WO2011085529A1 - Led光源的照明灯具模块 - Google Patents

Led光源的照明灯具模块 Download PDF

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Publication number
WO2011085529A1
WO2011085529A1 PCT/CN2010/001002 CN2010001002W WO2011085529A1 WO 2011085529 A1 WO2011085529 A1 WO 2011085529A1 CN 2010001002 W CN2010001002 W CN 2010001002W WO 2011085529 A1 WO2011085529 A1 WO 2011085529A1
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WO
WIPO (PCT)
Prior art keywords
light source
led light
heat sink
led
mounting panel
Prior art date
Application number
PCT/CN2010/001002
Other languages
English (en)
French (fr)
Inventor
楼满娥
郭邦俊
Original Assignee
浙江迈勒斯照明有限公司
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Filing date
Publication date
Application filed by 浙江迈勒斯照明有限公司 filed Critical 浙江迈勒斯照明有限公司
Publication of WO2011085529A1 publication Critical patent/WO2011085529A1/zh

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
    • F21V29/77—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20—Light sources comprising attachment means
    • F21K9/23—Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
    • F21V29/76—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2105/00—Planar light sources
    • F21Y2105/10—Planar light sources comprising a two-dimensional array of point-like light-generating elements
    • F21Y2105/14—Planar light sources comprising a two-dimensional array of point-like light-generating elements characterised by the overall shape of the two-dimensional array
    • F21Y2105/16—Planar light sources comprising a two-dimensional array of point-like light-generating elements characterised by the overall shape of the two-dimensional array square or rectangular, e.g. for light panels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • the invention relates to an LED light source lamp, in particular to a structure of a lighting lamp module using a high-power LED as a light source, and is used for a high-power, high-lumen output lamp such as a street lamp, a tunnel lamp, a floodlight and a wall washer. Module. Background technique
  • LED light sources have played an increasingly important role in functional lighting, such as street lights, tunnel lights, flood lights and wall washers.
  • street lamps on the market are patched on dozens of even hundreds of LED light sources on an aluminum substrate, and then the aluminum substrate is mounted in the street lamp housing.
  • the LED light source is damaged, it is necessary to open the tempered glass cover of the lamp, remove the lens or reflector, and then remove the power cord. It is not difficult to see that such a structure may cause difficulty in replacement, or even replacement, which causes great inconvenience to maintenance and brings economic loss to the user.
  • different models of lamps of this structure require different driving power sources, different light distribution structures, different heat dissipation and waterproof structures. Due to the complicated structure, especially when multiple models are combined, it will bring problems such as long design period and time-consuming labor for the manufacturer.
  • the heat dissipation problem of LED light source lamps still needs to be solved urgently, for example, the patent ZL02826127. 5 held by me, in which the heat dissipation of the LED light source is realized by the mechanical combination of the screw and the nut.
  • the applicant has applied for the invention as "a heat dissipating component for a light emitting diode and a light emitting diode and a white light emitting diode lamp" (Application No.: 200810182614. 0), and the applicant provides a heat dissipating skeleton made of carbon nano material.
  • semiconductor lighting has huge business opportunities.
  • the semiconductor light source has different characteristics from the traditional light source.
  • the application of this light source to the lamp needs to solve a series of optical, thermal, and material problems such as heat dissipation and light intensity distribution.
  • This is almost impossible for manufacturers who generally produce traditional lamps.
  • Many traditional lighting manufacturers want to enter the semiconductor lighting industry, but they are unable to do so. How to reduce the threshold for entering LED lighting production and realize the industrialization of LED lighting as soon as possible is a top priority. Summary of the invention
  • the purpose of the invention is to make up for the defects in the existing LED lighting fixtures on the market, the complicated structure, the difficulty in repairing and replacing parts, and the inability to replace parts; especially when the number of lighting fixtures is large, the design work is complicated and the cycle is complicated. Long defects;
  • simplify the LED lamp production process reduce the difficulty of LED lamp production, and realize the industrial production of the LED light source lighting lamp; thus providing a simple module assembly, A lighting fixture that achieves a high power LED light source.
  • the LED lighting fixture made by the lamp module has a simple structure and is convenient for maintenance and replacement.
  • the illumination lamp module of the LED light source provided by the invention comprises at least one LED light source, an LED driving power source and an LED heat sink; and the LED light source further comprising an integrated package may be fabricated by an integrated packaging method.
  • the heat sink is composed of a metal mounting panel and a nano carbon sheet, wherein a convex rib is disposed on a surface of the mounting panel, and a heat sink is opened downwardly at the upper portion of the rib, the nanometer a carbon sheet is embedded in the heat dissipating groove, and the nano carbon piece is fixedly fixed together with the heat dissipating groove wall by a mechanical method or a welded joint to form a heat dissipating fin of the heat sink (as shown in FIG.
  • the outer casing being an upper cylinder for accommodating the LED light source, and a lower cylinder for accommodating the LED driving power source; wherein: a ring is protruded from an inner wall of the upper port of the upper cylinder, and the ring is parallel to a plane where the upper port of the upper cylinder is located , for blocking the LED light source from falling out of the upper cylinder mouth, and also providing a card slot in the lower part of the gear ring, the mounting panel of the heat sink is locked in the card slot; and in the upper cylinder a lug on the outer wall of the lower port, Said lower cylindrical lumen wall corresponding to the port is provided with said lugs with a limiting slot for locking the lug so that the lower end of the upper cylinder is integrally connected with the upper end of the lower cylinder; the LED driving power source is placed in the lower cylinder
  • the method further includes: providing a protruding frame above the LED chip on the periphery of the base of the LED light source, the surrounding frame facilitating coating of the transparent dielectric layer to prevent the transparent medium from overflowing; Higher than the LED chip, it can also effectively prevent the LED chip from being damaged during production, use and transportation.
