JP6967741B2 - Ceiling-embedded lighting equipment and manufacturing method of the lighting equipment - Google Patents

Description

The present disclosure relates to a ceiling-embedded luminaire and a method for manufacturing the luminaire.

Conventionally, a ceiling-embedded lighting device having a metal housing for accommodating a light emitting module and being mounted on the ceiling in a state where the housing is inserted into an embedded hole formed in the ceiling is known (for example, Patent Document). 1). Such a luminaire, commonly referred to as a downlight, has an annular flange that overhangs the opening of the metal housing and abuts the ceiling surface around the embedding hole. A die-cast molded body may be used for the metal housing, but by using a drawn molded body, the manufacturing cost can be reduced.

Japanese Unexamined Patent Publication No. 2013-196900

FIG. 7 is a cross-sectional view showing a flange 101 of a metal housing 100 of a conventional lighting device. As illustrated in FIG. 7, an edge surface 102 is formed on the flange 101 of the draw-formed metal housing 100, but if the edge surface 102 comes into contact with the ceiling surface 103, the ceiling surface 103 may be damaged. be. Further, since rust is likely to occur on the edge surface 102, rust may be formed on the ceiling surface 103. An object of the present disclosure is to suppress damage to the ceiling surface caused by an edge surface in a ceiling-embedded lighting device provided with a metal housing which is a drawn body.

The ceiling-embedded lighting device according to one aspect of the present disclosure includes a metal housing which is a tubular drawing molded body having at least one end in the axial direction, including a back surface facing the ceiling side, and inside the metal housing. It is equipped with a light emitting module provided. The metal housing has an annular flange protruding around the opening, and the flange is formed with a curled portion whose edge surface is curved so as to face the back surface.

A method of manufacturing a ceiling-embedded lighting device according to one aspect of the present disclosure is to draw a metal plate to form a tubular body having at least one axially open opening and a flat flange overhanging around the opening. The first step of molding, the second step of forming a curl portion on the flat flange, and the third step of mounting a light emitting module inside the metal housing which is the tubular body on which the curl portion is formed are performed. include. In the second step, the tip portion of the flat flange is bent toward one surface side of the tubular body which is the back surface of the metal housing, and then the predetermined range of the flange including the tip portion is R-bent. It is processed to form the curled portion curved so that the edge surface faces one of the surfaces.

According to one aspect of the present disclosure, damage to the ceiling surface can be suppressed in a ceiling-embedded lighting device provided with a metal housing which is a draw-formed body.

It is a perspective view of the lighting apparatus which is an example of an embodiment. It is an exploded perspective view of the lighting apparatus which is an example of an embodiment. It is sectional drawing of the metal housing which is an example of Embodiment. It is an enlarged view of part A in FIG. It is a figure for demonstrating the manufacturing method of the metal housing which is an example of an embodiment. It is a figure for demonstrating the manufacturing method of the metal housing which is an example of an embodiment. It is sectional drawing which shows the metal housing of the conventional lighting apparatus.

Hereinafter, an example of an embodiment of the ceiling-embedded lighting device according to the present disclosure will be described in detail with reference to the drawings. Although the downlight is exemplified in the present embodiment, the ceiling-embedded lighting device of the present disclosure is not limited to the downlight. FIG. 1 is a perspective view of an illuminating device 10 which is an example of an embodiment, and FIG. 2 is an exploded perspective view of the illuminating device 10. FIG. 3 is a cross-sectional view of the lighting device 10 (the cover 56 and the lighting device 57 are not shown).

As illustrated in FIGS. 1 to 3, the lighting device 10 includes a metal housing 11 which is a cylindrical drawing molded body having one end opened in the axial direction, and a light emitting module 20 provided inside the metal housing 11. To prepare for. The lighting device 10 is a ceiling-embedded lighting device that is inserted into a ceiling-embedded hole with the opening of the metal housing 11 facing vertically downward. The lighting device 10 is generally called a downlight. In the present specification, for convenience of explanation, the vertically upper side of the lighting device 10 is referred to as “upper” and the vertically lower side is referred to as “lower” in a state where the lighting device 10 is attached to the ceiling.

The illuminating device 10 is attached to a horizontal ceiling, for example, in a living room, but it can also be attached to a ceiling inclined in the horizontal direction and the vertical direction. Further, the lighting device 10 can be attached to a corridor of a house, a ceiling such as an entrance, a public facility such as a library, a commercial facility such as a department store, an office, a store, a factory, or the like. The ceiling to which the lighting device 10 is attached may be a portion that divides the upper part of the building space, and may be, for example, a ceiling such as an entrance porch or a terrace.

