A self-adjusting light-emitting device and a manufacturing method thereof

Abstract

The present invention discloses a self-adjusting light-emitting device and a manufacturing method thereof. The self-adjusting light-emitting device includes: a substrate, on which a recess is provided; at least one light-emitting unit fixedly arranged in the recess; a shaping member fixed in the recess; a cavity is provided in the shaping member, and the upper and lower end faces of the shaping member are open; the shape of the shaping member is a frustum shape, a truncated cone shape, a cylindrical shape or a spherical frustum shape; the light-emitting unit is located in the cavity; a phosphor colloid is formed and fixed in the cavity to cover the light-emitting unit. The present invention provides a self-adjusting light-emitting device and a manufacturing method thereof, which can enable the same light-emitting device to exhibit different color temperature spectral performances, improve convenience, and is beneficial to reducing the manufacturing cost of lamps.

Description

Technical Field

[0001] The present invention belongs to the technical field of LED production, and particularly relates to a self-adjusting light-emitting device and a manufacturing method thereof. Background Art

[0002] The development of solid-state lighting technology is changing rapidly. Compared with traditional fluorescent lamps and energy-saving lamps, the excellent performance of light-emitting diodes makes their applications in general lighting and special fields more and more popular.

[0003] In daily life, the requirements for light quality in some scenarios are gradually increasing. Usually, various different elements need to be added to increase the light performance regulation of artificial light sources, such as color temperature adjustment, color change, small light-emitting surfaces, secondary lens light distribution, etc. to meet specific lighting needs. The existing dimming methods generally achieve this by controlling the proportion of different color temperature and different color packages in the lamp; or by adjusting the formula of red and green phosphors in the same package to achieve the target color gamut of the package. However, these methods often require a combination of many different devices to achieve different light performances, and a single light-emitting device can only exhibit a fixed color temperature and spectral performance, with low convenience and high manufacturing costs for lamps.

[0004] Therefore, a new technology is needed to solve the problems in the prior art that a single light-emitting device can only exhibit a fixed color temperature and spectral performance, with low convenience and high manufacturing costs for lamps. Summary of the Invention

[0005] To solve the above problems in the prior art, the present invention provides a self-adjusting light-emitting device and a manufacturing method thereof, which can enable the same light-emitting device to exhibit different color temperature and spectral performances, improve convenience, and is beneficial to reducing the manufacturing cost of lamps.

[0006] The present invention adopts the following technical solutions:

[0007] A self-adjusting light-emitting device, comprising:

[0008] A substrate, on which there is a depression;

[0009] At least one light-emitting unit, fixedly arranged in the depression;

[0010] A shaping member, fixed in the depression; there is a cavity in the shaping member, and the upper and lower end faces of the shaping member are open; the shape of the shaping member is a frustum shape, a truncated cone shape, a cylindrical shape or a spherical frustum shape; the light-emitting unit is located in the cavity;

[0011] A phosphor colloid, formed and fixed in the cavity to cover the light-emitting unit.

[0012] As a further improvement of the technical solution of the present invention, the material of the shaping member is a light guide material.

[0013] As a further improvement of the technical solution of the present invention, it further includes a light guide medium filled between the side wall of the recess and the side wall of the shaping member.

[0014] As a further improvement of the technical solution of the present invention, the light guide material and / or the light guide medium is one or more of light guide silica gel, light guide resin, light guide glass, and light guide acrylic.

[0015] As a further improvement of the technical solution of the present invention, the material of the shaping member is non-light guide silica gel, non-light guide resin, non-light guide glass, non-light guide acrylic or metal, and the inner surface of the shaping member is covered with a reflective layer.

