Source: http://www.google.es/patents/EP0921568A2?cl=en
Timestamp: 2018-01-17 20:29:02
Document Index: 575219019

Matched Legal Cases: ['arts 12', 'arts 13', 'arts 12', 'arts 12', 'arts 13', 'arts 12', 'art 19', 'arts 12', 'arts 13', 'art 20', 'art 20', 'arts 10']

Patente EP0921568A2 - LED Luminaire - Google Patentes
An LED luminaire is formed such that a plurality of LED chips are disposed three-dimensionally on an MID (molded interconnection device) substrate in a rectangular plate shape, by mounting three LED chips on bottom face of respective dents provided lengthwise and crosswise in one surface of the MID substrate,...http://www.google.es/patents/EP0921568A2?cl=en&utm_source=gb-gplus-sharePatente EP0921568A2 - LED Luminaire
Número de publicación EP0921568 A2
Número de solicitud EP19980203973
También publicado como DE69841798D1, EP0921568A3, EP0921568B1, US6331063, US20020006040
Número de publicación 1998203973, 98203973, 98203973.7, EP 0921568 A2, EP 0921568A2, EP-A2-0921568, EP0921568 A2, EP0921568A2, EP19980203973, EP98203973
Inventores Taishi Akiniwa, Nobuyuki Asahi, Jiro Hashizume, Kazuo Kamada, Shoichi Koyama, Eiji Shiohama, Masaru Sugimoto, Toshiyuki Suzuki, Takashi Tanaka, Shohei Yamamoto
Solicitante Matsushita Electric Works, Ltd.
Citas de patentes (2), Citada por (108), Clasificaciones (23), Eventos legales (20)
EP 0921568 A2
An LED luminaire comprising a plurality of LED chips, a substrate on which the plurality of LED chips are mounted, and a light control means provided to the substrate for controlling the distribution of light emitted by the respective LED chips, wherein the light control means includes at least one of a plurality of dents and a plurality of protrusions formed at positions where the LED chips are mounted.
The luminaire according to claim 1 wherein the substrate comprises a resin molded printed-circuit substrate.
The luminaire according to claim 1 wherein the plurality of the LED chips include at least two types of the LED chips mutually different in luminous color.
The luminaire according to claim 1 wherein the substrate is constituted for providing a regularity in the direction of emission to the plurality of the LED chips.
The luminaire according to claim 1 wherein the substrate is formed in multilayers the central portion of which is raised.
The luminaire according to claim 1 wherein at least one of the plurality of the dents and a plurality of the protrusions of the light control means are formed on both side surfaces of the substrate.
The luminaire according to claim 1 wherein the light control means comprises the substrate per se formed with a light transmitting material.
The luminaire according to claim 7 wherein the LED chips are respectively provided with a power-supplying electrode section made of a transparent conductor.
The luminaire according to claim 1 wherein the LED chips respectively comprise a P-type semiconductor and an N-type semiconductor which are arranged substantially in vertical with chip-mounting surface of the substrate.
The luminaire according to claim 1 wherein a fluorescent substance is applied at least to the positions of mounting the LED chips.
The luminaire according to claim 1 wherein the substrate is provided at least partly with a metal plate as a ground of the plurality of the LED chips, the chips being brought into contact with the metal plate.
The luminaire according to claim 1 wherein the substrate is provided integrally with a copper-clad metal substrate, the plurality of the LED chips being mounted on copper-clad part formed on one surface of the metal substrate to be a ground, and the light control means comprises circuit elements mounted on the other surface of the metal substrate.