The lighting device 10 includes a holder 30 fixed inside the metal housing 11 and holding the light emitting module 20, and a translucent cover 40 that engages with the holder 30 and covers the light emitting module 20 and the holder 30. Further, the lighting device 10 includes a lighting device 57 (see FIG. 2) that supplies electric power to the light emitting module 20, and a case 50 that houses the lighting device 57. In this embodiment, the case 50 is screwed to the metal housing 11. The case 50 is composed of a support metal fitting 51 and a cover 56. The support metal fitting 51 forms a part of the bottom plate and the side wall of the case 50, and supports the mounting spring 54.

The metal housing 11 is a tubular body having one end in the axial direction (hereinafter, may be referred to as “lower end”) open, and the tubular wall 12 and the other end in the axial direction (hereinafter, may be referred to as “upper end”). It has a top plate 13 formed in. The metal housing 11 is a cylindrical member having a substantially circular cross section perpendicular to the axial direction, and has a divergent shape whose diameter increases as it approaches the opening at the lower end. Further, the metal housing 11 has an annular flange 14 overhanging around the opening.

The metal housing 11 includes a front surface 11a and a back surface 11b facing the ceiling side. The surface 11a is an inner surface facing the inside of the metal housing 11 in which the light emitting module 20 is housed, and faces the indoor side in a state where the lighting device 10 is attached to the ceiling, for example. The back surface 11b is the outer surface of the metal housing 11, and is not visible from the indoor side when the lighting device 10 is attached to the ceiling. In the curl portion 15 described later, a part of the surface 11a faces the ceiling side. That is, the curl portion 15 is curled so that the surface 11a faces the ceiling side.

Generally, a film (not shown) such as a white coating film containing a coloring material such as a white pigment is formed on the surface 11a of the metal housing 11. A film such as a white coating film is formed over the entire surface 11a including the curl portion 15, for example. The color of the coating film formed on the surface 11a is not limited to white, and can be appropriately changed by changing the type of coloring material. A film of a metal or a metal compound may be formed on the surface 11a by vapor deposition, plating, sputtering, or the like. These coatings have a function of improving the light reflectance of the surface 11a, for example, and prevent corrosion such as rust. A film such as a coating film may also be formed on the back surface 11b of the metal housing 11.

The metal housing 11 is a drawn body manufactured by drawing, for example, a metal material containing aluminum or iron as a main component. The drawing process may be either press drawing process or spinning frame processing. By using the draw-formed body for the metal housing 11, the manufacturing cost can be reduced as compared with the case of using the die-cast molded body. The metal housing 11 is manufactured by drawing, for example, a metal plate on which a film such as a coating film is formed. An example of the thickness of the metal plate is 0.5 to 1 mm. The metal housing 11 is not limited to the divergent bottomed cylindrical member, and may be a member having a rectangular cross section perpendicular to the axial direction.

In the metal housing 11 manufactured by drawing, an edge surface 16 which is a cut surface of a metal plate is formed at the tip of a flange 14. Since the edge surface 16 is rougher than the front surface 11a and the back surface 11b, the edge surface 16 may damage the ceiling surface when it comes into contact with the ceiling surface. Further, since a film such as a coating film is not formed on the edge surface 16, rust is likely to occur. However, according to the lighting device 10, since the curl portion 15 is formed on the flange 14, it is possible to prevent damage to the ceiling surface due to the edge surface 16. The details of the curl portion 15 will be described later.

The tubular wall 12 is formed substantially along the axial direction at the upper part of the metal housing 11, and has a shape inclined so as to gradually spread outward in the radial direction from the central portion in the vertical direction toward the lower end. The cylinder wall 12 may be curved. The top plate 13 is formed at the upper end of the metal housing 11 as described above, and closes the upper end of the metal housing 11. The top plate 13 has, for example, a substantially perfect circular shape in a plan view, and a convex portion 13c bulging from the back surface 11b side to the front surface 11a side is formed in the central portion thereof. The heat radiating plate 23 of the light emitting module 20, which will be described later, is in contact with the convex portion 13c.

In this embodiment, the holder 30 is screwed to the top plate 13. The holder 30 is fixed from the outside of the top plate 13 using screws 35. Therefore, the top plate 13 is formed with a through hole 13a for passing the screw 35. Further, since the base 52 of the support metal fitting 51 constituting the bottom plate of the case 50 is fixed to the top plate 13 by using the screw 55, the top plate 13 is formed with a screw hole 13b into which the screw 55 is screwed. ..

