WO2012038997A1 - Light source lighting device and manufacturing method therefor - Google Patents

Abstract

A base plate (60) is applied to a plate-shaped member (10a) which is in a laid-out state, and components are mounted to construct a lighting circuit part (50), after which the areas that will form the side surfaces (12)-(15) are folded to form a housing (10).

Description

Light source lighting device and manufacturing method thereof

The present invention relates to a light source lighting device in which a light emitting diode or a discharge lamp and a casing that houses a lighting circuit are integrated, and a method for manufacturing the light source lighting device.

For light sources for general lighting and in-vehicle use, instead of conventional tungsten light bulbs, fluorescent lamps that light up brightly with low power, discharge lamps such as HID (High Intensity Discharge) bulbs, and long-life, maintenance-free LEDs (Light Emitting Diode) has become widespread. In order to light the discharge lamp and the LED, it is necessary to convert the input power supply voltage to an appropriate voltage and apply a voltage suitable for each light source, and a lighting device adapted to each is necessary.

In order to make the lighting device and the light source easy to handle and to reduce the size, for example, in Patent Document 1, the light source and the lighting device are integrally formed and can be attached to and detached from the lamp like a conventional light bulb (tungsten light bulb). A light source with a lighting device that is small and easy to handle has been proposed. Patent Document 2 proposes an idea for reducing the size of a lighting device, and Patent Document 3 proposes an idea for reducing the size of an electronic device using a flexible substrate, although there is no description relating to a light source. In addition, there exists an example of patent document 4 as a lighting device for vehicle-mounted headlamps.

The light bulb-type fluorescent lamp device according to Patent Document 1 includes a fluorescent lamp as a main light source, an LED as an auxiliary light source, and a lighting circuit that lights both light sources, and monitors the state of an input power source, Either one of the fluorescent lamp and the LED is turned on according to the stop timing. A lighting circuit board for LED is erected on a lighting circuit board for fluorescent lamps, two lighting circuits are integrated, and both light sources are integrated into the lighting circuit.

The electronic ballast for a discharge lamp according to Patent Document 2 is for fixing a lighting circuit for a fluorescent lamp to the inside of a metal case. Since it is not necessary to fix the lighting circuit board in a state of floating from the metal case using a spacer or the like, the metal case can be reduced in size by eliminating the fixing space. Although there is no description about the manufacturing method of this metal case, the lighting circuit is inserted and fixed to the metal case already formed in the box shape.

In the electronic circuit device according to Patent Document 3, an aluminum plate is attached to one side of a flexible substrate, and an electronic component that generates heat is mounted on the other side to improve heat dissipation. A portion of the flexible substrate without the aluminum plate is bent to form an electronic circuit and accommodated in a housing.

The discharge lamp lighting device according to Patent Document 4 is a lighting device for lighting a discharge lamp for an on-vehicle headlamp, and separates the discharge lamp from a lighting circuit and uses a waterproof structure for each. The headlamp case that houses the discharge lamp is fitted with a housing that houses the lighting circuit. Even if condensation or water vapor in the headlamp case penetrates into the housing of the lighting circuit, the lamp is installed on the ceiling side of the housing. It is a configuration that does not corrode the circuit.

JP 2007-311317 A Japanese Patent Laid-Open No. 3-55608 (FIG. 4) JP-A-64-787 Japanese Patent Laying-Open No. 2006-16951 (FIG. 1)

As in Patent Document 4, a conventional in-vehicle headlamp is configured by separating a light source and a lighting circuit, and the light source is installed in a waterproof headlamp case, and the lighting circuit is mounted on the bottom surface of the headlamp case. It was. For this reason, the casing for the lighting circuit also needs a waterproof structure, which hinders downsizing and makes the structure complicated.

In addition, the light source for general illumination and the lighting circuit are configured integrally as in Patent Document 1, and the lighting circuit board is attached to the housing as a measure for downsizing and improving heat dissipation as in Patent Document 2. Or, as in Patent Document 3, the use of a flexible substrate as a lighting circuit substrate has been conventionally performed. However, when manufacturing a light source lighting device that is integrally provided with a housing containing a lighting circuit and a light source and is detachable from the lamp, the lighting circuit board is attached to the unfolded plate member, There is no description of the structure which mounts and bends and forms a housing | casing.