FIGURE 1 is a sectioned view of the LED luminaire in an embodiment according to the present invention;
FIG. 15b is a front view of the embodiment of FIG. 15a;
FIG. 15c is a cross sectioned view of the embodiment of FIG. 15a;
FIG. 15d is a vertically sectioned view of the embodiment of FIG. 15a;
FIG. 16 is a fragmentary, schematic sectioned view of another embodiment of the present invention;
FIG. 18 and 19 are fragmentary sectioned views as magnified of respective further embodiments of the present invention;
FIG. 21b is a fragmentary, schematic sectioned view of another embodiment of FIG. 21a;
FIG. 22a is a fragmentary, schematic sectioned view in another aspect of the above;
FIG. 22b is a fragmentary, schematic perspective view of the aspect in FIG. 22a;
FIG. 23 is a fragmentary sectioned view as magnified of further embodiment of the present invention;
FIG. 24b is an explanatory view for the relationship between the wavelength and the intensity of light in the embodiment of FIG. 24a;
FIGS. 24 and 25 are fragmentary, schematic sectioned views respectively of another embodiments of the present invention;
In FIGS. 1 and 2, there is shown an embodiment of the present invention, in which a three-dimensional circuit substrate 10 in the form of a molded interconnect device (MID), in a rectangular plate shape is formed to have in one surface many dents 11 arranged lengthwise and crosswise, and preferably three light emitting diode elements (which shall be hereinafter referred to as "LED chip") 1 are mounted to a part or most part of a bottom, side or so face of each dent 11.
After subjecting this insulative base to an alkali degreasing, its surfaces are plasma-processed to activate the surfaces and to finely rougthen them. Thereafter, a metal film, that is, a plating ground layer of copper, silver, gold, nickel, platinum, paradium or the like is formed on the surfaces of the insulative base, by means of sputtering, vacuum evaporation or the like. This metal film should preferably be of a thickness of about 0.1 to 2.0 µm.
Next, an electric copper plating is performed through, for example, a copper sulfate plating bath (copper sulfate 80 g/l, sulfuric acid 180 g/l, chlorine and a brightner) while supplying an electric power to the circuit parts 12, an electric nickel plating is performed with, for example, a Watts bath (nickel surfate 270 g/l, nickel chloride 50 g/l, boric acid 40 g/l and a brightner), an electric gold plating is performed with, for example, articles sold as TEMPEREX 401 of a firm EEJA, and a circuit substrate on which metal films of a predetermined thickness, that is the three-dimensional circuit substrate 10 is obtained. Residual metal films at the non-circuit parts 13 may be removed as required, by means of a soft etching or the like.
The LED chips 1 are mounted in the dents 11 of the substrate 10 obtained through the foregoing process, and the circuit parts 12 and LED chips 1 are electrically connected (die-bonding) with an electrically conductive adhesive. Thereafter, top electrodes of the LED chips 1 and the circuit parts 12 are connected through gold wires (wire-bonding). Inner surface 11a of the dents 11 in which the LED chips 1 are mounted is mirror-finished to render the dents to act also as a reflector, so that a high luminance and a high efficiency can be attained. Next, a transparent resin is charged in the dents 11 to seal the LED chips 1. At this time, the substrate 10 should preferably be provided with a dam for preventing the transparent resin from flowing out of the dents 11. Finally, a diffuser plate 15 consisting of a transparent resin is mounted to the surface, that is, the mounting surface of the substrate 10, and a module of the LED luminaire in the present embodiment is completed.
In FIG. 3, there is shown another embodiment of the present invention, in which the luminaire is constituted such that a plurality (for example, 100 pieces) of the LED chips 1 are mounted on a surface of a resin-made substrate 10 (for example, 50×50 mm), a molded layer 10A of a transparent acrylic resin is formed on the surface of the substrate 10 to seal the LED chips 1, and a microlens plate 27 formed to have many microlenses as the optical control means for performing the emission control is disposed in consideration of the distribution of light of the entire LED luminaire 30 being made into a module, and the distribution of light is so set by the microlens plate 27 that light emitting angle of the entire LED luminaire 30 will be, for example, -60° to 60°.
In another embodiment shown in FIG. 5 of the present invention, in contrast to the microlens plate 27 formed separately from the molded layer 10A sealing the LED chips 1 in the embodiment of FIGS. 33 and 34, the molded layer 10A is formed to be provided on its surface with microlens section 27a as the optical control means for controlling the distribution of light of the respective LED chips 1, with the surface of the layer 10e spherically worked or worked into any optional configuration. Other constituents are the same as those in the embodiment of FIG. 3.
In this case, it is also possible to form the optical control means for a simultaneous light distribution control with respect to the light from a plurality (two to an optional number) of the LED chips 1, instead of attaining correspondence of the respective LED chips 1 to the optical control means. Accordingly, the light distribution control as shown by arrows can be realized by means of the microlens section 27a with respect to the light of the LED chips 1 in the LED luminaire 30 of the present embodiment.