  • the LED chip is further coated with an optical material layer or a light conversion material layer.
  • the assembled light source module can work by connecting to the power supply. Once the light source is damaged, it is only necessary to replace the light source. It is not necessary to discard the whole lamp, saving resources and conducive to environmental protection.
  • the manner in which the LED light source is mounted on the mounting panel includes two types, and one installation manner is: a screw hole is opened around the position where the LED light source is to be mounted on the mounting panel.
  • the screw light source is also provided with a screw hole on the base of the LED light source.
  • the screw hole on the mounting panel is opposite to the screw hole on the base of the LED light source, and the LED light source is fixed on the mounting panel by screws;
  • another installation method is: In the middle of the mounting panel, a screw hole for fixing the screw of the LED light source base is opened, and the screw of the LED light source base is screwed and fixed with the screw hole of the mounting panel.
  • the metal mounting panel is an aluminum plate or a copper plate.
  • the outer casing is made of plastic material, and has a gas permeable window or a gas permeable window and a venting hole on the outer casing; the outer casing combines the light source, the heat sink and the driving power source to form one Complete module product. At the same time, the electrical safety of the module is more secure when it is used.
  • the heat sink is a nano carbon sheet or a layer of nano carbon powder is coated on the surface of the metal copper.
  • the ribs provided on the surface of the mounting panel may be one or two or more, arranged in a concentric circle (as shown in FIG. 5b); or two or more The ribs, the ribs and the ribs are arranged in parallel, as shown in FIG. 4, or a vertical metal column is arranged on the surface of the mounting panel, surrounding the metal column, from the metal column
  • the head is downwardly opened with a vertical heat sink, and the heat sink is installed in the heat sink, and the heat sink is arranged radially (as shown in FIG. 5a).
  • the rib section has a zigzag shape, a trapezoidal shape, a rectangular shape or an involute profile; the width of the heat dissipation groove is equal to the thickness of the heat sink to be mounted, or the groove width is slightly smaller than the heat sink.
  • the thickness, the heat sink and the heat sink are interference fit, that is, the heat sink is deformed inward by the force applied, so that the heat sink is embedded in the heat sink, so that the heat generated by the LED chip is directly transmitted from the upper surface of the base to the rib and the nano carbon.
  • the film is quickly transferred to the outside; at the same time, due to the combination of the heat dissipation groove of the rib and the nano carbon piece, the heat sink and the heat dissipation groove wall are directly closely attached, the contact surface is large, and there is no heat resistance material in the middle, and the LED chip generates The heat is directly transmitted to the closely attached heat sink through the base, and the heat transfer is fast, and the heat dissipation is fast.
  • the volume is small, the weight is light, the heat dissipation effect is good, and the lamp design and installation are also convenient.
  • the insulating sheet is a paper sheet, a plastic sheet or a polyester sheet.
  • the LED provided by the invention is a light source lamp module, and the outer casing made of a plastic material combines the light source, the heat sink and the driving power source to form a complete module product, and the outer casing is provided with a ventilation window or a ventilation window. And venting holes, so that the heat generated by the LED light source is quickly transmitted; by simple module assembly, a high-power LED light source lighting fixture can be obtained, having at least one power input end and at least one light output end; other components are fixed Inside the enclosure, it works as long as the power is turned on.
  • the lamp module with LED as the light source provided by the invention has better heat dissipation performance than the existing LED lamp as the light source:
  • the existing LED light source is provided with a heat sink, the heat dissipation effect is not completely solved, for example, the applicant Holds the ZL02826127. 5 patent, which is cooled by the screw of the base and the screw hole of the heat sink.
  • the patent application number of 200810182614. 0 is inserted into the skeleton of the heat dissipating component through the screw of the LED base.
  • the heat dissipating component is made of nano carbon material, the screw is inserted into the skeleton. It is also necessary to glue the two together, so the heat dissipation effect is not ideal.
  • the heat sink of the present invention uses a nano carbon sheet to be directly extruded into the heat sink of the mounting panel.
  • the nano carbon sheet is used, and the area of the heat sink is increased.
  • the heat sink and the groove surface are passed.
  • the mechanical method achieves close contact with the surface without gaps, Therefore, the heat dissipation effect is better than that of the heat sink of any of the existing LED light sources.
  • the heat sink of the lamp module of the present invention uses a nano carbon sheet. Since the nano carbon sheet is lighter than the heat sink of the copper or aluminum used in the existing LED heat sink, the overall light source of the LED light source of the present invention is light. This has more practical application value for manufacturing high-power LED street lamps and the like.
  • the mounting panel used in the heat sink of the present invention is a flat plate
  • a screw hole for mounting the screw of the LED light source base may be opened on the flat plate, or no hole may be opened, that is, any LED supplied on the market.
  • Light sources can be mounted on the heat sink of the present invention.
  • the package casing used in the module of the present invention is made of plastic. Therefore, the weight of the entire LED lamp is not increased, and the electrical safety is greatly improved.
  • the LED light source and the driving power source are respectively packaged therein to make the LED illumination lamp integrated. When the damage occurs during use, the module can be directly replaced, which greatly facilitates the installation and maintenance of the LED lamp. And there are ventilation windows and air holes on the outer casing, which is very conducive to air circulation and achieve good heat dissipation.