[0016] The present invention also provides a manufacturing method of the self-adjusting light-emitting device as described above, including the following steps:

[0017] S1. Install the light-emitting unit in the recess of the substrate;

[0018] S2. Fix the separator in the recess; the separator is provided with a through slot, and the shaping member can be installed in the slot, and the bottom of the slot is closely attached to the bottom of the shaping member after installation; the light-emitting unit is surrounded in the slot;

[0019] S3. Add uncured phosphor colloid into the slot so that the phosphor colloid covers the light-emitting unit;

[0020] S4. Install the shaping member in the slot before the phosphor colloid solidifies, so that the phosphor colloid in the slot is extruded into the cavity, and the cavity shapes the phosphor colloid;

[0021] S5. Remove the separator from the substrate before the phosphor colloid solidifies;

[0022] S6. Fix the shaping member to the substrate.

[0023] As a further improvement of the technical solution of the present invention, in step S6, the shaping member is fixed to the substrate after the phosphor colloid is cured.

[0024] 8. The manufacturing method of the self-adjusting light-emitting device according to claim 7, characterized in that when the material of the shaping member is a non-light guide material, there is also a step S31 between step S3 and step S4;

[0025] S31. Cover the inner surface of the shaping member with a reflective layer by sputtering, evaporation, electroplating, deposition or etching process.

[0026] As a further improvement of the technical solution of the present invention, when the material of the shaping member is a light guide material, step S7 is further included after step S6;

[0027] S7. Fill a light guide medium between the side wall of the depression and the side wall of the shaping member.

[0028] As a further improvement of the technical solution of the present invention, in step S6, an adhesive is filled between the shaping member and the substrate to fix the shaping member to the substrate.

[0029] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0030] 1. In the self-adjusting light-emitting device of the present invention, the shaping member has various shapes. By selecting shaping members of different shapes, the morphological distribution of the phosphor colloid covering the surface of the light-emitting unit can be effectively controlled, thereby realizing the rapid adjustment of optical properties such as color temperature, color point, and spectrum;

[0031] 2. The shape of the shaping member is a frustum shape, a truncated cone shape, a cylindrical shape or a spherical frustum shape, so that the area of the upper end opening of the shaping member is smaller than the opening area of the depression, that is, the light-emitting area of the shaping member is smaller than the light-emitting area of the substrate. In this way, the near-field optics can be changed, which is more conducive to secondary optical design. In actual production, the secondary optical design of the present invention can also effectively improve the target accuracy rate after dotting the phosphor and improve the production yield; at the same time, the shaping member reduces the space in the depression of the substrate and reduces the material consumption of the phosphor colloid;

[0032] 3. The self-adjusting light-emitting device of the present invention can conveniently change the optical characteristics without re-producing a new light source, shortening the production cycle and saving the manufacturing cost. Description of the Drawings

[0033] The following further details the technology of the present invention in conjunction with the drawings and specific embodiments:

[0034] Figure 1 It is a cross-sectional view of an embodiment of the self-adjusting light-emitting device of the present invention with a light guide medium and the shaping member being frustum-shaped or truncated cone-shaped;

[0035] Figure 2 It is a cross-sectional view of an embodiment of the self-adjusting light-emitting device of the present invention with a light guide medium and the shaping member being cylindrical;

[0036] Figure 3 It is a cross-sectional view of an embodiment of the self-adjusting light-emitting device of the present invention with a light guide medium and the shaping member being spherical frustum-shaped;

[0037] Figure 4It is a cross-sectional view of an embodiment in which the self-adjusting light-emitting device of the present invention is fixed by an adhesive;

[0038] Figure 5 is Figure 1 The top view when the light guide medium has not been filled in the embodiment of;

[0039] Figure 6 It is a cross-sectional view when the separator is installed when the phosphor colloid is basically added later;

[0040] Figure 7 is in Figure 6 The cross-sectional view when the shaping member is installed on the basis of;

[0041] Figure 8 is in Figure 7 The top view of.

