电场调控聚合物成型技术及其LED封装应用

发布时间：2018-05-30 06:59

本文选题：LED封装 + 聚合物成型　；参考：《华中科技大学》2016年博士论文

【摘要】：LED光源光形是走向不同照明应用需求的必要条件,空间颜色均匀性是衡量LED照明品质的重要性能参数。决定LED光形和空间颜色均匀性的关键性因素为LED封装制造过程中透镜成型和荧光粉涂覆工艺。然而目前业界在这些关键工艺方面存在着不足,LED光形控制和空间颜色均匀性还需要进一步改进。本文基于荧光粉涂覆和透镜制造过程涉及的共性问题——聚合物流体到固体成型过程的形貌控制,研究电场调控聚合物成型技术,利用电场调控作用实现新型的荧光粉涂覆工艺和透镜制造技术。主要研究内容和创新点包括：开展电场调控聚合物成型过程的实验研究,并分析了电场强度和聚合物材料物性参数对其形貌变化的影响规律。结果表明,电场作用下,电压大小、电极间距、聚合物初始高度和温度载荷是聚合物形貌调控的关键影响因素；对于不同聚合物材料,其介电常数与表面张力相关的系数大小决定聚合物形貌变化规律。建立了基于静电-水平集两相流的多物理场耦合分析模型,理论分析了不同工艺参数对形貌调控的影响规律。结果表明,在电场作用下,较大的电压、聚合物初始高度和介电常数以及较小的电极间距和聚合物表面张力均能得到较大的聚合物流动变形；而聚合物粘度对稳态形貌并无影响。通过数值模拟获取了实现不同聚合物形貌的工艺条件：平板-平板电极实现锥形聚合物形貌,圆环-平板电极实现扁平聚合物形貌,非对称圆柱-平板电极实现非对称聚合物形貌,圆锥-平板电极实现火山口聚合物形貌。提出了电场调控成型的荧光粉涂覆工艺,获得了锥形荧光粉层,以调节封装LED的空间色温分布。通过光学模拟研究了锥形荧光粉层形貌对封装LED空间颜色均匀性的影响,模拟结果表明：与球帽形荧光粉层相比,锥形荧光粉层封装LED的空间颜色均匀性最大提高26.0%,荧光粉材料最多节约7.66%。开展了电场调控成型的荧光粉涂覆实验,实现了锥形荧光粉层。测试结果表明,锥形荧光粉层封装LED的空间相关色温差值从大于1000K减少为180K。提出了电场作用形貌可调控透镜制造技术。在不同电场作用下,分别获得了锥形、扁平和非对称形貌透镜,并且每种透镜的高度通过电场强度的调节实现了连续精确控制。测试结果表明,锥形、扁平和非对称形貌透镜封装LED分别实现了汇聚、发散和非对称光强分布,最大光强分别提高了35%、31%和39%。对于扁平和非对称透镜,最大光强发生视角分别由0°变为±46°和-48°。提出了电场作用对准的液滴蒸发法透镜制造技术,得到了火山口形貌透镜,实现了LED封装模块的均匀照明。基于电场作用实现了液滴位置对准,通过液滴蒸发法得到了火山口形貌,并分析了不同液滴体积对火山口形貌的影响以及对LED封装模块出光光强分布的调控效果。光学测试表明,制造的火山口形貌透镜实现了可应用于均匀照明的蝙蝠形光强分布,最大光强提高了17%,最大光强发生视角由00变为+540,光强比值从1增大为2.55。
[Abstract]:The optical shape of LED light source is a necessary condition for different lighting application requirements. Space color uniformity is an important performance parameter for measuring the quality of LED lighting. The key factor determining the LED light and space color uniformity is the lens molding and phosphor coating process in the LED packaging manufacturing process. However, the industry is currently in these key technologies. In this paper, LED optical control and space color uniformity need to be further improved. Based on the common problems involved in the coating of phosphor powder and lens manufacturing process, the morphology control of polymer fluid to solid molding process, the study of electric field controlled polymer molding technology, and the application of electric field regulation to the realization of new fluorescent powder coating. The main research contents and innovation points include: carrying out experimental research on the process of polymer forming by electric field regulation, and analyzing the influence of electric field intensity and material properties of polymer on the change of morphology. The results show that the voltage size, the distance between electrodes, the initial height and temperature of the polymer under the action of the electric field. Load is a key factor in the regulation of polymer morphology. For different polymer materials, the coefficient of dielectric constant related to surface tension determines the change law of polymer morphology. A multi physical field coupling analysis model based on electrostatic horizontal set two-phase flow is established. The influence of different process parameters on morphology control is analyzed. The results show that, under the action of the electric field, the larger voltage, the initial height and the dielectric constant of the polymer, the smaller electrode spacing and the surface tension of the polymer all get the larger flow deformation of the polymer, and the viscosity of the polymer has no effect on the steady state. A flat plate electrode was used to realize the morphology of the conical polymer, the circular ring plate electrode was used to realize the flat polymer morphology, the Asymmetric Cylinder plate electrode was used to realize the asymmetric polymer morphology, and the conical plate electrode was used to realize the morphologies of the crater polymer. The fluorescent powder coating process was proposed by the electric field control and the conical phosphor layer was obtained. The spatial color temperature distribution of LED is encapsulated. The effect of the conical phosphor layer morphology on the space color uniformity of the encapsulated LED is studied by optical simulation. The simulation results show that the space color uniformity of the conical phosphor layer packaging LED is increased by 26% compared with the ball cap phosphor layer, and the phosphor material saves most of the 7.66%. to carry out the electric field adjustment. The conical phosphor layer is realized by the coated fluorescent powder coating experiment. The test results show that the spatial correlation color temperature difference of the conical phosphor layer package LED is reduced from more than 1000K to 180K., and the electric field morphology can be used to regulate the lens manufacturing technology. The height of each lens is controlled continuously and accurately by the adjustment of the electric field intensity. The test results show that the conical, flat and asymmetric morphology lens package LED achieves convergence, divergence and asymmetric light intensity distribution, and the maximum light intensity is increased by 35%, 31% and 39%. for flat and asymmetric lenses, and the maximum light intensity angle of view is respectively. From 0 degrees to 46 degrees and -48 degrees, a lensing technology of droplet evaporation method is proposed. The morphology lens of the crater is obtained, and the uniform illumination of the LED package module is realized. The position alignment of the droplet is realized based on the effect of the electric field. The morphology of the crater is obtained by the droplet evaporation method, and the different droplet volume on the volcanic mouth shape is analyzed. The effect of the appearance and the intensity distribution of the light and light intensity of the LED package module. The optical test shows that the produced crater morphology lens can be applied to the uniform illumination distribution of the bat shaped light intensity, the maximum light intensity is increased by 17%, the maximum light intensity angle of light is changed from 00 to +540, and the light intensity ratio is increased from 1 to 2.55.
【学位授予单位】：华中科技大学
【学位级别】：博士
【学位授予年份】：2016
【分类号】：TN312.8

【相似文献】