JP2011181429A - Led lighting device and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an LED lighting device to facilitate molding of optical components and to easily cope with variation of a plurality of luminous intensity distribution characteristics by reducing the thickness of the structure of the LED lighting device and simplifying the structure of the optical components which control luminous intensity distribution of LED light; and to provide a method of manufacturing the LED lighting device. <P>SOLUTION: The LED lighting device includes an LED light source, a reflector and a lens. The lens is made from plastic, and has an outer diameter ϕ of ≥60 mm and ≤150 mm. The LED light source has 10 or more LEDs. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an LED lighting device and a method for manufacturing the LED lighting device.

  In recent years, replacement of incandescent lamps with LEDs is expected. However, when an LED is used as a lighting device, the individual illuminance is smaller than incandescent lamps, fluorescent lamps, HID lamps, and the like. Therefore, in order to obtain illuminance, it is necessary to use a plurality of LEDs.

  In general LED lighting devices, an optical member for controlling the light distribution around the LEDs is used to control the light distribution of the light emitted from the LEDs, but a plurality of LEDs are mounted on the lighting device, When the area where the LED is arranged increases, it is necessary to increase the size of the optical member.

  As a method of controlling light distribution using only a lens as an optical member, a method of controlling light distribution by providing a refracting surface and a reflecting surface on a lens is known, as described in Patent Document 1. However, in the case of a lens having such a complicated shape, it becomes more difficult to mold the lens as the size of the lens increases. In particular, this is particularly difficult in the case of injection molding in which plastic is used as the lens material.

  On the other hand, as described in Patent Document 2, there is a method of controlling light distribution by using only a reflector as an optical member. However, when the light distribution angle is controlled to be narrow, it is necessary to deepen the shape of the reflector. As a result, the merit of thinning, which is one of the features of the LED lighting device, may be impaired.

JP 2007-142178 A JP 2008-16412 A

  In addition, the lighting device has different light distribution characteristics depending on the place and use. Therefore, it is preferable that it is possible to easily cope with variations of plural kinds of light distribution characteristics.

  When controlling the light distribution using only a lens as described in Patent Document 1, it is difficult to mold due to an increase in the lens size, and it is possible to cope with variations of multiple types of light distribution characteristics. There is a fear that it will cause further molding and design difficulties.

  On the other hand, when trying to cope with variations of multiple types of light distribution characteristics using a plurality of reflectors of different sizes, it is necessary to change not only the reflector but also the size of the optical member used in contact with the reflector such as a lens after all. It will occur.

  Therefore, the present invention has been made in view of the problems of the prior art, and by using an LED as a light source of the illumination device, the configuration of the illumination device is thinned, and an optical member for controlling the light distribution of the LED is provided. An object of the present invention is to provide an LED lighting device and a method for manufacturing the LED lighting device that can be easily formed by variation of a plurality of kinds of light distribution characteristics while simplifying the configuration to facilitate the molding of the optical member. And

  The LED illumination device according to claim 1 includes an LED light source, a reflector, and a lens, the lens is made of plastic, an outer diameter Φ of the lens is 60 mm ≦ Φ ≦ 150 mm, and the LED light source is 10 It has the above LED.

  According to the present invention, since the LED lighting device includes the reflector and the lens, the light distribution control can be performed by the reflector and the lens, so that the configuration of the lens can be simplified. Since the configuration of the lens can be simplified, the lens can be easily formed even when the outer diameter Φ of the lens is increased to 60 mm ≦ Φ ≦ 150 mm due to having 10 or more LEDs. Become. In addition, since the configuration of the lens can be simplified, even when the outer diameter of the lens is increased to 60 mm ≦ Φ ≦ 150 mm, it is possible to perform injection molding using plastic as the lens material.

  In addition, since the LED lighting device includes the reflector and the lens, the light distribution control can be performed by the reflector and the lens. Therefore, even when the light distribution angle is controlled to be narrow, the shape of the reflector can be changed. Since it does not become too deep, the characteristic of thinning, which is an advantage of the LED lighting device, can be utilized to the maximum extent.