  • the module of the LED lighting provided by the invention can be conveniently combined into a plurality of lamps of various power or lumen output, for the manufacturers generally producing traditional lamps, the LED lamps can be carried out without investing a large amount of research and development expenses.
  • the production has reduced the threshold for entering the production of LED lamps, laying the foundation for the early realization of the industrialization of LED lighting.
  • the lamp module with LED as a light source provided by the invention can be used for modules of high-power, high-lumen output lamps such as street lamps, tunnel lamps, floodlights and wall washers, and can also be a module for indoor lighting, which has a simple structure.
  • the heat dissipation effect is good, which makes the design, assembly and maintenance of the luminaire quick and easy.
  • FIG. 1 is a schematic diagram of a lighting fixture module in which the LED is a light source of the present invention
  • FIG. 2 is an exploded perspective view of a lighting fixture module with LED as a light source of the present invention.
  • FIG. 3 is an illustration of an LED light source installed in a lighting panel of the lighting fixture module of the present invention.
  • FIG. 4 is a schematic view showing the structure of a heat sink mounted on a mounting panel to form a heat sink in the lamp module of the present invention
  • FIG. 5a is an embodiment of another heat sink arrangement in the heat sink of the present invention
  • FIG. Figure 5b is an embodiment of another heat sink arrangement in the heat sink of the present invention
  • Figure 6 is a cross-sectional view of the cylinder of the lighting fixture module of the present invention
  • Figure 7 is a schematic view of the cylinder of the lighting fixture module of the present invention
  • Figure 8 is a schematic view of the cylinder of the lighting fixture module of the present invention
  • Figure 9 is a cross-sectional view of the lower cylinder of the lighting fixture module of the present invention.
  • FIG. 10 is an LED produced by Taiwan Yuhong Industrial Co., Ltd. for use in Embodiment 1.
  • FIG. 11 is a schematic view showing the installation of a commercially available LED for Embodiment 2.
  • FIG. 12 is a schematic diagram of an implementation of a lighting fixture module of the present invention.
  • the picture is as follows:
  • an LED illuminating lamp module of the present invention for a 3 watt LED illuminating lamp is constructed.
  • the module is composed of an LED light source 1, a heat sink, an LED driving power source 4, and an assembled casing (as shown in Fig. 2).
  • LED light source 1 adopts ZL02826127.
  • LED drive power supply 4 uses conventional LED power supply
  • the radiator is installed by a length of 24 ⁇ X width 24 ⁇ X thick 2 ⁇ aluminum
  • the panel 2 is composed of a heat sink 3 made of a nano carbon sheet; a screw hole is formed in a central portion of the upper surface of the aluminum plate, and a screw hole size thereof is matched with a screw under the base of the LED light source 1, and the screw of the base of the LED light source 1 is The screw holes are tightly fitted.
  • each of the ribs and the ribs are parallel and equally spaced, and the row spacing may be 3 to 5 ⁇ ; and then the heat sink is opened downward at the center of the upper portion of the rib, and the width of the heat sink is equal to the thickness of the heat sink 3 to be mounted.
  • the width of the heat sink 3 is slightly smaller than the thickness of the heat sink 3, for example: the heat sink 3 is made of a commercially available nano carbon sheet, when the heat sink is 0. 6 inches, the thickness of the nano carbon sheet is 0. 65 mm, and then the heat sink 3 is inserted.
  • the pressing is performed by a pressing plate or other mechanical methods, so that the two sides of the nano-carbon sheet are closely combined with the wall surface of the heat-dissipating groove to form a seamless joint (as shown in FIG. 4), so as to achieve a good heat conducting effect.
  • the heat sink 3 can also be made by coating a layer of nano-carbon powder on the metal copper sheet, and the thickness of the nano-carbon powder can be coated according to the heat dissipation requirement, which can be implemented by those skilled in the art.
  • a vertical aluminum column is arranged on the surface of the mounting panel, surrounding the aluminum column, and vertically extending from the head of the aluminum column.
  • 10 heat sinks made of nano carbon sheets are embedded in 10 heat sinks, 10 heat sinks are radial, and the heat sink and the heat sink are interference fit to achieve good heat conduction.
  • the center of the surface of the mounting panel is centered, and is provided with a spiral continuous rib, or a plurality of concentric annular ribs,
  • the annular ribs are parallel and evenly spaced, and the row spacing is 3.5 ⁇ .
  • the annular rib has a heat dissipating groove at the upper portion, and a heat sink made of a piece of nano carbon sheet is embedded in the heat sink. The heat sink and the groove are interference-fitted to achieve good thermal conductivity.
  • LEDs available on the market can be used, for example: 3 watt white LEDs produced by Taiwan Shunhong Industrial Co., Ltd.
  • the entire LED is fabricated on a 2-inch aluminum-based circuit board with a flat back.
  • the entire circuit board is rectangular, as shown in Figure 10.
  • the four corners are semi-circular and easy to connect to the heat sink with screws.
  • the chip mounting frame has a rectangular shape with a white plastic frame around the frame.
  • the plastic frame is high in the chip mounting frame 0. 5 ⁇ 2 ⁇ to fill the conversion material or the light transmitting medium.
  • a heat sink with a positive surface greater than or equal to this LED area attaches the LED to the heat sink, and the four corners are screwed to secure the LED to the heat sink. Subsequent production steps are the same as before.
  • the assembled housing used in this embodiment is injection molded from plastic, from the upper cylinder 5 and the lower cylinder. 6 is composed of two parts; wherein the shape and structure of the upper cylinder 5 are shown in Figs. 6 and 7.
