JP6758446B2 - Light source module and light emitting device - Google Patents

Description

The present invention relates to a light source module and a light emitting device used in a lighting fixture or the like.

In recent years, there has been an increasing demand for lighting equipment using an LED module configured by mounting an LED (Light Emitting Diode), which is a light emitting element, on a substrate. Since LEDs are small and have a high degree of freedom in mounting, unlike incandescent lamps and fluorescent lamps that have been used as light sources in the past, the shape of the light emitting portion of a lighting fixture can be freely configured. The LED module is formed in a plate shape by a resin substrate or a metal substrate of a material such as FR4 (Flame Retardant Type 4) or CEM3 (Composite epitaxial material-3), and is attached to a sheet metal of a lighting fixture or the like for use.

Further, for example, Patent Document 1 describes that in a configuration in which an electronic component such as an LED is mounted on a metal substrate and bent, the metal substrate is creases so that the metal substrate can be bent freely. Further, Patent Document 2 describes that an LED is mounted on a flexible substrate. Further, Patent Document 3 proposes a luminaire including an LED module in which an LED is mounted on a flexible substrate. In the lighting fixture of Patent Document 3, the light distribution of the LED modules is controlled by adjusting the interval between the plurality of LED modules. Further, as another conventional technique, it is also known that a reflector made of another component is attached to the LED module to control the light distribution of the LED module.

Japanese Patent No. 5154387 (see FIG. 1) International Publication No. 2010/090519 (see Fig. 1B) Japanese Patent No. 5528238 (see FIG. 2)

Here, in the lighting fixture described in Patent Document 3, in order to control the light distribution of the LED, the optical axes of the light sources are arranged differently on the flexible substrate. Therefore, a large number of light sources are required to control the light distribution of the luminaire so as to satisfy the required luminous flux and the required light emitting area, which increases the product cost and increases the size of the product. Further, when the reflector is provided as a separate component, the product cost increases due to the increase in the number of components.

The present invention is for solving the above-mentioned problems, and an object of the present invention is to provide a light source module and a light emitting device capable of realizing light distribution control at low cost.

The light source module according to the present invention includes a light source and a substrate, and the substrate has a width wider than the width of the light source, and a mounting portion on which the light source is mounted and a deformation regulating portion provided on the mounting portion. it is formed from the deformation restricting portion on the outer side, a deformation restricting portion at the end portion than the reflection portion can be bent at a position outside, Ri Tona, the deformation restricting portion, a copper foil pattern constituting the wiring of the light source.

According to the light source module of the present invention, by providing a reflecting portion on a substrate on which a light source is mounted, light distribution control can be performed using the reflecting portion, and the number of parts can be reduced and the cost can be reduced. Can be done.

It is a perspective view of the light emitting device in Embodiment 1 of this invention. It is an exploded perspective view of the light emitting device in Embodiment 1 of this invention. It is sectional drawing explaining the light distribution control of the light source module in Embodiment 1 of this invention. It is a perspective view of the light emitting device in Embodiment 2 of this invention. It is an exploded perspective view of the light emitting device in Embodiment 2 of this invention. It is sectional drawing explaining the light distribution control of the light source module in Embodiment 2 of this invention. It is a top view of the light source module in Embodiment 3 of this invention. It is a perspective view which shows the state which the reflective part was formed on the flexible substrate in Embodiment 3 of this invention. It is a top view of the light source module in the comparative example. It is a perspective view which shows the state which the reflection part was formed on the flexible substrate in the comparative example. It is a figure explaining the light emitting device in the prior art. It is a figure explaining the light emitting device in the prior art.

