JP6835922B2 - Integrally molded luminous flux controller with positioning detection function - Google Patents

Description

The present invention relates to a luminous flux controller, and more particularly to an integrally molded luminous flux controller capable of detecting positioning with the naked eye.

A light emitting diode (LED) is a surface emitting light source, and the distribution angle of light intensity varies depending on different manufacturers, process methods, and power magnitudes. Therefore, for each luminous flux controller, whether or not its assembly position and the contraction curvature after mold release match the designed target determines the yield of the finished product. Similar to the large-area illuminator described in Japanese Patent Publication No. 5396606, the overall brightness is composed of a combination of luminous flux controllers from a plurality of LED light sources, and a considerable amount of request is made for mutual compensation cooperation between the light sources. As shown in the light stacking tree, if one light source cannot form a luminous flux at an accurate position, it takes a lot of time and effort to remove and replace the entire lamp origin. On the other hand, in the above patent publication, a multi-pod located below the luminous flux controller, which is used for confirming positioning before sealing, is designed corresponding to the multi-slot in the LED substrate.

Japanese Patent No. 5396606

However, the material of the luminous flux controller (lens) is often a mold release molding resin, and in the process of pouring the liquid resin into the mold, it is necessary to avoid forming an internal bubble and affecting the effect of the luminous flux control. , It is necessary to maintain a constant high temperature. The subsequent annealing process is the point where the shape is further solidified, and the multipod is prone to distortion in this process, and the protrusions are always too large or distorted and placed on a predetermined LED substrate. I can't. In order to solve the selection rate due to the release distortion, it is common to design a convex mold with a substantially small size, and the slot between the positioning pod and the light source board has an allowable value. , Make sure there is a considerable positioning error between the luminous flux controller and the light source substrate. Regarding the final luminous flux control effect, it is not possible to know at the time of assembly whether the shipped lamp strip conforms to the luminous flux design norms only after the entire lamp strip is sealed and the diffuser is energized.

If there is a positioning detection means that can confirm the lens positioning at the time of assembly and detect the integrity of the lens curvature at any time, it is possible to greatly improve the yield of the lamp and provide the customers behind with the quality that is sufficient for the request. it can.

The present invention mainly completes the detection of the yield of a product by confirming that the positioning pattern on the light source substrate has reached the standard pattern by the total reflection portion provided on the integrally molded luminous flux controller that can be seen with the naked eye. Purpose.

In order to achieve the above object, the present invention includes: an incoming surface 110 for collecting light rays of at least one half of the light source 210 toward the light source 210 in the light source substrate 20, and at least 80% or more of the light rays. At least one total reflecting portion 131 located at the outer edge of the light emitting surface 120, the light emitting surface 120 for emitting light, the bottom surface 140 for facing the positioning diagram layer 230 on the light source substrate, and the bottom surface α. Provided is a light source controller 10 including a positioning visual field surface 130 having the above. When the positioning visual field surface 130 is viewed from above by the human eye 30, all or part of the positioning diagram layer 230 cannot be seen. The luminous flux controller 10 is made of the same material, and the angle α between the total reflection portion 131 and the bottom surface is designed to be equal to or greater than the total reflection critical angle, and the specific refractive index of the material of the luminous flux controller 10 with respect to the emission atmosphere. Related to.

FIG. 2 is a schematic view of the optical path of the present invention, in which the positioning diagram layer 230 reflects the ambient light 2301 around a part and refracts the ambient light 2301 around the part, while the ambient light 2311 around the part. Is reflected and reflected by the total reflection unit 131, and is refracted once (or after being refracted through a plurality of reflections) to reach the outside of the human eye 30 visual field. Therefore, the total reflection pattern 231 in the positioning diagram layer 230 is not seen by the human eye 30 and seems to disappear, whereby the luminous flux control source 10 is left in the designed position. The ambient light is taken from an indoor or natural light source and does not require a separate polish or detector stand.

