JP7627863B2 - Holder, lighting fixture, and method for manufacturing lighting fixture - Google Patents

Description

The present invention relates to a holder, a lighting fixture equipped with the holder, and a method for manufacturing the lighting fixture.

Solid-state light-emitting devices such as LEDs (Light Emitting Diodes) are small, have good light-emitting efficiency, and have a long life span, so they are widely used as light sources for various devices in the lighting and imaging fields. For example, in the lighting field, LEDs are used as light sources for lighting fixtures such as downlights and ceiling lights.

Generally, LEDs are unitized into LED modules to serve as light sources for various devices. For example, an LED module (light source) includes a substrate on which wiring is formed, and one or more LED elements mounted on the substrate.

Specifically, a COB (Chip On Board) type LED module is known, which is constructed by mounting one or more LED chips (LED elements) directly on a substrate. Also known is an SMD (Surface Mount Device) type LED module, which is constructed by mounting one or more SMD type LED elements, which are packaged by housing an LED chip in a container, on a substrate.

The LED module configured in this manner is attached to the base of various devices. For example, in a lighting fixture, the LED module is placed in a predetermined position on the fixture body, which serves as the base, and fixed to the fixture body.

A method of using a holder is known as a method of fixing an LED module to a fixture body. Specifically, the LED module arranged on the fixture body is covered with the holder, and the holder and fixture body are fixed with screws, so that the LED module can be fixed to the fixture body via the holder (for example, Patent Document 1).

In this case, by using a holder incorporating a pair of conductive plates for supplying power to the light source, the LED module can be fixed to the fixture body while completing the electrical connection between the LED module and the pair of conductive plates at the same time.

JP 2008-153080 A

A known assembly method for fixing a light source (LED module) to a fixture body using a holder is to temporarily place the light source in the holder, press the board against the holder using the fixture body in that state, and then screw the holder to the fixture body with the light source sandwiched between the holder and the fixture body.

In this case, when temporarily placing the light source using a holder having a pair of conductive plates, one possible method is to place the light source on the light source placement section of the holder, restrict the horizontal movement of the light source board, and position the light source, while supporting the light source board from below with the pair of conductive plates.

However, if the light source's substrate is supported from below by a pair of conductive plates when the light source is temporarily placed in the holder, the light source may be temporarily placed with the substrate tilted. Specifically, the substrate will tilt in a direction perpendicular to the line passing through the two points where the pair of conductive plates and the substrate come into contact.

If the board is tilted in this way, when the board is pressed against the holder by the fixture body to fix the light source to the fixture body via the holder, the light source, fixture body, and holder may not be fixed in the desired state, which may result in poor assembly of the lighting fixture. Also, if the light source is temporarily placed on a tilted board, the light source may shift from its correct temporary placement position or fall when the holder on which the light source is temporarily placed is transported to the next process, resulting in poor assembly of the lighting fixture.

The present invention was made to solve these problems, and aims to provide a holder, a lighting device, and a method for manufacturing a lighting device that allows a light source to be temporarily placed in a stable state.

In order to achieve the above object, one aspect of the holder according to the present invention is a holder for fixing a light source having a substrate having a first surface and a light-emitting portion provided on the first surface to a device body, the holder comprising: an opening through which light emitted from the light source passes; a light source mounting portion on which the light source is mounted; a plurality of conductive plates that are power supply terminals for supplying power to the light source and are pressed against the first surface of the substrate by spring elastic force; and a plurality of spring portions that are biased toward the first surface of the substrate, and each of the plurality of spring portions is provided such that a plurality of contact portions where the plurality of spring portions come into contact with the substrate when the light source is mounted on the light source mounting portion surround the center of gravity of the substrate and form a substantially flat surface.

Another aspect of the lighting fixture according to the present invention includes a light source having a light-emitting portion and a substrate on which the light-emitting portion is provided, a fixture body, and the holder described above, and the substrate is pressed against the fixture body by at least the multiple spring portions of the holder.

In addition, one aspect of the manufacturing method of the lighting fixture according to the present invention is a manufacturing method of a lighting fixture in which a light source is held on a fixture body by a holder, the light source includes a substrate having a first surface and a second surface facing away from the first surface, and a light emitting portion provided on the first surface of the substrate, the holder includes an opening through which light emitted from the light source passes, a light source mounting portion on which the light source is mounted, a plurality of conductive plates that are power supply terminals for supplying power to the light source, and a plurality of spring portions that are biased toward the first surface of the substrate of the light source, and the manufacturing method of the lighting fixture includes a first step of mounting the light source on the light source mounting portion so that the first surface of the substrate contacts the plurality of spring portions, and a second step of pressing the substrate against the holder by the fixture body from the second surface side of the substrate, and in the first step, when the light source is mounted on the light source mounting portion, a plurality of contact portions where the plurality of spring portions and the substrate contact surround the center of gravity of the substrate and form a substantially flat surface.

According to the present invention, it is possible to obtain a holder that allows a light source to be temporarily placed in a stable state. Furthermore, by using such a holder, it is possible to reduce assembly defects of the lighting fixture.

FIG. 1 is a perspective view of a lighting fixture according to an embodiment. FIG. 2 is a cross-sectional view of the lighting fixture according to the embodiment taken along line II-II in FIG. FIG. 3 is a cross-sectional view of the lighting fixture according to the embodiment taken along line III-III in FIG. FIG. 4 is a perspective view of the holder according to the embodiment as viewed from one side (light exit side). FIG. 5 is a perspective view of the holder according to the embodiment as viewed from the other side (the device body side). FIG. 6 is an exploded perspective view of the holder according to the embodiment as viewed from the other side (the device body side). FIG. 7 is an exploded perspective view of the holder according to the embodiment as viewed from one side (light exit side). FIG. 8 is a cross-sectional view showing a configuration of a holder body in the holder according to the embodiment. FIG. 9 is an exploded perspective view of a heat dissipation sheet, a light source, and a holder in a lighting fixture according to an embodiment. FIG. 10 is a cross-sectional perspective view showing a step of placing a light source on a holder in a manufacturing method for a lighting fixture according to an embodiment. FIG. 11 is a cross-sectional perspective view showing a state in which a heat dissipation sheet is placed on a holder in a manufacturing method for a lighting fixture according to an embodiment. FIG. 12 is a cross-sectional perspective view showing a process of pressing down the light source and the heat dissipation sheet with the fixture body and the holder in the lighting fixture according to the embodiment. FIG. 13 is a diagram showing the relationship between the amount of pressure applied to the substrate of the light source and the temperature rise of the substrate.

The following describes embodiments of the present invention with reference to the drawings. Each embodiment described below shows a specific example of the present invention. Therefore, the numerical values, components, the layout and connection of the components, steps, and the order of steps shown in the following embodiments are merely examples and are not intended to limit the present invention. Therefore, among the components in the following embodiments, components that are not described in the independent claims that show the highest concept of the present invention are described as optional components.

Note that each figure is a schematic diagram and is not necessarily a precise illustration. In each figure, the same reference numerals are used for substantially the same configuration, and duplicate explanations may be omitted or simplified. Furthermore, in this specification, the terms "upper" and "lower" do not necessarily refer to the upper direction (vertically upward) and the lower direction (vertically downward) in an absolute spatial sense.

(Embodiment)
The overall configuration of a lighting fixture 1 according to an embodiment will be described with reference to Figures 1 to 3. Figure 1 is a perspective view of the lighting fixture 1 according to an embodiment. Figures 2 and 3 are cross-sectional views of the lighting fixture 1. Note that Figure 2 corresponds to the cross section taken along line II-II in Figure 5, which will be described later, and Figure 3 corresponds to the cross section taken along line III-III in Figure 5. Also, in Figures 2 and 3, the mounting spring 61 fixed to the frame body 60 is omitted.

