JP2012164518A - Wide orientation lighting system and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wide orientation lighting system excellent in selectivity of materials and productivity.SOLUTION: The wide orientation lighting system is provided with a substrate 2 obtained by punching out or cutting out a sheet of platy material of aluminum, copper, glass epoxy resin, polyester or the like into a spiral shape, and formed into a volute spring shape by displacing the vicinity of a center of the spiral upward, and a plurality of light-emitting elements 3, such as light-emitting diodes, mounted on a top surface of the substrate 2 arrayed in a winding direction. The light-emitting elements 3 are connected in series or parallel, for instance, through wirings on the substrate 2.

Description

  The present invention relates to a wide orientation illuminating device and a manufacturing method thereof, and particularly to a wide orientation illuminating device excellent in productivity.

  In recent years, an illuminating device using a light emitting element (LED) has long life and less power consumption than a heat bulb or a fluorescent lamp, and therefore, its spread is desired. By the way, the illuminance of the light emitting element is high due to its high directivity, but since the illuminance rapidly decreases as it goes away from the center, it is still not practical as a device for illuminating a wide area.

  Therefore, various ideas for obtaining desired alignment characteristics by arranging a plurality of light emitting elements in a three-dimensional manner have been proposed. For example, in paragraph 0053 of Patent Document 1, there is an illuminating device including a base material obtained by injection molding into a tower shape having a step in the height direction, and light emitting elements mounted on each step of the base material. Proposed. Patent Document 2 proposes a light emitting element module in which a plurality of light emitting elements are arranged in the longitudinal direction on one surface of a belt-like substrate and the substrate is wound in a spiral shape.

  On the other hand, in Patent Document 3, on the premise that a plurality of light emitting elements are three-dimensionally arranged, a case having an opening, a light emitting element mounted on one surface, and the other surface facing the inner surface of the main body. An illuminating device including a flexible substrate disposed in the space has been proposed.

Japanese Patent Laid-Open No. 11-163212 JP 2004-253328 A JP 2002-184209 A

However, the apparatus described in Patent Document 1 is limited to materials that can be injection-molded because the base material must be injection-molded, and cannot be designed with a material with high heat dissipation and high reflectivity. Not right. In addition, the LED chip must be mounted three-dimensionally, resulting in poor production efficiency. Moreover, in the light emitting element module of patent document 2, most light is emitted in radial direction, and the illumination intensity with respect to a front surface (axial direction) is remarkably low.
On the other hand, the lighting device of Patent Document 3 does not disclose an efficient method of forming a flexible substrate, although it is intended to improve production efficiency and output without keeping wide orientation in mind.
Therefore, an object of the present invention is to provide a wide orientation illuminating device excellent in material selectivity and productivity.

In order to solve the problem, the wide orientation illumination device of the present invention is
A board obtained by punching or cutting a single plate material in a spiral shape, and displacing the vicinity of the center of the vortex upward to form a bamboo spring shape,
And a plurality of light emitting elements mounted side by side in the winding direction on the upper surface of the substrate.

  According to this wide orientation lighting device, the substrate can be obtained by punching or cutting, so select a material with excellent productivity and workability, such as a metal plate such as a copper plate or an aluminum plate, or a plastic plate with a metal foil. Can do. And since the some light emitting element is mounted in the winding direction on the upper surface of the board | substrate formed in the shape of a bamboo shoot spring, it can irradiate the wide angle range centering on an axial direction front.

A suitable method for manufacturing this wide orientation lighting device is:
A step of obtaining a spiral substrate by punching or cutting out a single plate material,
Mounting a plurality of light emitting elements in a winding direction on the upper surface of the substrate;
A step of deforming the substrate into a bamboo spring shape by displacing the vicinity of the center of the vortex of the substrate upward.

  According to this method, since the original shape of the substrate can be obtained simply by punching out or cutting out a single plate material, the substrate can be mass-produced in a short time. At the stage of mounting the light emitting elements, the substrate is still flat, so that a plurality of light emitting elements can be easily and simultaneously mounted with an automatic machine.

  When the vortex is a square vortex, when removing a large number of substrates from a single plate material, a large number of vortices can be arranged close to each other in the plane direction of the plate material to reduce the loss (margin) of the substrate material. .