  Furthermore, since the configuration of the lens can be simplified, it becomes possible to easily mold various lenses having different light distribution characteristics. For this reason, it is possible to easily cope with variations of plural kinds of light distribution characteristics.

The LED illumination device according to claim ² is characterized in that, in the invention according to claim 1, an area S of the LED light source is 1256 mm ² ≦ S ≦ 11309 mm ² .

  According to a third aspect of the present invention, in the invention of the first or second aspect, at least one optical surface of the lens is a spherical surface.

  The LED lighting device according to claim 4 is the invention according to any one of claims 1 to 3, wherein at least one optical surface of the lens is an aspherical surface.

  According to a fifth aspect of the present invention, in the invention according to any one of the first to fourth aspects, at least one optical surface of the lens is a flat surface. By forming at least one optical surface of the lens as a plane, it is possible to further facilitate the molding of the lens. Further, by making at least one optical surface of the lens flat, the lens can be easily attached to another optical member such as a reflector.

  According to a sixth aspect of the present invention, in the invention according to any one of the first to fifth aspects, at least one optical surface of the lens is a discontinuous surface. By forming the discontinuous surface, for example, in the form of a Fresnel lens, the thickness of the lens in the optical axis direction can be reduced. Therefore, it becomes possible to further reduce the thickness of the LED lighting device.

  The LED illumination device according to claim 7 is the invention according to any one of claims 1 to 6, wherein the LED illumination device has a diffusion portion.

  By providing a diffusion part in the LED illumination device, even when a plurality of LEDs are used as the LED light source, the illuminance can be made uniform and the illuminance unevenness can be reduced. For example, even when 10 or more LEDs are used as the LED light source and the light distribution angle is as narrow as about 20 degrees, the illuminance can be made uniform and the illuminance unevenness can be reduced. In addition, by providing the LED illumination device with a diffusing portion, it is possible to avoid a phenomenon in which the light emitting portion of the LED light source is seen through, and it is possible to prevent the LED from being viewed in a dot shape.

  The LED lighting device according to an eighth aspect is the invention according to the seventh aspect, wherein the diffusing portion and the lens are integrated. By integrating the diffusing unit and the lens, it is possible to reduce the number of parts used in the LED lighting device and reduce the number of assembly steps.

  The LED illumination device according to a ninth aspect is characterized in that, in the invention according to the eighth aspect, the diffusion portion is a rough surface provided on an optical surface of the lens.

  The LED illumination device according to a tenth aspect is the invention according to the eighth aspect, characterized in that the diffusing portion has a lens array shape provided on the optical surface of the lens.

  The LED illumination device according to an eleventh aspect is the invention according to the seventh aspect, wherein the diffusing portion and the lens are separate. Since the configuration of the lens can be simplified by making the diffusing unit and the lens separate, the lens can be molded more easily.

  According to a twelfth aspect of the present invention, in the invention of the eleventh aspect, the diffusing section is a light diffusing sheet.

  According to a thirteenth aspect of the present invention, in the invention of the eleventh aspect, the diffusion unit is a lens array.

  15. The method for manufacturing an LED lighting device according to claim 14, wherein the LED lighting device includes an LED light source, a reflector, and a lens, the lens is made of plastic, and the outer diameter of the lens. Φ is set to 60 mm ≦ Φ ≦ 150 mm, the LED light source is composed of 10 or more LEDs, a step of preparing one type of the reflector, and a step of selecting one type of lens from the plurality of types of the lenses, And a step of manufacturing an LED lighting device by combining the reflector and the selected lens.

  According to the present invention, since the LED lighting device includes the reflector and the lens, the light distribution control can be performed by the reflector and the lens, so that the configuration of the lens can be simplified. Since the configuration of the lens can be simplified, the lens can be easily formed even when the outer diameter of the lens is increased to 60 mm ≦ Φ ≦ 150 mm due to having 10 or more LEDs. . In addition, since the lens configuration can be simplified, even when the outer diameter Φ of the lens is increased to 60 mm ≦ Φ ≦ 150 mm, it is possible to perform injection molding using plastic as the lens material. The lens can be molded more easily.

