WO2016004705A1 - 一种led节能灯用光源模块及led节能灯 - Google Patents

一种led节能灯用光源模块及led节能灯 Download PDF

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Publication number
WO2016004705A1
WO2016004705A1 PCT/CN2014/089519 CN2014089519W WO2016004705A1 WO 2016004705 A1 WO2016004705 A1 WO 2016004705A1 CN 2014089519 W CN2014089519 W CN 2014089519W WO 2016004705 A1 WO2016004705 A1 WO 2016004705A1
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Prior art keywords
light
led
source module
saving lamp
light source
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PCT/CN2014/089519
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English (en)
French (fr)
Inventor
刘文东
林建新
李碧祥
卢嘉贤
Original Assignee
广东祥新光电科技有限公司
刘文东
林建新
李碧祥
卢嘉贤
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Priority claimed from CN201410328508.4A external-priority patent/CN104048205B/zh
Priority claimed from CN201410532560.1A external-priority patent/CN104315374A/zh
Application filed by 广东祥新光电科技有限公司, 刘文东, 林建新, 李碧祥, 卢嘉贤 filed Critical 广东祥新光电科技有限公司
Publication of WO2016004705A1 publication Critical patent/WO2016004705A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S2/00—Systems of lighting devices, not provided for in main groups F21S4/00 - F21S10/00 or F21S19/00, e.g. of modular construction
    • 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
    • F21V23/00—Arrangement of electric circuit elements in or on lighting devices
    • 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

Definitions

  • the invention relates to the technical field of semiconductor illumination, in particular to a light source module for LED energy-saving lamps and an LED energy-saving lamp.
  • the traditional energy-saving lamp refers to a lighting device that combines a fluorescent lamp and a ballast into a whole. Its size is similar to that of an incandescent lamp, and the interface with the lamp holder is the same as that of an incandescent lamp, so that the incandescent lamp can be directly replaced.
  • the energy consumption of energy-saving lamps is generally 1/5 to 1/4 of that of ordinary incandescent lamps, which can save a lot of lighting power and cost.
  • the energy-saving lamps are not recyclable, and the mercury contained in the energy-saving lamps, if it is not handled properly, it will pollute the soil and water. Recently, relevant persons from the Ministry of Environmental Protection said that it is proposed to prohibit the production of new, rebuilt and expanded projects using fluorescent lamps using liquid mercury and manual mercury injection.
  • LED is called the fourth generation of illumination source or green light source, which is characterized by energy saving, environmental protection, long life and small size.
  • LED lighting technology In recent years, with the continuous advancement of LED lighting technology, its application in the field of general lighting has become more and more mature. It is an ideal substitute for incandescent lamps and fluorescent energy-saving lamps, replacing traditional fluorescent energy-saving lamps with LED energy-saving lamps. Lights have become a trend.
  • LED lamp beads are mostly single-sided, in order to obtain LED lamps with large angles of light, a common practice is to set up columns with multiple mounting sides, and set LED bead or LED strips on each mounting side.
  • a common practice is to set up columns with multiple mounting sides, and set LED bead or LED strips on each mounting side.
  • LED lamps of this structure can obtain a large angle of light, but must be equipped with a column, the manufacturing process and structure are relatively complicated, and the processing cost is relatively high.
  • there is also a technical means of setting the substrate of the LED light-emitting strip to be transparent, obtaining a large-angle light source, and using a plurality of large-angle light source as a filament as disclosed in CN201944638U.
  • the LED lamp of this structure avoids the use of the mounting post, a plurality of LED strips are connected together, the heat is relatively large, and the post is not installed for heat conduction, and the heat dissipation performance is relatively poor, and the overall life of the lamp is difficult. Guarantee.
  • the filament-shaped LED light-emitting strip is relatively thin, the package is not easy, and the packaging cost is high.
  • an object of the present invention is to provide a light source module for an LED energy-saving lamp which is convenient to manufacture, reliable in connection, and has good heat dissipation effect.
  • Another object of the present invention is to provide an LED energy saving lamp based on the above light source module.
  • the present invention adopts the following technical solutions.
  • a light source module for LED energy-saving lamps comprising: a sealed light-transmitting tube, a wick seat disposed on the light-transmitting tube, an LED light-emitting strip fixed in the light-transmitting tube and the wick seat, and being filled in the light-transmitting tube Heat transfer protection gas; a bottom glass piece is arranged on the wick base; when manufacturing, the LED light strip is first fixed on the wick seat, then the wick seat is mounted on the light transmission tube and sintered, so that the back cover glass piece and the light transmission The opening portion of the tube is sealed and connected, and finally, vacuuming and filling heat transfer protection gas treatment are performed.