  In addition to the substrate and the light emitting element, the wide orientation lighting device preferably further includes a main body having an upper surface formed following the lower surface of the substrate and supporting the lower surface. By providing the main body in this way, it is possible to form the substrate with a thinner or softer material (I think "Gaga" may be used here. "There are no limitations on the substrate material, but this is the case when the main body is provided. In addition to the increased choice of substrate material, the heat dissipation can be improved by forming the main body with a material having a thermal conductivity equivalent to or higher than that of the substrate. Therefore, the main body usually has a solid cone shape. However, when the manufacturing cost is important, the main body may have a hollow cone shape and may be formed by drawing.

  The surface exposed from the substrate of the main body, for example, the side surface may have a reflectance of 50% or more with respect to the light emitted from the light emitting element. In addition, the upper surface and / or the lower surface of the substrate may have a reflectance of 50% or more with respect to light emitted from the light emitting element. This is because both increase the irradiation efficiency.

When punching out or cutting out the plate material, two spiral patterns complementary to each other in a plan view are formed, and a spiral substrate corresponding to the first pattern is punched or cut out along the first pattern. It is desirable to obtain a spiral substrate corresponding to the second pattern at the same time.
In this way, the loss of the substrate material can be further reduced. In addition, since the adjacent turns of the vortex on one substrate are opened, when the light emitting element is mounted and used as a lighting device, the light emitted from the light emitting element mounted on the outer turn is transmitted to the inner turn substrate. The rate of blocking can be reduced and the irradiation efficiency can be increased.

  Since the material selectivity and productivity are excellent, it is possible to obtain a wide orientation illuminating device with high irradiation efficiency and high production efficiency using a material having high reflectance or high thermal conductivity in place.

It is a perspective view which shows the wide orientation illuminating device which concerns on Embodiment 1. FIG. (A) is a top view of the said wide orientation illuminating device, (b) is also a front view, (c) is a bottom view. It is a top view which shows the initial stage process of the method of manufacturing the said wide orientation illuminating device. It is a top view which similarly shows an intermediate process. It is a perspective view which shows the wide orientation illuminating device which concerns on Embodiment 2. FIG. (A) is a top view of the said wide orientation illuminating device, (b) is also a front view, (c) is a bottom view. It is a longitudinal cross-sectional view of the said wide orientation illuminating device. It is a front view of the wide orientation illuminating device which concerns on Embodiment 3. FIG.

Embodiment 1
A wide orientation illumination device according to a first embodiment of the present invention will be described with reference to the drawings. 1 is a perspective view showing a wide orientation lighting device according to the embodiment, FIG. 2A is a plan view, FIG. 2B is a front view, and FIG. 2C is a bottom view.

  The wide orientation illumination device 1 includes a substrate 2 and a large number of light emitting elements 3, 3. The substrate 2 is obtained by punching a plate material made of a metal such as aluminum or copper whose surface is covered with a white insulating resin except for the wiring portion into a 4-turn square spiral shape, and the vicinity of the center of the vortex is plastic upward. It is deformed and formed into a bamboo shoot spring shape. A wiring pattern is formed on the upper surface of the substrate 2 by photolithography. The light-emitting elements 3 are light-emitting diodes, which are mounted on the upper surface of the substrate 2 at regular intervals in the winding direction except for the four corners, and are connected in series or in parallel via wiring on the substrate 2. Then, terminals (not shown) are provided at both ends 2a and 2b of the substrate 2 in the winding direction.

The wide orientation lighting device 1 is manufactured by the following method.
As shown in FIG. 3, an aluminum (or copper) plate 4 whose front and back surfaces are coated with a white insulating resin except for a portion where a light emitting element is mounted is prepared. Then, the plate material 4 is fixed to a mold corresponding to two spiral patterns p and q that are complementary to each other in plan view, and punched along the first pattern p, whereby the first pattern as shown in FIG. At the same time as obtaining the spiral substrate 2 corresponding to p, the spiral substrate 2 ′ corresponding to the second pattern q is obtained.

