CN102095163B - LED plastic integration lens - Google Patents

Abstract

An LED shaping integrated lens, a shaping element integrating primary light distribution and secondary light distribution, one side is a refraction surface with optical power, which is used to collect and converge the light of the chip, and the other side is a diffraction surface , based on the principle that the modulation of the beam phase redistributes the far-field spot, the output light of the chip is shaped, and the output beam that meets the use requirements is obtained. It has simple system structure, flat surface, high integration, small size, and light weight; no secondary optical assembly is required, accurate positioning, and convenient use; various special functions can be obtained; good sealing performance, effectively preventing dust and mist from affecting the LED Significant advantages such as impact on chip performance.

Description

A LED shaping integrated lens

technical field

The invention belongs to the field of LEDs and relates to an LED shaping integrated lens.

Background technique

Light Emitting Diode (LED) is a semiconductor solid-state light-emitting device, which has unique advantages such as small size, long life, and low energy consumption. Under the condition of the same lighting brightness, LED lamps can save 40% to 50% more electricity than ordinary lamps on average, and the later maintenance costs are extremely low. There is almost no maintenance cost within 3 to 5 years after installation and use; secondly, LED lamps do not contain Mercury, lead and other harmful substances and harmful gases are contained in ordinary energy-saving lamps commonly sold in the market; third, the service life is long, with an average service life of 50,000 to 100,000 hours, which is 3 to 5 times that of ordinary lamps. From the perspective of long-term development, LED technology has become an important technology for energy saving and emission reduction, and a new important growth point for economic development.

The LED chip (chip) emits light at 360 degrees theoretically. In actual use, the chip is fixed and packaged on the LED bracket, and the maximum light emitting angle of the chip is 180 degrees. The commonly used technology is to effectively collect all the light rays of the chip through a lens to obtain light output angles such as 160 degrees, 140 degrees, 120 degrees, and 90 degrees (different needs). The primary lens is mostly made of PMMA or silicone material, which is directly encapsulated (or glued) on the LED chip holder, and becomes a whole with the LED. However, the large-angle light from the primary lens cannot meet the practical needs. Usually, the secondary lens is used to re-condense the large-angle light (generally 90-120 degrees) of the LED chip into any desired angle of 5 degrees to 80 degrees. Angle. Secondary lens and LED are two independent objects, but they are inseparable in application. Due to the differences in structure, packaging and light characteristics of LED chips of different specifications from major LED manufacturers, it is necessary not only to simulate and analyze the optical performance of the secondary lens when selecting the secondary lens, but also to consider the relationship between the secondary lens and the LED chip. Assembly problem. Targeted design, fabrication and assembly are necessary to obtain good performance.

Contents of the invention

The technical problem to be solved by the present invention is: to overcome the shortcomings of the existing multiple light distribution technology, and to adopt an LED shaping integrated lens to realize the shaping of the LED chip and meet the use requirements.

The technical solution adopted by the present invention to solve the technical problem is: according to the characteristics of the chip and the requirements for use, design and manufacture an integrated shaping lens, one side is a refracting surface with a focal power, and the integrated lens is used to converge the light of the chip; in addition One side is a diffractive surface to shape the output light of the LED light-emitting chip. A shaping element that integrates primary light distribution and secondary light distribution. One side is a refraction surface with optical power, which is used to collect and converge the light of the LED light-emitting chip, and the other side is a diffraction surface. The phase modulation makes the principle of redistribution of the far-field spot, and the output light of the chip is shaped to obtain the output beam that meets the use requirements. The integrated lens adopts the design method of integrating the micro-optical diffraction element and the refraction element, and the light after passing through the refraction surface re-modulates the phase and intensity distribution through the diffraction surface. In the process of processing, the diffractive surface is made by micromachining (lithography-transfer-overlay-transfer) of binary micro-optical elements, and the refraction surface is processed by conventional grinding technology, and the refraction surface and the diffraction surface need to be aligned .

The material of the integrated lens is PMMA, or silica gel, or PDMS, or PC, or glass.

The integrated lens is directly packaged on the LED chip support by bonding or fixing by mechanical parts, without secondary optical light distribution.

The integrated lens is formed into a circle, or a rectangle, or a ring, or a pattern, or a required distribution after lens shaping.

In the integrated lens, the outgoing angle of the light after being shaped by the lens is 5 degrees to 120 degrees.

The integrated lens is a single lens or a lens array, the number of the array is from 1 to 1000, and the size of the lens is from 1 mm to 500 mm.

