JP7130234B2 - LED lamp - Google Patents

Description

TECHNICAL FIELD The present invention relates to an LED lamp, and more particularly to an LED lamp that can be miniaturized.

As a conventional LED lamp, there is known one in which a cannonball-shaped LED is directly attached to a main body. However, the number of bullet-type LEDs manufactured is decreasing, and chip-type LEDs are gradually being used.
For example, Patent Literature 1 discloses an LED lamp in which a substrate is arranged so as to face a lens, and a chip-type LED is mounted on this substrate.

JP 2017-16924 A

However, in the above-described conventional LED lamp, the diameter of the cylindrical portion of the lamp must be large enough to accommodate the LED substrate. Specifically, the inner diameter of the cylindrical portion of the lamp must be set larger than the diagonal length of the LED substrate. For this reason, even if an attempt is made to reduce the diameter of the cylindrical portion of the lamp, the size of the LED substrate becomes an obstacle, and there is a problem that the size of the lamp cannot be sufficiently reduced.

The size of the lamp can be reduced by reducing the size of the LED substrate. .
SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide an LED lamp that can be downsized as a whole without forcibly reducing the size of the LED substrate.

The present invention has been made to solve the above-described problems, and includes a substrate with an LED mounted on the surface, a terminal component attached to the substrate, and a cylindrical member that accommodates the substrate inside, The substrate is arranged in parallel with the longitudinal direction of the tubular member, the LED is mounted so as not to protrude from the front end surface of the substrate, and the light emitting portion of the LED is provided on the front end surface of the substrate. characterized in that a notch is formed at a position facing the

The present invention is as described above, and the substrate is arranged parallel to the longitudinal direction of the tubular member. With such a configuration, it is not necessary to arrange the substrate parallel to the lens, so the inner diameter of the cylindrical member can be made smaller than the length of the diagonal line of the substrate. Therefore, the size of the LED lamp can be reduced.

Here, when the substrate is arranged in this way, the problem is how to irradiate the light of the LED in the direction of the lens. As one method of irradiating the light of the LED in the direction of the lens, it is conceivable to mount the LED on the tip surface of the substrate. However, when the LED is mounted on the front end surface of the substrate, the LED protrudes from the front end surface of the substrate, so there is a problem that the LED is easily damaged during the manufacturing process.

In this respect, according to the present invention, since the LED is mounted on the surface of the substrate so as not to protrude from the tip surface of the substrate, the risk of damage to the LED can be suppressed. A notch is formed at a position facing the light emitting portion of the LED in order to irradiate the light of the LED in the direction of the lens. By providing the notch in this way, when the LED is turned on toward the tip of the substrate, the LED light can be emitted to both the front side and the back side of the substrate. Therefore, the problem that only the front side of the substrate is bright and the back side of the substrate is not bright occurs, and a natural appearance can be obtained.

Moreover, the terminal component may include a pair of holding portions that sandwich and hold the substrate, and the pair of holding portions may be bilaterally symmetrical. With this configuration, the left and right terminal parts are eliminated, so that the right and left terminals are not mixed up during assembly, and the workability of the manufacturing process is improved. If the pair of holding portions are bilaterally symmetrical, the substrate comes to the center position with respect to the lens, so the position of the LED mounted on the surface of the substrate is offset with respect to the lens. However, as described above, by providing the notch in the substrate, the light from the LED reaches the back side of the substrate, so that the appearance does not look unnatural.

Further, an abutting portion for abutting the front end surface of the substrate may be formed inside the cylindrical member. With this configuration, it is possible to resist the pressing pressure of the board during assembly, and the board can be easily positioned, so that the workability of the manufacturing process is improved. Even if the front end face of the board is hit against the abutting part in this way, the LED does not protrude from the front end face of the board, so that the LED is not damaged.

Further, an insulating member may be provided so as to close the opening of the tubular member, and the insulating member may have a slit through which the terminal component is held. According to such a configuration, by attaching the insulating member, an insulating measure is taken and at the same time the assembly of the terminal component and the substrate is completed, so that the workability of the manufacturing process is improved.