Next, the light emitting elements 3, 3,... Are mounted on the upper surface of the substrate 2 in the winding direction.
Finally, the substrate 2 is plastically deformed in the shape of a bamboo spring by displacing the vicinity of the center of the vortex of the substrate 2 upward. Thus, the wide orientation lighting device 1 is completed. For the wide orientation lighting device of another specification, the light emitting elements 3, 3,... 3 are similarly mounted on the substrate 2 ′, and then the substrate 2 ′ is deformed.

  According to this wide orientation illuminating device 1, since the plurality of light emitting elements 3, 3,... 3 are mounted side by side in the winding direction on the upper surface of the substrate 2 formed in the shape of a bamboo shoot spring, the axial front is the center. A wide range of angles can be irradiated. Further, since the upper surface of the substrate 2 is coated with a white insulating resin, light emitted from the light emitting element 3 can be reflected with a high efficiency of 50% or more, and the irradiation efficiency is excellent. Furthermore, since the back surface of the substrate 2 is also coated with a white insulating resin, light can be reflected also to the back surface in the axial direction, and further wide orientation can be realized.

  Furthermore, since another substrate 2 ′ is formed between the turns of the substrate 2 at the same time as the substrate 2 is formed, the loss of the plate material 4 can be reduced. Moreover, since the adjacent turns of the vortex in one substrate 2 (or substrate 2 ′) are open, when the light emitting device 3 is mounted and used as a lighting device, the light emitting device 3 mounted on the outer turn is used. The rate at which the light emitted from the light is blocked by the inner turn substrate is low, and the irradiation efficiency to the front in the axial direction is high.

Embodiment 2
A wide orientation illumination device according to a second embodiment of the present invention will be described with reference to the drawings. FIG. 5 is a perspective view showing the wide orientation lighting device according to the embodiment, FIG. 6A is a plan view, FIG. 6B is a front view, FIG. 6C is a bottom view, and FIG. It is.

  The wide orientation illuminating device 11 of this embodiment includes a large number of light-emitting elements 3, 3... 3 having the same shape and the same quality as those used in Embodiment 1, and a substrate 12 and a main body 5 having the same shape. However, the light emitting element 3 and the substrate 12 may be different from those used in the first embodiment. The substrate 12 is obtained by cutting out a plate made of glass epoxy resin having a thermal conductivity of 0.4 W / mK or more whose surface is white coated into a four-turn square spiral shape, and the vicinity of the center of the vortex is displaced upward. It is formed in the shape of a bamboo shoot spring. A metal wiring pattern is formed on the upper surface of the substrate 12 by photolithography. The light-emitting elements 3 are light-emitting diodes, which are mounted on the upper surface of the substrate 12 so as to be arranged at equal intervals in the winding direction except for the four corners, and are connected in series or in parallel via wiring on the substrate 12. Then, terminals (not shown) are provided at both ends 12a and 12b in the winding direction of the substrate 12.

  The main body 5 is made of a material having a thermal conductivity equal to or higher than that of the substrate 12 such as Al or SUS, and the upper surface is formed in a solid cone shape following the lower surface of the substrate 12. To support. The main body 5 is mirror-finished so that light can be reflected with high efficiency of 50% or more with respect to the light emitted from the light emitting element 3 except for the bottom surface and the surface covered with the substrate 12. The main body 5 is provided with one or several holes (not shown) penetrating in the axial direction, and a lead wire for connecting the terminal of the substrate 12 and the external terminal is passed therethrough.

The wide orientation lighting device 11 is manufactured by the following method.
A plate made of the glass epoxy resin or the like having a wiring pattern formed thereon and a white painted surface is prepared. Then, two spiral patterns p and q that complement each other in a plan view are drawn and cut out along the first pattern p, so that the spiral shape corresponding to the first pattern p is similar to that shown in FIG. At the same time, a spiral substrate 12 ′ corresponding to the second pattern q is obtained.

Separately, a main body 5 is prepared in which a metal such as Al or SUS is formed into a turban shape that is displaced upward as the surface approaches the center, and the entire surface except the bottom surface is mirror-finished.
Next, the light emitting elements 3, 3,... Are mounted on the upper surface of the substrate 12 in the winding direction.
Finally, the lower surface of the substrate 12 is pasted along the upper surface of the main body 5 to deform the substrate 2 into a bamboo spring shape. Thus, the wide orientation illumination device 11 is completed. For a wide orientation lighting device of another specification, the light emitting elements 3, 3,... 3 are similarly mounted on a substrate 12 ′ (not shown), and then the substrate 12 ′ is attached to another body.