The integrated lens can be individually assembled on a single chip for low-power use, or combined into a module, combined with mechanical light distribution, and assembled on a chip array to meet the requirements of high-power use.

The integrated lens can be used in LED indoor lights, or LED street lights, or LED vehicle lights, or LED display screens, or LED backlight sources.

The design of the integrated lens diffraction surface is based on the principle of diffraction, using the modulation effect of the structure on the beam phase to redistribute the far-field spot; the design of the refraction surface is based on the principle of refraction, using the lens surface to converge and diverge light , to realize the principle design of redistribution of light energy.

The integrated lens diffractive surface can be quantized with two steps, quantized with four steps, or quantized with eight steps according to the requirements of use and different efficiencies.

Compared with the prior art, the present invention has the following advantages:

(1) The LED shaping integrated lens system of the present invention is simple in structure, smooth in surface, high in integration, small in size and light in weight;

(2) The LED shaping integrated lens of the present invention does not require secondary optical assembly, and is accurate in positioning and easy to use;

(3) Various special functions can be obtained by using the LED shaping integrated lens of the present invention.

(4) The LED shaping integrated lens of the present invention has good sealing performance and effectively avoids the influence of dust and aerosol on the performance of the LED chip.

Description of drawings

Fig. 1 is a schematic diagram of the LED shaping integrated lens of the present invention;

Fig. 2 is a schematic block diagram of the LED shaping integrated lens of the present invention;

3 is a schematic diagram of a circular output spot obtained in Embodiment 1 of the present invention;

4 is a schematic diagram of a 5×6 module used in Embodiment 2 of the present invention;

5 is a schematic diagram of a rectangular output spot obtained in Example 2 of the present invention;

Fig. 6 is a schematic diagram of the annular output spot obtained in Embodiment 3 of the present invention;

FIG. 7 is a schematic diagram of multi-ring output light spots obtained in Embodiment 3 of the present invention.

Detailed ways

The present invention will be described in detail below in conjunction with the accompanying drawings and specific embodiments. But the following examples are only limited to explain the present invention, and the protection scope of the present invention should include the entire content of the claims, and those skilled in the art can realize the entire contents of the claims of the present invention through the following examples.

An integrated lens for LED shaping. According to the characteristics of the chip and the requirements for use, the integrated shaping lens is designed and manufactured. One side is a refracting surface with optical power, which is used to converge the light of the chip; the other side is a diffractive surface to The effect of shaping the chip output light.

The realization process of the integrated lens is as follows: First, clarify the use requirements, determine the type of LED light-emitting chip to be used, that is, clarify the input and output parameters of the optical system. Secondly, the optical design is carried out to obtain the parameters of the LED shaping integrated lens, such as the refractive index of the lens material, the focal length and aperture of the refraction surface, the diffraction efficiency of the diffraction surface, the number of quantized steps, and the processing line width. Through the optical system simulation software, the system simulation results are obtained to see if the requirements are met, otherwise, the parameters of the integrated lens are optimized again until the input and output requirements are met. Then, the integrated lens is developed by means of micro-optical processing, and the single-chip assembly and testing are carried out. If an array is required to meet the requirements of high-power use, the single chip and the integrated lens are considered as a whole, and the module effect is obtained through mechanical light distribution.

Example 1

An integrated shaping lens for a low-power single chip. Requirements for the use of LED lights: single LED car lights, power 1 ~ 2W, the exit surface is circular, and the angle is 90°. At present, a single LED chip can meet the power requirements, so a single chip is used, such as an Osram 1.5W chip, with an emission angle of 160° and a Lambertian illuminant. The design and production of the integrated plastic lens is a single lens, the lens diameter is 500mm, the material is PMMA, the lower surface is a refractive surface, the focal length is 2mm, and the upper surface is a diffractive surface. Due to the low efficiency requirements, two-step quantization is used, and the efficiency is about 80. %. The schematic diagram of the shaping lens is shown in Figure 1, which is directly bonded to the LED chip substrate using silicone rubber. Through ZMAX simulation, the schematic diagram of the shaping effect is shown in Figure 3. After passing through the shaping lens, a circular light spot is output, and the emission angle is 89°. The processing process of the integrated lens is to process the refraction surface first, then use the double-sided exposure machine to align the photolithography to process the diffraction surface on the other side of the substrate, and use the photolithography method to transfer the pattern to the photoresist surface of the substrate. Then, the photolithographic pattern is transferred to the substrate by plasma etching technology to form the required integrated lens.

