ceramic sheets are connected in series with each other, and the head ends of the N-type semiconductor elements of each column in series are connected to the tail ends of the P-type semiconductor elements or the tail ends of the N-type semiconductor elements of each column and the P-type semiconductor The head ends of the elements are connected
  • the heat sink is composed of a heat-dissipating aluminum base, a heat pipe and a heat sink, and the heat-dissipating aluminum base is pressed against the heat sink.
  • the lower portion of the heat pipe is flat and embedded in the hole at the bottom of the heat dissipation aluminum base, and the flat surface of the lower portion of the heat pipe is attached to the beryllium copper plate block, and the heat sink is connected to the upper portion of the heat pipe.
  • the heat-dissipating aluminum base is fixed to the circuit by a screw to be filled with a heat-conducting liquid in the heat-conducting pipe of the heat sink.
  • a heat dissipation hole is provided on a side surface of the street lamp cover.
  • the present invention performs coloring mark processing on the semiconductor ingot slicing on the basis of the conventional fabrication of the N-type semiconductor element and the P-type semiconductor element, thereby being able to easily recognize the N-type semiconductor.
  • the head end or the trailing end of the element or the P-type semiconductor element, and the head or tail end is arranged in a direction that coincides with the arrangement direction on the ingot when not sliced.
  • the head end and the tail end cannot be distinguished, and the head and the tail are confusedly connected to each other, resulting in a decrease in the working efficiency of the fabricated semiconductor cold reactor galvanic element.
  • the order connection between the head end and the tail end can be conveniently performed, so that the working efficiency of each of the N-type and P-type semiconductor elements can be effectively improved, and Effectively improve the cooling effect of the entire cooling and cooling device.
  • the temperature difference between the cold end and the hot end is about 73 to 78 degrees, and the cooling effect is much better than the existing one.
  • the present invention directly forcibly cools or thermally neutralizes the circuit board of the LED light source through the N-type and P-type semiconductor elements, thereby greatly reducing the temperature during operation of the LED light source circuit board.
  • the LED light-emitting diode bulb on the circuit board on which the LED light bulb is mounted will normally emit light
  • the N-type and The semiconductor cold-stack galvanic component composed of a P-type semiconductor component starts to perform a cooling operation.
  • the semiconductor cold-stack galvanic component operates, the cold end of the semiconductor cold-stack galvanic component cools and cools the LED light source circuit board, and the semiconductor cold reactor
  • the heat from the hot end of the galvanic element is transferred to the heat sink through the heat pipe of the heat sink, which dissipates heat into the air.
  • the 200 watt low light decay high power LED street light of the invention has a weight of less than 5 kilograms, which is about 1/3 of the weight of the conventional same power LED street light, and its volume is about 1/2 of the volume of the conventional same power LED street light.
  • the present invention not only has the advantages of good heat dissipation effect, can greatly reduce the working temperature of the LED light source, and has no light decay, but also has long service life, low use cost, and good work stability. And can improve the working efficiency of LED light-emitting diode bulbs.
  • Figure 1 is a schematic structural view of the present invention
  • FIG. 2 is a cross-sectional view showing the structure of the A-A of the lamp cover and the transparent cover of FIG. DESCRIPTION OF REFERENCE NUMERALS: 1-way lamp housing, 1. 1- vent, 2-circuit board, 3-LED bulb,
  • 4-graphene thermal grease layer 5-transparent cover, 6-N semiconductor component, 7-P semiconductor component, 8-upper yttrium oxide ceramic chip, 9-lower yttrium oxide ceramic chip, 10-upper conductive film, 11-lower conductive sheet, 12-wire, 13-DC power supply unit, 14-inch copper plate clamp, 15-heat sink, 15. 1-heat-dissipating aluminum base, 15. 2-heat pipe, 15. 3-heat sink , 15. 4-heat-conductive liquid, 16-screw. detailed description
  • a method for fabricating a low-light-loss high-power LED street lamp according to the present invention includes using a conventional N-type semiconductor element and a P-type semiconductor element as a cooling element to perform a circuit board on which an LED light-emitting diode bulb is mounted
  • the conventional N-type semiconductor element and P-type semiconductor element are used as the cooling element, the semiconductor ingot for fabricating the N-type semiconductor element or the P-type semiconductor element is previously made into a large-diameter cone having a large diameter and a small diameter at the other end.