Since the molded layer 10A of the sealing material is made integral with the microlens section 27a in the present embodiment, there is an advantage that any light loss occurs less to render the efficiency excellent, and the light distribution control as to the plurality of LED chips 1 is rendered easier.
Now, in another embodiment shown in FIG. 6 of the present invention, the luminaire is featured in that a module with a combination of monochromatic LED chips 1a-1d of such four different colors as red, green, blud and yellow made as one unit is regarded as one cell S, and the LED luminaire is constituted by combining a plurality of the cells S.
That is, the above LED chips 1a-1d of four colors are mounted as disposed in a matrix state to the respective dents 11 of the sheet-shaped substrate 10 formed through the same process as in the embodiment of FIG. 1 (see also FIG. 7a). Each dent 11 in which the LED chips 1a-1d of four different colors are thus mounted is regarded as one cell S, and the cells S are cut into every cell at chain line portions in FIG. 6 by means of a dicing saw. Then each cell S thus cut is mounted again to a printed substrate or the like (see FIG. 7b).
The micromachine section 38 is constituted by three beam sections 38a supported at one end in a cantilever form, and crystal plates 38b provided on the beam sections 38a, and the LED chips 1 are provided in the vicinity of respective free ends of the beam sections 38a. Further, a lens 39 should preferably be provided in front of the LED chips 1.
Next, manufacturing steps of the substrate 10 of the present embodiment are described only as to different respects from the embodiment of FIG. 1. The substrate 10 is the MID substrate made of a ceramic, for which a mixture as kneaded of, for example, alumina powder, a slip agent and a resin is injection molded, and thus molded article is degreased, dried and sintered to prepare a ceramic molded article (molded substrate). Thereafter, this molded substrate is alkali-degreased, and surfaces of the ceramic are plasma-processed for the surface activation and fine roughening. Then the metal film of copper, silver, gold, nickel, platinum, palladium or the like (plating ground layer) is formed on the surfaces of the ceramic through such proper process as sputtering, vacuum evaporation or the like. At this time, the metal film should preferably be of a thickness about 0.1-2.0 µm. Thereafter, the patterning is performed in the same manner as in the embodiment of FIG. 1, thin crystal plates 38b are mounted on the beam sections 38a, the LED chips 1 are mounted thereon, and the LED chips 1 are mounted thereon, to complete the LED luminaire module.
Then, with an application of a voltage to the micromachine section 38, the beam sections 38a can be vibrated because of a reverse piezoelectric effect of crystal, and it is enabled to cause the mounted LED chips 1 on the beam sections 38a to be finely vibrated.
In another embodiment shown in FIG. 10 of the present invention, the luminaire is featured in that the substrate is formed to provide to the light emitting direction of the plurality of LED chips 1 a regularity, and, as seen in FIG. 10, the substrate 10 is formed to have a surface sawtoothed in section on the mounting surface side, and the LED chips 1 are mounted on slanted side faces 10a of respective sawtoothed ridges.
Further, in the above case, saw-tooth shaped slanted side faces 10a as the light control means may also be formed on the surface of the substrate 10 in a plurality, and the LED chips 1 are mounted on the slanted side faces 10a so as to render their p-n junction plane to be substantially vertical to sloped mounting surface of the slanted side faces 10a. As the LED chips 1 radiate the light in all direction in the p-n junction plane, the light radiated from the LED chips 1 is made substantially vertical to the surface of the slanted side faces 10a. Here, the surfaces of the slanted side faces 10a are formed to be mutually parallel, and therefore the emitted light of the respective LED chips 1 will be also mutually parallel, whereby it is enabled to radiate parallel light from the LED luminaire module, to improve the utilization of light.
Further, in contrast to the embodiment of FIG. 10 in which the LED chips 1 are mounted on the slanted side face 10a of the substrate 10, the LED chips 1 will be so arranged, as shown in FIG. 11, that light emitting direction of the respective LED chips 1 will be turned in a specific direction or, for example, converged to an object. In this aspect, the luminaire can be remarkably improved in the light distribution characteristic and the light focusing characteristic with respect to an existing object or objective zone.