Lighting fixture 1 is, for example, a downlight that irradiates light downward (floor, ground, wall, etc.). Lighting fixture 1 is installed, for example, on the ceiling of a building. In this embodiment, lighting fixture 1 is a ceiling-embedded lighting fixture, and is embedded in, for example, a circular opening provided in the ceiling.

As shown in Figures 1 to 3, the lighting fixture 1 includes a light source 10, a fixture body 20, a heat dissipation sheet 30, a holder 40, a lens 50, and a frame 60. The light source 10, the fixture body 20, the heat dissipation sheet 30, the holder 40, the lens 50, and the frame 60 are connected to each other by screws or a locking structure, etc., and are integrated into a lighting unit.

The lighting fixture 1 may further include a power supply unit (not shown) for supplying power to the light source 10 to make the light source 10 emit light. The power supply unit is disposed, for example, in the ceiling space near the lighting unit, but is not limited to this. The power supply unit and the lighting unit are connected by a power cable 70 shown in FIG. 1.

The power supply unit is a power supply box having a power supply circuit that generates power for illuminating the light source 10. In the power supply unit, the power supply circuit converts AC power from a commercial power source into DC power. The power supply circuit is composed of a printed circuit board and multiple electronic components mounted on the printed circuit board. The power supply circuit is housed in, for example, a metal or resin case. The DC power generated by the power supply circuit is supplied to the light source 10 of the lighting unit via the power cable 70.

The power cable 70 has multiple electric wires. In the power cable 70 shown in FIG. 1, multiple electric wires are housed in an insulating tube. The multiple electric wires include a pair of a first electric wire (high voltage electric wire) and a second electric wire (low voltage electric wire) for supplying power to the light source 10, and a third electric wire for earthing. In this embodiment, the first electric wire and the second electric wire are connected to the light source 10 via the holder 40, and DC power is supplied to the light source 10 via the first electric wire and the second electric wire. In addition, the third electric wire for earthing is in contact with the fixture body 20 via the holder 40. As a result, the fixture body 20 is grounded via the third electric wire.

The components of the lighting fixture 1 are described in detail below.

[light source]
Light source 10 emits light that serves as illumination light for lighting device 1. In this embodiment, light source 10 is an LED light source constituted by LEDs, and emits, for example, white light.

The light source 10 is configured as a light source module having a substrate 11 and a light-emitting section 12. In this embodiment, the light source 10 is a COB type LED module in which an LED is directly mounted on the substrate 11.

The substrate 11 is a light source substrate on which the light emitting section 12 is provided. In this embodiment, the substrate 11 is a mounting substrate for mounting an LED. Specifically, the substrate 11 is a wiring substrate on which metal wiring is formed in a predetermined pattern. The metal wiring formed on the substrate 11 is, for example, copper wiring made of copper foil. Note that a resist made of an insulating resin material may be formed on the surface of the substrate 11 so as to cover the wiring in order to protect the wiring and ensure the dielectric strength voltage.

The substrate 11 is a plate-shaped substrate and has a first surface 11a and a second surface 11b facing away from the first surface 11a. In this embodiment, the first surface 11a is the surface on which the light-emitting unit 12 is provided, and is the surface opposite the fixture body 20. On the other hand, the second surface 11b is the surface on the fixture body 20 side. The substrate 11 is a flat substrate (flat plate) with a constant thickness. In this embodiment, the substrate 11 is a rectangular flat plate, and the shape of the substrate 11 in a plan view is generally rectangular overall. The shape of the substrate 11 is not limited to this. The substrate 11 has a shape in which one of the four corners is cut out in order to specify the orientation of the rectangular substrate 11.

The substrate 11 may be a single-sided wiring substrate in which metal wiring is formed only on the first surface 11a on which the light-emitting portion 12 is provided, or a double-sided wiring substrate in which metal wiring is formed on both the first surface 11a and the second surface 11b.

The base material constituting the substrate 11 may be a metal-based substrate obtained by applying an insulating coating to the surface of a metal base material made of a metal material such as aluminum or copper, a resin substrate made of an insulating resin material, or a ceramic substrate made of a sintered body of a ceramic material such as alumina.

From the viewpoint of improving the heat dissipation of the substrate 11, it is preferable that the substrate constituting the substrate 11 is a metal-based substrate. On the other hand, from the viewpoint of ensuring a higher dielectric strength voltage for the substrate 11, it is preferable that the substrate constituting the substrate 11 is an insulating substrate, such as a resin substrate or a ceramic substrate, in which the entire substrate is made of an insulating material.

In this embodiment, a rigid substrate having rigidity is used as the substrate 11, rather than a film-like substrate. Specifically, a metal-based substrate is used as the substrate 11.

As shown in FIG. 2, the substrate 11 has a first electrode 11c and a second electrode 11d as a pair of electrodes that receive DC power from the outside to make the LED emit light. The first electrode 11c and the second electrode 11d are connected to metal wiring formed on the substrate 11. As an example, the first electrode 11c is a high-voltage electrode and is connected to the first wire of the power cable 70 via the first conductive plate 210 of the holder 40. The second electrode 11d is a low-voltage electrode and is connected to the second wire of the power cable 70 via the second conductive plate 220 of the holder 40.

The light-emitting unit 12 is provided on the first surface 11a of the substrate 11. In this embodiment, the light-emitting unit 12 is provided in approximately the center of the substrate 11. As an example, the light-emitting region of the light-emitting unit 12 is circular, but is not limited to this.

The light-emitting unit 12 emits light of a predetermined color. The light emitted from the light-emitting unit 12 becomes the light of the light source 10. Therefore, in this embodiment, the light-emitting unit 12 emits white light.

The light-emitting unit 12 has multiple LEDs mounted on the substrate 11 and a sealing member that seals the multiple LEDs.

The LED is an example of a light-emitting element, and in this embodiment, is a bare chip that emits monochromatic visible light. The LED is, for example, a blue LED chip that emits blue light when powered. A plurality of LEDs are arranged, for example, in a matrix on a substrate. It is sufficient that at least one LED is arranged.

For example, a translucent resin is used as the sealing member. The sealing member in this embodiment contains a phosphor as a wavelength conversion material that converts the wavelength of the light from the LED. The sealing member is, for example, a phosphor-containing resin in which a phosphor is dispersed in a silicone resin. As the phosphor particles, when the LED is a blue LED chip that emits blue light, for example, a YAG-based yellow phosphor can be used to obtain white light.

In this embodiment, the sealing member is formed to have a circular shape in plan view so as to collectively seal all the LEDs. The outer shape of the sealing member defines the outer shape of the light emitting section 12, so the shape of the light emitting section 12 in plan view is also circular. The sealing member may collectively seal the LEDs so as to have a shape other than a circle (e.g., a rectangular shape). The sealing member may seal a plurality of LEDs in a line by row, rather than collectively sealing all the LEDs, or may seal each LED individually.

The light source 10 configured in this manner is held in the fixture body 20 by the holder 40. In this embodiment, the light source 10 is disposed on the protruding portion 21 of the fixture body 20 and fixed to the fixture body 20. Specifically, the light source 10 is disposed on the protruding portion 21 by placing the substrate 11 on the upper surface (disposition surface) of the protruding portion 21.

[Instrument body]
The fixture body 20 is the main body of the lighting fixture 1. Specifically, the fixture body 20 is a base (base) on which the light source 10 is attached. The fixture body 20 has an arrangement portion in which the light source 10 is arranged. In the present embodiment, the lighting fixture 1 has a protrusion 21 as the arrangement portion in which the light source 10 is arranged. Thus, the light source 10 is arranged on the protrusion 21 of the fixture body 20 and attached to the fixture body 20.

The protrusion 21 is formed so as to protrude towards the light source 10. The protrusion 21 is formed in approximately the center of the fixture body 20. The top surface of the protrusion 21 is the arrangement surface on which the light source 10 is arranged. In other words, the top surface of the protrusion 21 is the mounting surface on which the light source 10 is attached. Specifically, the substrate 11 of the light source 10 is attached to the top surface of the protrusion 21. In this case, the top surface of the protrusion 21 and the second surface 11b of the substrate 11 face each other.

