JP2019087440A - Luminaire and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lighting device suitable for an attachment target having a different radius of curvature of a planar shape and a curved surface shape, and a method for manufacturing the same. A lighting device (10) comprises a flexible base material (11), an LED element (2), and an elastic transparent resin member (3). The flexible base material 11 is composed of a relatively thick base material 11 and a flexible substrate 12. The LED element 2 is mounted on the flexible base material 1. An elastic transparent resin member 3 made of, for example, silicone rubber is provided on the flexible base material 1 and the LED element 2. The elastic transparent resin member 3 is composed of a strut portion 31 located on the flexible base material 1 and a convex lens portion 32 located on the light emitting element 2 by bridging the gap G between the strut portions 31. Since the support column 31 is fixed to the flexible base material 1, it has high rigidity. Since the convex lens portion 32 bridges the void G, the rigidity is low. [Selection diagram] Fig. 1

Description

  The present invention relates to a lighting device suitable for mounting objects having different curvature radii such as planar shape and curved shape, and a method of manufacturing the same.

  The conventional lighting device includes a main body to be attached, a flexible flexible substrate attached to the main body and having an opening, and a light emitting element provided so as to close the opening (see Patent: Patent Literature 1). Therefore, by matching the flexible substrate to the planar shape, curved surface shape, etc. of the main body, it is possible to realize a lighting device suitable for main bodies of various shapes.

  Another conventional illumination device includes a base, a light source provided on the base, a cover for closing the light source, and a lens assembly provided on the cover, and the light source and lens assembly are manually deformed by the cover. There is one that changes the distance to the Lee to change the diffused light, concentrated light, ie, the light distribution (illumination) area (see: Patent Document 2). However, even if the cover of this other conventional irradiation device is adopted, the irradiation range can not be automatically changed.

Unexamined-Japanese-Patent No. 2011-82095 (patent 5556116) Patent reissued patent WO 2012/099173 (patent 5542218)

  However, in the above-described conventional lighting device, even if the curvature radius of the shape of the main body, that is, the mounting object is different, the irradiation range in which each light emitting element emits light is constant. As a result, when the curvature radius of the curved surface shape is small, there is a problem that the irradiation area becomes relatively small and the non-irradiation area which is not irradiated becomes large.

  FIG. 7 is a diagram for explaining the problem of the conventional lighting device. In FIG. 7, reference numeral 101 denotes a flexible substrate, and reference numeral 102 denotes a light emitting diode (LED) element.

    As shown in FIG. 7A, when the mounting object (main body) 100 has a planar shape, the irradiation (light distribution) region R1 of each LED element 102 is within a certain range, for example, the spot light distribution approaching. And the non-irradiated area N1 which is not irradiated is small. That is, the non-irradiation area N1 decreases as the radius of curvature of the mounting object 100 increases.

  On the other hand, as shown in FIG. 7B, when the mounting object 100 'is ring-shaped, the light distribution also becomes a spot light distribution, and the irradiation range R1 of each LED element 102 is the same in the case of FIG. There is a spot light distribution that is not close. Therefore, the non-irradiated area N2 which is not irradiated becomes large. That is, the smaller the radius of curvature of the mounting object 100 ', the larger the non-irradiation area N2.

  In order to solve the problems described above, a lighting device according to the present invention includes a flexible base, a light emitting element mounted on the flexible base, and an elastic transparent resin member provided on the flexible base and the light emitting element. The elastic transparent resin member is provided with at least two support portions located on the flexible base, and a convex lens portion located on the light emitting element by bridging the air gap between the support portions.

  Further, in the method of manufacturing a lighting device according to the present invention, the step of mounting the light emitting element on the flexible substrate, and the light emitting element of the flexible substrate are attached to the elastic transparent resin member formed by the insert molding method. And a step of embedding the light emitting element in the elastic transparent resin member, wherein the elastic transparent resin member bridges the space between the at least two support portions positioned on the flexible substrate and the support portions, And a convex lens portion positioned.

  According to the present invention, as the radius of curvature of the mounting object decreases, the focal length of the convex lens portion of the elastic transparent material member increases. Therefore, the increase in the non-irradiation area can be automatically reduced even if the curvature radius of the mounting object is reduced.