As described above, the flange 14 projects radially outward at the peripheral edge of the opening of the metal housing 11. The flange 14 is arranged along the ceiling surface with the upper portion of the metal housing 11 inserted into the space behind the ceiling through the embedding hole. An annular member 58 that abuts on the peripheral edge of the embedding hole may be mounted on the back surface 11b of the flange 14. The flange 14 is formed with a curled portion 15 that is curved so that the edge surface 16 faces the back surface 11b. In this case, for example, the surface 11a of the curved curl portion 15 comes into contact with the ceiling surface, but the edge surface 16 does not come into contact with the ceiling surface, and damage to the ceiling surface caused by the edge surface 16 is prevented.

The light emitting module 20 is held by the holder 30 and is provided inside the metal housing 11. The light emitting module 20 has, for example, a light source unit 21 and a substrate 22 on which the light source unit 21 is arranged. As the light emitting element constituting the light source unit 21, a semiconductor light emitting element such as an LED (Light Emitting Diode) is preferable. The light emitting device may be sealed with a sealing layer containing a phosphor. In this case, a part of the blue light of the light emitting element may be converted into light having a longer wavelength by the phosphor and mixed with the remaining part of the blue light to emit white light. The light emitting module 20 may have a heat sink 23 that diffuses the heat of the light source unit 21.

The holder 30 is fixed to the top plate 13 inside the metal housing 11 and holds the light emitting module 20. The holder 30 is generally made of a resin material. The holder 30 is inserted into the upper part of the metal housing 11 having a substantially constant diameter, and is fixed to the top plate 13 by using a screw 35 inserted into the through hole 13a from the outside of the top plate 13. The holder 30 has a boss portion 36 to which the screw 35 is fastened. The outer diameter of the holder 30 is smaller than the inner diameter of the upper part of the metal housing 11, and there is a gap between the holder 30 and the inner surface of the metal housing 11 into which the translucent cover 40 can be inserted.

The holder 30 has a substantially annular bottom plate 31 having a window hole 33 formed in the center, and a peripheral wall 32 erected on the outer peripheral edge of the bottom plate 31 and formed in a cylindrical shape. The light emitting module 20 is arranged in the holder 30 with the surface of the substrate 22 on which the light source unit 21 is mounted facing down so that light is emitted through the window hole 33 of the bottom plate 31. A protrusion 34 that functions as an engaging portion with the translucent cover 40 is formed on the outer peripheral surface of the peripheral wall 32.

The translucent cover 40 is a milky white resin translucent member containing, for example, a filler or a void for light diffusion. Alternatively, the translucent cover 40 may be a transparent member, or may have a lens function of forming light on an incident surface and an emitted surface. The translucent cover 40 has a function of covering and protecting the light emitting module 20 held in the holder 30 and transmitting or diffusing the light emitted from the light emitting module 20.

The translucent cover 40 has a bottom plate 41 having a substantially disk shape and a peripheral wall 42 erected on the outer peripheral edge of the bottom plate 41, and has a bottomed cylindrical shape capable of accommodating the holder 30. A fitting hole 43 that functions as an engaging portion with the holder 30 is formed in the peripheral wall 42, and the transparent cover 40 and the holder 30 are formed by fitting the protrusion 34 of the holder 30 into the fitting hole 43. Be integrated. The inner diameter of the translucent cover 40 is larger than the outer diameter of the holder 30, and the entire holder 30 for holding the light emitting module 20 is housed inside. On the other hand, the outer diameter of the translucent cover 40 is smaller than the inner diameter of the upper part of the metal housing 11, and the translucent cover 40 is inserted between the metal housing 11 and the holder 30.

An annular packing 44 may be attached to the lower portion of the translucent cover 40. As illustrated in FIG. 3, the packing 44 is pressed against the surface 11a of the metal housing 11 to close the gap between the metal housing 11 and the translucent cover 40. The bottom plate 41 projects outward from the outer peripheral surface of the peripheral wall 42, and the packing 44 is held by the overhanging portion. By providing the packing 44, it is possible to prevent insects, dust, etc. from invading the inside of the translucent cover 40.

The support metal fitting 51 forming a part of the case 50 has a base portion 52 fixed to the top plate 13 of the metal housing 11 by using a screw 55, and a pair of arm portions 53 extending downward from the base portion 52. The mounting spring 54 is fixed to each arm portion 53, respectively. The mounting spring 54 has a leaf spring structure and extends in the horizontal direction. The lighting device 10 is fixed to the ceiling by abutting the two mounting springs 54 around the embedded hole in the ceiling in the space behind the ceiling. The number, shape, fixing structure, etc. of the mounting springs 54 are not particularly limited.