The top surface of the protrusion 21 is a planar flat surface. The shape of the protrusion 21 in plan view is the same as the shape of the substrate 11 of the light source 10 in plan view, for example. In this embodiment, the shape of the substrate 11 of the light source 10 in plan view is rectangular, so the shape of the top surface of the protrusion 21 is also rectangular. The size of the top surface of the protrusion 21 is approximately the same as the size of the substrate 11 of the light source 10, but is not limited to this.

The fixture body 20 not only functions as a mounting member to which the light source 10 is attached, but also functions as a heat sink to dissipate heat generated by the light source 10. Therefore, the fixture body 20 is preferably made of a material with high thermal conductivity, such as a metal material. In this embodiment, the fixture body 20 is made of aluminum die-casting.

Heat generated by the light source 10 is conducted to the fixture body 20 and dissipated to the outside. In this embodiment, the fixture body 20 is an outer casing member of the lighting fixture 1, and the outer surface of the fixture body 20 forms the outer casing surface of the lighting fixture 1. As shown in FIG. 1, the fixture body 20 has a plurality of heat dissipation fins 22 as a heat dissipation section that dissipates heat generated by the light source 10 to the outside air. The plurality of heat dissipation fins 22 are flat and are provided on the back side of the fixture body 20 in an upright position. In this embodiment, the plurality of heat dissipation fins 22 are provided radially, but may be provided parallel to each other.

The fixture body 20 is provided with a number of screw holes for screwing the holder 40 to the fixture body 20. The fixture body 20 is also provided with an insertion hole for inserting the power cable 70 from the rear side to the light source side. Specifically, the tube portion 150 of the holder 40 is inserted into this insertion hole.

[Heat dissipation sheet]
The heat dissipation sheet 30 is an example of a heat conducting member, and is arranged to improve thermal conductivity from the light source 10 to the fixture body 20. In the present embodiment, the heat dissipation sheet 30 is made of an insulating material and has electrical insulation properties. As an example, the heat dissipation sheet 30 is made of an insulating resin material and has flexibility such as rubber elasticity.

The heat dissipation sheet 30 is a flat sheet with a constant thickness. In this embodiment, the heat dissipation sheet 30 is a rectangular sheet, and the shape of the heat dissipation sheet 30 in a plan view is generally rectangular overall. Note that the shape of the heat dissipation sheet 30 is not limited to this. Also, in this embodiment, the heat dissipation sheet 30 is larger than the substrate 11 of the light source 10. Therefore, the heat dissipation sheet 30 protrudes beyond the substrate 11 and the protruding portion 21 of the fixture body 20. Note that the heat dissipation sheet 30 may be smaller than the substrate 11.

The heat dissipation sheet 30 is disposed between the light source 10 and the fixture body 20. Specifically, the heat dissipation sheet 30 is disposed on the protruding portion 21 of the fixture body 20, and is disposed between the substrate 11 of the light source 10 and the protruding portion 21 of the fixture body 20. In this embodiment, the heat dissipation sheet 30 is in contact with the second surface 11b of the substrate 11 and in contact with the top surface of the protruding portion 21. In this way, by inserting the electrically insulating heat dissipation sheet 30 between the substrate 11 and the fixture body 20, it is possible to ensure the dielectric strength between the metallic fixture body 20 and the substrate 11, even if a metal-based substrate is used as the base material for the substrate 11.

The heat dissipation sheet 30 is fixed to the fixture body 20 together with the light source 10 by the holder 40. Specifically, the heat dissipation sheet 30 is pressed by the holder 40 against the protruding portion 21 of the fixture body 20. Therefore, the portion of the heat dissipation sheet 30 that protrudes from the substrate 11 and the protruding portion 21 is deformed toward the fixture body 20.

In addition, grease or the like may be further inserted between the heat dissipation sheet 30 and the device body 20 and/or between the heat dissipation sheet 30 and the substrate 11.

[Holder]
The holder 40 holds the light source 10. In the present embodiment, the holder 40 is a fixing member for fixing the light source 10 to the fixture body 20. Therefore, the light source 10 is fixed to the fixture body 20 via the holder 40. Specifically, the light source 10 is fixed to the fixture body 20 by attaching the holder 40 to the fixture body 20. More specifically, the holder 40 is disposed on the light emission side of the light source 10 so as to cover the light source 10, and the holder 40 is attached to the fixture body 20 with the substrate 11 of the light source 10 sandwiched between the holder 40 and the fixture body 20, thereby fixing the light source 10 to the fixture body 20.

In addition, in this embodiment, the holder 40 is a holder with an integrated reflector having the reflector 102. In other words, the holder 40 not only functions as a fixing member that fixes the light source 10 to the fixture body 20, but also functions as a reflecting member that reflects the light emitted from the light source 10. As a result, simply by attaching the holder 40 to the fixture body 20, the light source 10 can be fixed and the reflector can be attached to the fixture body 20 at the same time. Therefore, since there is no need to attach a separate reflector to the holder 40, the assembly work of the lighting fixture 1 can be simplified.

In addition, in this embodiment, the holder 40 is an electrical connection holder having a plurality of conductive plates 200. In other words, the holder 40 also functions as an electrical connection member for making an electrical connection to supply power to the light source 10. As a result, the electrical connection between the light source 10 and the conductive plates 200 can be completed simply by attaching the holder 40 to the fixture body 20. Therefore, the assembly work of the lighting fixture 1 can be further simplified.

The detailed configuration of the holder 40 will be described later.

[lens]
The lens 50 is a translucent optical member, and transmits the light emitted from the light source 10. The lens 50 is arranged so as to cover the light source 10. In the present embodiment, the lens 50 is arranged so as to cover the holder 40 arranged on the light emission side of the light source 10. Therefore, the lens 50 receives light that is emitted from the light source 10 and travels without being reflected by the reflector 102 of the holder 40, as well as light that is reflected by the reflector 102 of the holder 40 among the light emitted from the light source 10.

The lens 50 has a light distribution control function that controls the light distribution from the light source 10. In this embodiment, the lens 50 is a focusing lens that has a function of focusing the light emitted from the light source 10. Specifically, the lens 50 is a Fresnel lens. In addition, a plurality of irregularities are formed on the surface of the light emission side of the lens 50, and the lens 50 also has a light diffusion function. This can scatter the light passing through the lens 50, improving the uniformity of the light emitted from the lens 50 (the illumination light of the lighting device 1 in this embodiment). Note that the lens 50 may have only the lens function or only the light diffusion function out of the lens function and the light diffusion function.

The lens 50 is made of a light-transmitting material. Specifically, the lens 50 is made of a transparent resin material such as acrylic or polycarbonate, or a glass material.

[Frame]
The frame 60 is a cylindrical frame member through which the light emitted from the lens 50 passes. The light from the light source 10 that has passed through the lens 50 passes through the frame 60 and is emitted to the outside of the lighting device 1.

In this embodiment, the frame body 60 is a substantially cylindrical frame body. The outer diameter of the frame body 60 is approximately the same as the outer diameter of the instrument body 20. The frame body 60 can be formed from a metal material such as aluminum or a hard resin material such as polybutylene terephthalate (PBT). The frame body 60 is fixed to the instrument body 20 by, for example, screws.

The frame body 60 is an outer casing member of the lighting fixture 1, and the outer surface of the frame body 60 forms the outer casing surface of the lighting fixture 1. The frame body 60 has a flange portion that protrudes radially outward. The flange portion is provided on the edge of the opening on the light emission side (floor side) of the frame body 60.

A mounting spring 61 is attached to the outer surface of the frame body 60. In this embodiment, two mounting springs 61 are attached to the outer circumferential surface of the frame body 60. The mounting springs 61 are elastic members for fixing the lighting fixture 1 (lamp unit) to a mounting portion such as a ceiling. As an example, the mounting springs 61 are leaf springs made of a long metal plate.