  • connection filament is disposed on the wick base, and at least one connection hole is disposed on the electrode of the LED illuminating strip, and the connection filament passes through the connection hole to realize electrical connection between the wick holder and the LED illuminating strip.
  • connection holes extend through both sides of the LED light bar, and a conductive layer connected to the electrodes is provided on the inner surface of the connection hole.
  • a conversion joint is disposed on the wick base, and a socket with a metal dome is disposed on the adapter.
  • the electrode at the end of the LED strip is inserted into the metal dome to form an electrical connection structure.
  • a silver paste layer is provided on the electrode.
  • a positioning bracket is disposed on the LED lighting strip, and the LED light strip is limited by the positioning bracket to be parallel with the light transmitting tube.
  • the LED light bar includes: a light transmissive substrate, an LED chip disposed on a front surface of the transparent substrate, and a phosphor covering the back surface of the LED chip and the transparent substrate; the transparent substrate has a thickness of 0.4 Between -0.6 mm, the width of the light-transmitting substrate is between 4 and 10 mm.
  • the LED light bar includes: a light transmissive substrate, an LED chip disposed on a front surface of the light transmissive substrate, and the phosphor is coated on the light transmissive tube.
  • the light transmission tube is an H-shaped tube or a ⁇ tube.
  • the light-transmissive tube comprises at least two rows of glass tubes, and at least one connecting block is disposed between two adjacent rows of glass tubes, and a hollow tube connecting the two rows of glass tubes is disposed on the connecting block.
  • the diameter of the light-transmitting tube is 9 mm, 12 mm or 17 mm, and the distance between the edge of the LED light-emitting strip and the inner wall of the light-transmitting tube is not more than 7 mm.
  • the heat transfer shielding gas is nitrogen or an inert gas.
  • An LED energy-saving lamp comprising: a lamp holder, a driver and a light source module;
  • the lamp holder is any one of a threaded socket or a cross socket
  • the driver is a discrete device or integrated in a socket
  • the light source module comprises: a sealed light-transmitting tube, a wick seat disposed on the light-transmitting tube, an LED light-emitting strip fixed in the light-transmitting tube and the wick seat, and a heat-transfer shielding gas filled in the light-transmitting tube;
  • the LED light strip is first fixed on the wick seat, then the wick seat is sintered in the opening portion of the light-transmitting tube, and vacuuming and filling heat transfer protection gas treatment is performed; then, according to different product types, the corresponding light is selected.
  • the seat and the required size and number of light source modules can be mounted on the lamp holder to obtain the corresponding product.
  • a back cover glass piece is provided on the wick base, and the back cover glass piece is contracted upwardly in a flared shape.
  • the light source module for energy-saving lamps provided by the present invention has the following beneficial effects:
  • connection structure for punching holes on the LED light strips and attaching the connection filaments to the LED light strips, even if the solder is melted, the electrical connection between the connection filaments and the LED light strips can be ensured; in particular, The molten solder is also filled between the connecting filament and the electrode, and the conductive effect is very convex, thereby fundamentally eliminating the problem of poor conduction.
  • the existing fluorescent lamp technology and equipment can be used for production and processing, which is convenient for the transformation and upgrading of the lighting industry, and has great market benefits.
  • it is convenient to independently select the power and quantity of the modules according to actual needs. It is a brand-new LED lamp assembly method and can realize automatic and large-scale production.
  • the vertical distance between the side of the LED light-emitting strip and the inner wall of the light-transmitting tube is set to be no more than 7 mm, and the heat-transmission protection gas is filled in the light-transmitting tube, the heat dissipation of the LED light-emitting strip is facilitated, and the lamp has a long service life.
  • the LED light strip is inserted into the conversion joint to form a conductive connection, and the connection is convenient, and only the LED light strip is inserted into the plug socket, and the electrode welding is not required as in the conventional manufacturing process.
  • the entire LED light bar is basically parallel with the light-transmitting tube, and the plugging is stable, and the light-emitting and heat-dissipating effects are good.
  • the melting point of the silver paste electrode itself is low, when the light-transmitting tube is subjected to the melt-sealing process, the remaining heat is sufficient for the silver paste to be secondary-cured, and the silver paste is in full contact with the metal dome.
  • FIG. 1 is a schematic structural view of a first embodiment of a light source module provided by the present invention
  • Figure 2 is a schematic view showing the structure of an LED light bar
  • Figure 3 is a schematic view showing the structure of an LED energy-saving lamp
  • FIG. 4 is a schematic structural view of a second embodiment of a light source module provided by the present invention.
  • FIG. 5 is a schematic structural view of a third embodiment of a light source module according to the present invention.