  • the shape of the ingot (the diameter of the small diameter end of the cone-shaped ingot can be determined according to the needs of use, the taper can be controlled between 2 and 5 degrees), and then the cone-shaped semiconductor ingot is sliced to obtain
  • the small diameter end of each wafer is used as the head end and the large diameter end is used as the tail end, and the tail end surface of each wafer is colored with a mark number; then the conical surface of each wafer is cut and granulated.
  • Each of the wafers is cut into granules into the same polygonal cylinder shape, and the semiconductor of the polygonal cylinder shape is provided with a head end and a tail end.
  • N-type semiconductor element or a P-type semiconductor element An N-type semiconductor element or a P-type semiconductor element, and then the N-type semiconductor element and the P-type semiconductor element are arranged in a matrix Between the upper yttria ceramic sheet and the lower yttria ceramic sheet provided with a conductive circuit, so that each column
  • FIG. 1 and FIG. 2 are schematic diagrams showing a structure of a low-light-fading high-power LED street lamp according to the present invention.
  • the low-light-fading high-power LED street lamp includes a street lamp cover 1 and a circuit mounted with the LED bulb 3.
  • the board 2 and the DC power supply unit 13, the street lamp cover 1 and the circuit board 2 on which the LED bulb 3 is mounted and the DC power supply unit 13 can be made of the prior art, and the street lamp cover 1 should be made of plastic or metal material.
  • the finished lamp cover shell is connected with the pole bracket, and the circuit board 2 is connected to the DC power supply device 13 through wires in a conventional manner, and the circuit board 2 and the DC power supply device 13 are installed in the street lamp cover 1
  • Connect at least one piece of lower yttria ceramic sheet 9 through the graphene thermal grease layer 4 on the back side of the circuit board 2 (the number of lower yttria ceramic sheets 9 connected to the back surface of the circuit board 2 can be determined according to the area of the circuit board 2 used.
  • the lower yttria ceramic sheet 9 When manufacturing, it is preferable to stick the lower yttria ceramic sheet 9 on the back surface of the circuit board 2, and then to place the yttria ceramic sheet 8 on the lower yttria ceramic sheet 9, while at the same time, the lower yttria ceramic sheet 9 and the upper yttria ceramics sheet
  • the N-type semiconductor element 6 and the P-type semiconductor element 7 which are arranged in a conventional matrix shape arrangement between the terminals 8 are electrically connected to each other on both end faces of the N-type semiconductor element 6 and the P-type semiconductor element 7 during mounting.
  • each column of the N-type semiconductor element 6 and the P-type semiconductor element 7 are respectively passed through the upper conductive sheet 10 provided on the upper yttria ceramic sheet 8 and the lower conductive sheet 11 disposed on the lower yttria ceramic sheet 9.
  • the head ends of the N-type semiconductor elements 6 of each column in series are connected to the tail ends of the P-type semiconductor elements 7 or the tail ends of each of the columns of N-type semiconductor elements 6 are connected to the head ends of the P-type semiconductor elements 7.
  • the power supply device 13 is connected; on each of the upper surfaces of the yttrium oxide ceramic sheets 8, a copper-plate compact 14 having high mechanical strength and heat transfer performance is attached to
  • the heat sink 15 is mounted on the beryllium copper plate block 14; the heat sink 15 is composed of a heat dissipating aluminum base 15.1, a heat pipe 15.2 and a heat sink 15.3 (as shown in FIG. 2 and FIG.
  • the heat dissipating aluminum base 15.1 is pressed against the crucible.
  • the lower portion of the heat pipe 15.2 is formed into a flat shape and embedded in the hole at the bottom of the heat dissipation aluminum base 15.1, and the flat surface of the lower portion of the heat pipe 15.2 is attached to the beryllium copper plate block 14, Then, the heat sink 15.3 is connected to the upper portion of the heat pipe 15.2, and the heat sink 15.3 is placed above the heat dissipation aluminum base 15.1, and then the heat dissipation aluminum base 15.1 is fixed to the circuit board 2 by screws 16 (when connecting Note that the screw 16 and the circuit board 2 are insulated from each other.
