An LED module light source with uniform light color suitable for the centrifugal sedimentation process

Abstract

The present invention provides an LED module light source with uniform light color suitable for centrifugal sedimentation process, comprising: a substrate, a circular light-emitting surface, a wire bonding area, a dam and a plurality of light-emitting diode chips; the circular light-emitting surface is located at the geometric center of the substrate; the light-emitting diode chips are all arranged on the circular light-emitting surface and are arranged on a plurality of concentric circles with increasing radii, and a gap is formed between two adjacent light-emitting diode chips on the same concentric circle, and a filler is arranged in the gap; the wire bonding area is arranged on the periphery of the circular light-emitting surface; the dam covers above the wire bonding area and forms a bowl-shaped structure with the substrate; the bowl-shaped structure is filled with encapsulation silicone and a fluorescence conversion substance. The filler of the present invention can significantly prevent the generation of phosphor flow, further block the lateral movement of the phosphor, so that the phosphor will not move in a large range, thereby improving the light color consistency.

Description

Technical Field

[0001] The present invention belongs to the technical field of LED module light sources, and particularly relates to an LED module light source with uniform light color suitable for the centrifugal sedimentation process. Background Art

[0002] In the LED packaging process, the use of the sedimentation process for phosphor can bring many advantages, such as better light color consistency, higher long-term reliability of devices, etc. There are various ways to achieve phosphor sedimentation, such as standing at room temperature, standing with slight heating, using a centrifuge, etc. The first two methods require a long time, and the standing process requires strict protection: dust prevention, moisture prevention, shock prevention, anti-static, levelness, etc. Standing with heating also requires a large number of oven equipment and consumes a large amount of electrical energy, resulting in high production costs, uncontrollable yield, and easy batch scrapping. Therefore, the centrifuge sedimentation technology with high efficiency and good economy has become the optimal choice in the industry.

[0003] However, the LED module light source based on the existing technology is not suitable for using the centrifugal sedimentation process. The reason is that the sizes of the module light sources are relatively large. When using the centrifugal sedimentation process, the size span of a single product makes it impossible to closely adhere to the centrifuge drum. Therefore, the centrifugal forces received by both sides and the center of the light source are inconsistent, resulting in a lateral component force, which causes the phosphor to deflect to the left and right sides, leading to an abnormally high concentration of phosphor on the left and right sides and an abnormally low concentration of phosphor in the central part, and the light-emitting color of the product is uneven. Another reason is that the entire substrate of the module light source has a large rigidity and is not as flexible and deformable as the bracket sheet of the SMD type LED light source. During the production process, if the substrate of the module light source cannot fit well with the centrifuge drum, the above-mentioned uneven phenomenon of the phosphor will be aggravated.

[0004] To overcome the above problems, unless the effective rotation radius of the centrifuge is made large enough so that the distance value from the rotation center to the product center approaches the distance value from the rotation center to the product edge, that is: R’→R, making the lateral component force F’ negligible. Through rough calculation, to achieve this goal, the effective rotation radius needs to reach 3 meters, which is not generally economical in the centrifuge manufacturing industry. Therefore, the method of simply expanding the effective rotation radius to overcome the lateral component force is not feasible. Summary of the Invention

[0005] In order to overcome the above technical defects, the present invention provides an LED module light source with uniform light color suitable for the centrifugal sedimentation process, which can solve the problem of uneven phosphor.

[0006] To solve the above problems, the present invention is implemented according to the following technical solutions:

[0007] An LED module light source with uniform light color suitable for the centrifugal sedimentation process includes: a substrate, a circular light-emitting surface, a wire bonding area, a dam, and a plurality of light-emitting diode chips;

[0008] The circular light-emitting surface is located at the geometric center of the substrate;

[0009] The light-emitting diode chips are all arranged on the circular light-emitting surface and are arranged on a plurality of concentric circles with increasing radii. A gap is formed between two adjacent light-emitting diode chips on the same concentric circle, and the gap is provided with a filler;

[0010] The wire bonding area is arranged on the periphery of the circular light-emitting surface;

[0011] The dam covers above the wire bonding area and forms a bowl-shaped structure with the substrate;

[0012] The bowl-shaped structure is filled with encapsulation silicone and fluorescence conversion substances;

[0013] As a further improvement of the present invention, the light-emitting diode chips on adjacent concentric circles are arranged staggeredly.

[0014] As a further improvement of the present invention, the filler is dot-coated in the gap by means of dispensing.

[0015] As a further improvement of the present invention, the filler is dot-coated in the gap by means of linear motion dispensing.

[0016] As a further improvement of the present invention, the filler and the encapsulation silicone are made of the same material, or the filler is transparent silicone, silicone resin or epoxy resin.