  • FIG. 6 is a schematic structural view of a fourth embodiment of a light source module according to the present invention.
  • a light source module for an LED energy-saving lamp comprises: a sealed light-transmitting tube 1 , a wick holder 2 disposed on the light-transmitting tube 1 , and an LED light fixed in the light-transmitting tube 1 and fixed to the wick holder 2 Strip 3, and a heat transfer shielding gas filled in the light-transmitting tube 1.
  • the light-transmitting tube 1 is a transparent glass tube
  • the wick holder 2 is identical to the conventional fluorescent tube wick seat structure, and comprises a horn-shaped back cover glass and a connecting filament 21 embedded in the back cover glass.
  • a connection hole 4 is provided on the electrode 34 of the LED lighting strip 3, and the connection filament 21 passes through the connection hole 4 to realize an electrical connection between the wick holder 2 and the LED illuminating strip 3.
  • the connecting hole 4 penetrates both sides of the LED light-emitting strip 3, and a conductive layer connected to the electrode 34 is disposed on the inner surface of the connecting hole 4; a silver paste layer is coated on the electrode 34 and the conductive layer.
  • connection hole 4 is respectively formed on the positive electrode and the negative electrode of the LED light-emitting strip 3, and then the connection filament 21 is passed through the connection hole 4, and is wound and bound to the LED light-emitting strip 3 to realize the LED light-emitting strip.
  • the part When the part is sintered, it is affected by the high temperature, and the silver paste is melted and filled between the electrodes connecting the filament 21 and the LED light-emitting strip 3 to realize the close contact between the connecting filament 21 and the LED light-emitting strip; finally, the light-transmitting tube is vacuum-treated and pumped. After the vacuum, the heat transfer shielding gas is filled into the light transmission tube.
  • connection filament 21 is connected to the electrodes of the LED light-emitting strip, it is also subjected to sintering of the wick holder 2 and the light-transmitting tube 1, which is affected by high temperature during sintering, and between the electrode and the connection filament.
  • the solder is easily melted and lost, resulting in poor electrode contact and high rejection rate, which cannot meet the industrial production requirements.
  • the present embodiment ingeniously provides a connection structure for punching a LED light bar and attaching the connection filament to the LED light bar.
  • the connection between the filament and the LED light bar can be ensured.
  • the molten solder is also filled between the connecting filament and the electrode, and the conductive effect is very convex, thereby fundamentally eliminating the problem of poor conduction.
  • the LED light-emitting strip 3 includes a light-transmitting substrate 31, an LED chip 32 disposed on the front surface of the light-transmitting substrate 31, a phosphor 33 covering the LED chip 32 and the back surface of the light-transmitting substrate 31, and an electrode 34.
  • the LED chip 32 is formed by connecting 30 0.1W blue low-power chips in series, and preferably the phosphor 33 is a yellow phosphor, so that not only a single light source module has high power, but also the entire LED illumination can be improved.
  • the LED light bar 3 is a blue light bar, and the phosphor is coated on the inner wall of the light transmitting tube 1, and is not limited to the embodiment.
  • the heat transfer protection gas is a mixture of nitrogen gas and argon gas.
  • the volume ratio of nitrogen gas is 8%, and the volume ratio of argon gas is 92%.
  • the heat transfer protection gas uses a mixture of nitrogen and argon, which has the advantage of both heat dissipation and low manufacturing cost.
  • the heat transfer shielding gas is replaced with a high purity inert gas, and is not limited to the embodiment.
  • the thickness of the transparent substrate 31 is 0.4 mm, and the width of the transparent substrate is 4 mm.
  • the use of the transparent substrate of this size facilitates the arrangement of the LED chip and the coating of the phosphor, and the packaging cost is relatively low.
  • the service life of the LED light-emitting strip 3 is ensured.
  • the vertical distance between the side surface of the LED light-emitting strip 3 and the inner wall of the light-transmitting tube 2 Not more than 7mm.
  • FIG. 3 it is an LED lamp manufactured by the above-mentioned LED lamp module, and includes the lamp holder 5 and the LED lamp module mounted on the lamp holder 5.
  • the socket 5 is a threaded socket integrated with a driver, and two modules for LED lamps are mounted on the socket 5.
  • the lamp holder is replaced by a cross lamp holder, and the driver and the lamp holder are separate devices, and are not limited to the embodiment.
  • a light source module for an LED energy-saving lamp comprises: a sealed light-transmitting tube 1, a wick holder 2 disposed on the light-transmitting tube 1, and an LED light-emitting light fixed in the light-transmitting tube 1 and the wick holder 2 Strip 3, and a heat transfer shielding gas filled in the light-transmitting tube 1.