  • a ring 9 is protruded from the inner wall of the upper cylinder 5 (for example, the width of the ring 9 is 2 mm, and the inner diameter of the ring 9 is smaller than the inner diameter of the upper cylinder 5), the ring 9 and the upper circle
  • the plane of the upper port of the cylinder is parallel, and the ring 9 is used to block the LED light source from falling out of the upper cylinder mouth, and also in the lower part of the gear ring 9, a ring slot 10 is opened along the inner wall, the card slot 10 and the ring 9
  • the plane is parallel; the LED light source 1 is installed in the upper cylinder 5, the card slot 10 is used to clamp the mounting panel of the heat sink; and four square holes 11 are evenly opened on the outer cylinder wall at the bottom of the upper cylinder 5, A
  • the inner diameter of the upper cylinder 6 is matched with the inner diameter of the lower cylinder 5, and four limiting slots 13 are evenly disposed on the inner wall of the lower cylinder 6, and the driving power source 4 is electrically connected to the lead of the LED light source 1 and then loaded.
  • an insulating sheet such as a paper sheet or a polyester sheet, is inserted; the LED driving power source 4 leads through the tail of the lower cylinder 6, and the lower cylinder 5
  • the port is inserted into the upper cylinder port, and is fixed by the lug in the limiting slot.
  • the tail of the lower cylinder 6 has a conical shape, and an external thread 14 is provided on the outer wall of the tail to cooperate with the main lamp holder for cooperating with the external mains socket.
  • a protruding frame higher than the LED chip may be disposed along a peripheral portion of the upper surface of the base of the LED light source 1, and a layer of the transparent medium is coated in the protruding frame.
  • the frame is higher than the LED chip, which can effectively prevent the LED chip from being damaged during production, use and transportation.
  • the assembled LED light source module can work by plugging in the power supply. Once the light source is damaged, it is only necessary to change the light source, without having to discard the whole lamp, saving resources and conducive to environmental protection.
  • the outer casing of the embodiment is made of plastic, and four ventilation windows 15 are evenly arranged in the middle of the upper cylinder 5, and four sets of air holes are opened in the upper part of the upper cylinder 5, and one set has five air holes 16, as shown in Fig. 1 and 2 is shown.
  • Example 2
  • the LED light source 1 of the embodiment is mounted on an aluminum base plate with six commercially available LEDs mounted on a circuit board as a light source, as shown in FIG.