  • the heat transfer liquid 15.2 can be filled in the heat pipe 15.2 of the heat sink 15, and when filling the heat transfer liquid 15.4, be careful not to fill
  • the space inside the heat pipe 15.2 should be allowed to have a certain gap space in it, so that the heat transfer liquid 15.4 can flow therein.
  • the heat transfer liquid 15.4 can be ordinary water, distilled water or transformer oil; Cooling effect, the cooling holes can be made on both sides symmetrically 1.1 streetlight housing 1; and finally mounted on the bottom of the housing 1 lights transparent cover 5 Serve.
  • the transparent cover 5 can be made of glass or plexiglass in a conventional manner.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
  • Led Device Packages (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)

Abstract

一种低光衰大功率LED路灯及其制作方法，预先将制作N型半导体元件（6）或P型半导体元件（7）的尾端面上作色标记号；然后将该N型半导体元件（6）和P型半导体元件（7）按矩阵排列的方式排列在设有导电电路的上氧化铍陶瓷片（8）与下氧化铍陶瓷片（9）之间，使每一列串联的N型半导体元件（6）的头端与P型半导体元件（7）的尾端相连接或N型半导体元件（6）的尾端与P型半导体元件（7）的头端相连接，然后将下氧化铍陶瓷片（9）通过石墨烯导热脂层（4）贴合在安装有LED灯泡（3）的电路板（2）的背面上，并且在上氧化铍陶瓷片（8）上安装上散热器（15），然后将电路板（2）连同散热器（15）全部安装在路灯罩壳（1）内即成。

Description

一种低光衰大功率 LED路灯及其制作方法 技术领域
本发明涉及一种低光衰大功率 LED路灯及其制作方法，属于大功率 LED 灯路灯技术领域。
背景技术
目前， 由于 LED 发光二级管作为光源具有节能、 亮度高、 体积小的优 点， 已被广泛地用于作为照明的光源。 但现有技术中的 LED 光源的散热 结构方式普遍采用铝合金结构的散热片或采用效重的注铝件进行散热， 虽 然表面看具有结构简单的特点，但由于其存在着散热效果差、制造成本高、 不能有效地对工作时的 LED 灯进行降温等缺点， 其使用效果很不理想， 很不适用在 150瓦功率以上的大功率 LED灯上使用； 此外， 由于型材铝 散热会产生较大的梯级温度， 常常使作为发光源的 LED 发光二级管在高 温条件下工作， 有时 LED发光二级管甚至会在高于 70°C的温度下工作， 从而使 LED 发光二级管提前老化， 出现大幅度的光衰现象， 其发光效率 大大降低， 这不仅增加了 LED 发光二级管的能耗， 而且还大大缩短了其 使用寿命， 增加了使用成本； 而且现有的大功率 LED 路灯由于散热的需 要， 其散热片必须制作得很大， 因此其还存在着体积大、 重量重等问题。 所以现有的采用 LED发光二级管作为光源的 LED路灯的结构方式还是不 够理想， 还是不能充分发挥现有 LED光源的节能优势。