Hereinafter, embodiments of the light source module and the light emitting device of the present invention will be described in detail with reference to the drawings.
Embodiment 1.
1 and 2 are schematic views for explaining the light emitting device 10 according to the first embodiment of the present invention. FIG. 1 is a perspective view of the light emitting device 10, and FIG. 2 is an exploded perspective view of the light emitting device 10. The light emitting device 10 of the present embodiment is used, for example, as a light emitting unit of a lighting fixture. As shown in FIGS. 1 and 2, the light emitting device 10 includes a light source module 15 composed of a plurality of light sources 11 and a flexible substrate 12 on which the plurality of light sources 11 are mounted, and a holding member 13 for holding the light source module 15. Be prepared. Further, the light emitting device 10 further includes a connection wiring (not shown) in the light emitting device 10, a connector (not shown) for connecting the light emitting device 10 and the lighting equipment, and the like.

The light source 11 is, for example, a chip-type LED. The plurality of light sources 11 are arranged in a row at equal intervals along the longitudinal direction of the flexible substrate 12 at the center of the flexible substrate 12 in the lateral direction. The light source 11 is not limited to the LED, but may be an organic EL or the like. Further, the light sources 11 may be arranged in a plurality of rows on the flexible substrate 12. Further, although FIG. 1 shows an example in which the light sources 11 are connected in series, the light sources 11 may be connected in parallel or serially in parallel.

The flexible substrate 12 is, for example, a thin and flexible FPC (Flexible Printed Circuits) substrate, and is configured by forming wiring in a copper foil pattern (not shown) on a substrate made of polyimide or the like. The flexible substrate 12 has a mounting portion 12a on which the light source 11 is mounted, and reflecting portions 12b formed on both sides of the mounting portion 12a. The reflecting portion 12b is formed by being bent from the bending positions on both sides of the mounting portion 12a (positions shown by broken lines in FIG. 1) toward the surface side on which the light source 11 is mounted. Further, a reflective film is formed on the surface of the flexible substrate 12 on the side on which the light source 11 is mounted. The reflective film is formed, for example, by applying a highly reflective resist, but is not limited thereto.

The holding member 13 is made of, for example, sheet metal, and is a component for holding the light source module 15 and attaching it to a lighting fixture. The holding member 13 has an intermediate portion 13a and bent portions 13b located on both sides of the intermediate portion 13a and bent from the intermediate portion 13a toward the light source module 15. The bent portion 13b is formed by being bent from a predetermined bending position at a predetermined bending angle.

In the present embodiment, as shown in FIG. 2A, the flexible substrate 12 on a plane on which a plurality of light sources 11 are mounted is bent according to the shape of the holding member 13 as shown in FIG. 2B. By doing so, the reflective portion 12b is formed. Therefore, the width of the mounting portion 12a of the flexible substrate 12 is substantially the same as the width of the intermediate portion 13a of the holding member 13, and the bending angle of the reflecting portion 12b is substantially the same as the bending angle of the bending portion 13b. Then, the surface of the flexible substrate 12 on which the light source 11 is not mounted is joined to the holding member 13 to form the light emitting device 10. The flexible substrate 12 and the holding member 13 are joined by any method such as an adhesive sheet, double-sided tape, or an adhesive. By joining the light source module 15 to the holding member 13, the shape of the light source module 15, that is, the angle of the bent reflecting portion 12b and the like are held.

The light distribution of the light source module 15 is determined according to the bending position and bending angle of the reflecting portion 12b. FIG. 3 is a cross-sectional view illustrating the light distribution control of the light source module 15 of the present embodiment. As shown in FIG. 3, by providing the reflective portion 12b on the flexible substrate 12, among the light emitted from the light source 11, the light emitted from the side surface of the light source 11 is the light emitted from the side surface of the light source 11 of the reflective portion 12b on which the reflective film is formed. Reflected on the surface. FIG. 3A and FIG. 3B show light distribution control when the bending angles of the reflecting portions 12b are different from each other. As shown in FIGS. 3A and 3B, the direction of the reflected light differs depending on the bending angle of the reflecting portion 12b. Therefore, the light distribution control of the light source module 15 can be performed by adjusting the bending angle of the reflecting portion 12b (that is, the bending angle of the bending portion 13b of the holding member 13). Further, the light distribution control of the light source module 15 can be performed by similarly adjusting the bending position of the reflecting portion 12b.