Hereinafter, the curl portion 15 formed on the flange 14 of the metal housing 11 will be described in detail with reference to FIGS. 4 to 6. FIG. 4 is an enlarged view of part A in FIG. 3 (the annular member 58 is not shown). 5 and 6 are diagrams for explaining a method of manufacturing the metal housing 11.

As shown in FIGS. 3 and 4, the flange 14 of the metal housing 11 is formed with a curled portion 15 whose edge surface 16 is curved so as to face the back surface 11b. That is, the tip portion of the flange 14 is curled toward the back surface 11b so that the edge surface 16 does not come into contact with the ceiling surface and is not visible from the indoor side. By forming the curl portion 15 on the flange 14, it is possible to prevent damage to the ceiling surface such as scratches and rust due to the edge surface 16. As described above, a film such as a coating film is formed on the surface 11a of the metal housing 11, but by forming the gently curved curl portion 15, cracking, peeling, etc. of the film can be suppressed.

The flange 14 has a flat portion 17 and a curl portion 15. The flat portion 17 extends outward from the peripheral edge of the opening of the tubular metal housing 11. The curl portion 15 is formed at the peripheral end portion (tip portion) of the flange 14 over the entire circumference of the flange 14. The dimensions of the curl portion 15 vary depending on the dimensions of the metal housing 11 and the like, but for example, the length is about 10 to 30% of the length of the flange 14 (the length in the direction orthogonal to the axial direction of the metal housing 11). It has a height T (length along the axial direction of the metal housing 11) of about 2 to 4 mm.

The curl portion 15 is curved from the boundary portion with the flat portion 17 to the tip portion on the edge surface 16 side. The cross section of the curl portion 15 has an arc shape. It is preferable that the curl portion 15 does not have a bent portion, and for example, the entire curl portion 15 including the radial outer end and the upper end of the flange 14 is gently curved. In this case, cracking, peeling, and the like of the coating film formed on the surface 11a are suppressed, and damage to the ceiling surface is suppressed.

The curl portion 15 is curved so that the edge surface 16 cannot be seen when, for example, the metal housing 11 is viewed in a plan view (when viewed from the back surface 11b side). The edge surface 16 may be located closer to the flat portion 17 than the upper end of the curl portion 15, or may be in contact with the back surface 11b. The curl portion 15 may be curved so as to face the radial outer side of the flange 14 beyond the position where the edge surface 16 is parallel to the back surface 11b of the flat portion 17. The cross-sectional shape of the curl portion 15 exhibits an arc shape of, for example, 3/4 or more laps.

The curl portion 15 has substantially the same radius of curvature from the boundary portion with the flat portion 17 to the tip portion, and may be uniformly curved. Alternatively, the radius of curvature of the curl portion 15 may differ depending on the location. The radius of curvature of the curl portion 15 may be smaller at the tip portion than the boundary portion with the flat portion 17, for example, or the radius of curvature may be gradually reduced toward the tip portion. The radius of curvature of the curl portion 15 is maximum at the boundary portion with the flat portion 17, and may be substantially constant at a portion other than the boundary portion and its vicinity.

The radius of curvature R (A) at the tip of the curl portion 15 is, for example, 1.3 to 1.7 mm, preferably 1.4 to 1.6 mm. The radius of curvature R (C) at the boundary between the curled portion 15 and the flat portion 17 is, for example, larger than the radius of curvature (A) and is 1.4 to 1.8 mm, preferably 1.5 to 1.7 mm. be. The radius of curvature R (B) of the intermediate portion of the curl portion 15 including the radial outer end, the upper end, and the like of the flange 14 may be substantially the same as the radius of curvature R (A).

5 and 6 are diagrams for explaining a method of manufacturing the lighting device 10. Here, the flat flange until the curl portion 15 is formed and the pre-bent flange are referred to as the flange 14z.

The lighting device 10 can be manufactured, for example, by a manufacturing method including the following first to third steps.
First step: A metal plate is drawn to form a cylindrical body having at least one axial end open and a flat flange 14z overhanging around the opening.
Second step: The curl portion 15 is formed on the flat flange 14z. As a result, the metal housing 11 which is a tubular body on which the curl portion 15 is formed can be obtained.
Third step: The light emitting module 20 is attached to the inside of the metal housing 11.