发明内容
本发明的目的是： 提供一种结构简单、 体积小、 重量轻、 并且发光效率 高、 使用寿命长、 能耗较低的低光衰大功率 LED路灯及其制作方法， 以 克服现有技术的不足。
本发明是这样实现的： 本发明的一种低光衰大功率 LED路灯的制作 方法为，该方法包括采用 N型半导体元件和 P型半导体元件作为制冷元件 对安装有 LED灯泡的电路板进行散热降温， 在采用 N型半导体元件和 P 型半导体元件作为制冷元件时，预先将制作 N型半导体元件或 P型半导体 元件的半导体晶棒制作为一头直径大、 另一头直径小的圆锥体形晶棒， 然 后将该圆锥体形的半导体晶棒进行切片制得厚度相同的晶片， 将每片晶片 的小直径端作为头端、 大直径端作为尾端， 并在每片晶片的尾端面上作色 标记号； 然后对每片晶片的圆锥面进行切割制粒， 将每片晶片都切割制粒 成相同的多边形柱体形状， 该多边形柱体形状的半导体即为设有头端和尾 端的 N型半导体元件或 P型半导体元件， 然后将该 N型半导体元件和 P 型半导体元件按矩阵排列的方式排列在设有导电电路的上氧化铍陶瓷片 与下氧化铍陶瓷片之间，使每一列的 N型半导体元件与 P型半导体元件相 互串联，串联时使每一列的 N型半导体元件的头端与 P型半导体元件的尾 端相连接或 N型半导体元件的尾端与 P型半导体元件的头端相连接，然后 将下氧化铍陶瓷片通过石墨烯导热脂层贴合在安装有 LED灯泡的电路板 的背面上， 并且在上氧化铍陶瓷片上安装上散热器， 然后将电路板连同散 热器全部安装在路灯罩壳内即成。
根据上述方法构建的本发明的一种低光衰大功率 LED路灯， 包括路 灯罩壳和安装有 LED灯泡的电路板及直流电源装置， 电路板通过导线与 直流电源装置连接， 并且电路板和直流电源装置安装在路灯罩壳内， 在路 灯罩壳的底部设有透明罩盖， 在电路板的背面通过石墨烯导热脂层至少连 接有一片下氧化铍陶瓷片， 在下氧化铍陶瓷片上设有上氧化铍陶瓷片， 在 下氧化铍陶瓷片和上氧化铍陶瓷片之间连接有按矩阵形状排列的 N型半 导体元件和 P型半导体元件，在 N型半导体元件和 P型半导体元件的一个 端面上都设有导电的作色标记，该设有作色标记的端面为 N型半导体元件 或 P型半导体元件的尾端， N型半导体元件或 P型半导体元件的没有作色 标记的另一端为头端，每一列的 N型半导体元件与 P型半导体元件分别通 过设置在上氧化铍陶瓷片上的上导电片和设置在下氧化铍陶瓷片上的下 导电片相互串联，并且串联的每一列的 N型半导体元件的头端与 P型半导 体元件的尾端相连接或每一列 N型半导体元件的尾端与 P型半导体元件的 头端相连接，串联在一起的每一列的 N型半导体元件和 P型半导体元件通 过设置在该列两最外端的上导电片上或两最外端的下导电片上的导线与 直流电源装置连接； 在上氧化铍陶瓷片的上表面上贴合有铍铜板压块， 在 铍铜板压块上设有散热器。
上述散热器由散热铝基座、 导热管和散热片组成， 散热铝基座压在铍 铜板压块上， 导热管的下段部分为扁平形状并嵌固在散热铝基座底部的孔 中， 而且导热管下段的扁平面贴合在铍铜板压块上， 散热片连接在导热管 的上段部分并设置在散热铝基座的上方， 散热铝基座通过螺钉固定在电路 在上述散热器的导热管内充有导热液体。
在上述路灯罩壳的侧面设有散热孔。
由于采用了上述技术方案， 本发明在传统的制作 N型半导体元件和 P 型半导体元件的基础上， 在进行半导体晶棒切片时即对其进行着色标记处 理，从而能方便地识别出 N型半导体元件或 P型半导体元件的头端或尾端， 并且该头端或尾端的排列方向与在未切片时的晶棒上的排列方向相一致。 这样，在采用 N型半导体元件和 P型半导体元件构成半导体冷堆电偶元件 时， 就能够非常容易地辨别出尾端与头端， 从而避免了现有技术中在将 N 型和 P型半导体元件连接时， 因无法区分头端与尾端， 而造成的头尾相互 混乱连接、 从而导致所制作的半导体冷堆电偶元件工作效率降低的现象发 生。 