Further, the inside of the cylindrical member closed with the insulating member may be filled with translucent resin. As a result, the parts can be adhered and fixed with resin, and watertightness can be ensured. The insulating member may be formed with a groove that communicates the inside and the outside of the tubular member. According to such a configuration, when the amount of resin filled inside the cylindrical member is too large, the resin flows out from the groove of the insulating member and is discharged. That is, since the amount of resin can be automatically adjusted by providing the grooves, there is no need to strictly measure the amount of resin, and the workability of the manufacturing process is improved.

They are (a) a top view of an LED lamp, (b) a front view, (c) a bottom view, and (d) a side view. FIG. 2 is a cross-sectional view of the LED lamp taken along the line AA; 1 is an exploded view of an LED lamp; FIG. It is a figure which shows the (a) front surface of a board|substrate, (b) is a figure which shows the back surface. It is a figure which shows the internal structure of an LED lamp, (a) The figure which looked at the surface of a board|substrate from the front, (b) The figure which looked at the side of a board|substrate from the front. FIG. 3 shows how to assemble the LED lamp, (a) before inserting the terminal component into the insulating member, (b) after inserting the terminal component into the insulating member, and (c) inserting the board into the insulating member. It is a figure before inserting, (d) is a figure after inserting a board|substrate in an insulating member. It is a figure which shows how to assemble an LED lamp, (a) The figure before attaching an insulating member to a cylinder member, (b) The figure after attaching an insulating member to a cylinder member.

Embodiments of the present invention will be described with reference to the drawings.
The LED lamp 10 according to this embodiment is a small lamp that is used for parts that display the operating state of equipment, and as shown in FIG. Part 30 protrudes. The LED lamp 10 can be used by connecting a wire connected to a power source to the terminal part 30, and emits light from the lens 12 when the power is turned on.
The LED lamp 10 includes a tubular member 11, a substrate 20, a terminal component 30, and an insulating member 40, as shown in FIGS.

As shown in FIG. 2, the tubular member 11 is a tubular component having a hollow interior. A cavity inside the cylindrical member 11 serves as a housing space 13 for housing the substrate 20 . The accommodation space 13 is a cylindrical space with a constant inner diameter, and is large enough to accommodate the substrate 20 completely. Specifically, the diameter of the accommodation space 13 is larger than the length of the substrate 20 in the lateral direction, and the length of the accommodation space 13 in the axial direction is larger than the length of the substrate 20 in the longitudinal direction. there is

The base end side of the housing space 13 (end side where the lens 12 is not provided) is open to the outside, and serves as an opening 17 for inserting various components into the housing space 13. there is Therefore, when manufacturing the LED lamp 10, various parts are inserted from the opening 17 side and assembled.

A wall perpendicular to the axis (longitudinal direction) of the tubular member 11 is provided on the tip side (the side where the lens 12 is provided) of the accommodation space 13 . This wall separates the housing space 13 from its distal end side. At the center of this wall, a communication port 14 is formed to penetrate in the direction of the lens 12 . A flange-shaped wall around the communication port 14 forms an abutment portion 15 against which the tip surface 20a of the substrate 20 abuts.

In addition, a concave portion 16 for mounting the convex lens 12 is formed at the back (front end side) of the communication port 14 described above. The lens 12 attached to this concave portion 16 protrudes toward the distal direction. The lens 12 according to this embodiment has a two-layer structure using two types of resin. For example, the lens 12 is formed by first forming a cavity with one type of resin and then filling the cavity with another type of resin. Color variation can be increased by changing the color of the resin inside, and the appearance of the lens 12 can be changed by devising a material with a different refractive index or a filling material.

The board|substrate 20 mounts LED21 on the surface. On the surface of the substrate 20, as shown in FIG. 4A, in addition to the LED 21, a constant current element 22 for stabilizing the current and an electrode portion 23 for connecting the terminal component 30 are provided. ing. The electrode part 23 is provided with two positive and negative electrode parts 23 . A current path is provided between the two electrode portions 23, and the LED 21 and the constant current element 22 are arranged on this current path. By providing the constant current element 22, even if a chip-type LED is used, an external resistor is not required, and if the voltage is within a certain range (for example, 6V to 24V), the resistor does not need to be changed depending on the voltage used. can also be used.
The electrode portion 23 is formed with a through hole 23a for engaging a projecting portion 32 of a terminal component 30, which will be described later.