  The LED lighting device manufacturing method of the present invention includes a step of preparing one type of reflector, a step of selecting one type of lens from a plurality of types of lenses, and a combination of the reflector and the lens to manufacture the LED lighting device. A step of performing. Accordingly, since one type of lens can be selected from a plurality of types of lenses according to the required light distribution characteristics, the LED illumination device can cope with variations of the plurality of types of light distribution characteristics. It is possible to provide a manufacturing method. Further, since the reflector to be prepared is a single type, that is, a common reflector is used for a plurality of types of lenses, the outer diameter of the lens used in contact with the reflector can be made common. Furthermore, as described above, since the LED lighting device includes a reflector and a lens, even when the outer diameter Φ of the lens is increased to 60 mm ≦ Φ ≦ 150 mm, the lens can be easily molded. Since it is possible to easily mold a lens that satisfies the required light distribution characteristics, it is possible to more easily cope with variations in the light distribution characteristics.

The LED (Light Emitting Diode) illumination device according to the present invention includes an LED light source, a reflector, and a lens.
(LED light source)
The LED light source has 10 or more LEDs. The LED light source preferably has 100 or less LEDs. The area S of the LED light source is preferably 1256 mm ² ≦ S ≦ 11309 mm ² . More preferably, 1256 mm ² ≦ S ≦ 6361 mm ² is preferable. Here, the area S of the LED light source is the minimum area that the circle can take when one circle that can surround all the installed LEDs is created as shown in FIG. Here, when r is a radius of a circle having a minimum area, 20 mm ≦ r ≦ 45 mm is preferable.

  Here, the light distribution characteristics of the LED can be considered to largely depend on the area S of the LED light source, and the LED array may be any arrangement as long as the area S of the LED light source is equal. For example, as shown in FIG. 3 and FIG. 4, even if the arrangement of LEDs and the number of LEDs are different from each other, the area S of the LED light source is equal to S1, so if the same reflector and lens are used, Except for the difference in the amount of light, the same light distribution characteristics can be obtained.

Various LEDs can be used as the LED light source, but white LEDs are preferably used for illumination. As the white LED, a combination of a blue LED chip and a phosphor such as a YAG phosphor that emits yellow light by blue light emitted from the blue LED chip is preferably used. Further, a white LED that forms white light by combining a blue LED chip, a green LED chip, and a red LED chip without using a phosphor may be used.
(lens)
The lens is made of plastic. As the plastic constituting the lens, thermoplastics such as cyclic polyolefin and polycarbonate, thermosetting plastics, photo-curable plastics, UV-curable plastics, and the like can be used. When a thermoplastic such as cyclic polyolefin or polycarbonate is used, it can be more preferably used because it can be produced by injection molding and the production cost can be greatly reduced. In particular, polycarbonate can be used more preferably.

  The outer diameter Φ of the lens is 60 mm ≦ Φ ≦ 150 mm. More preferably, 80 mm ≦ Φ ≦ 150 mm. Here, the outer diameter Φ of the lens is the maximum diameter of the entire lens.

It is preferable that at least one optical surface of the lens is a spherical surface or an aspherical surface. Moreover, it is preferable that at least one optical surface of the lens is a flat surface. Further, both optical surfaces of the lens may be spherical or aspheric. The spherical and aspherical shapes may be convex or concave. In particular, the optical surface of the lens closer to the LED light source is preferably a flat surface, and the optical surface of the lens farther from the LED light source is preferably a spherical surface or an aspherical surface. Further, at least one optical surface of the lens may be a discontinuous surface. Here, examples of the discontinuous surface include an annular structure and a Fresnel lens shape.
(Reflector)
The reflector surrounds the LED light source and reflects light emitted from the LED.

