本研究主要是使用印刷塗布製程方式，在基材上塗布UV固化膠形成階梯式透鏡取代傳統二次光學元件製程，使原本是發散光的裸晶LED(如覆晶)達到聚光的效果和提升光的使用效率。本研究先以光學模擬軟體 TracePro進行模擬、設計與分析，接著利用田口實驗計畫法，設定各項參數並將其優化，最後將實品製作展示。本研究選擇四個不同的控制因子來進行優化，分別是印刷層厚、層間幅寬、印刷層數和UV膠折射率。研究結果顯示，在相同斜率下，若使用完美曲面可使原本的發散光源聚光到37.16度，但若利用階梯光學設計與優化，可使發散光源達到聚光效果37.68度，相同斜率的階梯曲面與完美曲面相差了0.52度相差了1.3%但是在製程上卻可以省去許多成本。最後實品製作將發光角度為140度的裸晶LED聚光為46.1度。;This study based on method of coating process to produce the secondary optical components to replace tradition production by coating echelon UV glue on the substrate .This method can achieve concentrating effect of nude crystal LED (such as Flip-chip) and improve the light efficiency. In this study, we use the software-TracePro, to simulate and analyze the model, and to optimize the result by Taguchi method in the end of this research, we realize the idea by a prototype. In the Taguchi method we choose four control factor to optimize including coating thickness, width between, layers coating, layers number and UV curing refractive index. According to result of study, compare to the conventional simulation using a perfect surface on the top of nude crystal LED (beam angle 180°) which can concentrate the LED beam angle to 37.16 deg, and in our structure LED beam angle can concentrate the light become 37.68 deg. Our method can reduce the cost ,although the beam angle different perfect surface 0.52 deg .Final product can concentrate the nude crystal LED beam angle from 140 deg to 46.1 deg.