  • a 6-watt LED module for illumination is produced.
  • the module power in this embodiment reaches 6 watts, which is much larger than 3 watts. Therefore, the size of the heat sink should be increased.
  • the area of the metal aluminum mounting panel 2 is increased to 35 mm X 35 mm, and eight trapezoidal ribs are formed on the back side of the mounting panel 2.
  • the rib section may be zigzag, trapezoidal, rectangular or involute.
  • a commercially available LED is most mature with a power of 1 watt, and a module is fabricated using this LED light source 1.
  • an aluminum-based circuit board 17 having a thickness of 2 inches and an area as large as the aluminum mounting panel of the above heat sink; the arrangement of the circuits is 3 strings 2 and drilling at appropriate positions of the four corners of the aluminum-based circuit board 17 Therefore, the LED light source 1 and the aluminum mounting panel of the heat sink are connected by the screw 7; that is, the bought LED light source 1 is soldered on the aluminum-based circuit board, and then fixed to the heat sink.
  • the plastic case used is the same as that of Embodiment 1, except that the size is larger than 3 watts.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Optics & Photonics (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
  • Led Device Packages (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Description

LED光源的照明灯具模块 技术领域
本发明涉及一种 LED光源灯具,特别是涉及一种以大功率 LED为 光源的照明灯具模块的结构， 用于路灯、 隧道灯、 投光灯和洗墙灯等 大功率， 高流明输出的灯具模块。 背景技术
随着 LED芯片技术的不断发展， 流明和功率的不断提高， LED光 源已经在功能型照明领域扮演着越来越重要的角色，像路灯、隧道灯、 投光灯和洗墙灯等。 目前市场上的路灯， 绝大多数是由几十颗甚至上 百颗 LED光源贴片在铝基板上， 再将铝基板安装在路灯外壳中。一旦 LED光源遭到损坏， 需要掀开灯具钢化玻璃罩， 卸下透镜或反射器， 再拆除电源线。 不难看出这种结构会导致更换困难， 甚至无法更换， 因此给维修带来极大地不便， 给用户带来经济损失。而且这种结构的 灯具的不同型号需要不同的驱动电源， 不同的配光结构， 不同的散热 和防水的结构。 由于结构复杂， 尤其是多型号组合时会给厂家带来设 计周期长和费时费工等问题。
目前 LED 光源灯具的散热问题还亟待解决， 例如本人持有的 ZL02826127. 5专利， 其中 LED光源的散热是通过螺杆与螺母机械结 合实现的。进一步本申请人又申请了发明名称为 "用于发光二极管的 散热组件和发光二极管及白光发光二极管灯" （申请号： 200810182614. 0 ) , 申请人提供一种用碳纳米材料制作的散热骨架， 将申请人制作的 LED 散热底座的螺杆***纳米碳管制作的骨架中实 现散热的， 但是， 由于螺杆***骨架中结合不紧密， 需要在两者之间 涂胶， 从而带来了热阻， 使得 LED光源散热不彻底。
市场上现有的 LED光源灯具， 正如上面所介绍的， 在结构上还是 有很多的不足之处。半导体照明作为世界各国扶持的项目， 它蕴藏着 巨大的商机。半导体光源有着和传统光源不同的特性， 应用这一光源 去制作灯具需要解决散热、 光强度分布等一系列光学、 热学、 材料学 的问题， 解决这些不仅需要一批专业人材， 还要时间和相当大的资金 投入， 这对一般生产传统灯具的厂家来说几乎是一件不可能的事。众 多的传统灯具生产厂家， 想进入半导体照明产业， 但却力不从心。 如 何降低进入 LED灯具生产的门槛，并尽快实现 LED照明灯具产业化已 是当务之急。 发明内容
本发明的目的在于弥补市场上现有的 LED照明灯具制作难度大、 结构复杂、 维修和零件更换困难， 甚至无法更换零部件的缺陷； 特别 是在照明灯具型号较多时， 使得设计工作复杂和周期长等缺陷； 为了 进一步解决 LED光源的散热问题， 简化 LED灯具生产工序， 降低 LED 灯具生产难度， 以实现 LED光源的照明灯具产业化生产的目的； 从而 提供一种通过简单的模块拼装，就可以获得大功率 LED光源的照明灯 具。 用此灯具模块制作的 LED照明灯具结构简单， 维修更换方便。