In another embodiment shown in FIG. 13, further, the LED luminaire is provided with a substrate 10 substantially of 50 mm in outer diameter in common, and a surface of the substrate 10 is polished to form a paraboloid 10b which functions as the light control means and also as a reflector surface. On the paraboloid 10b of this substrate 10, a plurlality of the LED chips 1 are mounted so that their p-n junction plane (boundary plane between p-type and n-type semiconductors) will be substantially vertical with respect to the paraboloid 10b. In this case, the LED chips 1 emit the light in all direction in the p-n junction plane, so that the light is radiated from the LED chips 1 substantially in vertical direction with respect to the paraboloid 10a, and the paraboloid 10a is so formed as to concentrate the emitted light of the respctive LED chips 1 to concentrate to a single point in the space.
In another embodiment shown in FIG. 14 of the present invention, the luminaire is provided with the substrate 10, a plurality of the LED chips 1 mounted on the surface of the substrate 10 in a matrix shape, and a reflector surface 10c formed with, for example, aluminum film on the surface of the substrate 10 between adjacent ones of the LED chips 1. And in the present embodiment the aluminum film high in the reflection efficiency is employed for the reflector surface 10c, it is not necessary to limit the reflector surface 10c to be of the aluminum film, but any other metal material than the aluminum film and high in the reflection factor such as silver may be employed. Further, when an insulative substance is employed as the material for the reflector surface 10c, it is possible to avoid any danger of short-circuiting between the LED chips 1 or a wiring pattern (not shown) forming a lighting circuit for the LED chips 1 and the reflector surface 10c.
Generally, the LED chip 1 is to emit the light upon movement of electrons on the p-n junction plane with a current made to flow through the p-n junction in forward direction, and the light emitting direction will be in all direction in the p-n junction plane. Therefore, in an event where the LED chips 1 are disposed on the substrate 10 so that their p-n junction plane will be substantially vertical to the surface of the substrate 10, the light is radiated not only on the front side of the substrate 10 but also to directions parallel to the substrate 10 or in directions toward rear surface of the substrate 10. Due to this, an effective utilization of the emitted light of the LED chips 1 is limited when the surface of the substrate 10 only is attempted to be made into the three-dimensional configuration as in the embodiment of FIG. 14. Accordingly, by causing the radiated light from the LED chips 1 in substantially parallel direction with the substrate 10 to be reflected in a desired direction by the reflector surface 10c as the light control means, it is made possible to utilize not only direct light radiated from the LED chips 1 onto the front side of the substrate 10 but also the light radiated from the LED chips 1 can be utilized, the utilization of the emitted light of the LED chips 1 is elevated, and the intensity of light of the modular LED luminaire can be raised sufficiently.
Further, the reflector surface 10c may be formed three dimensionally so as to be able to reflect the light from the LED chips 1 in a desired direction. Also, the reflector surface 10c may be so formed that the direct light radiated from the LED chips 1 on the front side of the substrate 10 and the relfected light by means of the reflector surface 10c will be respectively radiated in different directions, and the LED luminaire can be increased in the variation of the light distribution.
While in the above embodiment of FIG. 14 the reflector surface 10c for reflecting the emitted light of the LED chips 1 in the desired direction is formed on the surface of the substrate 10, another embodiment shown in FIGS. 28a-28d of the present invention employs an arrangement in which the wiring pattern of the lighting circuit for the LED chips 1 formed on the surface of the substrate 10 is made to also act as the reflector surface 10c.
In this case, the LED chips 1 are mounted on the substrate 10 so that the p-n junction plane will be substantially vertical to the surface of the substrate 10, slanted side faces 10a are formed around the LED chips 1 mounted on the substrate 10 so as to protrude on the front side of the substrate 10 as separated from the LED chips 1, and the plated nickel layers 17 on the slanted side faces 10a are reflecting the emitted light from the chips in a desired direction.
Accordingly, the luminaire comprises the substrate 10 made of a resin which does not transmit light, an electrode section 24 formed on the surface of the substrate 10, a plurality of the LED chips 1 mounted on the electrode section 24, and a further electrode section 24a provided on the top of the respective LED chips 1, wherein the electrode sections 24 and 24a are both formed with indium-tin oxide (ITO) which is a transparent conductor. In this case, the n-type semiconductors 1a of the respective LED chips 1 are electrically connected to the one electrode section 24 and the p-type semiconductors 1b are electrically connected to the other electrode section 24a. Further, the electrode section 24 is electrically connected to the wiring pattern (not shown) formed on the substrate 10, while the electrode section 24a is electrically connected through a bonding wire (not shown) to the other wiring pattern formed on the substrate 10. Thus, the LED chips 1 are connected through the electrode sections 24 and 24a to the wiring patterns. Further, the protrusions 10c are formed on the substrate 10 to be between adjacent ones of the LED chips 1, the light radiated from the p-n junction plane of the LED chips 1 is reflected on the protrusions 10c of the substrate 10 and is radiated in a direction of desired light distribution.