The present invention has been made to solve the above-described problems. The housing for housing the lighting circuit unit and the light source are integrally formed, and the light source lighting device is disposed at a light source position where the light source lighting device is not flooded. By using a non-waterproof housing that is formed by simple bending, the waterproofness of the housing, which was necessary to separate the light source from the conventional light source and attach it to the headlamp case, is eliminated. An object of the present invention is to provide a device and a method for manufacturing a light source lighting device.

A light source lighting device according to the present invention is formed by bending a substrate on which components constituting a lighting circuit unit are mounted and a developed plate-like member to which the substrate is attached, and housing the lighting circuit unit therein. A part of the body, and the housing and the light source are integrally provided so as to be detachable from the lamp.

The method of manufacturing the light source lighting device according to the present invention includes a substrate pasting step of pasting a substrate on a plate member in an unfolded state that forms a housing or a part of the housing by bending, and a paste on the plate member. A component mounting step for mounting components constituting the lighting circuit portion on the substrate and a case processing step for bending the plate-like member to form a case or a part of the case are provided.

According to this invention, since the light source lighting device can be disposed at a light source position that is not flooded by integrally configuring the light source and the lighting circuit portion, the waterproof property of the housing that houses the lighting circuit portion can be eliminated. . Therefore, it is possible to provide a light source lighting device using a non-waterproof casing formed by simple bending. Moreover, the light source lighting device can be configured at low cost by using a non-waterproof casing formed by bending. In addition, since the components can be easily arranged on the inner wall surface side of the casing, the light source lighting device can be miniaturized by effectively using the space in the casing. Furthermore, since the substrate is affixed to the wall surface of the housing, the heat generated by the electronic component can be effectively radiated using the wall surface as a heat radiating surface, and the heat stress of the electronic component can be reduced and the light source lighting device can be trusted. Can be improved.

Further, according to the present invention, it is possible to provide a method for manufacturing a light source lighting device that can be easily formed by bending a non-waterproof casing.

It is a top view which shows the unfolded state before the housing | casing bending of the light source lighting device which concerns on Embodiment 1 of this invention. It is an external appearance perspective view which shows the structure of the light source lighting device which concerns on Embodiment 1, and is the state after housing | casing bending. It is sectional drawing which cut | disconnected the light source lighting device which concerns on Embodiment 1 along the AA line shown in FIG. 3 is a block diagram illustrating a configuration of a lighting circuit unit that lights a light-emitting diode as a light source according to Embodiment 1. FIG. The modification of the light source lighting device which concerns on Embodiment 1 is shown, Fig.5 (a) is the unfolded state before a housing | casing bending, FIG.5 (b) is the state after a housing | casing bending. It is a side view which shows the structure inside a vehicle-mounted headlamp case to which the light source lighting device which concerns on Embodiment 1 is applied. It is a top view which shows the expansion | deployment state before the housing | casing bending of the light source lighting device which concerns on Embodiment 2 of this invention. It is an external appearance perspective view which shows the structure of the light source lighting device which concerns on Embodiment 2, and is the state after housing | casing bending. It is sectional drawing which cut | disconnected the light source lighting device which concerns on Embodiment 2 along the BB line shown in FIG. It is sectional drawing which cut | disconnected the light source lighting device which concerns on Embodiment 2 along CC line shown in FIG. It is a disassembled perspective view which shows the structure of the light source lighting device which concerns on Embodiment 2, and is the state in the middle of case bending. It is a block diagram which shows the structure of the lighting circuit part which starts the discharge lamp as a light source which concerns on Embodiment 2, and a starting circuit part. It is an enlarged view of the bending part of the light source lighting device which concerns on Embodiment 2. FIG.

Hereinafter, in order to explain the present invention in more detail, modes for carrying out the present invention will be described with reference to the accompanying drawings.
Embodiment 1 FIG.
In the first embodiment, a configuration example of a light source lighting device using a light emitting diode as a light source will be described. FIG. 1 is a plan view showing an unfolded state of the light source lighting device 1 before the case is bent. FIG. 2 shows an external perspective view of the state after the bending, and FIG. 3 shows a cross-sectional view cut along the line AA. . As shown in FIGS. 2 and 3, the light source lighting device 1 includes a housing 10 that houses the lighting circuit unit 50, a fixing member 20 that serves as a lid, a light emitting diode 30 of the light source, and heat generated by the light emitting diode 30. And a heat transfer member 40 to be transmitted to the outside. The lighting circuit unit 50 includes components such as a connector 51, a switching FET (Field Effect Transistor) 53, and a transformer 54, and each component is mounted on a substrate 60. The substrate 60 is fixed to the bottom surface 11 of the housing 10 with an insulating member 61 interposed therebetween. In the illustrated example, four light emitting diodes 30 are arranged, but the number may be arbitrary.

