CN100594327C - 大功率led电-光学器件组件 - Google Patents

大功率led电-光学器件组件 Download PDF

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CN100594327C
CN100594327C CN200580024181A CN200580024181A CN100594327C CN 100594327 C CN100594327 C CN 100594327C CN 200580024181 A CN200580024181 A CN 200580024181A CN 200580024181 A CN200580024181 A CN 200580024181A CN 100594327 C CN100594327 C CN 100594327C
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assembly
led
electrically
reflector
conductive
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CN101031751A (zh
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罗纳德·E·贝雷克
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Duotakeou Co ltd
Hailey Skon LLC
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Henkel Corp
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Abstract

本发明涉及一种大功率的LED电-光学器件组件(40)，包括导电散热器(18)和安装在散热器一端的LED(14)。LED(14)和散热器(18)电接合。组件(40)还包括安装在散热器的另一端的反射器(2)。在反射器和散热器之间提供绝缘的连接材料(19)。组件(40)还包括导电的连接销(15)，其通过反射器延伸，并与反射器导电接合，以及电接合部分(16)，用于使销(15)和LED(14)电接合。最后，对LED电-光学器件组件施加电套筒组件(30)，其中该套筒(32)涂覆有电绝缘涂层(34)。

Description

大功率LED电-光学器件组件
技术领域
本发明涉及发光二极管(LED)技术，尤其涉及LED组件的改进，以为各种照明应用提供所需的光输出。
背景技术
LED组件是熟知的，并且是可以在市场上得到的。这种组件被用于各种应用，一般用于产生紫外光辐射，例如用于进行光启动的粘合剂和涂覆合成物的固化。
在LED组件的制造中有若干个因素起作用。一个因素是施加于LED的大电流的控制，以提供稳定且可靠的UV源。另一个因素是用于保持输出光学器件在所需的位置的透镜的位置。此外，需要一种提供导电路径的装置以对LED的控制供电。当LED的电流增加时，需要大的电流，因此需要高可靠性的电接触。此外，通常需要用于形成来自LED光线的反射器。另外，需要冷却系统用于从组件带走热量。目前可得到的LED组件不能充分地满足所有这些要求。
当前，制造厂家正在提供各种形式的宽范围的LED封装。这些封装的范围从常规的LED灯到使用各种尺寸的发射器芯片的LED。虽然许多已知的LED组件产生高的光输出，但是它们产生非常分散的宽角度光束，这种光束难于捕获以在实际应用中被有效地准直和进行光束成像，例如在闪光灯中那样。结果，由于LED封装的侧部的泄露，损失了大量的输出能量。
此外，从LED组件发出的光通常是不均匀分布的。发光芯片的形状作为一个高密度区域被投影到目标上。来自不可预测的光的图案的从电极和壁的反射被叠加到主光束上。结果，在被照明的对象上出现不希望的热斑点和阴影。因而，对于在预定区域上要求光的分布基本上均匀的任何照明应用，必须使用透射或局部散射器，以分散从每个单个的LED组件发出的光，使得热斑点和阴影不出现在被照明的对象上。不过，虽然散射器将消除热斑点和阴影，但重要的是，从单个的LED组件发出的光束的“方向性”或几何形状不被变劣或变小。
为了克服已知光源的上述缺点，需要提供一种LED固化灯组件，其具有柔性的结构，容易制造并能够降低组件的成本。
发明内容
在本发明的一个实施例中，披露了一种LED电-光学器件电套筒组件，具有涂覆有电绝缘的基本上圆柱形的套筒。该组件被分成上部和下部，所述上部和下部由绝缘材料分开。至少一个LED和导电反射器被安装在上部，其中反射器包围着LED。导电的散热器被安装在下部，并和LED呈电接合。此外，导电的连接销通过导电的反射器延伸并和其呈导电接合。电接合部分使连接销和LED电接合，其中散热器和反射器形成用于向所述LED供电的导电位置。所述散热器可以是热管。