Since the transparent electrode sections 24 and 24a are employed for electrically connecting the LED chips 1 to the wiring pattenrs, the emitted light of the LED chips 1 is not intercepted by the electrode sections 24 and 24a, so that the utilization of the light of the LED chips 1 can be improved, and any loss of the emitted light can be reduced.
While in the present embodiment ITO is employed for the electrode sections 24 and 24a, they may not be limited to ITO, but such other transparent conductor than ITO as cadmium-tin oxide (CTO) or the like may be used. Further, with a use of a substrate of light transmission properties as the substrate 10, the emitted light of the LED chips 1 can be prevented from being intercepted, and the utilization of the emitted light of the LED chips 1 is further improved.
On the other hand, the LED chip 1 emits light upon movement of electrons at junction boundary plane between P-type semiconductor 1a and N-type semiconductor 1b, which light is radiated in all directions in a plane including the junction boundary plane, while it is apprehended that the light is intercepted in the direction in which the LED chip is mounted to the substrate 10 or by the metal wire 14, so that the radiating direction of light is restricted and shadows are cast (see FIG. 20).
Here, in the present embodiment, the luminaire is featured in that, as shown in FIGS. 21a and 21b, the LED chip 1 is disposed to position the P-type and N-type semiconductors 1a and 1b to be in a row substantially vertical to the mounting surface of the substrate 10. Other respects in the arrangement are the same as in the embodiment of FIG. 1 and their description is omitted here.
As shown in FIGS. 21a and 21b, in this case, the part of the substrate where the LED chip 1 is mounted is raised one stage from surrounding part, pads 33 are provided on both sides of the raised parts, and the connection of these pads 33 to the P-type and N-type semiconductors 1a and 1b of the LED chip 1 is performed by means of soldering or the electrically conductive adhesive. Here, as the LED chip 1 is mounted onto the raised part, so that any short-circuit trouble can be prevented from occurring at the time of such connection. For the LED chip 1, one of a cube of 0.3 mm, for example, is desirable.
According to the present embodiment as has been described, the LED chip 1 is disposed to position the P-type and N-type semiconductors 1a and 1b in the row substantially to be parallel with the mounting surface of the substrate 10, so that the junction plane of both semiconductors will be substantially orthogonal to the surface of the substrate 10, the emitted light from the LED chip 1 is radiated in the direction vertical to the substrate 10, whereby the metal wires 14 are made not to intercept the light so as not to cast any shadow, and the luminous efficiency of the LED chip 1 can be elevated.
Further, as shown in FIGS. 22a and 22b, by a provision of recesses 33A at fillet portions to join the LED chip 1 with the insulative adhesive or the like performed within the recesses 33A, the short-circuiting upon the electric connection can be also prevented from occurring.
Accordingly, by the disposition of the LED chips 1 so as to dispose the P-type and N-type semiconductors 1a and 1b in the row substantially vertical with the mounting surface of the substrate 10, the light emitting direction of the LED chip 1 can be rendered substantially vertical with the substrate 10, the metal wires 14 are caused not to cast any shadow, and the LED chip can be increased in the luminous efficiency.
In another embodiment shown in FIG. 23 of the present invention, the luminaire comprises the substrate 10, and the LED chips 1 disposed in respective dents 10d formed in the surface of the substrate 10, and a through hole 10e is formed as a light control means as penetrating through the substrate 10 at positions where the respective dents 10d are formed.
The LED chips 1 are disposed to position the p-n junction plane substantially vertical to the surface of the substrate 10, and the n-type and p-type semiconductors 1a and 1b of the respective LED chips 1 are electrically connected to the wiring patterns (not shown) formed on the substrate 10 respectively. As the LED chips 1 emit light in all direction in the p-n junction plane, so that part of the emitted light of the LED chips 1 will be radiated on the front surface side of the substrate but the rest will be radiated to the rear surface side of the substrate 10 through the penetrating hole 10e, and the light can be radiated on both sides of the substrate 10.