[0017] As a further improvement of the present invention, the filler includes fluorescence conversion substances.

[0018] As a further improvement of the present invention, the fluorescence conversion substance is phosphor.

[0019] As a further improvement of the present invention, the light-emitting diode chips are connected by bonding wires.

[0020] As a further improvement of the present invention, the substrate is a metal substrate, a ceramic substrate or a composite material substrate.

[0021] Compared with the prior art, the present invention has the following beneficial effects: At each gap formed between two adjacent light-emitting diode chips on each concentric circle, there is a filler, which is connected to the two adjacent light-emitting diode chips to form a complete and closed ring. The filler can significantly prevent the generation of phosphor flow and further block the lateral movement of the phosphor, so that the phosphor will not move in a large range, thereby improving the light color consistency. Description of the Drawings

[0022] The following further describes in detail the specific embodiments of the present invention with reference to the accompanying drawings, where:

[0023] Figure 1 It is a schematic structural diagram of the LED module light source described in Embodiment 1;

[0024] Figure 2 It is a cross-sectional view of the LED module light source described in Embodiment 1;

[0025] Figure 3 It is a layout diagram of the positions of the light-emitting diode chips described in Embodiment 1;

[0026] Figure 4 It is a partially enlarged cross-sectional view of the LED module light source described in Embodiment 1;

[0027] Figure 5 It is a partially enlarged cross-sectional view of the LED module light source described in Embodiment 2.

[0028] Marking description:

[0029] 1. Substrate; 2. Circular light-emitting surface; 3. Wire bonding area; 4. Dam; 5. Light-emitting diode chip; 6. Gap; 7. Filler; 8. Encapsulation silicone; 9. Fluorescent conversion substance; 10. Bonding wire; 11. Electrode. Specific embodiments

[0030] The following describes the preferred embodiments of the present invention with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention and are not used to limit the present invention.

[0031] Embodiment 1

[0032] An LED module light source with uniform light color suitable for the centrifugal sedimentation process in this embodiment, as shown in Figure 1 and Figure 2 , includes: a substrate 1, a circular light-emitting surface 2, a wire bonding area 3, a dam 4, and a plurality of light-emitting diode chips 5; the circular light-emitting surface 2 is located at the geometric center of the substrate 1; the light-emitting diode chips 5 are all arranged on the circular light-emitting surface 2 and are arranged on a plurality of concentric circles with increasing radii. A gap 6 is formed between two adjacent light-emitting diode chips 5 on the same concentric circle, and a filler 7 is provided in the gap 6 so that two adjacent light-emitting diode chips 5 are connected; the wire bonding area 3 is arranged on the periphery of the circular light-emitting surface 2; the dam 4 covers the wire bonding area 3 and forms a bowl-shaped structure with the substrate 1; the bowl-shaped structure is filled with an encapsulation silicone 8 and a fluorescent conversion substance 9. The fluorescent conversion substance 9 is contained in the encapsulation silicone 8.

[0033] Each gap 6 is filled, so that the filler 7 and the ring of chips alternately form a complete closed ring. It should be noted that the innermost ring of light-emitting diode chips 5 and the outermost ring of light-emitting diode chips 5 do not need to be filled. The gap 6 is formed between two adjacent light-emitting diode chips 5 and does not require additional processing. The concentric circles are the trajectory shape structure formed by the layout of the light-emitting diode chips 5 and are not physical substances.

[0034] As can be seen from Figure 3 Figure 5, starting from the central light-emitting diode chip 5, the rings of light-emitting diode chips 5 with gradually increasing radii and the filler 7 in the interval of the light-emitting diode chips 5 together form a phosphor barrier layer.

[0035] In this embodiment, at each gap 6 formed between two adjacent light-emitting diode chips 5 on each concentric circle, there is a filler 7, which is connected to the two adjacent light-emitting diode chips 5 to form a complete closed ring. The filler 7 can significantly prevent the generation of phosphor flow, play a further blocking effect on the lateral movement of the phosphor, prevent the phosphor from moving in a large range, and thus improve the light color consistency.

[0036] Furthermore, as Figure 2 shown in Figure 6, the light-emitting diode chips 5 on adjacent concentric circles are staggered. The purpose of this setting is to avoid forming an aligned or substantially aligned path, thereby preventing the generation of phosphor flow and playing a preliminary blocking effect on the lateral movement of the phosphor.

[0037] Specifically, the light-emitting diode chips 5 on adjacent concentric circles can be staggered in the following way: The light-emitting diode chips 5 located on different concentric circles are adjusted clockwise or counterclockwise along the tangent direction. This way can make the light-emitting diode chips 5 achieve the maximum degree of staggered arrangement. The light-emitting diode chips 5 on the relatively outer ring always lie outside the gap 6 on the relatively inner ring, thus avoiding the alignment or substantial alignment of the gap 6 to form a path and further preventing the generation of phosphor flow and playing a preliminary blocking role on the lateral movement of the phosphor.