附图说明
图1是本发明的LED光线形成接触组件的示意图；
图2是使用图1的光线形成接触组件的LED光学变换组件的示意图；
图3是本发明的电套筒组件的示意图；以及
图4是本发明的LED电-光学器件组件的示意图。
具体实施方式
参见本发明的图1，其中示出了LED光线形成接触组件10的示意图。组件10是一种紧凑的装置，用于提供使LED同时和电接触部分接触，并形成来自LED的光线的方式，如下所述。接触组件10被分成两个接触部分(即电极)，上电极10a和下电极10b，二者都用金属制成。上电极10a包括优选地由铝制成的金属反射器12。金属反射器12被按压装配到电极10a内而形成导体反射器组件。金属反射器12可以被制成弯曲的形状，并用于基本上准直和引导LED光朝向透镜，这将在下面详细说明。在优选实施例中，反射器12被制成椭圆的形状。LED芯片14被安装在电极10a内，最好位于中心，并局部地或全部地被反射器12包围。LED芯片14还和反射器12电绝缘。因为金属是良好的电导体，金属反射器12和金属电极10a都提供一个离开LED芯片14的电传递路径。最好涂覆有金的导电金属销15在上电极10a中被压入组件10内，如图1所示。电接合部分例如金线或导线16从上电极10a通过到LED芯片14。金线16的一端被焊接到金属销15，另一端被焊接到LED芯片14的顶表面，从而使金属销15和LED14电接合。
当电流通过芯片在各个LED组件中流动时，便产生光和热。增加通过芯片的电流使得增加光输出，但是增加的电流也升高各个LED组件中芯片的温度。温度的增加使得芯片的效率降低。过热是各个LED组件故障的主要原因。为了确保安全操作，或者电流因光输出而必须保持在低的值，或者必须在各个LED组件中提供其它用于从芯片散热的装置。因此，下电极10b可以由导电的散热器18限定，其还用于从LED芯片14带走热量。上电极10a和下电极10b由电绝缘材料19例如不导电的粘合剂保持在一起。LED14用这种方式被设置在组件10内，使得底面通过连接材料19被连接或焊接到散热器18上。为了允许通过LED14实现电连接，分别对上电极10a和下电极10b施加电压。这引起散热器18带走热量，并且反射器12的弯曲表面把来自LED14的光形成所需的图案。虽然在图1中只示出了单个LED14，应当理解，在组件10中可以使用多个LED。
通过提供带有反射器的电接触部分10a和带有散热器的另一个电接触部分10b之一，使得LED光线形成接触组件10易于制造，降低组件成本并简化最终的组件。此外，LED光线形成接触组件10还允许被扩大而使得在一个组件中具有多个LED，而不显著地增加复杂性。
为了进一步示例地说明整个光学组件的操作，图2A-图2C表示单个LED组件的示例的光线图。本领域的技术人员应当理解，当单个LED组件的LED芯片14被多个LED的芯片14代替时，将产生类似的光线图。
图2A-2C表示使用图1的LED形成接触组件10的LED光学变换组件20，其中结合有小型的光学元件以形成一个完整的光线形成系统。光学元件包括透镜22，其通过把LED芯片14发出的光准直到所需的位置，把光聚焦成为所需的光点尺寸来引导LED芯片14发出的光。透镜22可被连附或精确地模制在组件中，使得其位于被准直的光束的中心。透镜22的形状和/或尺寸可以改变，以整形由LED组件发出的锥形光束，使得产生所需的光照明图案。
透镜22的会聚作用取决于透镜22的半径和透镜22相对于各个LED组件20的位置。透镜22的半径和位置可以在设计过程中确定，使得对象的照明最佳。在这种应用中，能够精确地定位和固定光学透镜22的能力是一个关键的构思。透镜22需要被定位在离开LED14一个合适的距离，以便得到所需的光输出。
在图2A中，球形的光学透镜22a部分位于上电极10a的反射器12内。虽然在本发明中示出了球形光学透镜22a，但应当理解，可以选择其它不同形状的光学器件。光学器件可以根据所需的输出而改变。在本发明中，选择球形光学器件22a是为了由可利用的LED输出产生最大光功率密度。LED输出被聚焦到刚好落在球形光学透镜22a的外部的一个所需的光点上。如果需要准直的光束，则最好使用图2B中所示的半球形光学透镜22b或图2C中所示的抛物线光学透镜22c。图2B所示的半球形光学透镜22b用这种方式被定位，使得透镜的一部分位于反射器12内，而另一部分位于组件20的外部。透镜22b的这种定位发出如图2b所示的宽的光图案，由此照亮工件上的更大的区域。而图2C中所示的抛物线光学透镜22c则完全位于反射器12和/或组件20的外部。图2C中所示的这种定位发出比图2B中区域较窄的光图案，由此照亮工件上的特定区域。这种方法提供一种可被精确且快速地制造的刚性的组件。可以优选地修改LED光线形成接触组件的尺寸以及其它的光学透镜22，并可以改变LED14和透镜22之间的距离和位置，使得适应宽范围的光学元件，同时使整个组件的成本最低、复杂性最小。