When placing the lighting fixture 1 (lamp unit) in an opening in the ceiling, the flange portion of the frame body 60 is engaged with the ceiling surface, and the mounting spring 61 is elastically deformed between the side of the frame body 60 and the inner surface of the opening in the ceiling, and the spring restoring force of the mounting spring 61 is used to fix the lighting fixture 1 to the opening in the ceiling.

[Detailed structure of the holder]
Next, the detailed structure of the holder 40 will be described with reference to Figs. 2 and 3 and Figs. 4 to 8. Fig. 4 is a perspective view of the holder 40 according to the embodiment as viewed from one side (light emission side). Fig. 5 is a perspective view of the holder 40 as viewed from the other side (instrument body 20 side). Fig. 6 is an exploded perspective view of the holder 40 as viewed from the other side (instrument body 20 side), and Fig. 7 is an exploded perspective view of the holder 40 as viewed from one side (light emission side). Fig. 8 is a cross-sectional view showing the configuration of the holder body 100 in the holder 40.

As described above, the holder 40 in this embodiment not only functions as a fixing member for fixing the light source 10 to the device body 20, but also functions as an electrical connection member for electrically connecting the power cable 70 and the light source 10.

The holder 40 therefore has a holder body 100 and a number of conductive plates 200, as shown in Figures 4 to 8.

The holder body 100 is an insulating member made of insulating resin material or the like. As shown in Figs. 4 to 7, the holder body 100 is made of three resin parts: a frame body 101 which is a first part, a reflector plate 102 which is a second part, and a wire insertion member 103 which is a third part. The frame body 101, the reflector plate 102, and the wire insertion member 103 are resin molded products made of a hard resin material such as PBT. The resin materials making up the frame body 101, the reflector plate 102, and the wire insertion member 103 may be the same or different.

The frame body 101 and the reflector plate 102 are fixed to the fixture body 20 by, for example, screws. The wire insertion member 103 is fixed to the frame body 101 or the reflector plate 102 by, for example, engaging a claw portion provided on the wire insertion member 103 with the frame body 101 or the reflector plate 102.

Each of the multiple conductive plates 200 is a conductive member made of a conductive material such as a metal material. As shown in Figures 6 and 7, the multiple conductive plates 200 include a first conductive plate 210, a second conductive plate 220, and a third conductive plate 230.

As shown in Figures 5 to 7, the frame 101 has a frame-like shape and has an opening 110. The opening 110 is a through hole through which the light emitted from the light source 10 passes. In this embodiment, the frame 101 is generally rectangular. The opening shape of the opening 110 of the frame 101 is rectangular. As an example, the opening shape of the opening 110 is square. Note that the rectangular and square shapes do not strictly mean rectangular and square, but may mean any shape having four sides consisting of two sets of two parallel sides.

As shown in Figs. 5 to 8, the frame 101 has multiple spring portions 120. As shown in Fig. 2, the multiple spring portions 120 are biased toward the first surface 11a of the substrate 11 of the light source 10 when the light source 10 is attached to the fixture body 20 by the holder 40 (frame 101) (i.e., when the lighting fixture 1 is in a completed state). The multiple spring portions 120 press the substrate 11 toward the fixture body 20.

In this embodiment, the multiple spring parts 120 are in contact with the light source 10. Specifically, the multiple spring parts 120 are in contact with the first surface 11a of the substrate 11 of the light source 10. In other words, the multiple spring parts 120 press the first surface 11a of the substrate 11 toward the fixture body 20.

The multiple spring parts 120 elastically hold the light source 10 by spring elastic force. In this embodiment, the multiple spring parts 120 are resin springs made of resin. The multiple spring parts 120 are elastically deformable elastic members and have spring elastic force (spring restoring force). The resin spring parts 120 are configured to be elastically deformable due to the resin material and shape.

As shown in Figures 5 to 7, each of the multiple spring portions 120 is located inside the opening 110 of the frame body 101 and is fixed to an inner side of the frame body 101. In this embodiment, four spring portions 120 are provided in the frame body 101. Each of the four spring portions 120 is fixed to each of the four sides of the frame body 101. In other words, the connection portion of each spring portion 120 with the inner side of the frame body 101 serves as a fixed portion. Furthermore, each spring portion 120 extends toward an inner corner of the frame body 101 along the fixed side.

Specifically, as shown in Figs. 6 and 7, each spring portion 120 has an extension portion 121 (arm portion) that extends along the inner side of the frame body 101, and a tip portion 122 that is located at an inner corner of the frame body 101. In each spring portion 120, the tip portion 122 is larger in shape than the extension portion 121. Note that all of the extension portions 121 of the four spring portions 120 extend in one direction, either clockwise or counterclockwise, along the inner side of the frame body 101, but this is not limited to this.

In this way, the multiple spring portions 120 have a cantilever beam structure with a fixed portion (fixed end) on the inner side of the frame body 101 and an open end at the tip portion 122. In other words, each spring portion 120 has a spring structure with the connection portion (fixed portion) with the inner side of the frame body 101 as a fulcrum, and is elastically deformed when force is applied to the tip portion 122. Specifically, when force is applied to the tip portion 122, the extension portion 121 of the spring portion 120 bends with the connection portion with the inner side of the frame body 101 as a fulcrum.

The tip 122 of each spring portion 120 is the contact portion with the substrate 11 of the light source 10. Each tip portion 122 contacts the first surface 11a of the substrate 11. The substrate 11 is pressed against the fixture body 20 by the multiple spring portions 120.

As shown in FIG. 2, in this embodiment, the substrate 11 is pressed against the device body 20 not only by the multiple spring parts 120 but also by the multiple conductive plates 200. In other words, the multiple spring parts 120 and the multiple conductive plates 200 all function as pressing parts that press the substrate 11, and restrict the substrate 11 from moving in a direction perpendicular to the first surface 11a.

When the light source 10 is fixed to the fixture body 20 by the holder 40, the light source 10 receives a biasing force from the multiple spring parts 120 and multiple conductive plates 200. In other words, the light source 10 is subjected to a pressing force toward the fixture body 20 by the elastic restoring force of the multiple spring parts 120 and multiple conductive plates 200. As a result, the light source 10 is held between the holder 40 and the fixture body 20 so as not to move in the vertical direction of the substrate 11. In this way, by providing the holder 40 with not only the multiple conductive plates 200 but also the multiple spring parts 120, the light source 10 can be attached to the fixture body 20 in a stable state.

As shown in Figures 6 to 8, the tip portion 122 of each spring portion 120 has a bottom portion 122a and a side portion 122b. The bottom portion 122a and the side portion 122b are formed on the portion of the tip portion 122 on the side of the instrument body 20. In each tip portion 122, the bottom portion 122a is a flat portion having a flat bottom surface, and the side portion 122b is a wall portion having a flat side surface (wall surface). The bottom surface of the bottom portion 122a and the side surface of the side portion 122b are approximately perpendicular to each other.

At the tip 122 of each spring portion 120, the bottom portion 122a and the side portion 122b may be formed in a stepped shape, or may be formed with a gap. In this embodiment, the frame body 101 has a spring portion 120 in which the bottom portion 122a and the side portion 122b are formed in a stepped shape, and a spring portion 120 in which the bottom portion 122a and the side portion 122b are formed separately. Note that instead of only one side portion 122b being formed on one spring portion 120, two side portions 122b may be formed on one spring portion 120.

In each spring portion 120, the bottom portion 122a of the tip portion 122 becomes a light source mounting portion on which the light source 10 is placed when the light source 10 is attached to the device body 20 by the holder 40. In other words, the light source mounting portion on which the light source 10 is placed is a flat portion and is provided on the tip portions 122 of the multiple spring portions 120.