  • the light source module for an LED energy-saving lamp provided by this embodiment has the same structure as that of the first embodiment, and the difference is:
  • the size of the LED light bar is appropriately adjusted, the thickness of the light-transmitting substrate is adjusted to 0.6 mm, and the width of the light-transmitting substrate is adjusted to 8 mm.
  • the use of such a size of the transparent substrate is mainly to save packaging costs, because the substrate is too small, the packaging accuracy, packaging process requirements are high, and the substrate size is too large, resulting in waste of transparent substrate material, especially for some high quality sapphire This waste is unacceptable for the substrate.
  • the light-transmissive tube comprises two rows of H-shaped glass tubes, and a connecting block 6 is respectively arranged at the top and the bottom of the adjacent light-transmitting tube 1, and each connecting block 6 is provided with an adjacent transparent light-transmitting tube 1 Hollow pipe.
  • the front end of the module for the LED light receives a dark area due to the refraction of the light, which affects the visual effect; in this embodiment,
  • the advantage of using a H-shaped glass tube for the light pipe is to avoid the appearance of dark areas.
  • the H-shaped glass tube is replaced with a ⁇ tube.
  • a light source module for an LED energy-saving lamp comprises: a sealed light-transmitting tube 1, a wick holder 2 disposed on the light-transmitting tube 1, and an LED light-emitting light fixed in the light-transmitting tube 1 and the wick holder 2 Strip 3, and a heat transfer shielding gas filled in the light-transmitting tube 1.
  • the light source module for an LED energy-saving lamp provided by this embodiment has the same structure as that of the first embodiment, and the difference is:
  • the LED strip 3 is provided with a positioning bracket 7 which is limited by the positioning bracket 7 and is equally spaced from the light-transmitting tube 1 to ensure the light efficiency and heat dissipation of the entire lamp.
  • the heat transfer shielding gas is preferably a high concentration helium gas, and the high concentration helium gas refers to a concentration of 100%.
