JP6324470B2 - Method for manufacturing light source module or lighting apparatus - Google Patents

Description

  The present invention relates to a method for manufacturing a light source module or a lighting fixture.

There is a light source module in which a light source element such as an LED is mounted on a printed wiring board.
In order to change the circuit after forming the wiring pattern of the printed wiring board, there is a technique of cutting the wiring pattern by punching.

JP 2011-154832 A JP 2007-306038 A JP 2011-258381 A JP-A-62-69582

Lighting fixtures may require different light outputs depending on where they are installed and other factors. For this reason, manufacturers of lighting fixtures need to line up a plurality of types of lighting fixtures having the same appearance and different light outputs. In order to reduce the manufacturing cost, it is desirable to share parts used for different types of lighting fixtures.
Thus, in the lighting fixtures with different light outputs, the number and arrangement of the light source elements mounted on the light source module may be different. When the light source module has a configuration in which the light source elements are directly mounted on the printed wiring board, it is necessary to prepare different printed wiring board wiring patterns in order to manufacture light source modules having different numbers and arrangements of the light source elements. .

The following points are problems to apply to a light source module using a common printed wiring board and cutting a wiring pattern by punching to make a printed wiring board having a different wiring pattern.
First, since an area for cutting the wiring by punching is required, the arrangement of the light source elements is restricted. Since the light distribution of the light source module varies depending on the arrangement of the light source elements, it is desired that the light source elements have a high degree of freedom in arrangement.
Second, the types of circuits that can be formed by cutting the wiring by punching are limited. There are at most several types of circuits that can be formed using one printed wiring board. Considering the number of lineups of lighting fixtures, it is desirable that more circuits can be formed using one printed wiring board.

  An object of the present invention is, for example, to use a common printed wiring board and to have a high degree of freedom in arrangement of light source elements and to be able to form many types of circuits.

A method for manufacturing a light source module or a lighting fixture according to the present invention includes:
A plurality of light source mounting portions, each having a pair of terminal connection lands arranged adjacent to each other and configured so that a light source element can be mounted, are arranged in a fixed manner in the vertical direction and in a fixed manner in the horizontal direction. When,
A first connection portion that electrically connects between the terminal connection lands adjacent in the vertical and horizontal directions excluding the pair of terminal connection lands, and the periphery of the light source mounting portion disposed at the end among the plurality of light source mounting portions. A light source using a printed wiring board that is disposed so as to surround and has an inter-mounting-portion connection portion that includes a second connection portion that is electrically connected to the terminal connection land disposed at an end of the plurality of light source mounting portions. A method of manufacturing a module or lighting fixture,
A cutting step of cutting at least one of the first connecting portion and the second connecting portion provided in the connecting portion between the mounting portions in the printed wiring board;
A mounting step of mounting a light source element on at least one of the plurality of light source mounting portions of the printed wiring board before or after the cutting step.

  According to this invention, using a common printed wiring board, the degree of freedom of arrangement of the light source elements is high, and many types of circuits can be formed.

FIG. 3 is a perspective view illustrating an appearance of the lighting fixture 10 according to the first embodiment. FIG. 2 is a front view and a circuit diagram illustrating a light source module 12a according to the first embodiment. FIG. 3 is a front view and a circuit diagram illustrating a light source module 12b according to the first embodiment. FIG. 3 is a front view showing the printed wiring board 23 according to the first embodiment. The figure which shows the cutting | disconnection location 35 cut | disconnected by the cutting process in Embodiment 1. FIG. The figure which shows the cutting | disconnection location 35 cut | disconnected by the cutting process in Embodiment 1. FIG.

Embodiment 1 FIG.
The first embodiment will be described with reference to FIGS.

  FIG. 1 is a perspective view showing an external appearance of a lighting fixture 10 in this embodiment.

The lighting fixture 10 (lighting device) is used by being attached to a ceiling or the like, for example. There are various brightnesses required for the lighting fixture 10 depending on the mounting position and other factors. For this reason, there are a plurality of types of lighting fixtures 10. Different types of lighting fixtures 10 have different light outputs but the same appearance.
The lighting fixture 10 includes, for example, a light source module having a light source element, a lighting module that supplies power to the light source module, and the like.

  FIG. 2 is a front view and a circuit diagram showing the light source module 12a in this embodiment.

The light source module 12a (LED module) is used, for example, for the lighting fixture 10 having a relatively large light output. The light source module 12 a includes, for example, a connector 21, 25 light source elements 22, and a printed wiring board 23.
The printed wiring board 23 (wiring board) has, for example, a substantially octagonal plate shape, and a printed wiring made of copper foil or the like is provided on the surface on the front side.
The light source element 22 is, for example, an LED package. The light source element 22 is mounted on the printed wiring board 23 by soldering or the like.
The connector 21 is for connecting a wiring for electrically connecting the lighting module. The connector 21 is mounted on the printed wiring board 23 by soldering or the like. The connector 21 inputs electric power supplied from the lighting module through the connected wiring.
The connector 21 and the light source element 22 are electrically connected by printed wiring provided on the printed wiring board 23 to form a light source circuit 20a. The light source circuit 20a is, for example, a circuit in which 25 light source elements 22 are electrically connected in series.