The substrate 11 of the light source 10 is placed on the bottom 122a of the tip 122, which is the light source mounting portion. In this embodiment, the substrate 11 is placed on the bottom 122a of each tip 122 so as to straddle the four spring portions 120. When the light source 10 is placed on the bottom 122a (light source mounting portion) of each spring portion 120, the bottom surface of the bottom 122a contacts the first surface 11a of the substrate 11. In addition, the tip portions 122 of the four spring portions 120 are located at the inner corners of the rectangular opening 110 of the frame body 101, and the four tip portions 122 correspond to the four corners of the rectangular substrate 11. In other words, the tip portions 122 of the four spring portions 120 press down on the four corners of the substrate 11.

In addition, in each spring portion 120, the side portion 122b of the tip portion 122 serves as a positioning portion for determining the horizontal position of the board 11 (direction parallel to the first surface 11a of the board 11) when the light source 10 is attached to the fixture body 20 by the holder 40. In other words, the side portion 122b of the tip portion 122 is a board positioning portion (first positioning portion). In this embodiment, the side portion 122b of the tip portion 122 determines the horizontal position of the board 11 by restricting the horizontal movement of the board 11.

Specifically, when the light source 10 is placed on the bottom 122a (light source placement portion), the side portion 122b faces the side of the substrate 11. As a result, when the substrate 11 attempts to move horizontally, the side of the substrate 11 abuts against the side portion 122b, thereby preventing the substrate 11 from moving. In other words, the horizontal movement of the substrate 11 is restricted. The height of the side portion 122b at the tip 122 of the spring portion 120 is lower than the thickness of the substrate 11.

In addition, when the light source 10 is not placed on the light source mounting section, the portion of each of the multiple spring sections 120 that contacts the substrate 11 is located closer to the substrate 11 than the tip of each of the multiple conductive plates 200.

In the frame 101 configured in this manner, each of the multiple spring parts 120 is arranged so that when the light source 10 is placed on the bottom 122a (light source placement part) of the tip part 122, the multiple contact parts where the multiple spring parts 120 come into contact with the substrate 11 surround the center of gravity of the substrate 11 and form a substantially flat surface.

In this embodiment, the multiple contact portions where the multiple springs 120 and the substrate 11 are in contact are the portions where the tip 122 of each spring 120 and the first surface 11a of the substrate 11 are in contact. Specifically, since four springs 120 are provided on the frame 101, the springs 120 and the substrate 11 are in contact at four points. In addition, the tip 122 of each spring 120 is located at an inner corner of the frame 101. Therefore, the four points where the springs 120 and the substrate 11 are in contact are located at the inner corners of the frame 101. In addition, since the substrate 11 is placed on the bottom 122a of the tip 122 of each spring 120, each of the multiple springs 120 and the substrate 11 are in surface contact.

The holder body 100 also has an outer peripheral wall 130 as a positioning portion for determining the position of the heat dissipation sheet 30. In other words, the outer peripheral wall 130 is a heat dissipation sheet positioning portion (second positioning portion). As shown in Figs. 5 and 6, the outer peripheral wall 130 is provided on the reflector 102. Specifically, the outer peripheral wall 130 is formed in a rectangular frame shape on the surface of the reflector 102 facing the fixture body 20. The outer peripheral wall 130 is formed to surround the opening 110. The outer peripheral wall 130 prevents the heat dissipation sheet 30 from moving in the horizontal direction when the light source 10 and the heat dissipation sheet 30 are attached to the fixture body 20 by the holder 40.

The reflector 102 (second part) is a reflective member that reflects the light emitted from the light source 10. As shown in FIG. 4, the reflector 102 has a circular opening 140. Therefore, the reflector 102 reflects the light that is emitted from the light source 10 and passes through the opening 110 of the frame 101 and the opening 140 of the reflector 102. This makes it possible to control the distribution of the light emitted from the light source 10. Specifically, the reflector 102 reflects the light from the light source 10 toward the lens 50.

As shown in Figures 5 to 7, in the holder 40 (holder body 100), the opening 110 (first opening) of the frame body 101 and the opening 140 (second opening) of the reflector 102 are connected to each other. In this embodiment, the opening 140 of the reflector 102 has a smaller opening area than the opening 110 of the frame body 101, and the opening 140 of the reflector 102 is located inside the opening 110 of the frame body 101. In other words, as shown in Figure 5, the opening 110 of the frame body 101 surrounds the opening 140 of the reflector 102.

The surface of the reflector 102 facing the lens 50 is a light reflecting surface. As shown in FIG. 4, the light reflecting surface of the reflector 102 is formed in a funnel shape. As an example, the reflector 102 is made of a white resin material. This allows the surface of the reflector 102 to be a reflective surface. Note that the surface of the reflector 102 may also be made a reflective surface by forming a metal film or the like on the surface of the reflector 102.

In this embodiment, the reflector 102 holds the lens 50. Specifically, the lens 50 is held by the reflector 102 by engaging a retaining claw provided on the lens 50 with an engaging hole provided on the reflector 102.

As shown in Figures 5 to 7, the wire insertion member 103 (third part) has multiple tube portions 150 through which the wires of the power cable 70 are inserted. In this embodiment, the wire insertion member 103 has three tube portions 150 through which the first wire, the second wire, and the third wire of the power cable 70 are inserted.

The multiple tube portions 150 are inserted into insertion holes provided in the device body 20 and protrude from the back surface of the device body 20. As a result, when each electric wire of the power cable 70 is inserted into the tube portion 150, the each electric wire is guided by the tube portion 150, so that each electric wire can be easily inserted into the tube portion 150. Therefore, the connection work between the power cable 70 and the conductive plate 200 in the holder 40 can be easily performed.

As shown in Figures 6 and 7, the holder 40 has a plurality of conductive plates, namely, a first conductive plate 210, a second conductive plate 220, and a third conductive plate 230. The first conductive plate 210, the second conductive plate 220, and the third conductive plate 230 are fixed to the frame body 101 of the holder 40.

In this embodiment, the first conductive plate 210 is connected to the first wire (high voltage wire) of the power cable 70, the second conductive plate 220 is connected to the second wire (low voltage wire) of the power cable 70, and the third conductive plate 230 is connected to the third wire (earth wire) of the power cable 70. Therefore, the first conductive plate 210 and the second conductive plate 220 are conductive plates for power supply that serve as power supply terminals for supplying power to the light source 10, and the third conductive plate 230 is a conductive plate for earthing. In this way, by providing the third conductive plate 230 for earthing in addition to the first conductive plate 210 and the second conductive plate 220 for power supply, protective grounding of the lighting fixture 1 can be easily achieved.

The first conductive plate 210, the second conductive plate 220, and the third conductive plate 230 are constructed by bending and deforming a metal plate such as a copper alloy.

The first conductive plate 210 and the second conductive plate 220, which are a pair of conductive plates for power supply, have a leaf spring structure and are pressed against the first surface 11a of the substrate 11 by the elastic force of the spring.

The first conductive plate 210 and the second conductive plate 220 are electrically connected to the light source 10. Specifically, as shown in FIG. 2, the first conductive plate 210 contacts the first electrode 11c provided on the substrate 11 of the light source 10. The second conductive plate 220 contacts the second electrode 11d provided on the substrate 11 of the light source 10. As shown in FIGS. 6 and 7, the first conductive plate 210 has a first contact portion 211 that contacts the first electrode 11c of the substrate 11, and the second conductive plate 220 has a second contact portion 221 that contacts the second electrode 11d of the substrate 11.

The first conductive plate 210 is fixed to the frame body 101 such that the first contact portion 211 is located at the opening 110 of the frame body 101 in a plan view. The second conductive plate 220 is fixed to the frame body 101 such that the second contact portion 221 is located at the opening 110 of the frame body 101 in a plan view. In this embodiment, the first contact portion 211 and the second contact portion 221 are located at inner corners of the frame body 101. Specifically, the first contact portion 211 and the second contact portion 221 are located at diagonally opposite corners of the frame body 101.