  • a light source module for an LED energy-saving lamp comprises: a sealed light-transmitting tube 1 , a wick holder 2 disposed on the light-transmitting tube 1 , and an LED light fixed in the light-transmitting tube 1 and fixed to the wick holder 2 Strip 3, and a heat transfer shielding gas filled in the light-transmitting tube 1.
  • the light source module for an LED energy-saving lamp provided by the embodiment has the same structure as that of the first embodiment. The difference is that the yoke base 2 is provided with a conversion joint 8 and the conversion joint 8 is provided with a metal elastic piece.
  • the slot is provided with a silver paste electrode at the end of the LED light bar 3; when connected, the silver paste electrode is inserted into the metal dome to form an electrical connection structure.
  • connection method of the silver paste electrode and the adapter is of the following advantages.

Abstract

一种LED节能灯用光源模块，包括：密闭的透光管（1），设置在透光管（1）上的灯芯座（2），位于透光管（1）内与灯芯座（2）固定的LED发光条（3），以及填充在透光管（1）内的传热保护气体；在灯芯座（2）上设有连接灯丝（21），在LED发光条（3）的电极（34）上设有至少一个连接孔（4），连接灯丝（21）穿过连接孔（4）实现灯芯座（2）与LED发光条（3）之间的电连接。制造时，首先在LED发光条（3）的正极和负极上分别开设一个连接孔（4），然后，将连接灯丝（21）穿过连接孔（4），并绕制绑定在LED发光条（3）上，实现LED发光条（3）与灯芯座（2）的连接；接着将LED发光条（3）塞进透光管（1）内，使灯芯座（2）刚好封住透光管（1）的开口部位；最后，将灯芯座（2）烧结在透光管（1）开口部位，烧结时，受高温影响，银浆熔融填充在连接灯丝（21）和LED发光条（3）的电极之间，实现连接灯丝（21）和LED发光条（3）的紧密接触。

Description

一种LED节能灯用光源模块及LED节能灯 技术领域
本发明涉及半导体照明技术领域，尤其涉及一种LED节能灯用光源模块及LED节能灯。
背景技术
随着全球各国日益重视节能，在照明领域，节能灯大规模替代传统光源产品的浪潮已经来临。继全球十几个国家和地区陆续发布白炽灯淘汰计划之后，中国发布了《逐步淘汰白炽灯路线图》。到2016年前，国内将分阶段逐步彻底淘汰白炽灯，进而全面引入年可节电480亿度的节能灯。"十二五"期间，国内将加大推广绿色照明工程的力度，节能灯市场容量将出现数倍的增长，同时市场发展潜力巨大。
传统意义上的节能灯是指将荧光灯与镇流器组合成一个整体的照明设备，其尺寸与白炽灯相近，与灯座的接口也和白炽灯相同，所以可以直接替换白炽灯使用。节能灯的耗能一般是普通白炽灯用电量的1/5至1/4，从而可以节约大量的照明电能和费用。但由于节能灯不可回收，而节能灯中又含有的汞，如果处理不好会对土壤和水造成污染。近日，国家环保部有关人士表示，拟禁止批复使用液态汞和手动注汞的荧光灯生产新建、改建、扩建项目。
LED被称为第四代照明光源或绿色光源，具有节能、环保、寿命长、体积小等特点。近年来，随着LED照明技术的不断进步，其在普通照明领域的应用变得越来越成熟，是一种十分理想的白炽灯和荧光节能灯替代品，用LED节能灯代替传统的荧光节能灯已成一种发展趋势。
由于LED灯珠大都为单面出光，为获得大角度出光的LED灯具，一个常用的做法是：设置具有多个安装侧面的立柱，在每个安装侧面上都设置LED灯珠或LED灯条，如一篇公开号为CN102767709A的中国专利所述。这种结构的LED灯具，虽能获得大角度的出光，但必须配备一个立柱，制造工艺和结构都比较复杂，加工成本相对较高。为获得大角度出光的LED灯具，还有一种技术手段是，将LED发光条的基板设置成透明状，获得大角度出光光源，用多个大角度出光光源充当灯丝，如一篇公开号为CN201944638U的中国专利所述。这种结构的LED灯具，虽避免了安装立柱的使用，但多个LED发光条连在一起，发热量相对较大,而又没有安装立柱来导热，散热性能相对较差,灯具的整体寿命难以保障。同时,灯丝状的LED发光条相对较细，封装不易，封装成本高。