  FIG. 3 is a front view and a circuit diagram showing the light source module 12b in this embodiment.

The light source module 12b is used, for example, for the lighting fixture 10 having a relatively small light output. The light source module 12 b includes, for example, a connector 21, 12 light source elements 22, and a printed wiring board 23. The connector 21 and the printed wiring board 23 are the same as the light source module 12a. The light source element 22 may be the same as the light source module 12a, or may have a different correlated color temperature or light output.
The connector 21 and the light source element 22 are electrically connected by printed wiring provided on the printed wiring board 23 to form a light source circuit 20b. The light source circuit 20b is, for example, a circuit in which 12 light source elements 22 are electrically connected in series.

  FIG. 4 is a front view showing the printed wiring board 23 in this embodiment.

The printed wiring board 23 is used in common for the light source modules 12 (12a, 12b) used in different types of lighting fixtures 10. The printed wiring board 23 includes, for example, a substrate 31 and a printed wiring 32.
The substrate 31 is made of, for example, glass epoxy. The substrate 31 may be a single-sided substrate, a double-sided substrate, or a multilayer substrate.
The printed wiring 32 is formed on the surface of the substrate 31 by, for example, etching. The printed wiring 32 is the entire hatched portion in this figure. The printed wiring 32 includes, for example, connector connection lands 321 and 322, light source terminal connection lands 323 and 324, and inter-mounting-portion connection portions 325 to 327.

The connector connection lands 321 and 322 are portions that are densely hatched upward to the left in this figure. The pair of connector connection lands 321 and 322 are arranged to face each other and form a connector mounting portion 33. The connector 21 is mounted on the connector mounting portion 33. A high potential side terminal of the connector 21 is electrically connected to the connector connection land 321. A low potential side terminal of the connector 21 is electrically connected to the connector connection land 322.
The light source terminal connection lands 323 and 324 are meshed hatched portions in this figure. The pair of light source terminal connection lands 323 and 324 are arranged to face each other and form a light source mounting portion 34. The light source element 22 is mounted on the light source mounting portion 34. For example, 25 light source mounting portions 34 are formed on the printed wiring board 23 in total. For example, the 25 light source mounting portions 34 are arranged in a grid of 5 rows and 5 columns.

The inter-mounting-portion connecting portions 325 to 327 are sparse hatched portions that rise to the left in this figure. The inter-mounting-portion connection portions 325 to 327 electrically connect the connector connection lands 321 and 322 and the light source terminal connection lands 323 and 324.
The mounting part connection part 325 connects the light source terminal connection lands 323 or the light source terminal connection lands 324 of the light source mounting parts 34 adjacent in the vertical direction. In this example, there are ten inter-mounting part connection parts 325 between each row, and there are a total of 40 inter-mounting part connection parts 325.
The inter-mounting unit connection unit 326 connects the light source terminal connection land 323 and the light source terminal connection land 324 of the light source mounting unit 34 adjacent in the horizontal direction. In this example, there are five inter-mounting part connection portions 326 between each row, and there are 20 inter-mounting part connection portions 326 in total.
The inter-mounting-portion connecting portion 327 has a shape surrounding the light source mounting portion 34. The inter-mounting-portion connecting portions 327 are located between the light source terminal connecting lands 323 and 324 of the total ten light source mounting portions 34 located in the top row and the bottom row, and between the leftmost row. , The light source terminal connection lands 323 of the three light source mounting portions 34, the light source terminal connection lands 324 of the three light source mounting portions 34 positioned in the middle of the rightmost row, the connector connection lands 321, and the connector connection lands 322 is connected.

One light source terminal connection land 323 is connected with the inter-mounting-portion connection portions 325 to 327 in three directions excluding the direction in which the light source terminal connection land 324 provided facing each other is located. Similarly, the connection portions 325 to 327 between the mounting portions are connected to one light source terminal connection land 324 in three directions excluding the direction in which the light source terminal connection lands 323 provided to face each other are located.
Between the light source terminal connection lands 323 and 324 located at the corners, the inter-mounting part connection part 327 is connected from two directions, and the inter-mounting part connection part 325 is connected from the other one direction. Different inter-mounting-portion connection portions 325 to 327 are connected to the light source terminal connection lands 323 and 324 located at positions other than the corners from three directions.

  The mounting part connecting parts 325 to 327 are formed so as to be cut by laser processing. The inter-mounting-portion connection portions 325 to 327 are provided with narrow portions for easy cutting.