[Manufacturing method of lighting fixture]
Next, a method for manufacturing the lighting fixture 1 according to the embodiment will be described with reference to Figures 9 to 12. In particular, an assembly method for attaching the light source 10 and the heat dissipation sheet 30 to the fixture body 20 by the holder 40 will be described.

Figure 9 is an exploded perspective view of the heat dissipation sheet 30, light source 10, and holder 40 in the lighting fixture 1. Figure 10 is a cross-sectional perspective view showing the process of placing the light source 10 on the holder 40 in the manufacturing method of the lighting fixture 1. Figure 11 is a cross-sectional perspective view showing the state of placing the heat dissipation sheet 30 on the holder 40 in the manufacturing method of the lighting fixture 1. Figure 12 is a cross-sectional perspective view showing the process of pressing the light source 10 and heat dissipation sheet 30 with the fixture body 20 and the holder 40 in the lighting fixture 1.

As shown in FIG. 9, in this embodiment, the light source 10 and the heat dissipation sheet 30 are attached to the fixture body 20 via the holder 40. Specifically, the light source 10 and the heat dissipation sheet 30 are fixed to the fixture body 20 by sandwiching the light source 10 and the heat dissipation sheet 30 between the holder 40 and the fixture body 20.

In this case, first, as shown in FIG. 10, the light source 10 is placed on the light source placement portion of the holder 40, and the light source 10 is temporarily placed on the holder 40 (placement process). Specifically, as shown by the arrow in FIG. 10, the light source 10 is moved vertically, and the light source 10 is placed on the light source placement portion of the frame body 101 so that the first surface 11a of the substrate 11 contacts the multiple spring parts 120. In this embodiment, since the spring parts 120 are the light source placement portions, the light source 10 is placed on the multiple spring parts 120 so that the first surface 11a of the substrate 11 contacts the multiple spring parts 120. In other words, the multiple spring parts 120 support the substrate 11 of the light source 10. At this time, the substrate 11 is placed on the four spring parts 120 so that the four corners of the substrate 11 are placed on the bottom parts 122a (flat parts) of the tips 122 of the four spring parts 120.

In this mounting process, when the light source 10 is mounted on the light source mounting portion of the holder 40, the multiple contact portions where the multiple spring portions 120 contact the substrate 11 surround the center of gravity of the substrate 11 and form a substantially flat surface.

In this case, the plurality of contact parts surrounding the center of gravity of the substrate 11 means, for example, that if the first surface 11a of the substrate 11 is divided into four quadrants of 90° with the center of gravity of the substrate 11 as the center, then among the plurality of contact parts where the plurality of spring parts 120 contact the substrate 11, at least some are located in two quadrants, the first and third quadrants or the second and fourth quadrants. In other words, at least two of the plurality of contact parts are located in diagonal quadrants of the four quadrants.

In addition, when multiple contact parts form a substantially flat surface, it does not only mean that all of the multiple contact parts form a completely flat surface, but also that some of the multiple contact parts form an approximate flat surface. Therefore, when multiple contact parts form a substantially flat surface, it also includes cases where some of the multiple contact parts are slightly out of the plane formed by some of the contact parts. In addition, when there are two multiple contact parts, the two contact parts naturally form a flat surface. Note that the "substantially flat surface" includes manufacturing errors.

By placing the light source 10 on the light source placement portion of the holder 40 in this manner, the light source 10 supported by the multiple spring portions 120 is temporarily placed on the holder 40 in a position in which the first surface 11a of the substrate 11 is perpendicular to the vertical direction. In other words, the light source 10 can be temporarily placed on the holder 40 in a stable state without the substrate 11 being tilted.

In this embodiment, the frame body 101 is provided with four spring parts 120, so that the four contact parts where the four spring parts 120 contact the substrate 11 surround the center of gravity of the substrate 11 and form a substantially flat surface. These four contact parts are located at each of the four inner corners of the frame body 101.

In this case, as described above, when the first surface 11a of the substrate 11 is divided into four quadrants of 90° with the center of gravity of the substrate 11 as the center, in this embodiment, the four contact portions where the four spring portions 120 and the substrate 11 contact each other are present in each of the four quadrants. Specifically, the four contact portions where the four spring portions 120 and the substrate 11 contact each other are rotationally symmetric with respect to the center of gravity of the substrate 11 and are present at positions equidistant from the center of gravity of the substrate 11.

This allows the four spring parts 120 to stably support the substrate 11, further preventing the substrate 11 from tilting. Therefore, the light source 10 can be temporarily placed on the holder 40 in an even more stable state.

In addition, in this embodiment, the frame body 101 has a side portion 122b formed at the tip portion 122 of each of the multiple spring portions 120 as a positioning portion for determining the horizontal position of the substrate 11. This makes it possible to determine the position of the substrate 11 by restricting the horizontal movement of the substrate 11 when the substrate 11 is placed on the multiple spring portions 120. In other words, it is possible to prevent the light source 10 from shifting from the correct temporary placement position.

In addition, in this embodiment, a heat dissipation sheet 30 is used. Therefore, in this mounting step, as shown in FIG. 11, the heat dissipation sheet 30 is placed on the substrate 11 placed on the light source mounting portion of the holder 40. Specifically, as shown by the arrow in FIG. 11, the heat dissipation sheet 30 is moved vertically to place the heat dissipation sheet 30 on the second surface 11b of the substrate 11.

At this time, the holder 40 (holder body 100) is provided with an outer peripheral wall 130 as a positioning portion for determining the position of the heat dissipation sheet 30. As a result, when the heat dissipation sheet 30 is placed on the substrate 11, the outer peripheral wall 130 can regulate the horizontal movement of the heat dissipation sheet 30, so that the position of the heat dissipation sheet 30 can be determined. In other words, it is possible to prevent the heat dissipation sheet 30 from shifting from the correct temporary placement position.

In addition, in this embodiment, the height of the side portion 122b at the tip portion 122 of each spring portion 120 is lower than the thickness of the substrate 11 of the light source 10. This makes it possible to prevent the heat dissipation sheet 30 from being scratched, thereby preventing a decrease in the dielectric strength voltage between the metal device body 20 and the substrate 11. This point will be explained below.

If the height of the side portion 122b at the tip portion 122 of each spring portion 120 is higher than the thickness of the substrate 11 of the light source 10, when the heat dissipation sheet 30 is placed on the substrate 11 and pressed by the fixture body 20 in the next process, there is a risk that a part of the heat dissipation sheet 30 may be scratched by the substrate 11 or the holder 40. In this case, since a metal base substrate is used as the base material of the substrate 11 in this embodiment, if the heat dissipation sheet 30 is scratched, the dielectric strength voltage between the metal fixture body 20 and the substrate 11 decreases. In particular, if the heat dissipation sheet 30 is torn, there is a risk of dielectric breakdown. In contrast, as in this embodiment, the height of the side portion 122b is lower than the thickness of the substrate 11, so that it is possible to prevent the heat dissipation sheet 30 from being scratched. Therefore, it is possible to prevent a decrease in the dielectric strength voltage between the fixture body 20 and the substrate 11.

In addition, in this embodiment, the portion of each of the multiple spring portions 120 that contacts the substrate 11 is located closer to the substrate 11 than the tip of each of the multiple conductive plates 200. Therefore, in this placement process, the substrate 11 and the multiple conductive plates 200 are not in contact. In this embodiment, the tip of each of the multiple conductive plates 200 is the first contact portion 211 of the first conductive plate 210 and the second contact portion 221 of the second conductive plate 220.

In this manner, in this embodiment, when the light source 10 is placed on the holder 40, the substrate 11 is in contact only with the multiple spring portions 120, without contacting the substrate 11 with the multiple conductive plates 200. This allows the substrate 11 to be supported only by the multiple spring portions 120, making it easy to keep the substrate 11 horizontal. In other words, when the light source 10 is temporarily placed on the holder 40, tilting of the substrate 11 can be effectively prevented.