本发明的目的是这样实现的：
本发明提供的 LED光源的照明灯具模块，包括至少一个 LED光源， LED驱动电源和 LED散热器； 其特征在于， 还包括一集成封装用的外 所述的 LED光源可以是用集成封装方法制作的一个 LED, 也可以 是多个 LED安装在一块电路板上作为一个光源使用；
所述的散热器由一块金属的安装面板和纳米碳片组成， 其中， 在 所述的安装面板一表面上设有凸筋，并在所述的凸筋上部向下开散热 槽， 所述纳米碳片镶嵌在所述散热槽中， 该纳米碳片通过机械方法或 焊结与散热槽壁紧密接触固定在一起， 形成散热器的散热翅片（如图 4所示）； 在该安装面板的另一表面上安装所述的 LED光源； 在 LED 光源的上方， 通过透镜压板和密封圈固定玻璃透镜或其它光学***； 所述的外壳由用于容纳所述的 LED光源的上圆筒，和用于容纳所 述的 LED驱动电源的下圆筒组成； 其中， 所述的上圆筒的上端口内壁 上凸设一档环， 所述的档环与上圆筒的上端口所在的平面平行， 用于 阻挡 LED光源掉出上圆筒口外， 还在该档环下部设有卡槽， 所述的散 热器的安装面板卡装在所述的卡槽内；并在所述的上圆筒的下端口的 外壁上设凸耳，所述下圆筒上端口的内腔壁对应设有与所述的凸耳相 配的限位槽， 该限位槽用于卡止该凸耳， 以便上圆筒的下端与下圆筒 上端连接成一体； 所述的 LED驱动电源安放在所述的下圆筒内， 所述 的 LED光源的引线与该 LED驱动电源电连接，并在 LED驱动电源与散 热器之间垫一块绝缘片， 该 LED 驱动电源的导线穿出所述下圆筒尾 部， 所述上圆筒的下端口与所述的下圆筒上端口相插接， 通过凸耳与 限位槽固定成一体；所述的下圆筒的尾部设有与市电灯座相配合的结 构， 以便于用户随意与市电灯座相配合。
在上述的技术方案中， 还包括在所述的 LED光源的底座的***设 有高于 LED芯片的突起围框， 该围框便于透光介质层的涂布， 防止透 光介质外溢； 围框高于 LED芯片，还可有效防止 LED芯片在制作、使用、 运输过程中损坏。
在上述的技术方案中， 所述的 LED芯片上方还涂有光学材料层或 光转换材料层。 以满足生产不同光色光源。 装配完成的光源模块， 接 入电源便可工作，一旦光源损坏，只需更换光源便可，不必丢弃整灯， 节约资源， 利于环保。
在上述的技术方案中，所述的 LED光源安装在所述的安装面板上 的方式包括两种， 一种安装方式为： 在该安装面板上要安装 LED光源 的位置四周开有螺孔， 所述的 LED光源的底座上也开螺孔， 安装面板 上的螺孔与 LED光源的底座上的螺孔相对，通过螺钉将该 LED光源固 定在安装面板上； 另外一种安装方式为： 在所述的安装面板中部开有 与 LED光源底座的螺杆相固定用的螺孔，通过该 LED光源底座的螺杆 与安装面板的螺孔螺合固定在一起。
在上述的技术方案中， 所述的金属的安装面板为铝板或铜板。 在上述的技术方案中， 所述的外壳由塑料材质制作的， 并在外壳 上设有透气窗， 或者透气窗和透气孔； 外壳把光源、 散热器、 驱动电 源三者组合在一起， 形成一个完整的模块产品。 同时使得模块在使用 时电气的安全性更有保障。
在上述的技术方案中，所述的散热片为纳米碳片或在金属铜表面 涂覆一层纳米碳粉。
在上述的技术方案中，在所述的安装面板表面设有的凸筋可以是 一条或 2条以上， 呈同心圆排布（如图 5b所示）； 或者设有 2条以上 的凸筋， 凸筋与凸筋按照平行排列的， （如图 4所示）， 或者在所述的 安装面板表面设有一根垂直的金属柱， 围绕所述的金属柱四周， 从该 金属柱的头部向下开竖直的散热槽， 散热片安装在散热槽内， 所述的 散热片呈放射状排布 （如图 5a所示）。
在上述的技术方案中， 所述的凸筋截面呈锯齿形、 梯形、 矩形或 渐开线齿形； 所述的散热槽的宽度与要镶嵌的散热片厚度相等， 或者 槽宽略小于散热片厚度， 散热槽与散热片过盈配合， 即通过施力使散 热槽向内变形而使散热片镶嵌在散热槽中， 使 LED芯片产生的热从底 座的上表面直接传递至凸筋和纳米碳片， 而被迅速传递到外部； 同时 由于凸筋的散热槽与纳米碳片的结合，散热片与散热槽壁直接紧密贴 附， 接触面大， 且中间不存在热阻材料， LED芯片产生的热量通过底 座直接传递给紧贴的散热片， 热传递快， 散热就快， 相比同样的散热 效果的产品， 体积小， 重量轻， 散热效果好， 还便于灯具设计、安装。
在上述的技术方案中， 所述的绝缘片为纸片、 塑料片或聚酯片。 本发明提供的 LED 为光源的灯具模块， 由一塑料材质制作的外 壳， 把光源、 散热器、 驱动电源三者组合在一起， 形成一个完整的模 块产品， 外壳上设有透气窗， 或者透气窗和透气孔， 使得 LED光源产 生的热量迅速传出； 通过简单的模块拼装， 就可以获得大功率 LED光 源的照明灯具， 有至少一个电源输入端和至少一个光输出端； 其它各 个部件都被固定在外壳内， 只要接通电源即可工作。
本发明的优点在于：
一、本发明提供的以 LED为光源的灯具模块比现有的 LED为光源 的灯具散热性能好： 虽然已有的 LED光源都设置了散热器， 但是散热 效果解决的不彻底， 例如本申请人持有的 ZL02826127. 5专利， 通过 底座的螺杆与散热器的螺孔紧密结合在一起实现散热。进一步本发明 人又申请的申请号： 200810182614. 0的专利， 通过 LED底座的螺杆 插装在散热组件的骨架中， 虽然散热组件是由纳米碳材料制作的， 但 由于螺杆是插装在骨架中， 还需用胶将两者粘牢， 因此散热效果不够 理想。而本发明的散热器是采用一块纳米碳片直接挤压进安装面板的 散热槽中， 一方面使用的纳米碳片、 而且加大了散热片的面积， 另一 方面散热片与槽面是通过机械方法达到面与面无缝隙地紧密接触的， 因此散热效果比现有的任何一种 LED光源的散热器的散热都好。 二、本发明的灯具模块的散热片使用纳米碳片， 由于纳米碳片比 已有 LED散热器中使用的铜或铝材的散热片重量轻的多，所以本发明 的 LED光源整体重量轻，这对于制造大功率的 LED路灯等更具有实际 的应用价值。