  As a material of the reflector, a thin metal plate such as aluminum or steel may be used, glass, thermoplastic resin such as cyclic polyolefin, polycarbonate, thermosetting resin, photocurable resin, UV curable resin, or the like. Alternatively, a reflective surface may be formed by vapor-depositing a metal such as aluminum or silver on the surface of a substrate made of silicon, ceramic, or the like. When a thermoplastic resin such as cyclic polyolefin or polycarbonate is used, it can be manufactured by injection molding, so that the manufacturing cost can be greatly reduced.

  The reflector preferably has a reflective surface that reflects light emitted from the LED light source. Examples of the reflecting surface of the reflector include the following two types. 1) The reflecting surface is a curved surface. 2) The reflecting surface is a combination of a plurality of planes.

  The light emitted from the LED light source also includes light emitted in a direction substantially perpendicular to the optical axis. Reflecting such light so as to approach the optical axis direction is preferable because the light use efficiency can be improved. For the sake of convenience, the optical axis may be a line perpendicular to the LED plane of the LED light source.

  The shape of the reflector viewed from the optical axis direction is preferably a circular or elliptical reflecting surface, but is not limited thereto, and may be a polygon. In this case, aluminum or silver may be vapor-deposited on the entire surface including the main body of the reflector, or aluminum or silver may be vapor-deposited only on a circular or elliptical reflecting surface portion. The cross-sectional shape of the reflector in the direction perpendicular to the optical axis is preferably a circle or an ellipse, but is not limited to this, and may be a polygon.

  It is preferable that the reflector has a tapered shape that expands in the light emitting direction. The reflector preferably has openings on the light incident side and the light emitting side, respectively. In particular, it is preferable that the entrance and exit sides of the reflector have a circular shape. At this time, the diameter of the opening on the incident side of the reflector, in other words, the inner diameter D1 on the incident side of the reflector is preferably 20 mm ≦ D1 ≦ 60 mm. In other words, the diameter of the opening on the output side of the reflector, in other words, The inner diameter D2 on the emission side is preferably 60 mm ≦ D2 ≦ 120 mm.

  It is preferable that the reflector completely surrounds the light emitting part of the LED light source, but there may be a gap in part. In order to enclose the LED light source, it is sufficient that the proximity end of the reflecting surface of the reflector is located outside the LED light source in the direction orthogonal to the optical axis, and the distance between the light emission point and the proximity end is not limited. Moreover, the reflector may be formed in the cylinder shape for every light emission part of the LED light source. The reflector may be composed of a single member or a plurality of members. When the reflector is made of a single member, it is preferable to reduce the height of the reflector because it is difficult to perform vapor deposition if the reflector has a high height when the reflective surface is provided by vapor deposition or the like. However, the reflector may be formed in a divided state and may be formed by combining a plurality of members.

Further, the reflector may be doubled. Here, to make the reflector double means to arrange the first reflector so as to surround the LED light source and to arrange the second reflector so as to surround the first reflector. Thus, the second reflector is arranged so as to surround the first reflector, that is, by making it a double reflector, the outer reflector is raised to reflect the light emitted near the center of the LED light source. Thus, the height of the reflector can be reduced, and a thin lighting device that takes advantage of the thinness of the LED can be obtained. In addition, when the reflecting surface of the reflector is formed by vapor deposition of aluminum, silver, or the like, there is an advantage that vapor deposition is easy because the height of the reflector can be reduced. Furthermore, the light emitted from a part of the LED light source is reflected by the first reflector, and the light emitted directly from the LED illuminating device is reduced, thereby ensuring good light distribution characteristics. Moreover, since the light distribution of each of the first reflector and the second reflector can be controlled, the degree of freedom of light distribution control is increased. This is particularly advantageous when the light distribution angle is narrow. As the degree of freedom of light distribution control increases, the degree of freedom of arrangement of the LED light source also improves.
(Diffusion part)
The LED lighting device preferably has a diffusion part. Here, the diffusion unit has an action of diffusing light emitted from the LED light source. By providing the LED illumination device with a diffusing portion, even when a plurality of LEDs are used as the LED light source and the light distribution angle is as narrow as about 20 degrees, the illuminance can be made uniform and the illuminance unevenness can be reduced. It becomes possible. For example, even when 10 or more LEDs are used as the LED light source, the illuminance can be made uniform, and the illuminance unevenness can be reduced. In addition, by providing the LED illumination device with a diffusing portion, it is possible to avoid a phenomenon in which the light emitting portion of the LED light source is seen through, and it is possible to prevent the LED from being viewed in a dot shape.