FIG. 3 is a schematic view of the upper surface of the downward positioning diagram layer 230 blended in the present invention, and the total reflection pattern 231 is totally reflected by the total reflection unit 131 when the human eye directly looks down from the position of FIG. It is emitted separately as, and appears to disappear. At the time of design, three or three or more total reflection portions 131, or continuous total reflection portions 131 are provided along the outer edge of the light emitting surface 120, or corresponding positioning diagram layers 230 and 231 are provided. You may. When all of these total reflection patterns 231 disappear in direct view, it indicates that the luminous flux controller is at the center position of the lower light source 210. Unlike the conventional technology, confirmation is not performed by inserting a slot at the time of assembly, but the positioning detection method of the present invention detects with the naked eye even in the assembly factory or after shipment, improves the yield at the sales end of the product, and returns the product. Can be reduced.

The light emitting surface 120 has a first area 121 whose curvature gradually changes, and has a high height from the surrounding bottom surface 140. The light source substrate 20 that matches the present invention is similarly provided with a first detection layer toward the bottom surface 140. On the first detection diagram layer, some pattern gaps (between 221 and 222) corresponding to the curvature distribution of the first area 121 are distributed. 30 When the first area 121 is directly viewed with the human eye, the first area clearly sees the pattern gap in the first detection layer like a concave lens with respect to the first detection layer. It is reduced to no extent and used as a curvature standard for the assembler to recognize the first area. Similarly, the light emitting surface 120 has a second area 122 whose curvature is gradually changing, which is low in height from the surrounding bottom surface 140. A second detection diagram layer toward the bottom surface 140 is similarly provided on the light source substrate 20 matching the present invention. On the second detection map layer, some pattern gaps (between 222 and 223) corresponding to the curvature distribution of the two sections 122 are distributed. 30 When the second area 122 is directly viewed by the human eye, the second area is on the second detection layer, which is originally invisible to the naked eye like a convex lens with respect to the second detection layer. By expanding the pattern gap in, it is confirmed whether or not the curvature of the second area 122 matches the design standard.

Is a schematic cross-sectional view of a matching lower light source substrate structure of the luminous flux controller of the first embodiment of the present invention. Is a schematic diagram of the total reflection line of the first embodiment of the present invention. Is a visual effect overlooking the positioning diagram layer in the second embodiment of the present invention. Is a schematic diagram of an optical path according to a third embodiment of the present invention. Is a visual effect overlooking some of the detection layers in the third embodiment of the present invention.

Refer to “FIG. 1” which is a schematic view of the structure of the matching lower light source substrate of the luminous flux controller of the first embodiment of the present invention. The outer mold of the integrally molded luminous flux controller 10 may form a lower space 12 for placing the light source substrate 20, and may have a convex portion that does not easily slide out after the light source substrate 20 is placed. It may have a recessed portion for accommodating such a protruding member of the light source substrate 20. The light source substrate 20 includes a system circuit board, a printed circuit board (Printed Circuit Board, PCB), a metal core printed circuit board (Metal Core Printed Circuit Board, MCPCB), a ceramic substrate (Ceramic Printed Circuit Board, DCP, etc.). Consists of. Above, a light source 210 toward the light entering surface 110 of the luminous flux controller and at least one layer 230, 211, 222, 223 necessary for positioning or detection curvature are provided. These layers may be the substrate by masking, screen printing, thermal transfer, sandblasting, etching or electroplating, or may be dolling matching patterns. Alternatively, when manufacturing the gold wire (lead wire) mask, the necessary patterns may be completed by using these layers 230, 211, 222, and 223 as non-acting lead wires. Alternatively, separately, pattern cards displaying these layers 230, 211, 222, and 223 are printed, and the outer molds of these cards are manufactured by combining the dimensions of the lower space 12 so as to be useful for positioning. Although the present invention allows the pattern to be completely confirmed with ambient light when combined, these layers 230, 211, 222, 223 are made of fluorescent or metal reflective color blocks to improve their visibility.