The substrate 20 is arranged parallel to the longitudinal direction of the tubular member 11 and housed in the housing space 13 of the tubular member 11, as shown in FIG. At this time, the LED 21 is arranged on the front end side (lens 12 side), and the electrode portion 23 is arranged on the rear end side (opposite to the lens 12 side).

The LED 21 according to this embodiment is mounted so as not to protrude from the tip surface 20a of the substrate 20, as shown in FIGS. 4(a) and 4(b). That is, the substrate 20 according to this embodiment has a flat tip surface 20a that abuts against the abutting portion 15, and the LED 21 is arranged inside the tip surface 20a. Also, the LED 21 is arranged so as to emit light toward the tip of the substrate 20 , in other words, the light emitting portion 21 a of the LED 21 is arranged so as to face the lens 12 .

A substantially U-shaped or substantially U-shaped notch 20b is formed at the tip of the substrate 20 on which the LED 21 is mounted, as shown in FIG. 4B and the like. The notch 20b is formed by notching the center of the front end surface 20a of the substrate 20, and is formed at a position facing the light emitting portion 21a of the LED 21. As shown in FIG. Therefore, as shown in FIG. 4B and the like, when the substrate 20 is viewed from the back side, the light emitting portion 21a of the LED 21 mounted on the front surface of the substrate 20 is configured to be visible through the notch 20b. ing.

The terminal component 30 is a component attached to the substrate 20 as shown in FIG. The terminal component 30 is a thin flat terminal made of a conductive material. The flat terminal shape facilitates connection with the outside. As shown in FIG. 3, the terminal component 30 is formed in a substantially Y shape with a branched tip (lens 12 side). Two terminal components 30 are used for one LED lamp 10 , and the two terminal components 30 are attached to two electrode portions 23 provided on the substrate 20 , respectively.

The branched tip side (lens 12 side) of the terminal component 30 forms a holding portion 31 connected to the electrode portion 23 of the substrate 20 . The sandwiching portions 31 are for sandwiching and holding the substrate 20, and as shown in FIG. 3, a pair of sandwiching portions 31 are provided so as to face each other. A holding groove 34 for inserting the substrate 20 is formed between the pair of holding portions 31 . The width of the holding groove 34 is formed substantially equal to the thickness of the substrate 20 .

3, protrusions 32 projecting toward the other holding portion 31 are formed on the opposing surfaces of the pair of holding portions 31, as shown in FIG. The projecting portion 32 has a wedge shape with a sharp tip. The protruding portion 32 is for engaging with the through hole 23a of the electrode portion 23, as shown in FIG. 5(b). That is, when the board 20 is inserted into the holding groove 34, the pair of protrusions 32 are fitted into and engaged with each other from both sides of the through hole 23a, so that the board 20 can be sandwiched and held by the pair of holding parts 31. It has become. By holding in this way, the electrode portion 23 and the terminal component 30 are reliably electrically connected.

Note that the pair of holding portions 31 according to the present embodiment are formed symmetrically with each other as shown in FIG. Therefore, the terminal component 30 is left-right symmetrical, so that the terminal component 30 can be attached to the substrate 20 without worrying about the direction.

The base end side (opposite to the lens 12 side) of the terminal component 30 forms an extending portion 33 projecting to the outside of the cylindrical member 11, as shown in FIG. 1(b) and the like. The extending portion 33 is a portion for connecting an electric wire.

The insulating member 40 is a member made of an insulating material such as rubber or resin. As shown in FIGS. 3 and 5, the insulating member 40 includes a cylindrical plug portion 41 and a tongue portion 44 projecting from the bottom surface of the plug portion 41. As shown in FIGS.

The plug portion 41 is formed with a diameter that allows it to be inserted into the housing space 13 through the opening 17 . By inserting the plug portion 41 into the housing space 13 , the opening 17 of the cylindrical member 11 can be closed with the insulating member 40 . As shown in FIG. 1(c), the plug portion 41 is provided with two slits 42 in parallel to each other in the axial direction of the plug portion 41 (longitudinal direction of the tubular member 11). The slit 42 is formed to pass through and hold the terminal component 30 . The two slits 42 can independently hold the two terminal components 30 so as not to contact each other.