Example 2

An integrated shaping lens for high-power LED street lamps. Requirements for use: power greater than 150W, roadside lighting, lamp height 10m, rectangular exit surface, area 10m×25m. 150 chips of 1W are used to form 5 modules according to 6×5. Through calculation, it can be known that the emission angle in the road width direction is 45°, and the emission angle in the direction along the road is 51°. Design and manufacture a 6×5 5-module integrated plastic lens array with a lens diameter of 10mm. The diffraction efficiency of the required diffraction elements is high, so eight-step quantization is used, and the material is PC. Process the refractive surface first, then position and process a two-step diffractive surface on the reverse side of the substrate, form a four-step diffractive surface by overlaying, and form an eight-step diffractive surface by overlaying again. The schematic diagram of the 5×6 module layout is shown in Figure 4, which is fixed on the PCB board with the chip array soldered by mechanical screws. The schematic diagram of the output spot effect after passing through the lens is shown in Figure 5, and the area is about 10m×25m.

Example 3

An integrated shaping lens for an LED display lamp. Requirements for use: the output light output angle is 5°, and the spot shape is ring. Design and manufacture the integrated plastic lens. The diffraction surface of the integrated lens adopts four-step quantization. According to the different requirements of use, different diffraction surface shapes are designed and manufactured by micro-fabrication. The lens diameter is 50mm, and the single-ring plastic effect is obtained as shown in the figure. 6, the multi-ring shaping output is shown in Figure 7.

Claims (7)

1. A manufacturing method of an LED shaping integrated lens, characterized in that: the lens is a shaping element integrating primary light distribution and secondary light distribution, and one side thereof is a refracting surface with a focal power, The integrated lens is used to collect and converge the light of the LED light-emitting chip, and the other side is a diffraction surface. Based on the principle that the modulation of the beam phase makes the far-field spot redistributed, the output light of the LED light-emitting chip is shaped, and the light exits after shaping. The angle is 5 degrees to 120 degrees, and the output light beam that meets the use requirements is obtained; the integrated lens is directly packaged on the LED chip support by bonding or mechanical parts to meet the required use requirements. The specific implementation is as follows: First, clarify the use requirements, determine the type of LED light-emitting chip to use, that is, clarify the input and output parameters of the optical system; second, perform optical design to obtain the parameters of the LED shaping integrated lens, including the refractive index of the lens material, the focal length of the refraction surface, and the aperture , the diffraction efficiency of the diffraction surface, the number of quantized steps, and the processing line width. Through the optical system simulation software, the system simulation results are obtained to see if the requirements are met. Otherwise, the parameters of the integrated lens are optimized again until the input and output requirements are met; The integrated lens is developed by means of optical processing, and single-chip assembly and testing are carried out. If an array is required to meet the requirements of high-power use, the single-chip and integrated lens are considered as a whole, and the model is obtained through mechanical light distribution. group effect; The design of the integrated lens diffraction surface is based on the principle of diffraction, using the modulation effect of the structure on the beam phase to redistribute the far-field spot; the design of the refraction surface is based on the principle of refraction, using the lens surface to converge and diverge light , to realize the principle design of redistribution of light energy. 2 . The method for manufacturing an LED shaping integrated lens according to claim 1 , wherein the material of the integrated lens is PMMA, or silica gel, or PDMS, or PC, or glass. 3 . The method for manufacturing an LED shaping integrated lens according to claim 1 , wherein the lens is shaped to form a circle or a rectangle. 4 . 4. The manufacturing method of LED shaping integrated lens according to claim 1, characterized in that: said integrated lens is a single lens, or a lens array, the number of arrays is from 1 to 1000, and the lens size is from 1mm ~500mm. 5. The manufacturing method of LED shaping integrated lens according to claim 1, characterized in that: said integrated lens can be individually assembled on a single chip for low power use, or combined into modules, combined with mechanical Light distribution, assembled on the chip array to meet the requirements of high power use. 6. The manufacturing method of LED shaping integrated lens according to claim 1, characterized in that: said integrated lens can be used for LED indoor lights, or LED street lights, or LED car lights, or LED display screens, or LED backlight. 7. The manufacturing method of an LED shaping integrated lens according to claim 1, characterized in that: the diffractive surface of the integrated lens can be quantized with two steps, or quantized with four steps, or Eight-step quantization.

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