矽膠精密模具製程研究

Study of Silicon Precision Mold Manufacturing Process

廖顯大(Shand-Dad Liaw) ； 溫超東(Chu-Dong Wen) ； 黃依勝(Yi-Shen Huang)

《中華科技大學學報》 55期 (2013/04) Pp. 1-9

摘要

現今節能減碳意識提升，燈具的耗電量實為驚人，近來發光二極體技術趨於成熟，早期只可作為指示燈，現今發光亮度已趨近生活適用程度，因此發光二極體燈具取代現有燈具已逐漸明朗。本文為矽膠精密模具製程研究，主要將高功率發光二極體一次光源之矽膠透鏡成形過程受到矽膠材料、熱傳遞、溫度及壓力所影響，導致良率不佳，故成形模具將考量影響因素以重新製作，並變更及規劃製程順序，使生產良率有效提升。模具設置致冷晶片及熱管，製程由加壓改為抽氣降壓成形，其結果使得生產品質、速率皆有效提升，可應用於快速生產，執行成果已大幅減少矽膠材料成本損耗的問題，成品良率由60%提升至95%，光強度有效提升至120%至200%，分散120度光源聚集到120度呈單一方向光源。本研究之高功率發光二極體已可替換現有燈具，相信對未來普遍化有極大的幫助。

關鍵字

發光二極體 ； 矽膠精密模具 ； 高功率 ； 透鏡 ； 生產良率

並列摘要

Due to the strong demand for energy saving and carbon reduction, the Light Emitting Diodes (LED) used as indicator lamps in many devices are increasingly used for room lighting to replace the energy-consuming light bulbs. During manufacturing, the yield rate of the silicone lens for high power LED is greatly affected by the compositions of material, the rate of heat transfer, temperature and pressure. A novel process for improving the yield rate is studied in this research. As a result of applying thermoelectric coolers and heat pipes to manage the temperature for the silicone lens mold and by the assistance of vacuum during injection molding process, the yield rate, production rate and quality have been significantly improved. This process not only enables rapid production, but also greatly reduces raw material waste. From experiments, the yield rate is increased from 60% to 95%, the lighting intensity has increased by 120%-200%. Also the unidirectional light is obtainable from the scattering light within 120º. The LED fabricated by this process is suitable to replace the traditional light bulb and be widely used for room lighting.

並列關鍵字

Light Emitting Diode (LED) ； Silicon Precision Mold ； High Power ； Lens ； Production Yields