  As the diffusion part, the diffusion part and the lens may be integrated. By integrating the diffuser and the lens, the number of parts of the LED lighting device can be reduced. For example, the diffuser may be a rough surface provided on the optical surface of the lens. Here, the rough surface means, for example, a structure that has minute irregularities, has a high surface roughness with respect to the mirror surface, and easily scatters light. Further, a lens array shape in which the diffusing portion is provided on the optical surface of the lens may be used. Here, the lens array shape is, for example, a shape in which a plurality of single lenses are arranged. Here, it is preferable to form a rough surface or a lens array shape on the optical surface on the exit side of the lens, but it can also be formed on the optical surface on the incident side of the lens. In addition, as a method of integrating the diffusion portion and the lens, a resin material that diffuses light into the resin of the lens can be used.

  As the diffusion unit, the diffusion unit and the lens may be separate. For example, examples of the diffusion unit used as a separate body include a light diffusion sheet and a lens array. Here, it is preferable that the light diffusion sheet can be used by being attached to the optical surface of the lens. In addition, a light diffusion sheet can be attached to various optical members disposed between the lens and the LED light source. As the light diffusion sheet, it is possible to use a plastic film whose surface is subjected to chemical processing using chemicals or physical processing such as sandblasting to form fine irregularities having light diffusibility. Moreover, as a lens array used as a separate diffusing section, it is preferable to use an optical member having a lens array disposed between the lens and the LED light source.

When disposing a separate diffusing portion between the lens and the LED light source, it is preferable that the diffusing portion is formed so as to match the cross-sectional shape of the reflector and is fixed in close contact with the inner wall surface of the reflector. Thereby, it is possible to allow all of the light emitted from the LED light source to pass through the diffusion portion.
(Application of LED lighting device)
As lighting fixtures equipped with LED lighting devices, general lighting fixtures, residential lighting fixtures, office lighting fixtures, store / exhibit lighting fixtures, street lamp lighting fixtures, guide lamp fixtures used indoors and outdoors And signal devices, advertising towers, lighting poles, underwater lighting lights, strobe lights, spotlights, downlights, flashlights, electric bulletin boards, dimmers, automatic flashers, display backlights, video equipment, illumination Type switches, optical sensors, medical lights, in-vehicle lights, and the like.
(Manufacturing method of LED lighting device)
Below, the manufacturing method of an LED lighting apparatus is demonstrated. The manufacturing method of the LED lighting apparatus of this invention has a step which prepares one type of reflector. As one kind of reflector prepared here, the above-mentioned various reflectors can be used.

  Moreover, the manufacturing method of the LED lighting apparatus of this invention has a step which selects one type of lens from multiple types of lens. Here, as the plurality of types of lenses, the above-described various lenses can be used. In addition, the plurality of types of lenses are preferably lenses having different shapes in order to be able to cope with variations in light distribution characteristics. However, since all of the plurality of types of lenses are used corresponding to a type of reflector, the outer diameters of the plurality of types of lenses are preferably the same. Further, when selecting one type of lens, it is preferable to select a lens in accordance with the required light distribution characteristics.

  Furthermore, the manufacturing method of the LED lighting apparatus of this invention has a step which manufactures an LED lighting apparatus combining a reflector and the selected lens. The step of manufacturing the LED lighting device may include a step of mounting the LED on the circuit board. Moreover, it is preferable that the step of manufacturing the LED lighting device includes a step of attaching one kind of prepared reflector to the circuit board. As a step of attaching the reflector to the circuit board, it can be attached using an adhesive, or the uneven structure formed on the reflector and the uneven structure formed on the circuit board can be fitted and fixed.