FIG. 4 is a block diagram illustrating a configuration of the lighting circuit unit 50 that lights the light emitting diode 30. The connector 51 corresponds to the connector 51 shown in FIGS. 1 and 3, and receives power from an external power source such as a battery. The DC / DC converter unit 52 includes a switching FET 53 and a transformer (or coil) 54, and further a rectifier diode (not shown) and the like, and suppresses a current that increases or decreases the power supply voltage to the lighting voltage of the light emitting diode 30 or energizes. To do. The voltage detector 55 detects a voltage applied to the light emitting diode 30. The current detection unit 56 detects a current that is passed through the light emitting diode 30. The control unit 57 is configured by a microcomputer or the like, and controls the DC / DC converter unit 52 so that the detection current of the current detection unit 56 becomes constant, or stops operation when the detection voltage of the voltage detection unit 55 is abnormal. Or control.

A connector 51, a DC / DC converter unit 52, a voltage detection unit 55, a current detection unit 56, and a control unit 57 constituting the lighting circuit unit 50 are mounted on the substrate 60, but the connector 51 is representative in FIGS. 1 and 3. Only the switching FET 53 and the transformer 54 are shown.

Next, a procedure for creating the light source lighting device 1 will be described.
The housing 10 shown in FIG. 1 is a metallic plate-like member 10a in an unfolded state before being bent. The material and thickness of the plate member 10a may be determined in consideration of the rigidity, heat resistance, heat dissipation, and noise shielding properties required for the housing 10. In the first embodiment, an aluminum plate is used.
The plate-like member 10a is composed of a total of five regions, a region that becomes the bottom surface 11 and regions that become the four side surfaces 12 to 15 when bent, and no region that becomes the top surface is provided. A connector through hole 71 is opened in a portion facing the connector 51 when the plate-like member 10a is bent. Further, a wiring through hole 72 through which a conducting wire for electrically connecting the light emitting diode 30 and the lighting circuit unit 50 is opened in the region that becomes the bottom surface 11.

The bottom surface 11 has high rigidity because the four side surfaces 12 to 15 extend in all directions. Therefore, in the first embodiment, the lighting circuit unit 50 (particularly the connector 51) is fixed to the bottom surface 11. Since a metal plate is used for the plate-like member 10 a, an insulating member 61 is provided in a region that becomes the bottom surface 11 so that the circuit pattern of the substrate 60 is not short-circuited, and the plate-like substrate 60 is placed on the insulating member 61. paste. As the insulating member 61, an insulating adhesive or an insulating sheet is used. The lighting circuit unit 50 is configured by mounting electronic components such as the connector 51, the switching FET 53, and the transformer 54 on the substrate 60.

Subsequently, a heat transfer member 40 made of aluminum, copper, or the like is installed on the back surface of the region that becomes the bottom surface 11, and the light emitting diode 30 is fixed thereon. A conductive wire connecting the light emitting diode 30 and the lighting circuit unit 50 passes through the wiring through hole 72. Since the plate member 10a is a metal plate, the light emitting diode 30 can be directly installed on the bottom surface 11 and the plate member 10a can be used as a heat sink. However, a separate heat sink (heat radiating member) is prepared outside. If the heat transfer member 40 is brought into contact, the heat generated by the light emitting diode 30 can be transferred to the external heat sink via the heat transfer member 40 and suitably radiated.

In order to further improve the heat dissipation of the housing 10, the outer wall surface of the housing 10 may be recessed to form a large number of irregularities such as dimples. The unevenness generates a turbulent flow around the casing 10 and promotes heat radiation from the casing 10 to the outside air.

After mounting the electronic components, the casing 10 is formed by bending each boundary portion between the region that becomes the bottom surface 11 and the region that becomes the four side surfaces 12 to 15 of the plate-like member 10a. The bending process may be performed by pressing the bent portion of the plate-like member 10a from the surface to which the substrate 60 is attached with a rod-shaped jig and bending the side surfaces 12 to 15 from the back side.