采用本发明的 N型或 P型半导体元件在制作制冷器件时， 能够方便地 进行头端与尾端的有序连接，这样即可有效地提高每个 N型与 P型半导体 元件的工作效率， 并有效地提高整个制冷降温器件的制冷效果。 采用本发 明的 N型半导体元件和 P型半导体元件连接构成的半导体冷堆电偶元件在 工作时， 经测试其冷端与热端的温差达 73〜78度左右， 其制冷效果大大 优于现有技术中的半导体制冷器件。此外， 本发明直接通过 N型和 P型半 导体元件对 LED 光源的电路板进行强行降温制冷或进行热中和， 因此能 大大降低 LED 光源电路板工作时的温度。 本发明在工作时， 只需将市电 电源连接在直流电源装置上即可正常工作， 这时安装有 LED 灯泡的电路 板上的 LED发光二级管灯泡将会正常发光， 而由 N型和 P型半导体元件 组成的半导体冷堆电偶元件会开始进行制冷工作， 该半导体冷堆电偶元件 工作时， 半导体冷堆电偶元件的冷端对 LED 光源电路板进行制冷降温， 而半导体冷堆电偶元件的热端所发出的热通过散热器的导热管传递给散 热片， 散热片将热量散发到空气中。 经测试， 当 LED光源的电路板为 200 瓦功率时， 在采用本发明的方式进行冷却散热的情况下， 在连续工作 9000 小时后， 其 LED光源的电路板上的 LED发光二级管的温度不会超过 60 度， 其 LED发光二级管没有出现光衰现象。 本发明的 200瓦的低光衰大 功率 LED路灯的重量不到 5公斤，约为传统相同功率 LED路灯重量的 1/3， 其体积约为传统相同功率 LED路灯体积的 1/2。 因此， 本发明与现有技术 相比， 本发明不仅具有散热效果好、 能大大降低 LED 光源的工作温度、 无光衰的优点， 而且还具有使用寿命长、 使用成本低、 工作稳定性好、 并 能提高 LED发光二极管灯泡的工作效率等优点。
附图说明
图 1为本发明的结构示意图；
图 2为图 1的去掉路灯罩壳和透明罩盖后的 A-A剖视结构示意图。 附图标记说明： 1-路灯罩壳， 1. 1-散热孔， 2-电路板， 3-LED灯泡，
4-石墨烯导热脂层， 5-透明罩盖， 6-N型半导体元件， 7-P型半导体元件， 8-上氧化铍陶瓷片， 9-下氧化铍陶瓷片， 10-上导电片， 11-下导电片， 12- 导线， 13-直流电源装置， 14-铍铜板压块， 15-散热器， 15. 1-散热铝基座， 15. 2-导热管， 15. 3-散热片， 15. 4-导热液体， 16-螺钉。 具体实施方式
下面结合附图和实施例对本发明作进一歩的详细说。
本发明的实施例： 本发明的一种低光衰大功率 LED路灯的制作方法， 包括采用现有的 N型半导体元件和 P型半导体元件作为制冷元件对安装有 LED发光二极管灯泡的电路板进行散热降温， 在采用现有的 N型半导体 元件和 P型半导体元件作为制冷元件时，预先将制作 N型半导体元件或 P 型半导体元件的半导体晶棒制作为一头直径大、 另一头直径小的圆锥体形 晶棒 （该圆锥体形晶棒的小直径端直径的大小可根据使用的需要进行确 定， 其锥度可控制在 2〜5度之间） ， 然后将该圆锥体形的半导体晶棒进 行切片制得厚度相同的晶片， 将每片晶片的小直径端作为头端、 大直径端 作为尾端， 并在每片晶片的尾端面上作色标记号； 然后对每片晶片的圆锥 面进行切割制粒， 将每片晶片都切割制粒成相同的多边形柱体形状， 该多 边形柱体形状的半导体即为设有头端和尾端的 N型半导体元件或 P型半导 体元件，然后将该 N型半导体元件和 P型半导体元件按矩阵排列的方式排 列在设有导电电路的上氧化铍陶瓷片与下氧化铍陶瓷片之间， 使每一列的