For example, the light distribution of the light source module 15 in which the size of the light source 11 is 5 mm × 5 mm and the length of the flexible substrate 12 in the lateral direction (that is, the direction perpendicular to the direction in which the light sources 11 are arranged) is 12 cm. A case of performing control will be described. In this case, first, the bending position of the reflective portion 12b is set to 5 cm from each end of the flexible substrate 12 in the lateral direction. That is, the width of the mounting portion 12a on which the light source 11 is mounted is 2 cm, and the width of the reflecting portion 12b is 5 cm, respectively. Then, for example, in order to suppress the glare of the light emitting device 10, it is necessary to suppress the light emitted from the light source 11 at 30 ° or less from the horizontal direction. Therefore, by setting the bending angle of the bending portion 13b of the holding member 13 to 40 °, the bending angle of the reflecting portion 12b becomes 40 °, and light of 30 ° or less can be reflected from the horizontal direction to suppress glare. ..

As described above, in the light source module 15 of the present embodiment, the reflective portion 12b is formed on the flexible substrate 12, the light of the light source 11 is reflected, and the reflected light is utilized, so that many light sources 11 are not used. , The required light source and the required light emitting area can be satisfied. Therefore, the number of component parts and the product cost can be reduced. Further, by performing the light distribution control using a part of the flexible substrate 12, it is possible to prevent an increase in the number of parts and suppress a loss of light radiated from the light source 11.

Suppression of light loss will be described in comparison with the prior art described in FIGS. 11 and 12. FIG. 11 is a diagram illustrating a light emitting device 60 in the prior art. 11 (a) is a perspective view of the light emitting device 60, FIG. 11 (b) is an exploded perspective view, and FIG. 11 (c) is a partially enlarged enlarged perspective view. The light emitting device 60 is configured to include a reflector 63 as a separate component in order to control the light distribution without increasing the number of light sources 11. As shown in FIGS. 11A and 11B, the light emitting device 60 includes a rigid substrate 62 (non-deformable substrate) on which the light source 11 is mounted, a reflector 63 that reflects light emitted from the light source 11, and a reflector 63. Is held by the holding member 64.

In the case of the light emitting device 60, the product cost becomes high due to the increase in the parts cost and the assembly man-hours of the reflector 63. Further, as shown in FIG. 11C, since the reflector 63 and the rigid substrate 62 are separate parts, a gap is generated between the reflector 63 and the rigid substrate 62. Then, a part of the light radiated from the light source 11 enters this gap, so that the luminous efficiency of the light emitting device 60 is lowered.

Further, FIG. 12 is a diagram illustrating a light emitting device 70 according to another conventional technique. 12 (a) is a perspective view of the light emitting device 70, FIG. 12 (b) is an exploded perspective view, and FIG. 12 (c) is a partially enlarged enlarged perspective view. The light emitting device 70 is configured to include a high reflection sheet 73 as a separate component in order to increase the luminous efficiency. As shown in FIGS. 12A and 12B, the light emitting device 70 includes a rigid substrate 72 (non-deformable substrate) on which the light source 11 is mounted and a highly reflective sheet 73 that reflects light emitted from the light source 11. And are held by the holding member 74. Also in the case of the light emitting device 70, as shown in FIG. 12 (c), a gap may be formed between the highly reflective sheet 73, which is a separate component, and the rigid substrate 72. Then, a part of the light radiated from the light source 11 enters the gap, so that the luminous efficiency of the light emitting device 70 may not be improved as expected.