Next, as shown in Fig. 12, the substrate 11 is pressed against the holder 40 by the instrument body 20 (pressing process). Specifically, as shown by the arrows in Fig. 12, the substrate 11 is pressed against the holder 40 by the instrument body 20 from the second surface 11b side of the substrate 11. In this embodiment, the protrusion 21 of the instrument body 20 is pressed against the second surface 11b side of the substrate 11, and the substrate 11 is sandwiched between the instrument body 20 and the holder 40.

In this embodiment, the heat dissipation sheet 30 is placed on the substrate 11, so in this pressing process, the heat dissipation sheet 30 and the substrate 11 are pressed against the holder 40 by the device body 20 from above the heat dissipation sheet 30. In other words, by pressing the protruding portion 21 of the device body 20 against the heat dissipation sheet 30, the device body 20 and the holder 40 sandwich the substrate 11 and the heat dissipation sheet 30.

By pressing the device body 20 in this manner, the spring portion 120, which is a resin spring, is elastically deformed, and the first surface 11a of the substrate 11 is elastically held by the multiple spring portions 120. In other words, the substrate 11 is pressed down by the multiple spring portions 120. The heat dissipation sheet 30 is pressed down by a part of the frame 101, causing the outer periphery to deform.

In the pressing step, the substrate 11 is pressed against the holder 40 by the device body 20, so that the plurality of conductive plates 200 come into contact with the substrate 11. Specifically, the first contact portion 211 of the first conductive plate 210 comes into contact with the first electrode 11c of the substrate 11, and the second contact portion 221 of the second conductive plate 220 comes into contact with the second electrode 11d of the substrate 11.
1 and the conductive plate 200 are electrically connected.

Although not shown, during this pressing process, multiple tube portions 150 of the holder 40 (holder body 100) protrude from the insertion holes of the instrument body 20.

Then, the fixture body 20 and the holder 40 are screwed together. This allows the light source 10 and the heat dissipation sheet 30 to be attached to the fixture body 20 by the holder 40, and the light source 10 and the heat dissipation sheet 30 to be fixed to the fixture body 20. After that, the wires of the power cable 70 can be inserted into each of the multiple tube portions 150 of the holder 40 through the insertion holes of the fixture body 20, thereby connecting the wires to the conductive plate 200 of the holder 40.

[summary]
As described above, according to the holder 40 of this embodiment, when the light source 10 is placed on the light source mounting portion of the holder 40, the multiple contact portions where the multiple spring portions 120 and the substrate 11 come into contact surround the center of gravity of the substrate 11 and form an approximately flat surface.

This allows the light source 10 to be placed on the holder 40 without tilting the substrate 11. In other words, the light source 10 can be temporarily placed on the holder 40 in a stable state. This makes it possible to prevent defects in the assembly of the lighting device 1.

In addition, by preventing the substrate 11 from tilting when the light source 10 is temporarily placed on the holder 40, it is possible to prevent the light source 10 from shifting from the correct temporary placement position when the holder 40 on which the light source 10 is temporarily placed is transported to the next process (e.g., a pressing process). Specifically, when a comparative example holder not provided with the spring portion 120 was used, the defect rate was 2%, but by using the holder 40 provided with the spring portion 120 as in this embodiment, the defect rate was 0%. In addition, by using the holder 40 in this embodiment, the light source 10 did not shift from the correct temporary placement position even when the transport speed per unit was increased by 1 second. As a result, the tact time when assembling the lighting fixture 1 could be significantly improved.

In addition, according to the lighting fixture 1 of this embodiment, the holder 40 includes a plurality of conductive plates 200 pressed against the first surface 11a of the substrate 11 by the elastic force of the spring, and a plurality of spring portions 120 biased toward the first surface 11a of the substrate 11.

As a result, the substrate 11 of the light source 10 is not only elastically held by the multiple conductive plates 200, but also by the multiple spring parts 120. In other words, in the lighting fixture 1, the substrate 11 is pressed toward the fixture body 20 by the multiple conductive plates 200 and the multiple spring parts 120, and is pressurized by the multiple conductive plates 200 and the multiple spring parts 120. Therefore, since the light source 10 is firmly held by the holder 40, it is possible to prevent the light source 10 from shifting from its normal position even if the lighting fixture 1 vibrates.

The heat dissipation of the light source 10 can also be improved by applying pressure to the substrate 11 of the light source 10 using a plurality of conductive plates 200 and a plurality of spring portions 120. An experiment was conducted on the heat dissipation of the light source 10, and the results of the experiment will be described with reference to FIG. 13. FIG. 13 is a diagram showing the relationship between the amount of pressure applied when pressure is applied to the substrate 11 of the light source 10 and the temperature rise of the substrate.

In this experiment, the heat dissipation sheet 30 and the light source 10 were placed on the protruding portion 21 of the fixture body 20, and the temperature rise of the substrate 11 was measured when the substrate 11 was pressed by a press while the light source 10 was emitting light. The temperature rise of the substrate 11 was determined by subtracting the surface temperature of the fixture body 20 from the surface temperature of the substrate 11. In addition, in Fig. 13, n1 to n4 indicate values when different heat dissipation sheets 30 were used. In other words, four types of heat dissipation sheets 30 were used in this experiment.

As shown in Figure 13, this experiment shows that the temperature rise gradually decreases until the pressure applied to the substrate 11 reaches 20 kPa, and when the pressure applied to the substrate 11 reaches 20 kPa or more, the temperature rise stops changing.

Here, in a comparative example holder not provided with spring parts 120, the substrate 11 is pressurized only by the pair of conductive plates 200. In this case, although it depends on the spring force of each conductive plate 200, generally, the amount of pressure applied to the substrate 11 by the pair of conductive plates 200 is about 1.8 kPa to 7.7 kPa, less than 10 kPa. In contrast, in a holder provided with four spring parts 120 as in the present embodiment, in addition to the amount of pressure applied to the substrate 11 by the pair of conductive plates 200, the amount of pressure applied to the substrate 11 by the four spring parts 120 is added by about 20 kPa. In other words, the amount of pressure applied by each spring part 120 is about 5 kPa, and the amount of pressure applied by the pair of conductive plates 200 and the multiple spring parts 120 is at least 10 kPa or more. Therefore, as shown in FIG. 13, it can be seen that the substrate 11 is pressurized not only by the pair of conductive plates 200 but also by the multiple spring parts 120, so that the rising temperature can be effectively suppressed.

The variation in temperature rise caused by the four types of heat dissipation sheets 30 is about ±1°C (±3σ). In other words, the variation in temperature rise caused by differences in heat dissipation sheets 30 is not significantly different whether the amount of pressure applied is small or large, and it can be seen that there is almost no variation in temperature rise caused by the four types of heat dissipation sheets 30.

(Modification)
Although the present invention has been described based on the embodiment, the present invention is not limited to the above embodiment.

For example, in the above embodiment, when the light source 10 is placed on the light source placement portion of the holder 40, the multiple spring portions 120 and the substrate 11 are in surface contact, but this is not limited thereto. The multiple spring portions 120 and the substrate 11 may be in line contact or point contact.

In addition, in the above embodiment, when the light source 10 is temporarily placed by the holder 40, the substrate 11 and the multiple conductive plates 200 are not in contact with each other, but this is not limited to the above. For example, if the substrate 11 does not tilt or if it tilts, the tilt is slight, the substrate 11 and the multiple conductive plates 200 may be in contact with each other when the light source 10 is temporarily placed by the holder 40.

In addition, in the above embodiment, the light source 10 may be configured to be capable of adjusting the brightness and color. For example, the light-emitting unit 12 of the light source 10 may include multiple types of LED elements that emit light with different color temperatures.

In the above embodiment, the light source 10 is configured to emit white light using a blue LED chip and a yellow phosphor, but this is not limited to the above. For example, a phosphor-containing resin containing red and green phosphors may be used and combined with a blue LED chip to emit white light.