N型半导体元件与 P型半导体元件相互串联，串联时使每一列的 N型半导 体元件的头端与 P型半导体元件的尾端相连接或 N型半导体元件的尾端与 P型半导体元件的头端相连接， 然后将下氧化铍陶瓷片通过石墨烯导热脂 层贴合在安装有 LED灯泡的电路板的背面上， 并且在上氧化铍陶瓷片上 安装上散热器， 然后将电路板连同散热器全部安装在路灯罩壳内即成。 根据上述方法构建的本发明的一种低光衰大功率 LED 路灯的结构示意图 如图 1和图 2所示， 该低光衰大功率 LED路灯包括路灯罩壳 1和安装有 LED灯泡 3的电路板 2及直流电源装置 13， 其路灯罩壳 1和安装有 LED 灯泡 3的电路板 2及直流电源装置 13均可采用现有技术中的成品， 其路 灯罩壳 1应采用塑料或金属材料制作的并设有与电杆支架连接尾座的路灯 罩壳成品， 将电路板 2按传统方式通过导线与直流电源装置 13连接， 并 且将电路板 2和直流电源装置 13安装在路灯罩壳 1 内， 在电路板 2的背 面通过石墨烯导热脂层 4至少连接一片下氧化铍陶瓷片 9 (连接在电路板 2背面的下氧化铍陶瓷片 9的数量可根据所使用的电路板 2的面积确定， 制作时， 最好在电路板 2的背面贴满下氧化铍陶瓷片 9 ) ， 然后在下氧化 铍陶瓷片 9上设置上氧化铍陶瓷片 8， 同时在下氧化铍陶瓷片 9与上氧化 铍陶瓷片 8之间连接上按传统的矩阵形状排列方式排列的 N型半导体元件 6和 P型半导体元件 7， 安装时， 应在 N型半导体元件 6和 P型半导体元 件 7的一个端面上都制作出导电的作色标记， 将该设有作色标记的端面作 为 N型半导体元件 6或 P型半导体元件 7的尾端， 将 N型半导体元件 6 或 P型半导体元件 7的没有作色标记的另一端作为头端， 然后将每一列的 N型半导体元件 6与 P型半导体元件 7分别通过设置在上氧化铍陶瓷片 8 上的上导电片 10和设置在下氧化铍陶瓷片 9上的下导电片 11相互串联， 使串联的每一列的 N型半导体元件 6的头端与 P型半导体元件 7的尾端相 连接或使每一列 N型半导体元件 6的尾端与 P型半导体元件 7的头端相连 接，将串联在一起的每一列的 N型半导体元件 6和 P型半导体元件 7通过 设置在该列两最外端的上导电片 10上的导线 12或设置在两最外端的下导 电片 11上的导线 12与直流电源装置 13连接； 在每块上氧化铍陶瓷片 8 的上表面上都贴合一块机械强度较高并具有传热性能的铍铜板压块 14，在 铍铜板压块 14上安装上散热器 15 ; 该散热器 15由散热铝基座 15.1、导热 管 15.2和散热片 15.3组成 （如图和图 2所示） ， 将散热铝基座 15.1压在 铍铜板压块 14上， 将导热管 15.2的下段部分制作成扁平形状并嵌固在散 热铝基座 15.1底部的孔中， 同时使导热管 15.2下段的扁平面贴合在铍铜 板压块 14上， 然后将散热片 15.3连接在导热管 15.2的上段部分上， 并将 散热片 15.3设置在散热铝基座 15.1的上方， 然后将散热铝基座 15.1通过 螺钉 16固定在电路板 2上（连接时要注意使螺钉 16与电路板 2之间相互 绝缘） ·， 为了达到更好的传热和散热效果， 可在散热器 15 的导热管 15.2 内填充导热液体 15.4， 填充导热液体 15.4时， 注意不要填满导热管 15.2 内的空间， 要让其内留有一定的间隙空间， 这样便于导热液体 15.4在其内 流动， 导热液体 15.4可采用普通的水、 蒸馏水或变压器油； 为了达到更好 的散热效果， 可在路灯罩壳 1 的对称的两侧面上制作出散热孔 1.1 ; 最后 在路灯罩壳 1的底部安装上透明罩盖 5即成。透明罩盖 5可按传统的方式 采用玻璃或有机玻璃制作。

Claims

权 利 要 求 书