A reflecting material is applied to the inner walls of the penetrating holes 10e, so that the light from the LED chips 1 can be prevented from being absorbed by the substrate 10.
Since the emission of the LED chips 1 is normally a monochromatic light, further, it is required to mix a plurality of luminescent colors for obtaining such white light as solar light. Taking into account this respect, the white light is obtained in another embodiment shown in FIGS. 24a and 24b, by utilizing the emission of fluorescent substance and mixing the emission of the LED chips 1 with the emission of the fluorescent substrate.
That is, a luminaire is constituted by the substrate 10, the dents 10d formed in a surface of the substrate 10, a fluorescent substance 25 applied to inner surface of the dents 10d, and the LED chips 1 mounted in the respective dents 10d.
In manufacturing steps of the above substrate 10, such electrically insulating material as polyimide, polyether imide, polyamide, liquid crystal or the like is employed to form the insulative base by means of the injection molding, and the protrusions 26 are formed at mounting positions of the LED chips 1 while through holes 26a are formed within the protrusions 26.
After alkali-degreasing this insulative base, its surfaces are plasma-processed to perform the surface activation and fine roughening. Thereafter, the metal film (plating ground layer) is formed with copper, silver, gold, nickel, platinum, palladium or the like by means of the sputtering or vacuum evaporation on the surface of the insulative base. Then, the metal film at the boundary zone of the non-circuit parts 13 with respect to the circuit parts 12 is removed by the irradiation of such electromagnetic waves as laser or the like. Then an electric power is supplied to the circuit parts, and the substrate 10 is obtained in the form of a circuit substrate on which the metal film of a predetermined thickness is formed by means of electric copper plating, for example, with a copper sulfate plating bath. Thereafter heat emitting pins 26b are urged into the through holes 26a formed in the protrusions 26.
The LED chips 1 are mounted respectively onto each of the protrusions 26 of the substrate 10 thus obtained through the above process, and the circuit parts (including the heat emitting pins 26b) and the LED chips 1 are electrically joined (die-bonding) by means of an electrically conductive adhesive. Thereafter, the top electrodes of the LED chips 1 and the circuit parts are joined through metal wires (wire-bonding). By mirror-finishing peripheral slopes of the protrusions 26 on which the LED chips 1 are mounted so as to act also as reflector surfaces, it is possible to attain the high luminance and high luminous efficiency. Next, the LED chips 1 are sealed with the transparent resin, and eventually the diffuser consisting of transparent resin or the like is mounted on the mounting side surface of the substrate 10 to complete the LED luminaire module of the present embodiment.
According to the present embodiment as has been described, it is possible to remove the generated heat of the LED chips 1 as efficiently emitted by means of the heat emitting pins 26b provided within the substrate 10 below the LED chips 1 to be in contact with at least part of the LED chips 1, whereby the temperature of the LED chips 1 can be prevented from rising, the luminous efficiency and luminance can be prevented from being deteriorated, and the life of the LED chips 1 can be prolonged.
In another embodiment shown in FIG. 31 of the present invention, the luminaire is featured in that a copper clad metal element, i.e., a metal element 19 is provided on opposite side of the MID substrate 10 to the side having many of the dents 11, an electrically conductive layer 19a of this metal element 19 is made to be the ground for the LED chips 1, and a chip part 19A of such circuit elements as IC, resistors, capacitors and so on which forming a control circuit for controlling the light emission of the LED chips 1 is mounted on an insulative layer 19b of the metal element 19. For other respects of this embodiment, they are substantially the same as those in the embodiment of FIG. 1, and their description is omitted while the same constituents as those in FIG. 1 are denoted in FIG. 31 by the same reference symbols.
Next, the manufacturing steps of the substrate 10 of the present embodiment shall be briefly described. First, the insulative layer of the metal element 19 is formed in a mold through the insert injection molding. For the electrically insulating layer, similar to the embodiment of FIG. 1, polyimide, polyether imide, polyamide, liquid crystal or the like is used. After alkali-degreasing the insulative layer, its surfaces are plasma-processed to have them activated and finely roughened. Thereafter, the metal layer is formed to provide the circuit parts 12 and non-circuit parts 13, then the LED chips 1 are mounted on the conductive layer 19a of the metal element 19 exposed at the bottom of the dents 11 in the substrate 10 and are sealed with the transparent resin.