使用的LED组件的数量确定LED阵列的尺寸和所需的输出密度。最终用户可以通过向LED阵列添加LED组件和/或/从LED阵列中除去LED组件，来容易地增加或减少输出密度。此外，用户可以通过利用具有第二波长的一个或多个替代组件代替第一工作波长的一个或多个LED组件，来改变组件的工作波长。此外，用户可以替换被破坏的或者过期的LED组件而不更换整个LED阵列。
关于光学组件10和20每个的光学特性，LED14发出预定光功率和预定光波长的散射光。按照本发明的示例的LED14优选地在波长405nm，发出大于500mw光功率的光。当LED14位于反射腔内的所需位置时，反射腔准直由LED14发出的光的大部分。抛物线反射器12代表一种示例的反射腔，其当LED14位于椭圆形反射器12的焦点或附近时准直大部分的光，如图2所示。本领域技术人员应当理解，本发明的准直装置不限于椭圆反射器14。本领域技术人员应当理解，在本发明内也可以实施其它的LED准直装置。
为了制造小型的光学组件，优选地例如LED光学组件，需要具有一种用于保持输出光学器件在正确位置并提供导电路径的装置。一种这样的装置是图3中所示的电套筒组件30。组件30优选地由铝合金制成，其包括基本上圆柱形的套筒32，其优选地由铝制成，涂覆有电绝缘涂层34例如不导电的粘合剂的电绝缘涂层34。套筒32的外部被掩盖以允许和下面要详细说明的外部电连接接触。组件30表示一个剖面图，在上部具有槽36，如图3所示。优选地在套筒32被涂覆之后在套筒32内加工出这些槽36。因为槽36现在允许通过一个大的区域暴露赤裸的金属组件30，当导电涂层例如粘合剂被涂覆在套筒槽36和套筒36内部的金属接触部分之间时，总的暴露的表面提供电阻非常低的接触。导电的粘合剂连接组件内部的反射器12和外部的套筒32。另外，可以应用导线连接来连接反射器12和套筒32。两个槽36提供4个敞开的表面用于和套筒32进行接触。此外，由于槽36的长度，并由于两个槽36的每一个的两个表面在紧凑的组件中提供最大的表面积，使得导电率最大。套筒32的上端的形状优选地被修改使得保持用于组件30的光学器件。通过简单地把光学器件置于套筒32中并优选地在LED组件上滑动，然后对槽36或者连接反射器12和套筒32的导线涂覆导电粘合剂，电-光学器件组件被电气连接，如将在下面参照图4详细说明的。
LED14和光线形成接触组件10、LED可变光学组件20以及LED透镜保持电套筒组件30组合，从而形成图4中所示的完整的LED电-光学器件组件40。LED14被连接或焊接到由导电材料制成的散热器18上。一旦LED14与具有绝缘材料19的散热器18接触，光线形成接触组件10便被连接在适当位置。此外，LED14的顶表面通过金属线16连接到导电金属销15。销15优选地用金涂覆，并被压入金属接触组件中。因为接触组件的金属根据反射率和导电率选择，其将引导LED的输出并用于把LED14的顶表面电连接到光线形成接触组件10的外表面。接着，优选地安装具有球形光学透镜22a的LED可变光学组件20。
最后，在散热器18上涂覆结构粘合剂34的同时安装LED透镜保持电套筒组件30。反射器12优选地利用结构粘合剂34连接到散热器18上。这样，结构粘合剂34用于把组件牢固地保持在一起，提供一些热传导和与散热器18的附加的电绝缘。此外，导电粘合剂36优选地涂覆到槽36上，以便把外部套筒32连接到反射器12上。或者，如上所述，可以使用优选地是铝导线(未示出)导线在组件内部的反射器12和优选地由铝制成的外部套筒32之间进行导线连接。优选地，使用多个导线连接来连接反射器12和外部套筒32的表面下面的凹槽(未示出)。此外，所述凹槽优选地被涂覆以被保护。导电材料被热固化，并形成一个完整的LED电-光学器件组件40。此外，组件40只示出了单个LED14，优选地使多个LED器件和所述组件相连。
要求LED14或多个LED被单独对齐，因为没有两个单个的LED组件是完全相同的。差异是由芯片14在反射器12内的定位、反射器杯12的定位、电极10a和10b的定位以及光学透镜22的定位产生的。所有这些因素都影响光束的几何形状和方向。由于各个LED组件的制造工艺，在各个LED组件中的元件具有非常宽范围的位置关系。因此，对于要求特定区域照明的任何应用，每个单个的LED组件必须被手动地对齐，然后借助于一些机械支撑装置被永久地保持在合适位置上。
虽然这里使用了单个LED说明本发明，本领域技术人员应当理解，这里说明的本发明适用于多个LED或LED阵列。可以用照明所需的任何方式设置多个LED。
虽然在本发明中LED14被表示为一个矩形框，本领域技术人员应当理解，按照披露的本发明，可以形成任何形状的LED照明装置，以对一些应用的宽的阵列提供光，所述应用包括但不限于光固化、视频、商店橱窗、摄影或者特殊产品的显示。因为所披露的LED照明装置的耐用性和结实的结构，其可用于户外设施、海洋应用或敌对的环境中。