As illustrated in FIGS. 5 and 6, in the second step, first, the tip end portion of the flat flange 14z on the edge surface 16 side is one of a cylindrical body (metal plate) to be the back surface 11b of the metal housing 11. Preliminary bending is performed to bend to the surface 11bz side (see FIG. 5A). At this time, it is preferable to bend the tip of the flat flange 14z toward one surface 11bz to a height corresponding to 30 to 70% of the height T of the finally formed curl portion 15. The tip of the flat flange 14z may be bent small, but is preferably R-bent so that the radius of curvature is 1.3 to 1.7 mm.

It is preferable that a film such as a white coating film is formed on the other surface 11az of the metal plate to be the surface 11a of the metal housing 11. That is, the tubular body is formed so that the other surface on which the coating is formed becomes the surface 11a. By performing the preliminary bending, the flange 14z can be smoothly bent, and cracking or peeling of the coating film can be suppressed.

In the second step, a predetermined range of the flange 14z including the pre-bent tip portion is R-bent (see FIGS. 5 (c) and 6). As a result, the curled portion 15 is formed so that the edge surface 16 faces the back surface 11b of the metal housing 11. Further, in the second step, it is preferable to perform the second pre-bending (see FIG. 5 (b)). Specifically, after bending the tip of the flat flange 14z toward one surface 11bz, the flange is bent toward one surface 11bz to a height exceeding the height T of the curl portion 15, and then the curl portion 15 is bent. To form. That is, it is preferable that the curl portion 15 is formed through a three-step bending step.

In the second pre-bending, the portion of the pre-bent (first pre-bent) flange 14z away from the tip may be bent small, but the radius of curvature is preferably 1.3 to 1.7 mm. R-bend processing. At this time, it is preferable to bend the portion away from the tip portion to one surface 11bz side to a height exceeding the height T of the curl portion 15.

As illustrated in FIG. 6, by pressing the pre-bent flange 14z using the die 70 having the recess 71, the flange 14z bends along the curved surface of the recess 71 to form the curl portion 15. .. The surface of the recess 71 is, for example, a curved surface having a radius of curvature of about 1.3 to 1.7 mm. At this time, it is preferable to press the flange 14z from both sides by using the dies 72 and 73. By the above steps, the metal housing 11 having the curl portion 15 is manufactured.

10 Lighting device, 11 Metal housing, 11a front surface, 11b back surface, 12 cylinder wall, 13 top plate, 13a through hole, 13b screw hole, 13c convex part, 14 flange, 15 curl part, 16 edge surface, 17 flat part, 20 light emitting module, 21 light source part, 22 board, 23 heat dissipation plate, 30 holder, 31,41 bottom plate, 32,42 peripheral wall, 33 window hole, 34 protrusion, 35,55 screw, 36 boss part, 40 translucent cover, 43 Fitting holes, 44 packings, 50 cases, 51 support brackets, 52 bases, 53 arm parts, 54 mounting springs, 56 covers, 57 lighting devices, 58 annular members

Claims (7)

A metal housing that is a cylindrical draw-molded body that includes the back surface facing the ceiling and has at least one end in the axial direction.
The light emitting module provided inside the metal housing and
Equipped with
The metal housing has an annular flange overhanging around the opening.
A ceiling-embedded lighting device in which a curled portion is formed on the flange so that the edge surface faces the back surface. The lighting device according to claim 1, wherein a coating film is formed on the surface of the metal housing. The flange has a flat portion and a curled portion.
The lighting device according to claim 1 or 2, wherein the curled portion is curved from a boundary portion with the flat portion to a tip portion. The lighting device according to claim 3, wherein the curl portion has a radius of curvature at the tip portion thereof being smaller than that at the boundary portion with the flat portion. The first step of drawing a metal plate to form a cylindrical body having at least one axial opening and a flat flange protruding around the opening.
The second step of forming a curl portion on the flat flange and
The third step of mounting the light emitting module inside the metal housing which is the tubular body on which the curl portion is formed, and
Including
In the second step, the tip portion of the flat flange is bent toward one surface side of the tubular body which is the back surface of the metal housing, and then the predetermined range of the flange including the tip portion is R-bent. A method for manufacturing a ceiling-embedded lighting device, which is processed to form the curled portion curved so that an edge surface faces one of the surfaces. The method for manufacturing a lighting device according to claim 5, wherein a coating film is formed on the other surface of the metal plate which is the surface of the metal housing. In the second step, the tip portion of the flat flange is bent toward the one surface side, the flange is bent toward the one surface side to a height exceeding the height of the curl portion, and then the curl portion is formed. The method for manufacturing a lighting device according to claim 5 or 6, wherein the portion is formed.

Images