Depending on the installation location of the light source lighting device 1, waterproofing may not be necessary. In that case, a hole such as a round hole 73 and a slit 74 is opened in the bent portion of the plate-like member 10 a to make it easy to bend. Also good. By providing the round hole 73 and the slit 74, the heat dissipation of the housing 10 is improved. The hole may have any shape, and the number and position of the holes may be arbitrary. However, the size is such that no foreign matter enters the inside of the housing 10. Moreover, although the structure which provided both the round hole 73 and the slit 74 in FIG. 1 is illustrated, you may make it all the round hole 73, or you may make it all the slit 74 on the contrary. 2 and 3, the round hole 73 and the slit 74 are not shown.

The casing 10 in a state where the regions to be the four side surfaces 12 to 15 of the plate-like member 10a are folded may be completed. However, since the four side surfaces 12 to 15 may be opened outward by the springback only by bending, Here, a lid-like fixing member 20 is fitted and fixed to the open end of the housing 10. The fixing member 20 is also made of the same aluminum as the housing 10. Further, the fixing member 20 may be merely fitted to the housing 10, or the fixing member 20 may be provided with one uneven shape and the housing 10 may be provided with the other uneven shape to be engaged with each other. If the fixing member 20 closes the open side of the housing 10, foreign matter does not enter the housing 10 and the internal components can be protected.

The fixing member 20 may have a shape other than the lid. 5A and 5B are diagrams for explaining another example of the structure of the fixing member. FIG. 5A shows the plate-like member 10a in an unfolded state before being bent, and FIG. 5B shows the casing 10 after being bent. In this example, regions corresponding to the top surfaces 16a and 16b of the housing 10 are provided in the plate-like member 10a to form the concave and convex shapes 17 and 18 that engage with each other. The top surfaces 16a and 16b and the concavo-convex shapes 17 and 18 correspond to fixing members, and when the plate-like member 10a is bent, the concavo-convex shapes 17 and 18 are engaged with each other to make it difficult to open the open end of the casing 10. . In FIG. 5, four sets of uneven shapes 17 and 18 are provided, but the number of sets may be arbitrary.

By the above procedure, the light source lighting device 1 employing the simple housing 10 that can be formed by bending work can be realized. Since this light source lighting device 1 can eliminate the space for fixing the substrate 60 (the space necessary for screw or claw placement) and can effectively use the internal space of the housing 10 to mount electronic components. , Miniaturization becomes possible. Further, since the heat generated by the electronic component can be transmitted to the housing 10 via the substrate 60, the heat radiation effect can be enhanced to reduce the thermal stress of the electronic component, and the reliability as the light source lighting device is improved. be able to.

The light source lighting device 1 may be used for general lighting or for an in-vehicle headlamp. Hereinafter, an example in the case of using the light source lighting device 1 for an in-vehicle headlamp will be described.

FIG. 6 is a side view showing an internal configuration of an in-vehicle headlamp case, and the heat sink 100 represents a cross-sectional structure. Inside the headlamp case (not shown), a heat sink 100 also serving as a lamp is arranged. Inside the heat sink 100, a substantially conical space is provided and a reflecting mirror 101 is formed. A projection convex lens 103 is fixed to the bottom surface of the cone, and a light source installation portion 102 for installing a light emitting diode 30 serving as a light source is formed on the apex side of the cone. The configuration of the lamp is not limited to the illustrated example. For example, the mirror surface of the reflecting mirror 101 may be curved by making the substantially conical space hemispherical.

When the light source lighting device 1 is attached to the heat sink 100 that also serves as a lamp, the light emitting diode 30 and the heat transfer member 40 are inserted into the light source installation unit 102 so that the seating surface 41 contacts the back side of the light source installation unit 102. Then, the light emitting diode 30 can be fixed at a predetermined position of the reflecting mirror 101. A power connector 104 for connecting to an external power source is inserted into the connector 51 of the lighting circuit unit 50. Thus, the light source lighting device 1 can be easily attached to and detached from the lamp.

The normal headlamp case has a waterproof structure to prevent the light source from getting wet. Therefore, the light source lighting device 1 configured integrally with the light emitting diode 30 as the light source is also installed inside the headlamp case, and there is no fear of getting wet. Accordingly, the light source lighting device 1 does not require a waterproof structure, and it is possible to employ a simple bent housing 10 in which a gap exists at the joint portion between the four side surfaces 12 to 15.