In contrast to the above conventional technique, in the light emitting device 10 of the present embodiment, the light source 11 is mounted on the flexible substrate 12, and a part of the flexible substrate 12 is bent to reflect the light emitted from the light source 11. And. As a result, light loss occurs due to a part of the light radiated from the light source 11 entering the gap between the reflector 63 and the rigid substrate 62 or the gap between the high reflection sheet 73 and the rigid substrate 72 as in the prior art. Is suppressed. As a result, the luminous efficiency of the light emitting device 10 can be improved. Further, since it is not necessary to provide the reflector 63 or the high reflection sheet 73 as a separate component, low cost can be realized.

Embodiment 2.
Subsequently, the second embodiment of the present invention will be described. In the light emitting device 20 of the present embodiment, the shapes of the flexible substrate 22 and the holding member 23 are different from those of the first embodiment. The other configurations of the light emitting device 20 are the same as those in the first embodiment.

4 and 5 are schematic views for explaining the light emitting device 20 according to the present embodiment. FIG. 4 is a perspective view of the light emitting device 20, and FIG. 5 is an exploded perspective view of the light emitting device 20. As shown in FIGS. 4 and 5, the light emitting device 20 includes a light source module 25 composed of a plurality of light sources 11 and a flexible substrate 22 on which the plurality of light sources 11 are mounted, and a holding member 23 for holding the light source module 25. Be prepared. Further, the light emitting device 20 further includes a connection wiring (not shown) in the light emitting device 20, a connector (not shown) between the light emitting device 20 and the lighting equipment, and the like.

The light source 11 is the same as that of the first embodiment. The flexible substrate 22 is a thin and flexible FPC substrate, and is configured by forming wiring in a copper foil pattern (not shown) on a substrate made of polyimide or the like. The flexible substrate 22 has a mounting portion 22a on which the light source 11 is mounted, and reflecting portions 22b formed on both sides of the mounting portion 22a. The reflecting portion 22b is formed by being bent (arc) from the bending positions on both sides of the mounting portion 22a (positions shown by broken lines in FIG. 4) toward the surface side on which the light source 11 is mounted. Further, a reflective film is formed on the surface of the flexible substrate 22 on the side on which the light source 11 is mounted. The reflective film is formed, for example, by applying a highly reflective resist, but is not limited thereto.

The holding member 23 is made of, for example, sheet metal, and is a component for holding the light source module 25 and attaching it to a lighting fixture. The holding member 13 has an intermediate portion 13a and bent portions 13b located on both sides of the intermediate portion 13a and bent toward the light source module 15 from the intermediate portion 13a. The bent portion 13b is formed by being bent in a curved shape (arc shape) with a predetermined radius of curvature.

In the present embodiment, as shown in FIG. 5A, the flexible substrate 22 on a plane on which a plurality of light sources 11 are mounted is bent according to the shape of the holding member 23 as shown in FIG. 5B. As a result, the reflective portion 22b is formed. Therefore, the width of the mounting portion 22a of the flexible substrate 22 is substantially the same as the width of the intermediate portion 23a of the holding member 23, and the radius of curvature of the reflecting portion 22b is substantially the same as the radius of curvature of the bent portion 23b. Then, the surface of the flexible substrate 22 on which the light source 11 is not mounted is joined to the holding member 23 to form the light emitting device 20. The flexible substrate 22 and the holding member 23 are joined by any method such as an adhesive sheet, double-sided tape, or an adhesive. By joining the light source module 25 to the holding member 23, the shape of the light source module 25, that is, the curved shape of the reflecting portion 22b and the like are held.

The light distribution of the light source module 25 is determined according to the bending position and the radius of curvature of the reflecting portion 22b. FIG. 6 is a cross-sectional view illustrating the light distribution control of the light source module 25 of the present embodiment. As shown in FIG. 6, by providing the reflective portion 22b on the flexible substrate 22, among the light emitted from the light source 11, the light emitted from the side surface of the light source 11 is the light emitted from the side surface of the light source 11 of the reflective portion 22b on which the reflective film is formed. Reflected on the surface. Therefore, the light distribution control of the light source module 25 can be performed by adjusting the radius of curvature of the reflecting portion 22b (that is, the radius of curvature of the bent portion 23b of the holding member 23). Further, the light distribution control of the light source module 25 can be performed by similarly adjusting the bending position of the reflecting portion 22b.