Here, in the present embodiment, the circuit (wiring pattern) for providing the control circuit is formed on the insulative layer 19b of the metal element 19, after sealing by the transparent resin the LED chips 1 mounted in the dents 11. This pattern forming process may be either one of exposure/etching process and laser patterning process which are general processes for forming printed wiring board. Then, the LED luminaire module is completed by mounting with solder the chip part 20 of such circuit elements as the IC, resistors, capacitors and so on after forming the circuit pattern.
According to the present embodiment, as has been described, the metal element 19 and LED chips 1 are brought into direct contact with each other by forming a ground with the LED chips 1 mounted to the conductive layer 19a of the copper clad metal element 19 insert-molded on the substrate 10, so that the heat generated by the LED chips 1 can be removed as efficiently emitted by the metal substrate 19, whereby the temperature of the LED chips 1 can be prevented from rising, the light emitting efficiency and luminance can be prevented from being deteriorated, and the life of the LED chips 1 can be prolonged. Further advantage can be attained in that the module can be minimized in size by mounting the circuit elements of the circuit for controlling the light emission of the LED chips 1 to the insulative layer 19b of the metal element 19, and a shielding of the circuit chip part 20 with respect to noise also can be achieved.
In another embodiment shown in FIG. 32 of the present invention, the luminaire is featured in that the substrate 10 having many dents 11 in one surface is provided with ventilating through holes 26a communicating the respective dents 11 mounting therein the LED chips 1 with rear surface side of the substrate 10.
The through holes 26a are formed upon molding the MID substrate 10. The following steps are the same as in the embodiment of FIG. 1, and their description is omitted here, except that the sealing with the synthetic resin is not performed after the mounting of the LED chips 1 in the dents 11 of the substrate 10.
As has been referred to, in the present embodiment, it is possible to prevent the temperature of the LED chips 1 from rising, by causing the generated heat of the LED chips to be dispersed with air current of convection, with the provision of the ventilating through holes 26a communicating the dents 11 with the rear surface side of the substrate 10, whereby the luminous efficiency and luminance of the LED chips can be prevented from being deteriorated, and the life of the chips also can be prolonged.
Here, manufacturing steps of the substrate 10 of the present embodiment shall be described only for different respects from the embodiment of FIG. 1. The flexible substrate 10C made of polyimide on which a circuit has been preliminarily formed is put in a mold, and the flexible substrate 10C is copied on a molded article by means of an injection molding. At portions of the molded article where the LED chips 1 are mounted, thick parts, i.e., protrusions 43 are formed. Taking into account the bendability, the flexible substrate 10C is left as it is at portions between the respective thick parts 10D. The sealing with the resin is also performed only in the vicinity of the LED chips 1, so that the sealing resin twill not be directly bent and the whole substrate will be still rendered easily bendable. The thus molded substrate is alkali-degreased and, thereafter, the same steps as in the embodiment of FIG. 1 are performed to complete the substrate 10.
In another embodiment as shown in FIG. 35 of the present invention, the luminaire is featured in that the substrate 10 in the respective dents 11 of which a plurality of the LED chips 1 are mounted as in the embodiment of FIG. 1 can be freely cut along line "O" into every dimensional unit containing a predetermined number of the LED chips 1. Basic constituents of the substrate 10 and so on are substantially the same as those in the embodiment of FIG. 1, and their description is omitted here by denoting the same constituents as those in FIG. 1 with the same reference symbols in FIG. 35.
Then, the substrate 10 is made for easy cutting at proper cutting position "O" between the respective series circuits of the LED chips 1, so as to be a unit with required number of the LED chips 1. Here, the number of the LED chips 1 for each unit should correspond to an output, likewise the fluorescent lamp which is formed with a lamp tube corresponding to the output (10, 15, 20 and 30 W), to be convenient in handling. Further, the substrate 10 should preferably be provided with grooves for rendering it to be easily cut. Since the manufacturing steps of the substrate 10 are the same as those in the embodiment of FIG. 1, their description is omitted here.