[0038] As Figure 4 shown in Figure 7, the filler 7 is dot-coated in the gap 6 by means of dispensing, thereby forming a three-dimensional structure connecting two light-emitting diode chips 5. This part of the structure can be a regular shape or an irregular shape, and both can achieve the purpose designed in this embodiment.

[0039] Preferably, the filler 7 is made of the same material as the encapsulation silicone 8, or the filler 7 is transparent silicone, silicone resin, or epoxy resin. In addition, the filler 7 may or may not include the fluorescence conversion substance 9.

[0040] Preferably, the fluorescence conversion substance 9 is a phosphor, which can be one or a combination of red, green, yellow and other phosphors.

[0041] The light-emitting diode chips 5 are connected by bonding wires 10 and connected in a certain series, parallel, or series-parallel relationship in an appropriate manner, and are electrically connected to the arc-shaped wire bonding area 3. The light-emitting diode chips 5 can be blue, red, green, ultraviolet or other color LED light-emitting diode chips 5, or a combination of multiple light-emitting diode chips 5;

[0042] Preferably, the substrate 1 is a metal substrate 1, a ceramic substrate 1 or a composite material substrate 1.

[0043] In addition, the LED module light source of this embodiment further includes other necessary elements such as positive and negative electrodes, as well as characters, identification symbols, Ts temperature measurement point marks, etc.

[0044] In summary, this embodiment has the following technical effects: The "staggered" distribution of the light-emitting diode chips 5 on adjacent two rings forms a blocking effect, and a plurality of concentric blocking rings formed by the adjacent light-emitting diode chips 5 on the same ring and the transparent filling silicone filling part therebetween have a significant blocking effect on the lateral movement of the phosphor pushed by the lateral component force generated during centrifugal sedimentation. When the radially moving phosphor encounters the blocking ring, its movement is restricted, thereby effectively preventing too much phosphor from accumulating on the outermost side of the light-emitting surface, resulting in uneven light color.

[0045] Embodiment 2

[0046] This embodiment provides another light color-uniform LED module light source suitable for the centrifugal sedimentation process, as Figure 5 shown. The difference from Embodiment 1 is that the filler 7 is dot-coated in the gap 6 by means of linear motion dispensing, so that the filler 7 naturally forms a three-dimensional structure connecting two light-emitting diode chips 5 between the chips. Similarly, the filler 7 can be in a regular shape or an irregular shape, and both can achieve the purpose designed by the present invention. The filler 7 formed by this method is an integral structure on the entire ring, and part of the filler 7 will fall on the upper surface of the light-emitting diode chip 5. Since the filler 7 used is a transparent silicone material, it does not affect its original function and the function designed in this case.

[0047] For the specific implementation process of this embodiment, please refer to Embodiment 1 and will not be elaborated here one by one.

[0048] The above are only the preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. An LED module light source with uniform light color suitable for the centrifugal sedimentation process, characterized in that, Including: A substrate, a circular light-emitting surface, a wire bonding area, a dam, and a plurality of light-emitting diode chips; The circular light-emitting surface is located at the geometric center of the substrate; The light-emitting diode chips are all arranged on the circular light-emitting surface and are arranged on a plurality of concentric circles with increasing radii. A gap is formed between two adjacent light-emitting diode chips on the same concentric circle, and the gap is provided with a filler; The wire bonding area is arranged on the periphery of the circular light-emitting surface; The dam covers above the wire bonding area and forms a bowl-shaped structure with the substrate; The bowl-shaped structure is filled with encapsulation silicone and a fluorescence conversion substance.

2. The LED module light source according to claim 1, characterized in that, The light-emitting diode chips on adjacent concentric circles are arranged staggeredly.

3. The LED module light source according to claim 1, characterized in that, The filler is dot-coated in the gap by a dispensing method.

4. The LED module light source according to claim 1, wherein, The filler is dot-coated in the gap by a linear motion dispensing method.

5. The LED module light source according to any one of claims 1 to 4, characterized in that The filler and the encapsulation silicone are made of the same material, or the filler is transparent silicone, silicone resin, or epoxy resin.

6. The LED module light source according to claim 5, characterized in that, The filler includes a fluorescence conversion substance.

7. The LED module light source according to claim 1, characterized in that The light-emitting diode chips are connected by bonding wires.

8. The LED module light source according to claim 1, wherein The substrate is a metal substrate, a ceramic substrate, or a composite material substrate.

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