有鉴于此,如何开发设计一种制造成本低，散热效果好,能直接与现有白炽灯、节能灯进行替换的LED灯具有十分重要的意义。
 技术问题
针对现有技术中存在的问题，本发明的一个目的在于提供一种制造方便、连接可靠、散热效果好的LED节能灯用光源模块。
本发明的另一个目的在于提供一种基于上述光源模块的LED节能灯。
 技术解决方案
为达到以上目的，本发明采用如下技术方案。
一种LED节能灯用光源模块，其特征在于，包括：密闭的透光管，设置在透光管上的灯芯座，位于透光管内与灯芯座固定的LED发光条，以及填充在透光管内的传热保护气体；在灯芯座上设有封底玻璃片；制造时，首先将LED发光条固定在灯芯座上，接着将灯芯座安装到透光管上并烧结，使封底玻璃片与透光管开口部位密封连接，最后进行抽真空和填充传热保护气体处理。
作为上述方案的进一步说明，在灯芯座上设有连接灯丝，在LED发光条的电极上设有至少一个连接孔，所述连接灯丝穿过连接孔实现灯芯座与LED发光条之间的电连接。
作为上述方案的进一步说明，所述连接孔贯穿LED发光条的两侧，在连接孔的内表面设有与电极连接的导电层。
作为上述方案的进一步说明，在灯芯座上设有转换接头，在转换接头上设有带金属弹片的插接槽，所述LED发光条端部的电极插接在金属弹片内构成电连接结构。
作为上述方案的进一步说明，在电极上设有银浆层。
作为上述方案的进一步说明，在LED发光条上设有定位支架，所述LED灯条被定位支架限位而与透光管平行。
作为上述方案的进一步说明，所述LED发光条包括：透光基板，设置在透光基板正面的LED芯片，以及覆盖LED芯片和透光基板背面的荧光粉；所述透光基板的厚度在0.4-0.6mm之间，透光基板的宽度在4-10mm之间。
作为上述方案的进一步说明，所述LED发光条包括：透光基板，设置在透光基板正面的LED芯片，所述荧光粉涂布在透光管上。
作为上述方案的进一步说明，所述透光管为H形管或π管。
作为上述方案的进一步说明，所述透光管包括至少两排玻璃管，相邻两排玻璃管之间通过至少一个连接块，在连接块上设有将两排玻璃管连通的中空管道。
作为上述方案的进一步说明，所述透光管的管径为9mm、12mm或17mm，所述LED发光条边缘到透光管内壁的间隔不大于7mm。
作为上述方案的进一步说明，所述传热保护气体为氮气或惰性气体。
一种LED节能灯，其特征在于，包括：灯座，驱动器和光源模块；
所述灯座为螺纹灯座或十字灯座中的任一种；
所述驱动器为分立器件或集成在灯座内；
所述光源模块包括：密闭的透光管,设置在透光管上的灯芯座,位于透光管内与灯芯座固定的LED发光条,以及填充在透光管内的传热保护气体；
实际制备时，首先将LED发光条固定在灯芯座上，接着将灯芯座烧结在透光管开口部位，并进行抽真空和填充传热保护气体处理；然后根据产品类型的不同，选择相应的灯座，并将所需规格和数量的光源模块安装到灯座上即可获得相应产品。
作为上述LED节能灯的进一步说明，在灯芯座上设有封底玻璃片，所述封底玻璃片向上收缩呈喇叭形。
 有益效果
与现有技术相比，本发明提供的一种节能灯用光源模块具有以下有益效果：
一、巧妙设计一种在LED发光条上打孔，将连接灯丝绑接在LED发光条上的连接结构，即使焊料熔融，也能保证连接灯丝与LED发光条之间的电连接；特别地，熔融后的焊料还填充在连接灯丝和电极之间，导电效果十分凸出，从根本上杜绝了导电不良问题。
二、能利用现有的荧光灯工艺和设备进行生产加工,便于实现照明产业的转型升级,极具市场效益。实际制造节能灯时，方便根据实际需求，自主选择模块的功率和数量，是一种全新的LED灯具组装方式，并能实现自动化、规模化生产。
三、由于LED发光条的侧面与透光管内壁之间的垂直距离设置成不大于7mm,且在透光管内填充传热保护气体,便于LED发光条热量的散发,灯具使用寿命长。
四、通过设置转换接头，将LED发光条插接在转换接头上构成导电连接，连接方便，只需将LED灯条对准插接座插入即可，无需像传统制造工艺那样进行电极焊接。且插接后整个LED灯条基本上与透光管呈平行状态，插接稳固，出光、散热效果好。特别地，由于银浆电极本身的熔点较低，在透光管进行熔融封管工艺时，其余热足以让银浆进行二次固化，银浆与金属弹片充分接触。
 附图说明
图1所示为本发明提供的光源模块实施例一的结构示意图；
图2所示为LED发光条结构示意图；
图3所示为LED节能灯结构示意图；
图4所示为本发明提供的光源模块实施例二的结构示意图；
图5所示为本发明提供的光源模块实施例三的结构示意图；
图6所示为本发明提供的光源模块实施例四的结构示意图。
附图标记说明：
1、透光管，2、灯芯座, 3、LED发光条, 4、连接孔, 5、灯座， 6、连接块， 7、定位支架， 8、转换接头；
21、连接灯丝；
31、透光基板， 32、LED芯片， 33、荧光粉， 34、电极。
 本发明的最佳实施方式
为方便本领域普通技术人员更好地理解本发明的实质，下面结合附图对本发明的具体实施方式说明如下。
实施例一
如图1所示，一种LED节能灯用光源模块，包括：密闭的透光管1，设置在透光管1上的灯芯座2，位于透光管1内与灯芯座2固定的LED发光条3，以及填充在透光管1内的传热保护气体。