  In the manufacturing process of the light source module 12 (or the lighting fixture 10), for example, using a laser processing machine or the like, some of the inter-mounting-portion connection portions 325 to 327 are irradiated with a laser beam to cut the desired light source circuit 20. The printed wiring board 23 is processed so as to form (20a, 20b) (cutting step). Thereafter, the light source element 22 and the connector 21 are mounted on the printed wiring board 23 (mounting process).

  FIG. 5 is a diagram showing a cutting point 35 cut in the cutting step in this embodiment.

The cutting part 35 shown by mesh-like hatching shows the part cut | disconnected when manufacturing the light source module 12a.
In this example, 32 of the 40 mounting part connection parts 325 and 4 of the 20 mounting part connection parts 326 are cut, and the mounting part connection part 327 is cut at 17 points. Thereby, the electrical connection as shown on the right is formed. A light source circuit 20a shown in FIG. 2 is formed by mounting the light source element 22 on all 25 light source mounting portions 34 of the printed wiring board 23 processed in this way.

  FIG. 6 is a diagram showing a cut portion 35 cut in the cutting step in this embodiment.

The cut part 35 shown in this figure shows a part cut when manufacturing the light source module 12b.
In this example, 14 of the 40 mounting part connection parts 325 and 12 of the 20 mounting part connection parts 326 are cut, and the mounting part connection part 327 is cut at 14 points. Thereby, the electrical connection as shown on the right is formed. A light source circuit 20b shown in FIG. 3 is formed by mounting the light source element 22 on 12 hatched 12 of the 25 light source mounting portions 34 of the printed wiring board 23 processed in this way.

Thus, the light source module 12 from which the number and arrangement | positioning of the light source elements 22 differ can be manufactured by cut | disconnecting some of the connection parts 325-327 between mounting parts. Since the same printed wiring board 23 can be used with a plurality of types of light source modules 12, manufacturing costs such as design costs and inventory costs can be suppressed.
Since the printed wiring is cut by laser processing, the occupied area of the portion for enabling cutting is small, and the degree of freedom of arrangement of the light source elements is high.
Further, by providing a large number of severable portions, many types of light source circuits 20 can be formed using a common printed wiring board 23.

  The configuration described above is an example, and other configurations may be used. For example, a configuration in which a configuration of a non-essential part is replaced with another configuration may be used.

The above is summarized as follows.
The printed wiring board according to Embodiment 1 is
Each light source mounting portion has a pair of terminal connection lands, and a plurality of light source mounting portions formed so that a light source element can be mounted;
Each mounting part connection part has a printed wiring which electrically connects between the plurality of terminal connection lands, and the plurality of mounting part connections can be disconnected by laser processing. Part.

The light source module according to Embodiment 1 is
A printed wiring board in which at least one of the plurality of mounting portion connection portions is cut by laser processing; and
And a light source element mounted on at least one of the plurality of light source mounting portions.

The lighting apparatus according to Embodiment 1 is
A light source module;
And a lighting circuit for supplying power to the light source element.

The method of manufacturing the light source module or the lighting fixture according to Embodiment 1 is as follows:
Laser processing on the printed wiring board, cutting at least one of the plurality of mounting part connection parts,
A light source element is mounted on at least one of the plurality of light source mounting portions.

  DESCRIPTION OF SYMBOLS 10 Lighting fixture, 12 Light source module, 20 Light source circuit, 21 Connector, 22 Light source element, 23 Printed wiring board, 31 Substrate, 32 Printed wiring, 321,322 Connector connection land, 323,324 Light source terminal connection land, 325-327 Mounting Inter-part connection part, 33 Connector mounting part, 34 Light source mounting part, 35 Cutting location.

Claims (2)

A plurality of light source mounting portions, each having a pair of terminal connection lands arranged adjacent to each other and configured so that a light source element can be mounted, are arranged in a fixed manner in the vertical direction and in a fixed manner in the horizontal direction. When,
A first connection portion that electrically connects between the terminal connection lands adjacent in the vertical and horizontal directions excluding the pair of terminal connection lands, and the periphery of the light source mounting portion disposed at the end among the plurality of light source mounting portions. A light source using a printed wiring board that is disposed so as to surround and has an inter-mounting-portion connection portion that includes a second connection portion that is electrically connected to the terminal connection land disposed at an end of the plurality of light source mounting portions. A method of manufacturing a module or lighting fixture,
A cutting step of cutting at least one of the first connecting portion and the second connecting portion provided in the connecting portion between the mounting portions in the printed wiring board;
A method of manufacturing a light source module or a lighting fixture comprising: a mounting step of mounting a light source element on at least one of the plurality of light source mounting portions of the printed wiring board before or after the cutting step. The method of manufacturing a light source module or a lighting fixture according to claim 1, wherein in the cutting step, at least one of the first connection portion and the second connection portion is cut by laser processing.

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