The 1st Embodiment of the illuminating device which concerns on this invention is shown, (A) is a perspective view, (B) is a longitudinal cross-sectional view of (A). It is a figure for demonstrating the case where the illuminating device of FIG. 1 is attached to curved-surface-shaped attachment object. It is a figure for demonstrating the irradiation range of the illuminating device of FIG. 1, (A) shows the case where it attaches to plane shape attachment object, (B) shows the case where it attaches to curved surface shape attachment object. It is a top view of the flexible substrate for demonstrating the manufacturing method of the illuminating device of FIG. It is a figure for demonstrating the effect of the illuminating device of FIG. 1, (A) shows the case where it attaches to plane shape attachment object, (B) shows the case where it attaches to ring shape attachment object. The 2nd Embodiment of the illuminating device which concerns on this invention is shown, (A) is a perspective view, (B) is a longitudinal cross-sectional view of (A). It is a figure for demonstrating the subject of the conventional illuminating device, (A) shows the case where it attaches to plane shape attachment object, (B) shows the case where it attaches to ring shape attachment object.

  FIG. 1 shows a first embodiment of a lighting device according to the present invention, in which (A) is a perspective view and (B) is a longitudinal sectional view of (A).

  In FIG. 1, the lighting device 10 is composed of a flexible base 1, a light emitting element such as an LED element 2 and an elastic transparent resin member 3. The flexible substrate 1 is composed of a relatively thick base material 11 made of, for example, 2 mm propylene and a flexible substrate 12 made of relatively thin, for example 1 mm polyimide. In addition, the LED element 2 is mounted on the flexible base 1. Furthermore, on the flexible base 1 and the LED element 2, an elastic transparent resin member 3 made of elastic, for example, silicone rubber is provided. An air gap G is provided between the LED element 2 and the elastic transparent resin member 3.

  The height of the elastic transparent resin member 3 is, for example, about 10 mm. The elastic transparent resin member 3 is composed of a column 31 positioned on the flexible base 1 and a convex lens 32 positioned on the light emitting element 2 to bridge the gap G between the columns 31. The upper surface of the convex lens portion 32 is convex, and the lower surface of the convex lens portion 32 is flat, but both the upper surface and the lower surface may be convex. In this case, since the support portion 31 is fixed to the flexible base 1, the rigidity is large. On the other hand, since the convex lens portion 32 bridges the air gap G, its rigidity is small.

  FIG. 2 is a view for explaining the case where the illumination device 10 of FIG. 1 is attached to a curved attachment target.

  As shown in FIG. 2, when the lighting device 10 of FIG. 1 is attached to a curved mounting object 100 ′, the lighting device 10 is curved along the curved shape of the mounting target 100 ′. At this time, although the elastic transparent resin member 3 expands due to the difference between the inner ring and the outer ring, the column portion 31 with high rigidity hardly expands, and only the convex lens unit 32 with small rigidity expands as shown by the arrow. As a result, the focal length of the convex lens portion 32 is increased. Accordingly, as shown in FIG. 3B, the curved shape attached object 100 is larger than the irradiation region R1 of the flat shape attachment object 100 shown in FIG. 3A as the focal length of the convex lens portion 32 is increased. The irradiation area R2 of 'is increased.

  The manufacturing method of the illuminating device 10 of FIG. 1 is demonstrated using FIG.

  First, as shown in FIG. 4A, the flexible substrate 12 is formed in advance with a silicone rubber penetration fixing hole 12 a for silicone rubber of the elastic transparent resin member 3. Also, a wiring pattern (not shown) is formed on the flexible substrate 12. Next, the flexible substrate 12 is attached to the base 11 by an adhesive or the like.

  Next, as shown in FIG. 4B, the LED element 2 is mounted on the flexible substrate 12 with an adhesive or the like, and at that time, the bump electrode of the LED element 2 and the wiring pattern are connected.

  Finally, the flexible substrate 1 is bonded into the elastic transparent resin member 3 molded by the insert molding method using silicone rubber or the like, and at this time, the LED element 2 is pressed. At this time, the elastic transparent resin member 3 such as silicone rubber penetrates into the silicone rubber penetration fixing hole 12a. Thereby, the lighting device 10 of FIG. 1 is completed.

  FIG. 5 is a figure for demonstrating the effect of the illuminating device of FIG. 1, (A) shows the case of plane shape attachment object, (B) shows the case of ring shape attachment object.

  As shown in FIG. 5A, when the mounting object 100 has a planar shape, as in FIG. 7A, the irradiation area R1 of each LED element 2 is in a certain range, for example, a spot that is in proximity It becomes a light distribution, and non-irradiation area | region N1 is small.