[0042] Reference numerals:

[0043] 1 - Substrate; 11 - Depression;

[0044] 2 - Light-emitting unit;

[0045] 3 - Shaping member; 31 - Cavity;

[0046] 4 - Phosphor colloid;

[0047] 5 - Light guide medium;

[0048] 6 - Adhesive;

[0049] 7 - Separator; 71 - Slotted. Detailed implementation manners

[0050] The concept, specific structure and technical effects of the present invention will be clearly and completely described below in conjunction with the embodiments and the drawings, so as to fully understand the purpose, scheme and effects of the present invention. It should be noted that, without conflict, the embodiments in this application and the features in the embodiments can be combined with each other. The same reference numerals used throughout the drawings indicate the same or similar parts.

[0051] It should be noted that, unless otherwise specified, when a certain feature is referred to as "fixed" or "connected" to another feature, it can be directly fixed or connected to another feature, or indirectly fixed or connected to another feature. In addition, the up, down, left, right, etc. descriptions used in the present invention are only relative to the mutual positional relationship of the components of the present invention in the drawings.

[0052] Embodiment 1:

[0053] Referring to Figures 1 to 5, this embodiment discloses a self - regulating light - emitting device, including a substrate 1, at least one light - emitting unit 2, a shaping member 3, and a phosphor colloid 4.

[0054] Among them, a recess 11 is provided on the substrate 1. The substrate 1 can specifically be an LED bracket. The light - emitting unit 2 is fixedly arranged in the recess 11. The light - emitting unit 2 is specifically a diode light - emitting unit 2, which is installed on the LED bracket to ensure its normal electrical connection with an external power source.

[0055] The shaping member 3 is fixed in the recess 11; a cavity 31 is provided in the shaping member 3, and the upper and lower end faces of the shaping member 3 are open - ended; the shape of the shaping member 3 is trapezoidal, frustum - shaped, cylindrical, or spherical - frustum - shaped; the light - emitting unit 2 is located in the cavity 31. As Figure 1 FIG. 1 is a cross - sectional view when the shape of the shaping member 3 is trapezoidal or frustum - shaped; FIG. 2 is a cross - sectional view when the shape of the shaping member 3 is cylindrical, as Figure 3 FIG. 3 is a cross - sectional view when the shape of the shaping member 3 is spherical - frustum - shaped.

[0056] Among them, the shape of the cavity 31 can be trapezoidal, frustum - shaped, cylindrical, or spherical - frustum - shaped. One shape of the shaping member 3 can be matched with different shapes of the cavity 31, so that the shape of the phosphor colloid 4 after shaping has a large difference, and thus the optical properties such as color temperature, color point, and spectrum are also different. For shaping members 3 with different shapes, even if the shapes of their cavities 31 are the same, due to the different shapes of the shaping members 3 themselves, for the quantitative phosphor colloid 4, its optical properties such as color temperature, color point, and spectrum are also different.

[0057] The phosphor colloid 4 is formed and fixed in the cavity 31 to cover the light - emitting unit 2, and the shape of the phosphor colloid 4 is adapted to the shape of the cavity 31. The cavity 31 of the shaping member 3 plays a role in shaping the shape of the phosphor colloid 4 during the manufacturing process of this self - regulating light - emitting device. By selecting shaping members 3 with different shapes, the surface area and height of the phosphor colloid 4 after shaping will be different.

[0058] Based on the above structure, in the self-adjusting light-emitting device of the present invention, the shaping member 3 has various shapes. By selecting shaping members 3 with different shapes, the morphological distribution of the phosphor colloid 4 covering the surface of the light-emitting unit 2 can be effectively controlled, thereby achieving rapid adjustment of optical properties such as color temperature, color point, and spectrum. The shape of the shaping member 3 is a frustum shape, a truncated cone shape, a cylindrical shape, or a spherical frustum shape, such that the area of the upper opening of the shaping member 3 is smaller than the area of the opening of the recess 11, that is, the light-emitting area of the shaping member 3 is smaller than the light-emitting area of the substrate 1. This can change the near-field optics and is more conducive to secondary optical design. In actual production, the secondary optical design of the present invention can also effectively improve the aiming accuracy after dotting the phosphor and increase the production yield. At the same time, the shaping member 3 reduces the space in the recess 11 of the substrate 1 and reduces the material usage of the phosphor colloid 4. The self-adjusting light-emitting device of the present invention can conveniently change the optical characteristics without re-producing a new light source, shortening the production cycle and saving manufacturing costs.

