Injection moulded lens array for high power LED modules

Eveliina Juntunen, Antti Keränen, M. Paakkinen, V. Vuorinen, E. Tetri, L. Halonen, Veli Heikkinen

Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientificpeer-review

1 Citation (Scopus)

Abstract

Light emitting diodes (LED) are increasingly replacing traditional light sources due to their better energy efficiency and potential for reliable operation with long lifetime.
The price of LED-based luminaires is still fairly high. One way to decrease the manufacturing cost is to use single lens optics for many LEDs. Optics should provide high efficiency together with low cost and excellent reliability.
This paper introduces injection moulded lens array designed for high power LED modules. The lenses were employed with a series of modules containing 4 × 4 white LEDs whose total luminous flux varied from 660 to 2280 lm. The lens had dimensions of 73.4 mm × 73.4 mm × 13.9 mm and it included alignment pins and sides that could be used for sealing.
The lens optics gave elliptical 30° × 90° lighting pattern with the uniformity of the illuminance on plane surface better than 3:2. The lens was optimized for Philips Lumileds Luxeon Rebel, but it was tested also with Cree X-Lamp, Luxeon K2, OSRAM Golden Dragon Plus, OSRAM Diamond Dragon and Seoul Z-power LEDs.
This paper presents goniometer measurements of the luminous intensity and compares them to the simulations. Two different lens materials, namely cyclo olefin polymer (COP) and polyamide (PA), was used.
The paper lists experiences obtained using these lenses. Especially the reliability of the lens and its attachment is discussed. In total, 24 LED modules were stressed in environmental tests including thermal cycling, thermal shock, moisture and corrosion. Observations made on the lens materials as well as lens attachment materials are depicted.
Moisture and corrosion was not a problem but high temperatures challenged both the lens and adhesive materials. 22 modules were subjected to a life test of 6000 h where they were driven with a constant current of 700 mA and monitored continuously.
The life test revealed failures in both lens materials. The results challenge the reliability of the plastic lenses in high power LED ...
Original languageEnglish
Title of host publicationProceedings
Subtitle of host publication3rd Electronic System-Integration Technology Conference, ESTC 2010
Place of PublicationPiscataway, NJ, USA
PublisherInstitute of Electrical and Electronic Engineers IEEE
Number of pages6
ISBN (Electronic)978-1-4244-8555-0
ISBN (Print)978-1-4244-8553-6
DOIs
Publication statusPublished - 2010
MoE publication typeA4 Article in a conference publication
Event3rd Electronics System Integration Technology Conference, ESTC 2010 - Berlin, Germany
Duration: 13 Sep 201016 Sep 2010

Conference

Conference3rd Electronics System Integration Technology Conference, ESTC 2010
Abbreviated titleESTC 2010
CountryGermany
CityBerlin
Period13/09/1016/09/10

Fingerprint

light emitting diodes
modules
lenses
injection
optics
moisture
luminaires
attachment
corrosion
environmental tests
illuminance
goniometers
thermal shock
sealing
lists
illuminating
adhesives
luminous intensity
alkenes
light sources

Cite this

Juntunen, E., Keränen, A., Paakkinen, M., Vuorinen, V., Tetri, E., Halonen, L., & Heikkinen, V. (2010). Injection moulded lens array for high power LED modules. In Proceedings: 3rd Electronic System-Integration Technology Conference, ESTC 2010 Piscataway, NJ, USA: Institute of Electrical and Electronic Engineers IEEE. https://doi.org/10.1109/ESTC.2010.5643006
Juntunen, Eveliina ; Keränen, Antti ; Paakkinen, M. ; Vuorinen, V. ; Tetri, E. ; Halonen, L. ; Heikkinen, Veli. / Injection moulded lens array for high power LED modules. Proceedings: 3rd Electronic System-Integration Technology Conference, ESTC 2010. Piscataway, NJ, USA : Institute of Electrical and Electronic Engineers IEEE, 2010.
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abstract = "Light emitting diodes (LED) are increasingly replacing traditional light sources due to their better energy efficiency and potential for reliable operation with long lifetime. The price of LED-based luminaires is still fairly high. One way to decrease the manufacturing cost is to use single lens optics for many LEDs. Optics should provide high efficiency together with low cost and excellent reliability. This paper introduces injection moulded lens array designed for high power LED modules. The lenses were employed with a series of modules containing 4 × 4 white LEDs whose total luminous flux varied from 660 to 2280 lm. The lens had dimensions of 73.4 mm × 73.4 mm × 13.9 mm and it included alignment pins and sides that could be used for sealing. The lens optics gave elliptical 30° × 90° lighting pattern with the uniformity of the illuminance on plane surface better than 3:2. The lens was optimized for Philips Lumileds Luxeon Rebel, but it was tested also with Cree X-Lamp, Luxeon K2, OSRAM Golden Dragon Plus, OSRAM Diamond Dragon and Seoul Z-power LEDs. This paper presents goniometer measurements of the luminous intensity and compares them to the simulations. Two different lens materials, namely cyclo olefin polymer (COP) and polyamide (PA), was used. The paper lists experiences obtained using these lenses. Especially the reliability of the lens and its attachment is discussed. In total, 24 LED modules were stressed in environmental tests including thermal cycling, thermal shock, moisture and corrosion. Observations made on the lens materials as well as lens attachment materials are depicted. Moisture and corrosion was not a problem but high temperatures challenged both the lens and adhesive materials. 22 modules were subjected to a life test of 6000 h where they were driven with a constant current of 700 mA and monitored continuously. The life test revealed failures in both lens materials. The results challenge the reliability of the plastic lenses in high power LED ...",
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Juntunen, E, Keränen, A, Paakkinen, M, Vuorinen, V, Tetri, E, Halonen, L & Heikkinen, V 2010, Injection moulded lens array for high power LED modules. in Proceedings: 3rd Electronic System-Integration Technology Conference, ESTC 2010. Institute of Electrical and Electronic Engineers IEEE, Piscataway, NJ, USA, 3rd Electronics System Integration Technology Conference, ESTC 2010, Berlin, Germany, 13/09/10. https://doi.org/10.1109/ESTC.2010.5643006