  On the other hand, as shown in FIG. 5B, when the mounting object 100 'has a ring shape, the focal length of the lens portion 32 of the elastic transparent resin member 3 becomes large, so the non-irradiated area N2 not irradiated becomes small. For example, in FIG. 5B, a wide light distribution in which no non-irradiation area exists is obtained. Thus, the non-irradiated area is small even if the radius of curvature of the mounting object is reduced.

  FIG. 6 shows a second embodiment of the lighting apparatus according to the present invention, in which (A) is a perspective view and (B) is a longitudinal sectional view of (A).

  In the lighting device 10 'of FIG. 6, an elastic transparent resin member 1' of about 2.5 mm in thickness made of silicone rubber or the like is used instead of the flexible base 1 for the components of the lighting device 10 of FIG. The wiring board 4 and the wiring 5 connected to the wiring board 4 are added for mounting of the LED element 2 while being provided. Further, the elastic transparent resin member 3 is provided with a groove 33 for the wiring 5. As described above, FIG. 6 is different in that the wiring substrate 4 is provided instead of the flexible substrate 12 provided with the wiring pattern of FIG.

  A method of manufacturing the lighting device 10 'of FIG. 6 will be described.

  First, the elastic transparent resin members 1 'and 3 are formed by insert molding using silicone rubber or the like.

  Next, the wiring substrate 4 is attached to the elastic transparent resin member 1 ′ with an adhesive or the like, and the LED element 2 is mounted on the wiring substrate 4 with the adhesive or the like. At that time, the bump electrode of the LED element 2 and the wiring on the wiring substrate 4 are connected.

  Next, the wiring 5 is provided on the elastic transparent resin member 1 ′ and connected to the wiring pattern on the wiring substrate 4.

  Finally, the elastic transparent resin member 1 'is attached to the elastic transparent resin member 3 with an adhesive or the like. At this time, the LED element 2 and the wiring board 4 are pushed into the gap G of the elastic transparent resin member 3 and the wiring 5 is accommodated in the groove 33 of the elastic transparent resin member 3. Thus, the lighting device 10 'of FIG. 6 is completed.

  In the above embodiment, the number of LED elements 2 is two, but may be one or three or more. The LED element 2 may be another light emitting element such as a laser diode (LD) element.

  Furthermore, the present invention can be applied to any modifications of the obvious scope of the above-described embodiment.

  The present invention can be used as a line-shaped lighting device wound around a human head.

10, 10 ': Lighting device 1: Flexible base 1': Elastic transparent resin member 11: Base material 12: Flexible substrate 2: LED element 3: Elastic transparent resin member 31: Support portion 32: Convex lens portion 33: Groove 4: Wiring substrate 5: Wiring G: Air gap R1, R2: Irradiation (light distribution) region N1, N2: Non-irradiation region

Claims (5)

Flexible substrate,
A light emitting element mounted on the flexible substrate;
The flexible base material and an elastic transparent resin member provided on the light emitting element;
The elastic transparent resin member is
At least two struts located on the flexible substrate;
An illumination device comprising: a convex lens portion which is located on the light emitting element by bridging an air gap between the support portions. The flexible substrate is
A base material,
The lighting device according to claim 1, further comprising: a flexible substrate attached to the base substrate and having the light emitting element mounted thereon. The flexible substrate comprises another elastic transparent resin member,
Furthermore, a wiring board provided on the other elastic transparent resin member for mounting the light emitting element is provided.
The lighting device according to claim 1, wherein a groove for wiring to the wiring substrate is provided in the elastic transparent resin member. A process for mounting the light emitting device on a flexible substrate;
And affixing the light emitting element of the flexible substrate to an elastic transparent resin member molded by an insert molding method, and embedding the light emitting element in the elastic transparent resin member.
The elastic transparent resin member is
At least two struts located on the flexible substrate;
A method of manufacturing an illumination device, comprising: a convex lens portion that is located on the light emitting element by bridging the air gap between the support portions. A process for forming a first elastic transparent resin member having voids and grooves by an insert molding method;
Forming a second elastic transparent resin member by an insert molding method;
A process for attaching a wiring board having a light emitting element mounted on the first elastic transparent resin member;
A process for providing wiring to the wiring substrate;
Attaching the first elastic transparent resin member to the second elastic transparent resin member and inserting the wire into the groove;
The first elastic transparent resin member is
At least two struts located on the flexible substrate;
A method of manufacturing an illumination device, comprising: a convex lens portion that is located on the light emitting element by bridging the air gap between the support portions.

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