其中,所述透光管1为透明玻璃管，所述灯芯座2与传统的荧光管灯芯座结构一致，包括喇叭形的封底玻璃和埋在封底玻璃内的连接灯丝21。在LED发光条3的电极34上设有连接孔4，所述连接灯丝21穿过连接孔4实现灯芯座2与LED发光条3之间的电连接。本实施例中，所述连接孔4贯穿LED发光条3的两侧，在连接孔4的内表面设有与电极34连接的导电层；在电极34和导电层上涂布有银浆层。
实际制造时,首先在LED发光条3的正极和负极上分别开设一个连接孔4，然后，将连接灯丝21穿过连接孔4，并绕制绑定在LED发光条3上,实现LED发光条与3灯芯座2的连接；接着将LED发光条3塞进透光管1内,使灯芯座2刚好封住透光管1的开口部位；最后，将灯芯座2烧结在透光管1开口部位，烧结时，受高温影响，银浆熔融填充在连接灯丝21和LED发光条3的电极之间，实现连接灯丝21和LED发光条的紧密接触；最后对透光管进行抽真空处理，抽真空后往透光管内填充传热保护气体。
在LED光源产品的加工制造中,电极与导线之间通常采用焊接的方式,以达到高效、快速、便于产业化的目的。然而,在本实施例中,由于连接灯丝21与LED发光条的电极连接后,还要经历灯芯座2与透光管1的烧结，在烧结时，受高温影响，电极与连接灯丝之间的焊料极易熔融流失，造成电极接触不良，废品率极高，根本满足不了工业化生产需求。为此,本实施例巧妙的提供一种在LED发光条上打孔，将连接灯丝绑接在LED发光条上的这么一种连接结构，即使焊料熔融,也能保证连接灯丝与LED发光条之间的电连接；特别地,熔融后的焊料还填充在连接灯丝和电极之间，导电效果十分凸出，从根本上杜绝了导电不良问题。
如图2所示，所述LED发光条3包括：透光基板31,设置在透光基板31正面的LED芯片32，覆盖LED芯片32和透光基板31背面的荧光粉33，以及电极34。本实施例中,优选LED芯片32由30颗0.1W的蓝光小功率芯片串联而成，优选荧光粉33为黄色荧光粉，这样不仅保证单个光源模块具有较高的功率，而且能提高整个LED发光条3的光效。在其他实施方式中，所述LED发光条3为蓝光灯条，所述荧光粉涂布在透光管1的内壁上，不限于本实施例。
所述传热保护气体为氮气和氩气的混合气，在传热保护气体中,氮气所占体积比为8%,氩气所占体积比为92%。传热保护气体采用氮气和氩气混合气的好处是，兼顾散热的同时有效降低制造成本。在其他实施方式中，所述传热保护气体采用高纯度惰性气体代替，不限于本实施例。
进一步地，为封装方便，所述透光基板31的厚度为0.4mm，透光基板的宽度为4mm。与现有的灯丝形发光源相比，采用该尺寸的透光基板，利于实现LED芯片的排布和荧光粉的涂布，封装成本相对较低。为控制LED发光条3与透光管2之间的热阻，保证LED发光条3的使用寿命，本实施例中，所述LED发光条3的侧面与透光管2内壁之间的垂直距离不大于7mm。
如图3所示，其为利用上述LED灯用模块制得的LED灯具，包括灯座5及安装灯座5上的LED灯用模块。本实施例中，所述灯座5为集成有驱动器的螺纹灯座，在灯座5上安装有两个LED灯用模块。在其他实施方式中，所述灯座采用十字灯座代替，驱动器与灯座互为分立器件，不限于本实施例。
 本发明的实施方式
实施例二
如图4所示，一种LED节能灯用光源模块，包括：密闭的透光管1，设置在透光管1上的灯芯座2，位于透光管1内与灯芯座2固定的LED发光条3，以及填充在透光管1内的传热保护气体。
本实施例提供的一种LED节能灯用光源模块，其结构与实施例一基本一致，区别在于：
一、LED发光条的尺寸进行了适当调整，将透光基板的厚度调整为0.6mm，将透光基板的宽度调整为8mm。采用这种尺寸的透光基板主要是为了节约封装成本，因为基板过小，对封装精度、封装工艺要求较高，而基板尺寸过大造成透光基板材料的浪费，尤其对一些高品质的蓝宝石基板而言，这种浪费是不可接受的。
二、所述透光管包括两排H形玻璃管，在相邻透光管1的顶部和底部分别设有连接块6,在各连接块6上设有将相邻透光管1连通的中空管道。这样,实际制备时,不仅能够一次实现抽真空和充气工艺,而且便于实现各相邻透光管1之间的对流，使整个光源模块均匀散热，避免出现局部灯坏死现象。另外，因为LED灯用模块中只有LED发光条上有光发出，如果采用传统的U形管，LED灯用模块的前端受光的折射作用出现一个暗区，影响视觉效果；本实施例中，透光管采用H形玻璃管的好处是避免暗区的出现。在其他实施方式中，H形玻璃管采用π管代替。
实施例三
如图5所示，一种LED节能灯用光源模块，包括：密闭的透光管1，设置在透光管1上的灯芯座2，位于透光管1内与灯芯座2固定的LED发光条3，以及填充在透光管1内的传热保护气体。
本实施例提供的一种LED节能灯用光源模块，其结构与实施例一基本一致，区别在于：
一、在LED发光条3上设有定位支架7，所述LED发光条被定位支架7限位而与透光管1保持等间距，以保证整个灯具的光效和散热。
二、所述传热保护气体优选为高浓度的氦气，所述高浓度氦气是指浓度为100%。
实施例四
如图6所示，一种LED节能灯用光源模块，包括：密闭的透光管1，设置在透光管1上的灯芯座2，位于透光管1内与灯芯座2固定的LED发光条3，以及填充在透光管1内的传热保护气体。
本实施例提供的一种LED节能灯用光源模块，其结构与实施例一基本一致,区别在于：在灯芯座2上设有转换接头8,在转换接头8上设有带金属弹片的插接槽,在LED发光条3的端部设有银浆电极；连接时，银浆电极插接在金属弹片内构成电连接结构。