In addition, the light source for in-vehicle headlamps (in this case, the light emitting diode 30) has a feature that it emits a large amount of light per unit area. Since the lighting circuit unit 50 also generates a large amount of heat and the temperature rises, it is necessary to efficiently dissipate heat. In this Embodiment 1, since the heat-transfer member 40 is contact | abutted to the heat sink 100 as shown in FIG. 6, the temperature of the light emitting diode 30 can be lowered | hung and degradation can be suppressed. Further, as described above, the heat dissipation of the housing 10 can be improved by providing the housing 10 with holes such as the round holes 73 and slits 74 or providing irregularities such as a large number of dimples.

As described above, the light source lighting device 1 according to Embodiment 1 is formed by bending the substrate 60 on which components constituting the lighting circuit unit 50 are mounted and the unfolded plate member 10a to which the substrate 60 is attached. The housing 10 that houses the circuit unit 50 and the light emitting diode 30 that is provided integrally with the housing 10 that houses the lighting circuit unit 50 are provided. As a result, the light source lighting device 1 can be installed in a waterproof headlamp case, and the housing 10 does not need to have a waterproof structure. The light source lighting device 1 for lighting the diode 30 can be realized at low cost. In addition, the space for fixing the substrate 60 can be eliminated, components can be mounted using the internal space of the housing 10 effectively, and the compact light source lighting device 1 can be realized. Furthermore, by sticking the substrate 60 to the inner wall surface of the housing 10, the wall surface can be used as a heat radiating surface to enhance the heat radiating effect, thereby reducing the stress due to heat applied to the electronic component, and the light source lighting device 1. Reliability can be improved.

Further, according to the first embodiment, the plate-like member 10 a is a metal member, and the light source lighting device 1 is configured to include the insulating member 61 that insulates the plate-like member 10 a and the substrate 60. For this reason, the lighting circuit portion 50 is not short-circuited while using the metal housing 10 having rigidity, heat resistance, heat dissipation, and noise shielding properties.

Moreover, according to Embodiment 1, since it comprised so that at least one of the round hole 73 and the slit 74 might be provided in the bending part of the plate-shaped member 10a, it becomes easy to bend the plate-shaped member 10a, and with simple jigs Can be bent easily.

Further, according to the first embodiment, the light source lighting device 1 is configured to include the fixing member 20 that fixes the casing 10 formed by bending the plate-like member 10a, so that the four side surfaces 12 to 15 are outward. Therefore, it is easy to handle and the housing 10 with stable dimensions can be configured.
Further, since the fixing member 20 is used as a lid of the housing 10, the fixing member 20 constitutes a part of the outer wall of the housing 10, and the housing 10 with less unevenness can be realized. Further, it is possible to prevent foreign matters from entering the housing 10 and protect internal components.

Further, according to the first embodiment, since the surface of the plate member 10a is provided with irregularities such as dimples, the heat dissipation effect of the housing 10 can be enhanced.

In addition, according to the first embodiment, the light source lighting device 1 is configured to include the heat transfer member 40 that absorbs the heat generated by the light emitting diode 30 and transmits the heat to the external heat radiating member. Heat can be suitably dissipated.

Moreover, according to the manufacturing method of the light source lighting device 1 according to the first embodiment, the substrate pasting step of pasting the substrate 60 on the unfolded plate member 10a that forms the housing 10 by bending, and the plate member 10a. The board 60 affixed to is configured to include a component mounting process for mounting components constituting the lighting circuit unit 50 and a casing processing process for forming the casing 10 by bending the plate member 10a. As described above, since a non-waterproof casing can be used as the casing 10 of the light source lighting device 1, a method of manufacturing a light source lighting device that can be easily formed by bending the casing 10 can be provided.

In the first embodiment, the configuration is such that one substrate 60 is attached to the region to be the bottom surface 11. However, the present invention is not limited to this, and the substrate 60 may be attached to a region other than the bottom surface 11. . Moreover, although the plate-shaped board | substrate was used as the board | substrate 60, it is not limited to this, For example, you may use a flexible substrate.