The light guiding 29 has a reflection pattern sheet 10g on which a reflection pattern 10f is printed, as disposed on another side surface intersecting at right angles the one side surface on which the substrate 10 is disposed. Further, the substrate 10 is provided as covered by a reflector plate (not shown) so that the light from the LED chips 1 will be efficiently incident inside the light guiding 29. The reflection pattern sheet 10g is formed by printing the reflection pattern 10f with white color for performing an optional distribution of light, while the reflection pattern 10f of circular marks will be coarse on the side closer to the substrate 10 but dense on the side separated from the substrate 10.
Accordingly, the light emitted from the LED chips 1 is made incident into the light guiding 29 and, through multiple reflection on the reflection pattern 10f and so on, radiated out of the side surface opposing the reflection pattern sheet 10g, as shown by arrows. Here, as the light is caused to perform the multiple reflection inside the light guiding 29 to be of uniform distribution of luminance, and it is enabled to prevent any non-uniform luminance of the LED chip 1 from occurring.
The reflection pattern 10f may even be directly printed on the surface of the light guiding 29 or may be replaced by any other means than the printing, such as a grooving work or the like, suitable for an irregular reflection. In this case, the light is radiated out of both side surface of the light guiding 29, and the emission efficiency can be improved.
In another embodiment shown in FIG. 38 of the present invention, the optical control means is made movable in contrast to the foregoing optical control means disposed stationary in the embodiments of FIGS. 33-37. That is, the LED luminaire 30 is constituted with the substrate 10, LED chips 1R, 1G and 1B of red, green and blue and disposed in each dent 11b formed in the substrate 10, molded layer 10A for the sealing, prism lens plate 27c acting as a stationary optical control means for the light distribution control, and further prism lens plate 27d of the same configuration and disposed rotatable in a plane parallel with the substrate 10 and in front of the stationary prism lens plate 27c.
With the further prism lens plate 27d rotated, it is possible to control the distribution of light as a whole of the LED chips 1R, 1G and 1B arranged on the substrate 10, to have the state of color blending varied. At this time, the LED chips 1 may be monochromatic.
Further, while in the embodiment of FIG. 38 only one of the two prism lens plates 27c and 27d is made rotatable, it is possible to dispose both of them rotatable. Further, it is also possible to form the optical control means with a single movable prism lens plate.
In another embodiment shown in FIG. 39 of the present invention, the luminaire is so formed that the substrate 10 is provided with a plurality of parallel rows of sloped side surfaces 10a of the protrusions substantially of a right angled triangle in section, the LED chips 1 are disposed on sloped side surface of the respective sloped side faces 10a to control the distribution of light of the LED chips 1 at the stage of their mounting, and microlens plate 27 is disposed rotatable in the plane parallel to the substrate 10 in front of the LED chips, the lens being thus single here.
Thus, in the present embodiment, at least one of the movable optical control means such as the prism lens plate 27c is employed, so that the distribution of light can be optionally varied by actuating the optical control means, and the user is allowed to easily perform the light distribution control desired at installed position of the luminaire. Therefore, the illumination appliance incorporating this LED luminaire 30 is not required to be changed in its direction when the distribution of light is modified.
In the above, the resin material for use as the MID substrate may be any resin material, while such one desirably excellent in the electrical properties or in heat emission properties as the liquid crystal polymer is employed in the present embodiment. Further, the substrate is formed in the three-dimensional configuration having the protrusions of the right angled triangle in section similar to the embodiment of FIG. 38, so as to be able to mount the LED chips 1 in the direction of light distribution, and the sloped side surface 10a of such protrusion is used as the mounting surface.
JPH0492660U Título no disponible
JPH01283883A Título no disponible
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Clasificación internacional H05K1/18, H01L25/075, H05K1/00, F21V5/02, H01L25/16
Clasificación cooperativa F21Y2107/90, F21Y2107/00, F21Y2115/10, F21Y2107/50, F21Y2107/10, F21V5/02, H05K1/0284, H01L25/167, H01L25/0753, F21Y2105/00, H05K1/182, H01L2224/73265, H01L2224/45144, H01L2224/48091, H01L2924/3025
Clasificación europea F21V5/02, H01L25/075N, H01L25/16L
Ipc: H01L 25/16 20060101AFI20091214BHEP
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