三、又由于本发明的散热器使用的安装面板是一块平板， 在平板 上可以开有安装 LED光源底座螺杆的螺孔， 也可以不开孔， 也就是说 市场上所供应的任何一款 LED 光源， 都可以安装在本发明的散热器 上。
四、 本发明的模块使用的封装外壳采用塑料制成， 因此， 对整个 LED灯不增加多少重量， 而电气安全性大大提高， 将 LED光源、 驱动 电源分别封装其内使 LED照明灯成为一体，当使用时发生损坏直接取 换模块即可， 这样极大方便了 LED灯的安装和维修。并且在外壳上开 有透气窗和气孔， 非常利于空气流通， 实现良好地散热。
五、 由于利用本发明提供的 LED照明灯的模块， 可以方便地组合 成多种功率或流明输出的灯具， 对一般生产传统灯具的厂家来说， 不 用再投入大量研发费用， 即可进行 LED灯的生产， 降低了进入 LED灯 具生产的门槛， 为尽早实现 LED照明灯具产业化奠定了基础。
本发明提供的以 LED为光源的灯具模块， 可用于路灯、 隧道灯、 投光灯和洗墙灯等大功率、高流明输出的灯具的模块， 也可以是室内 照明用的模块， 它结构简单、 散热效果好， 可以使灯具的设计、 装配 和维修简便快捷。 附图说明
图 1是本发明的 LED为光源的照明灯具模块示意图
图 2是本发明的 LED为光源的照明灯具模块分解示意图 图 3是本发明照明灯具模块中的 LED光源安装在安装面板上的示 意图
图 4是本发明灯具模块中散热片安装在安装面板上组成散热器的 结构示意图
图 5a是本发明的散热器中的另一种散热片排布方式的实施例示 图 5b 是本发明的散热器中的又一种散热片排布方式的实施例: 图 6是本发明的照明灯具模块夕 1上圆筒剖面图
图 7是本发明的照明灯具模块^ 上圆筒示意图
图 8是本发明的照明灯具模块夕 1下圆筒示意图
图 9是本发明的照明灯具模块 下圆筒剖面图
图 10是实施例 1用的台湾佰鸿工业股份有限公司生产的 LED 图 11是实施例 2用的市售 LED安装示意图
图 12是本发明的照明灯具模块的一种实施示意图
图面说明如下：
1-LED光源 3-散热片
4-LED驱动电源 6-下圆筒
7-螺钉 9-档环
10-卡槽 11-方孔 12-凸耳
13-限位槽 14-外螺纹 15-透气
17-铝基线路板 具体实施方式
为了使本发明的目的、 技术方案及优点更加清楚明白， 以下结 合附图和实施例对本发明进行详细说明。
实施例 1
参考图 1， 制做一个 3瓦 LED照明灯用的本发明的 LED照明灯模 块， 该模块由一个 LED光源 1、 散热器、 LED驱动电源 4和组装外壳 组成 （如图 2所示）。 其中， LED光源 1采用 ZL02826127. 5专利的技 术方案制成具有 3瓦的一个 LED光源， LED驱动电源 4使用常规 LED 电源， 散热器由一块长 24匪 X宽 24匪 X厚 2匪铝的安装面板 2， 和 纳米碳片做的散热片 3组成； 在该铝板的上表面中心部位打一螺孔， 其螺孔大小与 LED光源 1的底座下的螺杆相配，将 LED光源 1底座的 螺杆与该螺孔紧密配合。在安装面板 2的下表面做 6条锯齿状的凸筋， 每一条凸筋与凸筋之间平行且间距相等， 行间距可以为 3〜5匪； 再 在凸筋上部中心位置向下开散热槽，散热槽的宽度与要镶嵌的散热片 3厚度相等， 或者散热槽宽略小于散热片 3厚度， 例如： 散热片 3使 用市场上购买的纳米碳片， 当散热槽宽 0. 6匪， 纳米碳片厚度为 0. 65mm, 然后将散热片 3插在散热槽内， 再通过压板或其它机械方法 进行挤压，使纳米碳片的两面分别与散热槽壁面之间达到无缝隙地紧 密结合 （如图 4所示）， 以实现良好的导热效果。 散热片 3还可利用 在金属铜片上涂覆一层纳米碳粉制成，可以根据散热要求涂覆纳米碳 粉的厚度， 这是本专业技术人员可以实施的。
还可以做成如图图 5a所示的散热器结构： 在所述的安装面板表 面设有一根垂直的铝柱， 围绕该铝柱的四周， 从该铝柱的头部向下竖 直开 10条散热槽， 将 10块纳米碳片做的散热片分别镶嵌在 10条散 热槽内， 10 条散热片呈放射状， 散热片与散热槽过盈配合， 实现良 好的导热效果。
还可以做成如图 5b所示的散热器结构： 在所述的安装面板表面 的中心为圆心， 设成螺旋形连续的一条凸筋， 或设成多个同心圆环形 的凸筋， 多个圆环形凸筋之间平行且间距相等， 行间距为 3. 5匪， 圆 环形的凸筋上部开散热槽，将一条一条的纳米碳片做的散热片镶嵌在 该散热槽内， 使散热片与槽过盈配合， 以实现良好的导热效果。
另外， 还可以使用市场上供应的 LED, 例如： 台湾佰鸿工业股份 有限公司生产的 3瓦白光 LED。 整个 LED制作在一块厚度为 2匪的铝 基线路板上， 背面是平的。 整个线路板呈矩形， 如图 10。 四角为半 圆孔状， 便于用螺钉把它和散热器连接。 芯片安放框呈矩形， 在这个 框的周围有一白色塑料框。 塑料框高出于芯片安装框 0. 5〜2匪， 以 便灌光转换材料或透光介质。有一个正表面大于或等于此 LED面积的 散热器把 LED贴在散热器上， 四个角用螺钉把 LED和散热器固定。其 后的制作步骤就和以前相同了。
在散热器的安装面板 2的四周设有 4个安装螺孔 8， 将 LED的底 座上也开 4个定位螺孔，直接用螺钉 7将 LED光源的底座固定在安装 面板 2的上表面上。
本实施例采用的组装外壳由塑料注塑而成，由上圆筒 5和下圆筒 6二部份组成； 其中， 上圆筒 5的形状和结构参见图 6和图 7所示。 在上圆筒 5上端口内壁上凸设一档环 9 (例如档环 9的宽度为 2mm， 其档环 9的内径只要比上圆筒 5的内径小就可以）， 档环 9与上圆筒 的上端口所在的平面平行，档环 9用于阻挡 LED光源掉出上圆筒口外， 还在该档环 9下部， 沿内壁上开一圈卡槽 10， 该卡槽 10与档环 9所 在的平面平行； LED光源 1装入上圆筒 5内， 该卡槽 10用于卡住散 热器的安装面板； 还在上圆筒 5底部的外筒壁上均匀开 4个方孔 11， 在每一个方孔的下方都设置一个凸耳 12。 下圆筒 6上口内径与上圆 筒 5下部内径相配， 在下圆筒 6上口内壁上均匀设置 4个限位槽 13， 将驱动电源 4与 LED光源 1的引线电连接后， 装入下圆筒 6内， 并在 LED驱动电源 4与散热片之间垫一块绝缘片， 例如纸片或聚酯片； 该 LED驱动电源 4的导线穿出下圆筒 6尾部， 上圆筒 5的下端口与下圆 筒上端口相插接， 通过凸耳卡于限位槽内而固定成一体。下圆筒 6的 尾部呈圆锥状， 并在尾部的外壁上设置与市电灯座相配合的外螺纹 14， 以便与外部市电灯座相配合。