In addition, as shown in FIG. 5, a concave groove is formed on the upper surface (surface facing the lens 12) of the plug portion 41 into which the rear end side of the substrate 20 (the side opposite to the lens 12) can be inserted. The substrate 20 inserted into the groove is connected to the terminal component 30 inside the groove. That is, by inserting the substrate 20 into the recessed groove, the electrode portion 23 is buried in the insulating member 40 , and the buried electrode portion 23 and the terminal component 30 are engaged inside the insulating member 40 . It is designed to With such a configuration, the board 20 and the terminal component 30 are fixed by the insulating member 40 in a connected state. can be reliably insulated. In addition, since the substrate 20, the terminal component 30 and the insulating member 40 can be unitized, the assembling property during manufacturing is improved.

In addition, as shown in FIGS. 1(c) and 5(b), a groove portion 43 communicating vertically is formed on the outer peripheral surface of the plug portion 41. As shown in FIG. The groove portion 43 is for communicating the inside (accommodating space 13) of the cylindrical member 11 closed with the insulating member 40 and the outside. This groove portion 43 is for discharging the excess resin filled inside the tubular member 11 to the outside.

That is, in the present embodiment, the inside of the tubular member 11 is filled with a translucent liquid curable resin during manufacturing. After that, the inside of the cylindrical member 11 is closed with the insulating member 40, and the resin is cured to integrally connect the cylindrical member 11, the substrate 20, the terminal component 30, and the insulating member 40 together. The groove portion 43 of the plug portion 41 described above is for discharging excess resin to the outside when the inside of the cylindrical member 11 is closed with the insulating member 40 .

As shown in FIGS. 1(c) and 5(a), the tongue-shaped portion 44 is a tongue-shaped portion protruding from the bottom surface of the plug portion 41. As shown in FIG. This tongue-shaped portion 44 is for electrically isolating the two terminal components 30 held by the slit 42 . That is, the slit 42 holds the two terminal components 30 and the tongue 44 separates the two terminal components 30, thereby preventing the two terminal components 30 from coming into contact with each other.
Next, a procedure for assembling the components described above will be described.

First, as shown in FIG. 6A, two terminal components 30 are inserted into the slit 42 of the insulating member 40 from the extending portion 33 side. As a result, the terminal component 30 is attached to the insulating member 40 as shown in FIG. 6(b).

Next, as shown in FIG. 6C, the rear end portion of the substrate 20 (on the opposite side of the LED 21) is inserted into the groove of the insulating member 40. Then, as shown in FIG. As a result, the substrate 20 is attached to the insulating member 40 as shown in FIG. 6(d). At this time, the electrode portion 23 (through hole 23a) of the substrate 20 is sandwiched and held by the pair of holding portions 31 (projections 32) of the terminal component 30, so that the substrate 20 is held so as not to fall off the insulating member 40. be done. As a result, the board 20, the terminal component 30, and the insulating member 40 are combined to form a unit.

Finally, as shown in FIG. 7(a), the unit is attached to the tubular member 11. Then, as shown in FIG. At this time, the inside of the cylindrical member 11 (accommodating space 13) is filled in advance with a translucent liquid curable resin. After that, the unit is inserted through the opening 17 of the cylindrical member 11 and pushed into the cylindrical member 11 until the tip surface 20 a of the substrate 20 abuts against the abutment portion 15 of the cylindrical member 11 . If too much resin is filled, excess resin is discharged from the groove 43 to the outside. By such work, the unit is assembled to the tubular member 11 as shown in FIG. 7(b). After that, if the liquid curable resin is cured in a constant temperature bath or the like, the tubular member 11 and the unit are joined to complete the LED lamp 10 .

As described above, according to this embodiment, the substrate 20 is arranged parallel to the longitudinal direction of the cylindrical member 11 . Therefore, since the substrate 20 does not have to be arranged parallel to the lens 12 , the inner diameter of the cylindrical member 11 can be made smaller than the diagonal length of the substrate 20 . Therefore, the LED lamp 10 can be miniaturized.