  Also in this wide orientation illuminating device 11, since the plurality of light emitting elements 3, 3,... 3 are mounted side by side in the winding direction on the upper surface of the substrate 12 formed in the shape of a bamboo shoot spring, the axial front is the center. A wide angle range can be irradiated. In addition, it is possible to obtain a wider orientation by using the reflection from the main body as well as the substrate 12. And since the board | substrate 12 is supported by the main body 5 of high thermal conductivity, heat dissipation can be improved and the lifetime of the light emitting element 3 can be extended.

  The main body 5 may be made of resin. By using resin, it is not possible to expect heat dissipation as high as that made of metal, but it contributes to the weight reduction of the entire apparatus and can be easily processed to reduce the molding cost. Further, instead of mirror finishing, film formation, foil formation, white coating, or the like may be applied so that reflection can be performed with high efficiency. Although the reflectance as high as the mirror finish cannot be obtained, the choice of the material of the main body 5 increases and the manufacturing cost can be reduced. When the manufacturing cost is important, the main body 5 may be formed in a hollow cone shape.

Embodiment 3
A wide orientation lighting device according to a third embodiment of the present invention will be described with reference to the drawings. FIG. 8 is a front view showing the wide orientation illumination device according to the embodiment.

  The wide-orientation illumination device 21 of this embodiment includes a large number of light-emitting elements 3, 3... 3 that are the same shape and the same as those used in Embodiment 1, and a substrate 22. However, the light emitting element 3 may be different from the one used in the first embodiment. The substrate 22 is formed by cutting a polyester plate into a four-turn square spiral shape, and then hanging by attaching a lifting tool 6 near the center, so that the substrate 22 is elastically deformed so that the vicinity of the center of the vortex is displaced upward. It is formed in a shape. Instead of polyester, polyimide may be used. In any case, it is possible to increase the amount of displacement upward as compared with the glass epoxy resin in the second embodiment.

  A metal wiring pattern is formed on the upper surface of the substrate 22 by photolithography. Necessary electrical connections, such as power supply, are made through the hanger 6. Also in this wide orientation illuminating device 21, the plurality of light emitting elements 3, 3.. 3 are mounted side by side in the winding direction on the upper surface of the substrate 22 formed in the shape of a bamboo shoot spring, so that the axial front is the center. A wide angle range can be irradiated.

1,11,21 Wide orientation lighting device 2,12,22 Substrate 3 Light emitting element 4 Plate material 5 Main body

Claims (9)

A board obtained by punching or cutting a single plate material in a spiral shape, and displacing the vicinity of the center of the vortex upward to form a bamboo spring shape,
A wide orientation illuminating device comprising: a plurality of light emitting elements mounted side by side in a winding direction on an upper surface of the substrate.   The wide orientation lighting device according to claim 1, wherein the vortex is a square vortex.   Furthermore, the wide orientation illuminating device of Claim 1 or 2 provided with the main body which an upper surface is formed following the lower surface of the said board | substrate, and supports the said lower surface.   The wide-orientation lighting device according to claim 3, wherein the main body has a solid cone shape.   The wide orientation lighting device according to claim 3 or 4, wherein the main body is made of a material having a thermal conductivity equivalent to or higher than that of the substrate.   The wide orientation lighting device according to claim 3, wherein a surface exposed from the substrate of the main body has a reflectance of 50% or more with respect to light emitted from the light emitting element.   The wide orientation illumination device according to any one of claims 1 to 6, wherein an upper surface and / or a lower surface of the substrate has a reflectance of 50% or more with respect to light emitted from the light emitting element. A step of obtaining a spiral substrate by punching or cutting out a single plate material,
Mounting a plurality of light emitting elements in a winding direction on the upper surface of the substrate;
And a step of deforming the substrate in the shape of a bamboo shoot spring by displacing the vicinity of the center of the vortex of the substrate upward.   When punching out or cutting out the plate material, two spiral patterns complementary to each other in a plan view are formed, and a spiral substrate corresponding to the first pattern is punched or cut out along the first pattern. The method according to claim 8, wherein a spiral substrate corresponding to the second pattern is obtained simultaneously.

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