Refer to “FIG. 3” which is a schematic view of the matching downward positioning diagram layer 230 of the luminous flux controller of the second embodiment of the present invention. The positioning diagram layer 230 may be provided at at least three portions (shown below) on the outer edge of the light emitting surface for displaying the front / rear / left / right positioning state, and is continuously arranged along the outer edge of the light emitting surface. It may be done (upper figure). The positioning layer 230 may be designed as a pattern 231 (after total reflection) that is partially visible and partially invisible, and may be designed as a visible (after total reflection) pattern such as a concentric circle or a graduated pattern. May be good. When provided in this contrast, the assembler may visually understand the degree of eccentricity of the luminous flux controller 10, finely adjust the relative position with respect to the light source substrate 20, and then seal the light flux controller 10. ..

Refer to “FIG. 4” which is a schematic optical path diagram of the matching lower detection diagram layers 221, 222, and 223 of the luminous flux controller of the third embodiment of the present invention. Although the central curvature is quite important for the uniform illuminance after combination, as in the large angle scattered flux controller referred to in the prior art, current assembly means do not have a requestable curvature detection assembly process. .. By using the invention model according to the present invention, it is possible to further detect the curvature of the light flux controller 10 on the light emitting surface 120 after mold release. The light emitting surface 120 has a first area 121 and a second area 122, and the first area 121 is a concave lens with respect to the first detection layer (between 221 and 222). The second area 122 is like a convex lens with respect to the second detection layer (between 222 and 223). As shown in FIG. 4, the optical path between 2211 and 2221 represents the reduced first detection layer (between 2210 and 2220), so that when viewed from above, the first detection layer The gaps originally present in the detection map layer appear to disappear (FIG. 5). On the contrary, since the optical path 2221 to 2223 represents the enlarged second detection layer (between 2220 and 2230), a gap that is originally invisible to the second detection layer when looking down from above. Seems to be clear (Fig. 5). The assembler first looks at the positioning diagram layer 230 and confirms that all the total reflection patterns 231 are invisible, and then the gap of the first detection diagram layer 221 is not clearly visible. By clearly seeing the gap in the second detection diagram layer 223, it can be confirmed that the curvature of the light emitting surface 120 of the luminous flux controller matches the design standard, and even the client is expressed and the entire lamp strip is returned. There is no such thing.

Finally, the assembler can fix the relative position of the light flux controller 10 and the light source substrate 20 with double-sided tape, a rubber-like adhesive, a liquid adhesive, a clip or a screw. The present invention not only provides the assembler with positioning and curvature detection, but also continuously and at any time detects the assembly pattern during or after combination of subsequent parts and avoids assembly errors. As a result, the yield of products can be reliably improved.

The present invention can also be detected by the non-human eye, and the luminous flux controller 10 includes a light-shielding cover assembled with the light source substrate 20, an automatic scanning light source or a large-angle uniform light source, and a luminous intensity sensor in the vicinity of the light source. After completing the stand including, send it to the detection table in order. In the positioning diagram layer 230, a material having a high reflectance other than the total reflection pattern 231 may be made, or the total reflection pattern may be made of a high absorption material. Then, when the luminous flux controller 10 is not assembled at an accurate position, a part of the positioning diagram layer 230 having a high reflectance is blocked by the total reflection unit 131 and cannot reflect the automatic scanning light source. In this case, since the detection value of the luminous intensity sensor is low, it is measured that the assembly of the luminous flux controller 10 and the light source substrate 20 is unacceptable, the unacceptable assembly is removed, and the detection table is removed. Can leave. The highly reflective material can be changed to a special photoreactive material, but the light intensity sensor may be equipped with a filter or a grid for selectively measuring the luminous intensity of the special light beam.

The above are only preferred examples of the present invention, but this does not limit the scope of the present invention. Therefore, the claims of the present invention and the simple equivalent changes and modifications made based on the contents of the specification of the invention still belong to the scope of the present invention.