Moreover, since LED21 is mounted in the surface of the board|substrate 20 so that it may not protrude from the front end surface 20a of the board|substrate 20, the risk of LED21 being damaged can be suppressed. A notch 20b is formed at a position facing the light emitting portion 21a of the LED 21 in order to irradiate the light of the LED 21 in the direction of the lens 12. As shown in FIG. By providing the notch 20 b in this way, when the LED 21 is turned on toward the tip of the substrate 20 , the light of the LED 21 can be emitted to both the front side and the back side of the substrate 20 . Therefore, the problem that only the front side of the substrate 20 is bright and the back side of the substrate 20 is not bright occurs, and a natural appearance can be obtained.

In addition, the terminal component 30 includes a pair of holding portions 31 that sandwich and hold the substrate 20, and the pair of holding portions 31 are bilaterally symmetrical. With this configuration, the left and right terminal components 30 are eliminated, so that the right and left are not mixed up during assembly, and the workability of the manufacturing process is improved. When the pair of holding portions 31 are bilaterally symmetrical, the substrate 20 comes to the center position with respect to the lens 12 , so the position of the LED 21 mounted on the surface of the substrate 20 is offset with respect to the lens 12 . Become. However, as described above, by providing the notch 20b in the substrate 20, the light from the LED 21 reaches the back side of the substrate 20, so that the appearance does not look unnatural.

Further, inside the cylindrical member 11, an abutting portion 15 is formed for abutting the front end surface 20a of the substrate 20. As shown in FIG. With this configuration, it is possible to resist the pressing pressure of the substrate 20 during assembly, and the substrate 20 can be easily positioned, so that the workability of the manufacturing process is improved. In addition, even if the tip surface 20a of the substrate 20 hits the abutting portion 15 in this way, the LED 21 does not protrude from the tip surface 20a of the substrate 20, so that the LED 21 is not damaged. .

Further, an insulating member 40 is provided so as to close the opening 17 of the cylindrical member 11 , and the insulating member 40 has a slit 42 through which the terminal component 30 is held. According to such a configuration, by attaching the insulating member 40, an insulating measure is taken and at the same time, the assembly of the terminal component 30 and the substrate 20 is completed, so that the workability of the manufacturing process is improved.

Further, the inside of the cylindrical member 11 closed with the insulating member 40 may be filled with translucent resin. As a result, the parts can be adhered and fixed with resin, and watertightness can be ensured. A groove 43 may be formed in the insulating member 40 to allow communication between the inside and the outside of the tubular member 11 . According to such a configuration, when the amount of resin filled inside the cylindrical member 11 is too large, the resin flows out from the groove portion 43 of the insulating member 40 and is discharged. That is, since the amount of resin can be automatically adjusted by providing the groove portion 43, there is no need to strictly measure the amount of resin, and the workability of the manufacturing process is improved.

REFERENCE SIGNS LIST 10 LED lamp 11 cylindrical member 12 lens 13 accommodation space 14 communicating port 15 abutting portion 16 concave portion 17 opening 20 substrate 20a tip surface 20b notch 21 LED
21a light-emitting portion 22 constant current element 23 electrode portion 23a through hole 30 terminal component 31 holding portion 32 protrusion 33 extension portion 34 holding groove 40 insulating member 41 plug portion 42 slit 43 groove portion 44 tongue portion

Claims (5)

a substrate with an LED mounted on its surface;
a terminal component attached to the substrate;
a cylindrical member that accommodates the substrate therein;
with
The substrate is arranged parallel to the longitudinal direction of the cylindrical member,
The LED is mounted so as not to protrude from the tip surface of the substrate,
The LED lamp, wherein a notch is formed in a front end surface of the substrate at a position facing the light emitting portion of the LED. 2. The LED lamp according to claim 1, wherein said terminal component has a pair of holding portions for sandwiching and holding said substrate, said pair of holding portions being bilaterally symmetrical. 3. The LED lamp according to claim 1, wherein an abutting portion for abutting the tip surface of said substrate is formed inside said cylindrical member. An insulating member attached so as to block the opening of the cylindrical member,
4. The LED lamp according to claim 1, wherein the insulating member has a slit through which the terminal component is held. The inside of the cylindrical member closed with the insulating member is filled with translucent resin,
5. The LED lamp according to claim 4, wherein the insulating member is formed with a groove that communicates the inside and the outside of the tubular member.

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