  Preferably, the step of manufacturing the LED lighting device includes a step of attaching a lens to the reflector. In the step of attaching the lens to the reflector, the lens can be attached in close contact with the inner wall surface of the reflector by matching the outer diameter of the lens with the inner diameter of the exit side opening of the reflector. Further, the lens can be attached so that the outer diameter of the lens is larger than the inner diameter of the exit side opening of the reflector, and the lens is supported by the upper end portion of the reflector. Further, instead of attaching the lens to the reflector, a holding member for holding the lens can be separately prepared, and the lens can be attached to the holding member.

  The step of manufacturing the LED lighting device may include a step of attaching the diffusion portion to the LED lighting device. When the diffusing unit and the lens are integrated, the diffusing unit is attached at the same time by attaching the lens. On the other hand, when the diffusing portion and the lens are separate, the diffusing portion can be attached to the optical surface of the lens, or can be attached in the reflector so as to be fixed in close contact with the inner wall surface in the reflector.

  According to the present invention, by using an LED as a light source of the lighting device, the configuration of the lighting device is thinned, and the configuration of the optical member for controlling the light distribution of the LED is simplified, so that the optical member can be easily molded. In addition, it is possible to provide an LED lighting device and a method for manufacturing the LED lighting device that can be easily handled by variations of a plurality of types of light distribution characteristics.

It is sectional drawing which shows one Embodiment of the LED lighting apparatus which concerns on this invention. It is an example of the figure which looked at the LED light source from the optical axis direction output side. It is an example of the figure which looked at the LED light source from the optical axis direction output side. It is an example of the figure which looked at the LED light source from the optical axis direction output side.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant description is omitted. In addition, the dimensional ratios in the drawings are exaggerated for convenience of explanation, and may be different from the actual ratios.

  FIG. 1 is a diagram showing the LED illumination device of the present embodiment cut along a cross section including the optical axis, and FIG. 2 is a diagram of the LED light source of the LED illumination device of the present embodiment as viewed from the optical axis direction emission side. It is. The LED illumination device according to the present embodiment includes an LED light source, a reflector 3 and a lens 1.

The LED light source is composed of 13 LEDs 2. Each LED 2 is fixedly provided on the circuit board 5. The LED 2 is a white LED, and is configured by combining a blue LED chip and a YAG phosphor that emits yellow light by blue light emitted from the blue LED chip. The area S of the LED light source is S = 5026 mm ² .

  The reflector 3 is attached to the circuit board 5. The reflector 3 has a tapered shape whose diameter increases toward the upper side, and the inner side is a reflecting surface. The cross section of the reflecting surface of the reflector 3 in the optical axis direction is curved. The cross section in the direction orthogonal to the optical axis of the reflector 3 is circular. The reflector 3 has an incident-side opening and an exit-side opening. The entrance-side opening has an inner diameter D1 of D1 = 42 mm, and the exit-side opening has an inner diameter D2 of D2 = 86 mm. The reflector 3 is formed by performing aluminum vapor deposition on the reflecting surface after being formed by resin injection molding.

  A lens 1 is attached to the opening on the exit side of the reflector 3. The lens 1 is made of polycarbonate, and the outer diameter Φ of the lens 1 is Φ = 85 mm. Further, the optical surface of the lens 1 closer to the LED light source is a flat surface, and the optical surface of the lens 1 farther from the LED light source has a convex spherical shape.

  In addition, the diffusing unit 4 is attached to the reflector 3 between the lens 1 and the LED 2. The diffusing unit 4 has a lens array shape in which fine single lenses are two-dimensionally arranged.

  Below, an example of the manufacturing method of an LED lighting apparatus is shown.