The present invention creates a luminous flux controller with a visual positioning function in a simple process, and the existing surface layer of the light source substrate simplifies the assembly process and cost, while at the same time providing positioning and curvature detection means synchronized with assembly. We will file a patent claim in accordance with the law because it provides, improves the yield of products, balances the eco-friendly concept of beauty and energy saving carbon reduction, and meets the requirements of invention claims.

10 Integrally molded light beam controller 20 Light source substrate 30 Human eye 12 Lower accommodation space of integrally molded light beam controller 110 Incoming light surface 120 Emitting light surface 130 Positioning viewing surface 140 Bottom surface 121 First area 122 First area 131 Total internal reflection part 210 Light source 221 First detection layer 222 Pattern between the first detection layer and the second detection layer 223 Second detection layer 230 Positioning layer 231 Total internal reflection pattern 2211 The first detection layer Line 2221 that reflects the ambient light to the human eye Line 2221 that the first or second detection layer reflects the ambient light elsewhere 2231 The second detection layer reflects the ambient light elsewhere 2210 Image after refraction by the first area of the first detection diagram layer 2220 Image after refraction by the first area and the second area 2230 Refraction by the second area of the second detection diagram layer Later formation 2301 Route where the positioning diagram layer reflects ambient light to the human eye 2311 Route where the positioning diagram reflects ambient light to the human eye

Claims (10)

An incoming surface for light rays of more than half the amount of light in the light source substrate toward the light source substrate,
An emission surface for emitting at least 80% of the light beam,
The bottom surface of the light source substrate toward the positioning diagram layer,
Includes a positioning visual field surface located on the outer edge of the light emitting surface and having at least one total reflection portion forming an angle α with the bottom surface.
A luminous flux controller in which all members are made of the same light-transmitting material, and when the positioning visual field surface is viewed by the human eye, a part of the positioning diagram layer cannot be seen due to the angle α. The first aspect of claim 1, wherein the outer mold of the luminous flux controller constitutes a cavity, and the cavity has substantially the same dimensions as the light source substrate and is used for accommodating the light source substrate. Luminous flux controller. The light source substrate is characterized by further including at least one convex portion that does not slide out of the cavity after the light source substrate is inserted because the inclinations of the upper and lower surfaces of the convex portion are different toward the cavity. The light source controller according to claim 2. The luminous flux controller according to claim 1, wherein the angle α between the total reflection portion and the bottom surface is related to the specific refractive index of the luminous flux controller with respect to the emission atmosphere. The luminous flux controller according to claim 1, wherein these total reflection portions are uniformly distributed or symmetrically distributed on the outer edge of the light emitting surface. The luminous flux controller according to claim 1, wherein the connection portion between the light emitting surface and the total reflection portion forms an angle β with the bottom surface, and β is α or more. The light emitting surface has a first area where the curvature gradually changes, the periphery is high from the bottom surface, and the bottom surface is further used to face the first detection diagram layer in the light source substrate. and to the first detection Figure layers, the several patterns clearance corresponding to the curvature distribution of the first zone is distributed, when viewing the first zone in the human eye, of the first section high Saga is higher than the height of the bottom surface, the light flux controller of claim 1, these patterns gaps, characterized in that the lost look. The light emitting surface has a second area where the curvature gradually changes, the height from the bottom surface of the periphery is low, and the bottom surface is further used to face the second detection diagram layer on the light source substrate. were and are some patterns gap distribution corresponding to the curvature distribution of the second zone, when viewing the second zone in the human eye, since the height of the second section is less than the height of the bottom surface The light flux controller according to claim 1 , wherein these pattern gaps are clearly visible. The luminous flux controller according to claim 1, further comprising at least one through hole for inserting a screw to lock the luminous flux controller onto the light source substrate. The luminous flux controller according to claim 1, wherein a screw is introduced from a through hole in the light source substrate, and at least one female screw for locking the light source substrate to the luminous flux controller is further included.

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