Effects of micro stamping process on optical performance of lead frame LED module

In this paper, firstly, the precise lead frame LED module is built with the help of 3D microscopy. Secondly, the micro stamping technological parameters and processing steps are analyzed according to the actual production. With the information obtained, the micro stamping processing is simulated by non-linear FEA software ABAQUS, which focuses on angle deflection of lens in the process of micro stamping. The simulation results show that the lens of LED module has a small angle deformation caused by the gap in the asymmetric stamping process. The angle deformations vary from 1 degree to 3 degrees according to varying stamping width and depth. Finally, the light intensity distribution and the illumination distribution of lead frame LED module are compared in normal situation and angle deformation situation of lens, which shows that the light intensity and illumination distributions become asymmetric. The maximum light intensity is no longer in 90° vertical to the emitting surface. The light flux also decreases with the increase of the angle deflection.