陣列式LED之光學元件設計分析與開發(pptx檔案)

Report
Precision Manufacturing Laboratory
陣列式LED之光學元件設計
分析與開發
Analysis on design and fabrication of optical
elements for LED array
計畫編號:NSC 99-2622-E-011 -013-CC3
陳炤彰1、詹家銘1、王瀅智2、湯峻清1 、許育豪1
Chao-Chang A. Chen, Chia-Ming Chan 1, Ying-Chih Wang 2 , Jyun-Cing Tang1 , Yu-Hao Hsu1
1國立台灣科技大學
機械工程學系
2洋鑫科技股份有限公司
中華民國一零一年十一月十三日
National Taiwan University of Science and Technology
Department of Mechanical Engineering
Content
Precision Manufacturing Laboratory
• 研究背景
• 實驗設備與流程
• 實驗結果與討論
• 結論與建議
• 應用實例
National Taiwan University of Science and Technology
Department of Mechanical Engineering
2
研究背景(1/2)
Precision Manufacturing Laboratory
隨著LED照明需求日益增進,而使得在亮度、均勻度方面也日
益增加,所以在LED的要求方面也隨之改變,已從過往的單一
LED chip慢慢地轉變成由多顆LED chip所構成之陣列式分佈型
式,故在鏡片方面也漸漸的由一曲面型式,轉變成由數個曲面
所構成之陣列式LED光學元件。
http://www.glaciallight.com/
National Taiwan University of Science and Technology
Department of Mechanical Engineering
3
研究背景(2/2)
Precision Manufacturing Laboratory
• 研究目的
本研究對 Multifaceted reflector, MR照明燈具模組之二次光
學元件進行相關研究,期望在提升發光效率及照度的目標
下,達到所要求之光束角。
• 研究方法
以光學設計軟體TracePro ,配合Moldex3D 模流分析軟體
進行二次光學元件模擬與分析,並由射出成形方式模造成
形,最後進行成形與光學品質檢測探討。
National Taiwan University of Science and Technology
Department of Mechanical Engineering
4
實驗流程
Precision Manufacturing Laboratory
National Taiwan University of Science and Technology
Department of Mechanical Engineering
5
光學設計
Precision Manufacturing Laboratory
表1 光學模擬參數表
Type
Flux (lumens)
Total Rays
Material
Ref. Index
Recive distance (m)
NICHIANS6W083BT
300
27000
PMMA
1.49
2
Lens
6
National Taiwan University of Science and Technology
Department of Mechanical Engineering
成形材料
Precision Manufacturing Laboratory
• ASAHI PMMA DELPET 80N (模擬)
黏度與剪切率圖
pvT圖
• ASAHI PMMA DELPET 80NH (射出成形)
National Taiwan University of Science and Technology
Department of Mechanical Engineering
7
射出成形設備及模具
Precision Manufacturing Laboratory
Thermometer
PMMA
Drying equipment
Mold
Injection molding machin
Mold temperature controller
National Taiwan University of Science and Technology
Department of Mechanical Engineering
8
量測設備
Precision Manufacturing Laboratory

綠干涉儀(Talysurf CCI)

配光曲線儀

積分球
National Taiwan University of Science and Technology
Department of Mechanical Engineering
9
結果與討論
Precision Manufacturing Laboratory
經由優化後之陣列式光學元件發光角度為30o
光束角30o
配光曲線
中心照度值: 140 lux、總光通量: 224 lm
National Taiwan University of Science and Technology
Department of Mechanical Engineering
10
模流分析
Precision Manufacturing Laboratory
• Filling: melt front time
• Cooling temperature
National Taiwan University of Science and Technology
Department of Mechanical Engineering
11
模流分析
•

Precision Manufacturing Laboratory
Warpage: zx axis displacement • Warpage: ytotal
axisdisplacement
displacement
Shrinkage
0.00978
0.000155mm
mm
0.000242
0.0519 mm
National Taiwan University of Science and Technology
Department of Mechanical Engineering
12
短射實驗
Parameters
Mold Temperature
Melt Temperature
Injection Speed
Cooling time
11 ㎜
14 ㎜
Precision Manufacturing Laboratory
Stage
1st
Value
95
240
80
60
Unit
℃
℃
mm/s
s
17 ㎜
75%
20 ㎜
90%
23 ㎜
100%
30%
55%
National Taiwan University of Science and Technology
Department of Mechanical Engineering
13
微結構轉寫率量測
0~1結構
高度
(μm)
2~3結構
高度
(μm)
平均結
構高度
(μm)
模仁
59.43
58.97
59.20
成品
57.17
57.27
57.22
Precision Manufacturing Laboratory
平均結
構複製
率(%)
96.65
National Taiwan University of Science and Technology
Department of Mechanical Engineering
14
光學量測
Precision Manufacturing Laboratory

(a)840cd
暖色系燈具發光角度量測- 32°

(b) 冷色系燈具發光角度量測- 30°
980cd
National Taiwan University of Science and Technology
Department of Mechanical Engineering
15
光學量測
Precision Manufacturing Laboratory
暖色系
冷色系
Voltage:12Vdc
Current:0.339A
Input Power:4.07W
Electrical Characteristics
Correlated Color
Temperature(CCTٕ )
3072 K
5038 K
Color Rendering Index
(CRI)
85 Ra
66.5 Ra
暖色系
冷色系
National Taiwan University of Science and Technology
Department of Mechanical Engineering
16
結論與建議
Precision Manufacturing Laboratory
• 成功利用射出成形製造出陣列式光學元件,建立陣列式二次光
學元件之光學設計方法及整合模流分析軟體進行模具設計,並
檢測成品光學性質。
• 光學模擬設計值與實際量測之光束角結果相當接近,其軟體輔
助具有相當之可靠性。
• 本研究開發之陣列式光學元件,成品厚度差異變化甚大,需要
較長冷卻時間,導致成形週期甚長,未來可對模具進行修改,
結合變模溫技術(Varithermo Mold Temperature, VMT),以減少
成形週期、收縮及翹曲的發生。
National Taiwan University of Science and Technology
Department of Mechanical Engineering
17
應用實例
Precision Manufacturing Laboratory
National Taiwan University of Science and Technology
Department of Mechanical Engineering
18
Acknowledgement
Precision Manufacturing Laboratory
• 感謝國科會NSC-99-2622-E-011-013-CC3計畫與洋
鑫科技股份有限公司提供相關技術資料及經費協
助,另有教育部顧問室數位化模具計畫使本論文
得以順利進行,特此致上感謝之意。
National Taiwan University of Science and Technology
Department of Mechanical Engineering
19
Precision Manufacturing Laboratory
Thank you!
National Taiwan University of Science and Technology
Department of Mechanical Engineering
20

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