LED散熱燈座設計與模具開發

近年來節能、環保意識抬頭，如何節能減碳一直是熱門話題，而LED的發明無疑是節能產品代表，它具有省電能、體積小、壽命長及反應時間快等優點，雖然看似商機無窮卻仍有幾個問題需要克服，例如發光效率再提高及如何有效散熱等，其中又以會直接影響到使用壽命的散熱問題更為重要，所以LED燈座的散熱設計是必要之趨勢。有鑑於燈罩散熱片幾何形狀複雜，傳統LED散熱燈座材質多半為鋁合金配合切削、壓鑄或擠製來製作生產，各種加工法各有優缺點，擠形加工鰭片形狀易受限制；切削加工速度慢、成本高；國業廠商還是採用壓鑄生產為大宗，但壓鑄又受限於材料特性，雖然材質越接近純鋁散熱特性越好，但也因純鋁較軟導致二次加工不易，加熱後流動性差故市面上大多以鋁合金來代替，本文是以AL-1050來鍛造出LED散熱燈座，因AL-1050接近純鋁有良好的導熱率，而鍛造出的產品具有尺寸精度高、結構強及表面粗糙度佳等優點，也不需考慮材料流動性的問題。本文流程由產品設計開始，經歷模具開發、模具製造、成品比對及組裝實驗等過程，首先設計散熱燈座初步尺寸，設定不同數量散熱圓柱及厚度等散熱參數，利用熱流軟體求出散熱率較佳之外型後決定燈座尺寸，依此外型設計成形模具，再以有限元素軟體模擬金屬成形過程，找出適合之胚料尺寸、鍛造溫度及母模圓角等參數，將依模擬結果決定參數及模具尺寸並實際製作模具來鍛造出LED散熱燈座，經成品比對考慮是否需要修模，最後組裝零組件做熱效率實驗來與熱效率模擬比對並討論；本文藉由鍛造AL-1050來製作散熱燈座，未來亦可配合連續模大量生產來降低成本以滿足龐大的市場需求量。

關鍵字

LED散熱燈座； AL-1050 ；鍛造；有限元素軟體

並列摘要

In recent years, due to energy conservation and environmental awareness, how to reduce carbon emissions has been a hot topic. Therefore, energy saving product is getting more and more important in the market, such as the LED which is undoubtedly representative of the invention, it reduces power usage, comes in small size, long life and fast response time, etc. benefits. Although it has seemingly endless business opportunities, there are still several problems to overcome, such as light-emitting efficiency and how to further improve the effective heat dissipation, etc., among which the heat issue which will directly affect the life is more important, so the LED lamp radiating design is a necessary trend. Due to the complexity of light shade design, most of the traditional LED heat lamp are made up of the aluminum alloy material with the cutting, die casting or extrusion to make production. There are advantages and disadvantages of various processing methods, for example, extruded shape restrictions, high costs and long manufacturing time; Most of the manufacturers use die-cast production, but it is limited by material properties, even though the material is closer to the pure aluminum which has better heat features. Also because of the softness creates difficulty during secondary aluminum processing and it is heated illiquid, it usually uses aluminium-alloy instead in the marketplace. This piece of writing is about using the AL-1050 to forging the LED heat lamp, which is close to pure aluminum due to good thermal conductivity of aluminum while forging a product with high dimensional accuracy, structural strength, surface roughness, and no need to consider the material flow issues. This article starts from product design, through die exploitation, die manufacture,assembly of finished product and then comparison the process of experiments. First of all, designing the initial size of the heat lamp, sets with different numbers and thickness of the cylindrical cooling parameters, using thermal heat flow rate and the software to calculate the better appearance holder size leading to shape forming mold design, then the finite element simulation of metal forming process software to find suitable size of the material, forging temperature and the die rounded, …etc. parameters. Based on the simulation results determines parameters and the actual size of the die and die making to forge a LED heat lamp and the finished product and then consider the need to repair, and the final assembly of components for thermal efficiency and thermal efficiency of simulation experiments to compare and discuss. In this paper, using forging AL-1050 with the continuous die and can be mass-produced to reduce costs to meet the market demand.

並列關鍵字

LED heat lamp ； AL-1050 ； Forging ； Finite element simulation

參考文獻

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