[0059] Preferably, as Figures 1 to 3 shown, the material of the shaping member 3 is a light-guiding material, which can change the emission direction of the light emitted by the light-emitting unit 2, facilitating near-field optical adjustment.

[0060] Preferably, the self-adjusting light-emitting device further includes a light-guiding medium 5 filled between the side wall of the recess 11 and the side wall of the shaping member 3, as Figures 1 to 3 shown. The function of the light-guiding medium 5 is the same as that of the shaping member 3 made of a light-guiding material, both of which can change the emission direction of the light emitted by the light-emitting unit 2, facilitating near-field optical adjustment.

[0061] Among them, the light-guiding material and / or the light-guiding medium 5 is one or more of light-guiding silica gel, light-guiding resin, light-guiding glass, and light-guiding acrylic. The materials of the shaping member 3 and the light-guiding medium 5 can be the same or different, and their combination can produce different adjustment effects on the emission direction of the light emitted by the light-emitting unit 2.

[0062] On the other hand, the material of the shaping member 3 can also be set as non-light-guiding silica gel, non-light-guiding resin, non-light-guiding glass, non-light-guiding acrylic, or metal, and the inner surface of the shaping member 3 is covered with a reflective layer. The reflective layer is a high-reflection performance material layer or a Bragg reflective layer, which is beneficial to improving the light extraction efficiency.

[0063] Example 2:

[0064] This example discloses a manufacturing method of the self-adjusting light-emitting device as in Example 1 above, as Figures 1 to 8 , including the following steps:

[0065] S1. Mount the light-emitting unit 2 in the recess 11 of the substrate 1 by means of metal welding, wire bonding or conductive adhesive bonding, ensuring that the light-emitting unit 2 can be normally electrically connected;

[0066] S2. Fix the separator 7 in the recess 11; wherein, the separator 7 is provided with a through slot 71 from top to bottom, and the shaping member 3 can be installed in the slot 71, and after installation, the bottom of the slot 71 is in close contact with the bottom of the shaping member 3; the light-emitting unit 2 is surrounded in the slot 71; the function of the separator 7 is to separate the side wall of the recess 11 from the phosphor colloid 4 and the shaping member 3 in the subsequent steps; as Figures 6 to 8 shown;

[0067] S3. Add the unfixed phosphor colloid 4 into the slot 71 so that the phosphor colloid 4 covers the light-emitting unit 2. The unfixed phosphor colloid 4 is in a jelly-like state and has a certain fluidity;

[0068] S4. Before the phosphor colloid 4 solidifies, install the shaping member 3 in the slot 71. Since the bottom of the slot 71 is in close contact with the bottom of the shaping member 3 after installation, the shaping member 3 occupies part of the space in the slot 71, so that the phosphor colloid 4 in the slot 71 is extruded into the cavity 31, and then the cavity 31 can shape the phosphor colloid 4;

[0069] S5. Remove the separator 7 from the substrate 1 before the phosphor colloid 4 solidifies, to prevent the phosphor colloid 4 adhering to the separator 7 from fixing the separator 7 to the substrate 1 and the shaping member 3;

[0070] S6. Fix the shaping member 3 to the substrate 1 to complete the basic production of this self-adjusting light-emitting device.

[0071] Among them, in the step S6, there are two specific fixing methods. One of the fixing methods is: after the phosphor colloid 4 is cured, fix the shaping member 3 to the substrate 1, as Figures 1 to 3 shown.