Claims (39)

1.一种LED电-光学器件组件，包括：
至少一个LED；
导电散热器，所述LED安装在所述散热器的一端并与其电接合；
安装在所述散热器的所述一端并包围所述LED的导电反射器，其中所述散热器在垂直方向上长于所述导电反射器；
电绝缘所述导电反射器和所述散热器的绝缘部件；
延伸通过所述导电反射器并和导电反射器呈导电接合的导电连接销；以及
使所述连接销与所述LED接合的电接合部；
其中分别对所述散热器和所述导电反射器施加电压以允许通过所述LED形成电连接。
2.如权利要求1所述的组件，其中所述散热器包括在其所述一端上的平的表面，并且其中所述LED被安装到所述表面上。
3.如权利要求2所述的组件，其中所述导电反射器是椭圆形反射器，其具有贯通其中的中央开口，以及其中所述LED被安装在所述中央开口中。
4.如权利要求3所述的组件，其中所述绝缘部件包括用于把所述导电反射器固定到所述散热器上的连接剂。
5.如权利要求1所述的组件，其中所述散热器是热管。
6.如权利要求1所述的组件，其中所述连接销是镀金的。
7.如权利要求1所述的组件，其中所述电接合部是用于互连所述连接销和所述LED的金线或者导线。
8.如权利要求1所述的组件，还包括：
位于所述导电反射器附近的光学透镜部件，所述光学透镜部件和所述LED隔开，用于聚焦从所述LED发出的光线。
9.如权利要求8所述的组件，其中所述光学透镜部件被至少部分地支撑在所述导电反射器内。
10.如权利要求8所述的组件，其中所述光学透镜部件是用于产生增强的光功率密度的球形光学器件。
11.如权利要求8所述的组件，其中所述光学透镜部件是用于产生准直光的半球形光学器件。
12.如权利要求8所述的组件，还包括支撑着所述散热器、所述导电反射器和所述光学透镜部件的导电保持套筒。
13.如权利要求12所述的组件，其中所述导电保持套筒被放置使得和所述导电反射器呈电连接。
14.如权利要求13所述的组件，其中所述散热器是热管，并且所述导电保持套筒与所述热管绝缘地隔开。
15.如权利要求13所述的组件，其中所述散热器是热管，并且所述导电保持套筒借助于绝缘粘合剂与所述热管绝缘地隔开，所述粘合剂把所述导电保持套筒固定到所述热管上。
16.如权利要求13所述的组件，其中所述导电保持套筒内部被绝缘地涂覆。
17.如权利要求15所述的组件，其中所述导电保持套筒包括和所述导电反射器相邻的至少一个贯通其中的槽。
18.如权利要求17所述的组件，其中所述槽被填充导电粘合剂，以在所述导电保持套筒和所述导电反射器之间建立导电接合。
19.如权利要求17所述的组件，其中所述槽和所述导电保持套筒以及所述导电反射器电接合。
20.一种用于形成LED电-光学器件组件的方法，包括以下步骤：
将至少一个LED导电地连附到导电散热器上；
由导电反射器包围所述LED，所述反射器包括延伸通过其的连接销，其中所述散热器在垂直方向上长于所述反射器；以及
使所述连接销和所述LED电接合。
21.如权利要求20所述的方法，还包括以下步骤：
在所述反射器和所述散热器之间插入绝缘材料。
22.如权利要求20所述的方法，其中所述包围步骤包括：
在所述反射器和所述散热器之间配置绝缘连接剂。
23.如权利要求20所述的方法，其中所述导线连接步骤包括：
在所述连接销和所述LED之间插入导电连接导线。
24.如权利要求20所述的方法，其中所述散热器是热管。