In addition, in the above embodiment, a blue LED chip is used as the LED, but this is not limited to this. For example, an LED chip that emits a color other than blue may be used as the LED. In this case, the phosphor may be appropriately selected according to the emission wavelength of the LED.

In the above embodiment, the light source 10 is an LED module having a COB structure in which an LED chip is directly mounted on a substrate, but the present invention is not limited to this. For example, the light source 10 may be an SMD
An LED module having a surface mount device (SMD) structure may be used. An LED module having an SMD structure can be realized by mounting one or more SMD type light emitting elements as the light emitting section 12 on the substrate 11. The SMD type light emitting element is, for example, a packaged LED element having a resin or ceramic package (container), an LED chip mounted in a recess of the package, and a sealing member (phosphor-containing resin or transparent resin) sealed in the recess of the package.

In addition, in the above embodiment, an LED is used as an example of a light-emitting element, but a semiconductor light-emitting element such as a semiconductor laser, or other solid-state light-emitting element such as an organic EL (Electro Luminescence) or inorganic EL may also be used as the light-emitting element.

In addition, in the above embodiment, the lens 50 has a light distribution control function of a lens function and/or a light diffusion function, but this is not limited to the above. For example, the lens 50 may be a transparent panel of a certain thickness without having a light distribution control function such as a lens function and a light diffusion function. In this case, the transparent panel may be a flat panel in the shape of a flat plate, or a curved panel.

The lighting fixture in the above embodiment may be installed on a mounting portion other than a ceiling. The present invention may also be applied to lighting fixtures other than recessed lighting fixtures, and may also be applied to lighting fixtures other than downlights.

In addition, the present invention also includes forms obtained by applying various modifications to each embodiment that a person skilled in the art may conceive, and forms realized by arbitrarily combining the components and functions of each embodiment within the scope of the spirit of the present invention.

REFERENCE SIGNS LIST 1 Lighting fixture 10 Light source 11 Substrate 11a First surface 11b Second surface 12 Light-emitting portion 20 Fixture body 30 Heat dissipation sheet 40 Holder 101 Frame 110, 140 Opening 120 Spring portion 121 Extension portion 122a Bottom portion 122b Side portion 200 Conductive plate

Claims (16)

A holder for fixing a light source having a substrate having a first surface and a light emitting portion provided on the first surface to a fixture body,
an opening through which light emitted from the light source passes;
a light source mounting portion on which the light source is mounted;
a plurality of conductive plates that are pressed against the first surface of the substrate by a spring elastic force and serve as power supply terminals for supplying power to the light source;
a plurality of spring portions biased toward the first surface of the substrate;
each of the plurality of spring portions is provided such that a plurality of contact portions where the plurality of spring portions come into contact with the substrate when the light source is placed on the light source mounting portion surrounds a center of gravity of the substrate and forms a substantially flat surface;
The light source mounting portion has a portion that restricts horizontal movement of the substrate.
Holder. a portion of each of the plurality of spring portions that contacts the substrate is located closer to the substrate than a tip end of each of the plurality of conductive plates;
The holder of claim 1 . the holder includes a frame having the opening and the light source mounting portion,
The opening has a rectangular shape,
The substrate is rectangular,
each of the plurality of spring portions is fixed to an inner side of the frame body and has a tip portion at an inner corner of the frame body;
The tip portion has a contact portion with the substrate.
A holder according to claim 1 or 2. A holder for fixing a light source having a substrate having a first surface and a light emitting portion provided on the first surface to a fixture body,
an opening through which light emitted from the light source passes;
a light source mounting portion on which the light source is mounted;
a plurality of conductive plates that are pressed against the first surface of the substrate by a spring elastic force and serve as power supply terminals for supplying power to the light source;
a plurality of spring portions biased toward the first surface of the substrate;
each of the plurality of spring portions is provided such that a plurality of contact portions where the plurality of spring portions come into contact with the substrate when the light source is placed on the light source mounting portion surrounds a center of gravity of the substrate and forms a substantially flat surface;
the holder includes a frame having the opening and the light source mounting portion, and four spring portions as the plurality of spring portions;
The opening has a rectangular shape,
The substrate is rectangular,
Each of the four spring portions is fixed to an inner side of the frame body and has a tip portion at an inner corner of the frame body,
the tip portion has a contact portion with the substrate,
Each of the four spring portions is fixed to each of the four sides of the frame body and has an extension portion extending along the fixed side toward an inner corner of the frame body.
Holder . The light source mounting portion is a planar portion formed on the plurality of spring portions.
A holder according to any one of claims 1 to 4. A holder for fixing a light source having a substrate having a first surface and a light emitting portion provided on the first surface to a fixture body,
an opening through which light emitted from the light source passes;
a light source mounting portion on which the light source is mounted;
a plurality of conductive plates that are pressed against the first surface of the substrate by a spring elastic force and serve as power supply terminals for supplying power to the light source;
a plurality of spring portions biased toward the first surface of the substrate;
each of the plurality of spring portions is provided such that a plurality of contact portions where the plurality of spring portions come into contact with the substrate when the light source is placed on the light source mounting portion surrounds a center of gravity of the substrate and forms a substantially flat surface;
the light source mounting portion is a flat portion formed on the plurality of spring portions,
The holder has a first positioning portion for determining a horizontal position of the substrate.
Holder . The first positioning portion is a side surface portion formed on each of the plurality of spring portions.
The holder according to claim 6. Each of the plurality of spring portions has a bottom portion as the planar portion,
The bottom surface of the bottom portion and the side surface of the side surface portion are substantially perpendicular to each other,
When the light source is placed on the light source mounting portion, the side surface portion faces a side surface of the substrate, and the bottom surface of the bottom portion contacts the first surface of the substrate.
The holder according to claim 7. The height of the side portion is less than the thickness of the substrate.
The holder according to claim 8. The holder has a second positioning portion for determining the position of an electrically insulating heat dissipation sheet that is fixed to the fixture body together with the light source.
A holder according to any one of claims 1 to 9. The plurality of spring portions are made of resin.
A holder according to any one of claims 1 to 10. a light source having a light emitting portion and a substrate on which the light emitting portion is provided;
The instrument body,
The holder according to any one of claims 1 to 11,
The substrate is pressed against the device body by at least the plurality of spring portions of the holder.
Lighting fixtures. Further, a heat dissipation sheet having electrical insulation properties is provided between the substrate and the device body.
13. A lighting device according to claim 12. A method for manufacturing a lighting fixture in which a light source is held in a fixture body by a holder, comprising the steps of:
The light source is
a substrate having a first surface and a second surface opposite to the first surface;
a light emitting portion provided on the first surface of the substrate,
The holder includes:
an opening through which light emitted from the light source passes;
a light source mounting portion on which the light source is mounted;
A plurality of conductive plates serving as power supply terminals for supplying power to the light source;
a plurality of spring portions biased toward the first surface of the substrate of the light source;
The method for manufacturing the lighting fixture includes the steps of:
a first step of mounting the light source on the light source mounting portion so that the first surface of the substrate is in contact with the plurality of spring portions;
a second step of pressing the substrate against the holder by the device body from the second surface side of the substrate,
in the first step, when the light source is placed on the light source placement section, a plurality of contact portions where the plurality of spring portions contact the substrate surround a center of gravity of the substrate and form a substantially flat surface ;
The light source mounting portion has a portion that restricts horizontal movement of the substrate.
A method for manufacturing lighting fixtures. In the first step, a heat dissipation sheet having electrical insulation is placed on the substrate placed on the light source placement section,
In the second step, the heat dissipation sheet and the substrate are pressed against the holder by the device body from above the heat dissipation sheet.
A method for manufacturing a lighting fixture according to claim 14. In the first step, the substrate and the plurality of conductive plates are not in contact with each other,
In the second step, the substrate is pressed against the holder by the device body to bring the conductive plates into contact with the substrate.
A method for manufacturing a lighting fixture according to claim 14 or 15.

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