这种银浆电极和转换接头插接的连接方式具有以下几个好处，一是连接方便，只需将LED灯条对准插接座插入即可，无需像传统制造工艺那样进行电极焊接。二是LED灯条稳固，插接后整个LED灯条基本上与透光管呈平行状态，出光、散热效果好。三是导电效果好，由于银浆本身的熔点较低，在透光管进行熔融封管工艺时，其余热足以让银浆进行二次固化，银浆与金属弹片充分接触。
以上具体实施方式对本发明的实质进行了详细说明，但并不能以此来对本发明的保护范围进行限制。显而易见地，在本发明实质的启示下，本技术领域普通技术人员还可进行许多改进和修饰，需要注意的是，这些改进和修饰都落在本发明的权利要求保护范围之内。

Claims (14)

  1. 一种LED节能灯用光源模块,其特征在于,包括：密闭的透光管,设置在透光管上的灯芯座,位于透光管内与灯芯座固定的LED发光条,以及填充在透光管内的传热保护气体；在灯芯座上设有封底玻璃片；制造时，首先将LED发光条固定在灯芯座上，接着将灯芯座安装到透光管上并烧结，使封底玻璃片与透光管开口部位密封连接，最后进行抽真空和填充传热保护气体处理。
  2. 根据权利要求1所述的一种LED节能灯用光源模块，其特征在于，在灯芯座上设有连接灯丝,在LED发光条的电极上设有至少一个连接孔,所述连接灯丝穿过连接孔实现灯芯座与LED发光条之间的电连接。
  3. 根据权利要求2所述的一种LED节能灯用光源模块，其特征在于，所述连接孔贯穿LED发光条的两侧，在连接孔的内表面设有与电极连接的导电层。
  4. 根据权利要求1所述的一种LED节能灯用光源模块，其特征在于，在灯芯座上设有转换接头，在转换接头上设有带金属弹片的插接槽，所述LED发光条端部的电极插接在金属弹片内构成电连接结构。
  5. 根据权利要求1、2或4所述的一种LED节能灯用光源模块，其特征在于，在电极上设有银浆层。
  6. 根据权利要求1所述的一种LED节能灯用光源模块，其特征在于，在LED发光条上设有定位支架，所述LED灯条被定位支架限位而与透光管平行。
  7. 根据权利要求1或6所述的一种LED节能灯用光源模块，其特征在于，所述LED发光条包括：透光基板，设置在透光基板正面的LED芯片，以及覆盖LED芯片和透光基板背面的荧光粉；所述透光基板的厚度在0.4-0.6mm之间，透光基板的宽度在4-10mm之间。
  8. 根据权利要求1或6所述的一种LED节能灯用光源模块，其特征在于，所述LED发光条包括：透光基板，设置在透光基板正面的LED芯片，所述荧光粉涂布在透光管上。
  9. 根据权利要求1所述的一种LED节能灯用光源模块，其特征在于，所述透光管为H形管或π管。
  10. 根据权利要求1或9所述的一种LED节能灯用光源模块,其特征在于,所述透光管包括至少两排玻璃管,相邻两排玻璃管之间通过至少一个连接块，在连接块上设有将两排玻璃管连通的中空管道。
  11. 根据权利要求1所述的一种LED节能灯用光源模块，其特征在于，所述透光管的管径为9mm、12mm或17mm，所述LED发光条边缘到透光管内壁的间隔不大于7mm。
  12. 根据权利要求1所述的一种LED节能灯用光源模块，其特征在于，所述传热保护气体为氮气或惰性气体。
  13. 一种LED节能灯,其特征在于,包括：灯座,驱动器和光源模块；
    所述灯座为螺纹灯座或十字灯座中的任一种；
    所述驱动器为分立器件或集成在灯座内；
    所述光源模块包括：密闭的透光管,设置在透光管上的灯芯座,位于透光管内与灯芯座固定的LED发光条,以及填充在透光管内的传热保护气体；
    实际制备时，首先将LED发光条固定在灯芯座上,接着将灯芯座烧结在透光管开口部位,并进行抽真空和填充传热保护气体处理；然后根据产品类型的不同,选择相应的灯座，并将所需规格和数量的光源模块安装到灯座上即可获得相应产品。
  14. 根据权利要求13所述的一种LED节能灯，其特征在于，在灯芯座上设有封底玻璃片，所述封底玻璃片向上收缩呈喇叭形。
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CN104048205A (zh) * 2014-07-10 2014-09-17 佛山市铂利欧照明有限公司 一种led节能灯用光源模块及led节能灯
CN204005350U (zh) * 2014-07-10 2014-12-10 佛山市铂利欧照明有限公司 一种led节能灯用光源模块及led节能灯

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US20180010742A1 (en) * 2015-06-30 2018-01-11 Jianfeng Ke Led energy-saving lamp, manufacturing method thereof and corn lamp
US10429015B2 (en) * 2015-06-30 2019-10-01 Zhejiang Setec Lighting Co., Ltd LED energy-saving lamp, manufacturing method thereof and corn lamp

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