25.一种LED电-光学器件保持组件，包括：
具有上部和下部的基本上圆柱形的套筒，所述套筒内部涂覆有电绝缘材料；
位于所述套筒的上部的至少一个槽，用于在套筒和上部的内部之间提供导电接合，其中所述上部的形状被修改以保持所述电-光学器件。
26.如权利要求25所述的组件，其中所述套筒由铝或铝的合金构成。
27.如权利要求25所述的组件，其中所述导电接合是导电粘合剂。
28.如权利要求25所述的组件，其中所述导电接合是导线。
29.如权利要求25所述的组件，其中所述上部包括第一电极部件和被安装在其内的压入配合的反射表面。
30.如权利要求25所述的组件，其中所述下部包括第二电极部件，具有被安装在其内的导电散热器。
31.一种LED电-光学器件电套筒组件，包括：
内部涂覆有电绝缘材料的基本上圆柱形的套筒，具有上部和下部，所述上部和下部由绝缘部件分开；
至少一个LED和已被安装在所述上部上的导电反射器，其中所述导电反射器包围所述LED；
已被安装在所述下部上的导电散热器，所述LED和其呈电接合；
延伸通过所述导电反射器并和其呈导电接合的导电连接销；以及
使所述连接销与所述LED接合的电接合部分；
其中分别对所述散热器和所述导电反射器施加电压以允许通过所述LED形成电连接。
32.如权利要求31所述的组件，还包括位于所述套筒的上部的一对槽。
33.如权利要求32所述的组件，其中所述槽涂覆有导电粘合剂，以便把所述套筒连接到所述导电反射器上。
34.如权利要求32所述的组件，其中所述导电反射器通过铝线连接到所述套筒上。
35.如权利要求31所述的组件，其中所述导电反射器借助于所述绝缘部件连接到所述散热器上。
36.如权利要求31所述的组件，还包括被设置在所述导电反射器附近的光学透镜部件，所述光学透镜部件与所述LED隔开并被定位用于聚焦从所述LED发出的光线。
37.如权利要求36所述的组件，其中所述上部保持所述光学透镜部件。
38.如权利要求36所述的组件，其中所述光学透镜部件至少部分地被支撑在所述导电反射器内。
39.如权利要求36所述的组件，其中所述光学透镜部件全部位于所述导电反射器外部。
CN200580024181A 2004-06-15 2005-05-13 大功率led电-光学器件组件 Expired - Fee Related CN100594327C (zh)

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JP2008503057A (ja) 2008-01-31
CA2589570A1 (en) 2006-01-05
EP1766287A4 (en) 2007-07-18
US7540634B2 (en) 2009-06-02
CA2589570C (en) 2010-04-13
WO2006001928A1 (en) 2006-01-05
US20070091618A1 (en) 2007-04-26
ATE553505T1 (de) 2012-04-15
US20080273329A1 (en) 2008-11-06
MXPA06014522A (es) 2007-03-23
CN101031751A (zh) 2007-09-05
EP1766287A1 (en) 2007-03-28

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