For example, the light distribution of the light source module 25 in which the size of the light source 11 is 5 mm × 5 mm and the length of the flexible substrate 22 in the lateral direction (that is, the direction perpendicular to the direction in which the light sources 11 are arranged) is 12 cm. A case of performing control will be described. In this case, first, the bending position of the reflective portion 22b is set to 5 cm from each end of the flexible substrate 22 in the lateral direction. That is, the width of the mounting portion 22a on which the light source 11 is mounted is 2 cm, and the width of the reflecting portion 22b is 5 cm, respectively. Then, for example, in order to suppress the glare of the light emitting device 20, it is necessary to suppress the light emitted from the light source 11 at 30 ° or less from the horizontal direction. Therefore, by setting the radius of curvature of the bent portion 23b of the holding member 23 to 4.7 cm, the radius of curvature of the reflecting portion 22b becomes 4.7 cm, and synchrotron radiation of 30 ° or less is reflected from the horizontal direction to suppress glare. be able to.

As described above, also in the present embodiment, as in the first embodiment, the number of component parts of the light emitting device 20 and the product cost can be reduced, and a part of the flexible substrate 22 is used for arrangement. By performing light control, loss of light emitted from the light source 11 can also be suppressed.

Embodiment 3.
Subsequently, the third embodiment of the present invention will be described. The present embodiment is different from the first embodiment in that the deformation regulating portion 31 is formed on the mounting portion 32a of the flexible substrate 32. Other configurations are the same as those in the first embodiment.

FIG. 7 is a plan view of the light source module 35 according to the present embodiment. The light source module 35 of the present embodiment is used in the light emitting device 10 for a lighting fixture as in the first embodiment. The light source module 35 includes a flexible substrate 32 and a plurality of light sources 11 mounted on the flexible substrate 32. The configuration of the light source 11 and the flexible substrate 32 is the same as that of the first embodiment. However, as shown in FIG. 7, the flexible substrate 32 of the present embodiment is formed with a deformation regulating portion 31 having a width wider than the width of the light source 11. Specifically, the deformation regulating unit 31 is, for example, a copper foil pattern constituting the wiring of the light source 11. The width of the deformation regulating portion 31 is substantially the same as the width of the mounting portion 32a of the flexible substrate 32 (that is, the width of the intermediate portion 13a of the holding member 13).

FIG. 8 is a perspective view showing a state in which the reflective portion 32b is formed on the flexible substrate 32 in the present embodiment. FIG. 8A shows a case where the flexible substrate 32 of the present embodiment is bent as in the first embodiment to form a reflective portion 32b, and FIG. 8B shows a case where the flexible substrate 32 is implemented. A case where the reflecting portion 32b is formed by being bent in a curved shape as in the second embodiment is shown.

As shown in FIGS. 8A and 8B, the deformation is formed by having the deformation regulating portion 31 which is wider than the width of the light source 11 and substantially the same width as the width of the mounting portion 32a as in the present embodiment. The end of the restricting portion 31 is the bending position of the reflecting portion 32b. That is, the deformation regulating unit 31 regulates that the flexible substrate 32 is bent from an unintended position inside the bending position. Further, since the deformation regulating portion 31 and the flexible substrate 32 are in close contact with each other to increase the strength, the deformation regulating portion 31 inside the bending position does not bend. Therefore, bending stress on the solder joint on which the light source 11 is mounted is suppressed.