还可以沿该 LED光源 1底座的上表面的***部分， 设一圈高于 LED 芯片的突起围框， 所述的突起围框内涂布一层透光介质层。 围框高于 LED芯片， 还可有效防止 LED芯片在制作、 使用、 运输过程中损坏。 装 配完成的 LED光源模块， 接入电源便可工作， 一旦光源损坏， 只需更 换光源便可， 不必丢弃整灯， 节约资源， 利于环保。
本实施例的外壳采用塑料制作， 并在上圆筒 5 中部均匀设置 4 个透气窗 15， 和在上圆筒 5的上部开 4组气孔， 一组有 5个气孔 16， 如图 1和图 2所示。 实施例 2
本实施例的 LED光源 1， 在一块铝基线板上， 装上 6个市售的 LED安装在一块电路板上作为一个光源使用， 如图 11所示；
参照图 12， 制作一个 6瓦的照明用 LED模块。 本实施例中的模 块功率达到了 6瓦， 远大于 3瓦。 因此散热器的尺寸要加大。在本例 中金属铝的安装面板 2的面积增大到 35 mm X 35mm, 在安装面板 2的 背面做 8条梯形的凸筋， 凸筋截面可以呈锯齿形、 梯形、 矩形或渐开 线齿形；每一条凸筋与凸筋之间平行且间距相等，行间距可以为 4匪; 再在凸筋上部中心向下开散热槽， 散热槽宽 0. 8匪， 纳米碳片厚度为 0. 85mm, 然后将 8片散热片 3分别插在每一个散热槽内， 再通过压板 或其它机械方法进行挤压， 通过散热槽与散热片过盈配合， 使纳米碳 片的两面分别与槽壁面之间达到无缝隙地紧密结合，以实现良好的导 热效果。 本实施例中的其它结构和实施例 1中的结构相同。
另外的实施例， 以市售的 LED以功率为 1瓦的最为成熟， 就以这 种 LED光源 1制作模块。 用一块厚度为 2匪， 面积和上述散热器的铝 安装面板面积一样大铝基线路板 17; 电路的布置为 3串 2并， 在铝 基线路板 17的四个角的适当位置上钻孔， 以便于 LED光源 1和散热 器的铝安装面板用螺钉 7连接；即把买来的 LED光源 1焊接在铝基线 路板上， 然后再固定到散热器上即可。 当然所用塑料外壳和实施例 1 的结构相同， 只是尺寸要比 3瓦的大。

Claims

权利要求
1.一种 LED光源的照明灯具模块， 包括至少一个 LED光源， LED 驱动电源和 LED散热器； 其特征在于， 还包括一集成封装用的外壳； 所述的散热器由一块金属的安装面板和纳米碳片组成， 其中， 在 所述的安装面板一表面上设有凸筋，并在所述的凸筋上部向下开散热 槽， 所述纳米碳片镶嵌在所述散热槽中， 该纳米碳片通过机械方法或 焊结与散热槽壁紧密接触固定在一起， 形成散热器的散热翅片； 在该 安装面板的另一表面上安装所述的 LED光源；在 LED光源的上方通过 透镜压板和密封圈固定玻璃透镜或其它光学***；
所述的外壳由用于容纳所述的 LED光源的上圆筒， 和用于容纳所 述的 LED驱动电源的下圆筒组成， 其中， 所述的上圆筒的上端口内壁 上凸设一档环， 所述的档环与上圆筒的上端口所在的平面平行， 用于 阻挡 LED光源掉出上圆筒口外， 还在该档环下部设有卡槽， 所述的 LED 光源的安装面板卡装在所述的卡槽内；并在所述的上圆筒的下端口的 外壁上设凸耳，所述下圆筒上端口的内腔壁对应设有与所述的凸耳相 配的限位槽， 该限位槽用于卡止该凸耳； 所述的 LED驱动电源安放在 所述的下圆筒内， 所述的 LED光源的引线与该 LED驱动电源电连接， 并 在 LED驱动电源与散热器之间垫一块绝缘片，该 LED驱动电源的导线穿 出所述下圆筒尾部，所述上圆筒的下端口与所述的下圆筒上端口相插 接， 通过凸耳与限位槽固定成一体； 所述的下圆筒的尾部设有与市电 灯座相配合的结构， 以便于用户随意与市电灯座相配合。
2.按权利要求 1所述的 LED光源的照明灯具模块， 其特征在于， 所述的 LED光源是用集成封装方法制作的一个 LED, 或是多个 LED安 装在一块电路板上作为一个光源使用。
3.按权利要求 1所述的 LED光源的照明灯具模块， 其特征在于， 所述的 LED光源安装在所述的安装面板上的方式包括两种，一种安装 方式为: 在该安装面板上要安装 LED光源的位置四周开有螺孔， 所述 的 LED光源的底座上也开螺孔，安装面板上的螺孔与 LED光源的底座 上的螺孔相对， 通过螺钉将该 LED光源固定在安装面板上； 另外一种 安装方式为：在所述的安装面板中部开有与 LED光源底座的螺杆相固 定用的螺孔，通过该 LED光源底座的螺杆与安装面板的螺孔螺合固定 在一起。
4.按权利要求 1所述的 LED光源的照明灯具模块，其特征在于， 沿所述的 LED光源的底座上表面的***部分设一圈高于 LED芯片的突 起围框， 所述的突起围框内涂布一层透光介质层。
5.按权利要求 1所述的 LED光源的照明灯具模块， 其特征在于， 所述的散热片为纳米碳片或在金属铜表面涂覆一层纳米碳粉。
6.按权利要求 1所述的 LED光源的照明灯具模块， 其特征在于， 在所述的安装面板表面设有的凸筋为 2条以上， 呈同心圆排布； 或者 凸筋与凸筋按照平行排列的，或者在所述的安装面板表面设有一根垂 直的金属柱， 围绕所述的金属柱四周， 从该金属柱的头部向下开竖直 的散热槽， 散热片安装在散热槽内。
7.按权利要求 1所述的 LED光源的照明灯具模块， 其特征在于， 所述的凸筋截面呈锯齿形、梯形、 矩形或渐开线齿形； 所述的散热槽 的宽度与要镶嵌的散热片厚度相等， 或者槽宽小于散热片厚度， 散热 槽与散热片过盈配合。
8.按权利要求 1所述的 LED光源的照明灯具模块， 其特征在于， 所述的外壳由塑料材质制作的， 并在外壳上设有透气窗， 或者设有透 气窗和透气孔。
9.按权利要求 1所述的 LED光源的照明灯具模块， 其特征在于， 所述的绝缘片为纸片、 塑料片或聚酯片。
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