[0072] Preferably, in order to improve the light extraction efficiency, when the material of the shaping member 3 is a non-light guiding material, there is also a step S31 between the step S3 and the step S4;

[0073] S31. Cover the inner surface of the shaping member 3 with a reflective layer by means of sputtering, evaporation, electroplating, deposition or etching process.

[0074] Or, in order to facilitate the near-field optical adjustment of this self-adjusting light-emitting device, when the material of the shaping member 3 is a light guiding material, there is also a step S7 after the step S6;

[0075] S7. Fill a light guiding medium 5 between the side wall of the recess 11 and the side wall of the shaping member 3. The filled light guiding medium 5 can change the emission direction of the light emitting unit 2, facilitating near-field optical adjustment.

[0076] In the step S6, another fixing method is as follows: in the step S6, an adhesive is filled between the shaping member and the substrate to fix the shaping member and the substrate. As Figure 4 shown, the adhesive can specifically be glue.

[0077] For other contents of the self-adjusting light emitting device and its manufacturing method according to the present invention, reference can be made to the prior art and will not be elaborated herein.

[0078] The above are only the preferred embodiments of the present invention, and do not impose any form of limitation on the present invention. Therefore, any modification, equivalent change, and modification made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A self - regulating light - emitting device, characterized in that, comprising: a substrate, with a recess provided on the substrate; at least one light - emitting unit, fixedly arranged in the recess; a shaping member, fixed in the recess; a cavity is provided in the shaping member, and the upper and lower end faces of the shaping member are open - ended; the shape of the shaping member is trapezoidal, frustum - shaped, cylindrical or spherical - frustum - shaped; the light - emitting unit is located in the cavity; a phosphor colloid, formed and fixed in the cavity to cover the light - emitting unit; when the material of the shaping member is a light - guiding material, it further includes a light - guiding medium filled between the side wall of the recess and the side wall of the shaping member; when the material of the shaping member is a non - light - guiding material, the inner surface of the shaping member is covered with a reflective layer; the non - light - guiding material is non - light - guiding silica gel, non - light - guiding glass, non - light - guiding acrylic or metal.

2. The self - regulating light - emitting device according to claim 1, characterized in that: the light - guiding material and / or the light - guiding medium is one or more of light - guiding silica gel, light - guiding glass and light - guiding acrylic.

3. The manufacturing method of the self - regulating light - emitting device according to claim 1 or 2, characterized in that, comprising the following steps: S1. Install the light - emitting unit in the recess of the substrate; S2. Fix a separator in the recess; the separator is provided with a through - slot from top to bottom, and the shaping member can be installed in the through - slot, and after installation, the bottom of the through - slot is in close contact with the bottom of the shaping member; the light - emitting unit is surrounded in the through - slot; S3. Add an uncured phosphor colloid into the through - slot to make the phosphor colloid cover the light - emitting unit; S4. Before the phosphor colloid solidifies, install the shaping member in the through - slot, so that the phosphor colloid in the through - slot is extruded into the cavity, and the cavity shapes the phosphor colloid; S5. Remove the separator from the substrate before the phosphor colloid solidifies; S6. Fix the shaping member to the substrate.

4. The manufacturing method of the self - regulating light - emitting device according to claim 3, characterized in that, in step S6, after the phosphor colloid is cured, the shaping member is fixed to the substrate.

5. The manufacturing method of the self - regulating light - emitting device according to claim 4, characterized in that, when the material of the shaping member is a non - light - guiding material, there is also step S31 between step S3 and step S4; S31. Cover the inner surface of the shaping member with a reflective layer by sputtering, evaporation or electroplating process.

6. The manufacturing method of the self - regulating light - emitting device according to claim 4, characterized in that, when the material of the shaping member is a light - guiding material, there is also step S7 after step S6; S7. Fill a light - guiding medium between the side wall of the recess and the side wall of the shaping member.

7. The manufacturing method of the self - regulating light - emitting device according to claim 3, characterized in that, in step S6, an adhesive is filled between the shaping member and the substrate to fix the shaping member to the substrate.

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