1、 一种低光衰大功率 LED路灯的制作方法， 包括采用 N型半导体元 件和 P型半导体元件作为制冷元件对安装有 LED灯泡的电路板进行散热 降温， 其特征在于： 在采用 N型半导体元件和 P型半导体元件作为制冷元 件时，预先将制作 N型半导体元件或 P型半导体元件的半导体晶棒制作为 一头直径大、 另一头直径小的圆锥体形晶棒， 然后将该圆锥体形的半导体 晶棒进行切片制得厚度相同的晶片， 将每片晶片的小直径端作为头端、 大 直径端作为尾端， 并在每片晶片的尾端面上作色标记号； 然后对每片晶片 的圆锥面进行切割制粒， 将每片晶片都切割制粒成相同的多边形柱体形 状，该多边形柱体形状的半导体即为设有头端和尾端的 N型半导体元件或 P型半导体元件， 然后将该 N型半导体元件和 P型半导体元件按矩阵排列 的方式排列在设有导电电路的上氧化铍陶瓷片与下氧化铍陶瓷片之间， 使 每一列的 N型半导体元件与 P型半导体元件相互串联，串联时使每一列的 N型半导体元件的头端与 P型半导体元件的尾端相连接或 N型半导体元件 的尾端与 P型半导体元件的头端相连接， 然后将下氧化铍陶瓷片通过石墨 烯导热脂层贴合在安装有 LED灯泡的电路板的背面上， 并且在上氧化铍 陶瓷片上安装上散热器， 然后将电路板连同散热器全部安装在路灯罩壳内 即成。
2、 一种低光衰大功率 LED路灯， 包括路灯罩壳 （1) 和安装有 LED 灯泡 （3) 的电路板 （2) 及直流电源装置 （13) ， 电路板 （2) 通过导线 与直流电源装置 （13) 连接， 并且电路板 （2) 和直流电源装置 （13) 安 装在路灯罩壳 （1) 内， 在路灯罩壳 （1) 的底部设有透明罩盖 （5) ， 其 特征在于： 在电路板 （2) 的背面通过石墨烯导热脂层 （4) 至少连接有一 片下氧化铍陶瓷片 （9) ， 在下氧化铍陶瓷片 （9) 上设有上氧化铍陶瓷片 (8) ， 在下氧化铍陶瓷片 （9) 和上氧化铍陶瓷片 （8) 之间连接有按矩 阵形状排列的 N型半导体元件 （6) 和 P型半导体元件 （7) ， 在 N型半 导体元件 （6) 和 P型半导体元件 （7) 的一个端面上都设有导电的作色标 记， 该设有作色标记的端面为 N型半导体元件（6)或 P型半导体元件（7) 的尾端， N型半导体元件 （6) 或 P型半导体元件 （7) 的没有作色标记的 另一端为头端， 每一列的 N型半导体元件（6) 与 P型半导体元件（7)分 别通过设置在上氧化铍陶瓷片 （8) 上的上导电片 （10) 和设置在下氧化 铍陶瓷片 （9) 上的下导电片 （11) 相互串联， 并且串联的每一列的 N型 半导体元件 （6) 的头端与 P型半导体元件 （7) 的尾端相连接或每一列 N 型半导体元件 （6) 的尾端与 P型半导体元件 （7) 的头端相连接， 串联在 一起的每一列的 N型半导体元件（6)和 P型半导体元件（7)通过设置在 该列两最外端的上导电片 （10) 上或两最外端的下导电片 （11) 上的导线 (12) 与直流电源装置 （13) 连接； 在上氧化铍陶瓷片 （8) 的上表面上 贴合有铍铜板压块 （14) ， 在铍铜板压块 （14) 上设有散热器 （15) 。
3、 根据权利要求 2所述的低光衰大功率 LED路灯， 其特征在于： 散 热器（15) 由散热铝基座 （15.1) 、 导热管（15.2)和散热片 （15.3)组成， 散热铝基座 （15.1) 压在铍铜板压块 （14) 上， 导热管 （15.2) 的下段部 分为扁平形状并嵌固在散热铝基座（15.1)底部的孔中，而且导热管（15.2) 下段的扁平面贴合在铍铜板压块 （14) 上， 散热片 （15.3) 连接在导热管 ( 15.2)的上段部分并设置在散热铝基座（ 15.1 )的上方，散热铝基座（ 15.1 ) 通过螺钉 （16) 固定在电路板 （2) 上。
4、 根据权利要求 3所述的低光衰大功率 LED路灯， 其特征在于： 在 散热器 （15) 的导热管 （15.2) 内充有导热液体 （15.4) 。
5、 根据权利要求 2所述的低光衰大功率 LED路灯， 其特征在于： 在 路灯罩壳 （1) 的侧面设有散热孔 （1.1) 。
PCT/CN2014/078442 2013-06-25 2014-05-26 一种低光衰大功率led路灯及其制作方法 WO2014206165A1 (zh)

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