On the other hand, FIG. 9 is a plan view of the light source module 55 in the comparative example. The light source module 55 in the comparative example includes a flexible substrate 52 and a plurality of light sources 11 mounted on the flexible substrate 52. The configuration of the light source 11 and the flexible substrate 52 is the same as that of the present embodiment. However, as shown in FIG. 9, in the present embodiment, the deformation regulating portion 31 is not formed on the flexible substrate 52. Specifically, in the comparative example, the width of the copper foil pattern 51 formed on the flexible substrate 52 is substantially the same as the width of the light source 11, and is substantially the same as the width of the mounting portion 52a as in the deformation regulating portion 31. is not.

FIG. 10 is a perspective view showing a state in which the reflective portion 52b is formed on the flexible substrate 52 in the comparative example. FIG. 10A shows a case where the flexible substrate 52 of the comparative example is bent as in the first embodiment to form the reflecting portion 52b, and FIG. 10B shows the case where the flexible substrate 52 is the second embodiment. The case where the reflective portion 32b is formed by being bent in a curved shape as shown above is shown.

As shown in FIGS. 10A and 10B, in the light source module 55 of the comparative example, bending of the flexible substrate 52 may occur at an unintended position. Specifically, the flexible substrate 52 may be bent at the inner position L2 shown by the broken line from the bending position L1 shown by the alternate long and short dash line in FIGS. 10A and 10B. As a result, bending stress may be applied to the solder joint on which the light source 11 is mounted. Further, in the comparative example, the width, bending angle or radius of curvature of the reflecting portion 52b may be different from that of the holding member 13. As a result, the light distribution control according to the design intention is not performed.

As described above, in the light source module 35 of the present embodiment, in addition to the same effect as that of the first embodiment, the deformation restricting portion 31 regulates the bending position of the reflecting portion 32b to the solder joint portion of the light source 11. It is possible to suppress the bending stress of the light source 11 and maintain the joint reliability of the light source 11 without impairing it. Further, the light distribution can be controlled according to the intention at the time of design.

The above is the description of the embodiment of the present invention, but the present invention is not limited to the configuration of the above-described embodiment, and various modifications or combinations are possible within the scope of the technical idea. .. For example, in the above embodiment, the flexible substrate 12 is bent according to the shape of the holding member 13, but the flexible substrate 12 may be bent in advance to form the reflecting portion 12b and then joined to the holding member 13. ..

Further, the reflective film may be applied to the entire surface of the flexible substrate 12 on which the light source 11 is mounted, or may be applied only to the reflective portion 12b. Further, the shape of the reflecting portion 12b is not limited to the above embodiment, and may be any shape as long as it reflects the light radiated from the side surface of the light source 11.

10, 20, 60, 70 Light emitting device, 11 light source, 12, 22, 32, 52 flexible substrate, 12a, 22a, 32a, 52a mounting part, 12b, 22b, 32b, 52b reflecting part, 13, 23, 64, 74 Holding member, 13a, 23a intermediate part, 13b, 23b bent part, 15, 25, 35, 55 light source module, 31 deformation control part, 51 copper foil pattern, 62, 72 rigid substrate, 63 reflector, 73 high reflection sheet.

Claims (5)

Light source and
With a board,
The substrate is
A mounting portion having a width wider than the width of the light source and on which the light source is mounted,
Deformation control part provided on the mounting part and
Formed outside than the deformation restricting portion, a reflecting portion can be bent at a position outside from the end portion of the deformation restricting portion, Ri Tona,
The deformation regulating unit is a light source module which is a copper foil pattern constituting the wiring of the light source. The deformation control unit
The light source module according to claim 1, which is provided in close contact with the mounting portion. The light source module according to claim 1 or 2, wherein a reflective film is formed on the surface of the reflecting portion on the side on which the light source is mounted. The light source module according to any one of claims 1 to 3, wherein the width of the mounting portion and the width of the deformation regulating portion are the same. The light source module according to any one of claims 1 to 4.
A holding member for holding the light source module, and
The holding member is a light emitting device having a bent portion that holds the reflecting portion.

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