Injection moulded lens array for high power LED modules. / Juntunen, Eveliina; Keränen, Antti; Paakkinen, M.; Vuorinen, V.; Tetri, E.; Halonen, L.; Heikkinen, Veli.

Proceedings: 3rd Electronic System-Integration Technology Conference, ESTC 2010. Piscataway, NJ, USA : Institute of Electrical and Electronic Engineers IEEE, 2010.

Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientificpeer-review

TY - GEN

T1 - Injection moulded lens array for high power LED modules

AU - Juntunen, Eveliina

AU - Keränen, Antti

AU - Paakkinen, M.

AU - Vuorinen, V.

AU - Tetri, E.

AU - Halonen, L.

AU - Heikkinen, Veli

PY - 2010

Y1 - 2010

N2 - Light emitting diodes (LED) are increasingly replacing traditional light sources due to their better energy efficiency and potential for reliable operation with long lifetime. The price of LED-based luminaires is still fairly high. One way to decrease the manufacturing cost is to use single lens optics for many LEDs. Optics should provide high efficiency together with low cost and excellent reliability. This paper introduces injection moulded lens array designed for high power LED modules. The lenses were employed with a series of modules containing 4 × 4 white LEDs whose total luminous flux varied from 660 to 2280 lm. The lens had dimensions of 73.4 mm × 73.4 mm × 13.9 mm and it included alignment pins and sides that could be used for sealing. The lens optics gave elliptical 30° × 90° lighting pattern with the uniformity of the illuminance on plane surface better than 3:2. The lens was optimized for Philips Lumileds Luxeon Rebel, but it was tested also with Cree X-Lamp, Luxeon K2, OSRAM Golden Dragon Plus, OSRAM Diamond Dragon and Seoul Z-power LEDs. This paper presents goniometer measurements of the luminous intensity and compares them to the simulations. Two different lens materials, namely cyclo olefin polymer (COP) and polyamide (PA), was used. The paper lists experiences obtained using these lenses. Especially the reliability of the lens and its attachment is discussed. In total, 24 LED modules were stressed in environmental tests including thermal cycling, thermal shock, moisture and corrosion. Observations made on the lens materials as well as lens attachment materials are depicted. Moisture and corrosion was not a problem but high temperatures challenged both the lens and adhesive materials. 22 modules were subjected to a life test of 6000 h where they were driven with a constant current of 700 mA and monitored continuously. The life test revealed failures in both lens materials. The results challenge the reliability of the plastic lenses in high power LED ...

AB - Light emitting diodes (LED) are increasingly replacing traditional light sources due to their better energy efficiency and potential for reliable operation with long lifetime. The price of LED-based luminaires is still fairly high. One way to decrease the manufacturing cost is to use single lens optics for many LEDs. Optics should provide high efficiency together with low cost and excellent reliability. This paper introduces injection moulded lens array designed for high power LED modules. The lenses were employed with a series of modules containing 4 × 4 white LEDs whose total luminous flux varied from 660 to 2280 lm. The lens had dimensions of 73.4 mm × 73.4 mm × 13.9 mm and it included alignment pins and sides that could be used for sealing. The lens optics gave elliptical 30° × 90° lighting pattern with the uniformity of the illuminance on plane surface better than 3:2. The lens was optimized for Philips Lumileds Luxeon Rebel, but it was tested also with Cree X-Lamp, Luxeon K2, OSRAM Golden Dragon Plus, OSRAM Diamond Dragon and Seoul Z-power LEDs. This paper presents goniometer measurements of the luminous intensity and compares them to the simulations. Two different lens materials, namely cyclo olefin polymer (COP) and polyamide (PA), was used. The paper lists experiences obtained using these lenses. Especially the reliability of the lens and its attachment is discussed. In total, 24 LED modules were stressed in environmental tests including thermal cycling, thermal shock, moisture and corrosion. Observations made on the lens materials as well as lens attachment materials are depicted. Moisture and corrosion was not a problem but high temperatures challenged both the lens and adhesive materials. 22 modules were subjected to a life test of 6000 h where they were driven with a constant current of 700 mA and monitored continuously. The life test revealed failures in both lens materials. The results challenge the reliability of the plastic lenses in high power LED ...

U2 - 10.1109/ESTC.2010.5643006

DO - 10.1109/ESTC.2010.5643006

M3 - Conference article in proceedings

SN - 978-1-4244-8553-6

BT - Proceedings

PB - Institute of Electrical and Electronic Engineers IEEE

CY - Piscataway, NJ, USA

ER -

Juntunen E, Keränen A, Paakkinen M, Vuorinen V, Tetri E, Halonen L et al. Injection moulded lens array for high power LED modules. In Proceedings: 3rd Electronic System-Integration Technology Conference, ESTC 2010. Piscataway, NJ, USA: Institute of Electrical and Electronic Engineers IEEE. 2010 https://doi.org/10.1109/ESTC.2010.5643006