  First, one type of reflector 3 is prepared. In this embodiment, as shown in FIG. 1, a reflector 3 having a tapered shape whose diameter increases as it goes upward is prepared. The reflector 3 has a reflecting surface.

  Next, 10 or more LEDs 2 are mounted on the circuit board 5. Next, the prepared one type of reflector 3 is attached to the circuit board 5. The circuit board 5 and the reflector 3 are fixed by fitting the convex structure formed on the reflector 3 to the concave structure formed on the circuit board 5.

  Next, the diffusion part 4 is attached to the reflector 3. In the present embodiment, attachment is performed by fixing the diffusing portion 4 in close contact with the inner wall surface in the reflector 3.

  Next, one type of lens 1 is selected from a plurality of types of lenses. Here, the lens 1 is made of polycarbonate, and the outer diameter Φ of the lens 1 is Φ = 85 mm. As the plurality of types of lenses, various lenses having different shapes can be used, but the outer diameters are unified. In the method of the present embodiment, as shown in FIG. 1, a lens 1 is selected as the lens 1 in which the optical surface closer to the light source is a flat surface and the optical surface far from the light source is a convex spherical surface. .

Next, one kind of lens 1 selected from a plurality of kinds of lenses is attached to one kind of prepared reflector 3. In the present embodiment, the lens 1 is attached to the reflector 3 by matching the outer diameter of the lens 1 with the inner diameter of the exit-side opening of the reflector 3, the lens 1 being in close contact with the inner wall surface of the reflector 3. As described above, the LED lighting device according to the present embodiment is manufactured.
(Industrial applicability)
The LED illumination device and the LED illumination device manufacturing method of the present invention use an LED as the light source of the illumination device to reduce the thickness of the illumination device and simplify the configuration of the optical member that controls the light distribution of the LED light. Thus, the optical member can be easily molded and can be easily dealt with by variations of plural kinds of light distribution characteristics, which can contribute to the popularization of LED lighting devices.

1 Lens 2 LED
3 reflector 4 diffusion part 5 circuit board

Claims (14)

In LED lighting device,
The LED lighting device has an LED light source, a reflector, and a lens,
The lens is made of plastic,
The outer diameter Φ of the lens is 60 mm ≦ Φ ≦ 150 mm,
The LED light source includes 10 or more LEDs. ^2. The LED lighting device according to claim 1, wherein an area S of the LED light source is 1256 mm ² ≦ S ≦ 11309 mm ² .   The LED illumination device according to claim 1, wherein at least one optical surface of the lens is a spherical surface.   The LED illumination device according to any one of claims 1 to 3, wherein at least one optical surface of the lens is an aspherical surface.   The LED illumination device according to any one of claims 1 to 4, wherein at least one optical surface of the lens is a flat surface.   The LED illumination device according to any one of claims 1 to 5, wherein at least one optical surface of the lens is a discontinuous surface.   The LED illumination device according to any one of claims 1 to 6, wherein the LED illumination device has a diffusion portion.   The LED illumination device according to claim 7, wherein the diffusion unit and the lens are integrated.   The LED illumination device according to claim 8, wherein the diffusing portion is a rough surface provided on an optical surface of the lens.   The LED illumination device according to claim 8, wherein the diffusing portion has a lens array shape provided on an optical surface of the lens.   The LED illumination device according to claim 7, wherein the diffusion unit and the lens are separate bodies.   The LED illuminating device according to claim 11, wherein the diffusion portion is a light diffusion sheet.   The LED illuminating apparatus according to claim 11, wherein the diffusion unit is a lens array. In the manufacturing method of the LED lighting device,
The LED lighting device has an LED light source, a reflector, and a lens,
The lens is made of plastic;
The outer diameter Φ of the lens is 60 mm ≦ Φ ≦ 150 mm,
The LED light source is composed of 10 or more LEDs,
Providing one type of said reflector;
Selecting one type of lens from among the plurality of types of lenses;
And a step of manufacturing an LED lighting device by combining the reflector and the selected lens.

Images