Embodiment 2. FIG.
In the second embodiment, a configuration example of a light source lighting device using a discharge lamp (for example, an HID bulb) as a light source will be described. FIG. 7 is a plan view showing an unfolded state of the light source lighting device 2 according to the second embodiment before the housing is bent. FIG. 8 is an external perspective view of the state after the bending, and is cut along the line BB. 9 is a sectional view taken along the line CC, and FIG. 10 is a sectional view taken along the line CC. The state during the bending is shown in FIG. In FIG. 9, the internal structure of the starting circuit unit 90 is not shown. 7 to 11, the same or corresponding parts as those in FIGS. 1 to 6 are denoted by the same reference numerals, and the description thereof is omitted.

8 to 11, the light source lighting device 2 includes a casing 10 that houses the lighting circuit unit 50 and the starting circuit unit 90, a fixing member 20 that serves as a lid, and a discharge lamp 80 of the light source. The lighting circuit unit 50 includes components such as a connector 51, a switching FET 53, a transformer 54, and an H bridge 59, and each component is mounted on a flexible substrate 62 having flexibility. The flexible substrate 62 is affixed across a plurality of inner wall surfaces of the housing 10.

FIG. 12 is a block diagram showing the configuration of the lighting circuit unit 50 and the starting circuit unit 90 that light the discharge lamp 80. The connector 51 inputs power from an external power source such as a battery. The DC / DC converter unit 52 includes a switching FET 53, a transformer (or coil) 54, a rectifier diode (not shown), and the like, and boosts the power supply voltage to the lighting voltage of the discharge lamp 80. The voltage detector 55 detects the voltage applied to the discharge lamp 80. The current detection unit 56 detects the current that is supplied to the discharge lamp 80. The inverter unit 58 includes an H bridge 59, and converts the DC voltage output from the DC / DC converter unit 52 into AC. The control unit 57 is configured by a microcomputer or the like, and controls the DC / DC converter unit 52 and the inverter unit 58 so that the detection current of the current detection unit 56 becomes constant, or the detection voltage of the voltage detection unit 55 is abnormal. Sometimes stop operation. The starting circuit unit 90 generates a high voltage pulse and applies it to the discharge lamp 80 to start it.

The connector 51, the DC / DC converter unit 52, the voltage detection unit 55, the current detection unit 56, the inverter unit 58, and the control unit 57 that constitute the lighting circuit unit 50 are mounted on the flexible substrate 62. FIG. In FIG. 11, only the connector 51, the switching FET 53, the transformer 54, and the H bridge 59 are shown as representatives.

The starting circuit unit 90 is accommodated in a rectangular parallelepiped case, and a part of the case protrudes to the outside through the housing 10, and is seated on a lamp to be described later and the light source lighting device 2. , A projecting portion 92, 92 for fixing the starter circuit unit 90 to the housing 10, a high voltage terminal 93 for applying a high voltage pulse to the discharge lamp 80, and the application portion And an insulating member 94 for covering.

Next, a procedure for creating the light source lighting device 2 will be described.
A housing 10 shown in FIG. 7 is a plate-like member 10a in an unfolded state before being bent, and an aluminum plate is also used in the second embodiment. The plate-like member 10a is composed of a total of six regions, a region that becomes the bottom surface 11 when bent, a region that becomes the four side surfaces 12 to 15, and a region that becomes the partial top surface 16 that partially covers the top surface. Concave and convex shapes 19 a and 19 b that are engaged with each other are formed in the region that becomes the partial top surface 16 and the region that becomes the side surface 15. In the illustrated example, the convex shape 19 a is formed in the region that becomes the partial top surface 16, and the concave shape 19 b is formed in the region that becomes the side surface 15, but conversely, the concave shape 19 b is formed in the region that becomes the partial top surface 16 and the side surface 15. You may form the convex shape 19a in the area | region which becomes.

Further, a connector through hole 71 is opened in a portion facing the connector 51 when the plate-like member 10a is bent. In addition, a circuit through hole 75 is formed in the region to be the bottom surface 11 for penetrating the seat surface 91 of the starting circuit unit 90 and projecting it to the outside. Further, fixing holes 76 and 76 for engaging with the fixing convex portions 92 and 92 of the starting circuit unit 90 are formed.

The flexible substrate 62 is pasted over the region that becomes the side surface 15, the bottom surface 11, the side surface 13, and the partial top surface 16 of the plate-like member 10 a. It is assumed that the affixing surface of the flexible substrate 62 has already been insulated.
Then, the lighting circuit unit 50 is configured by mounting electronic components that generate heat such as the switching FET 53, the transformer 54, and the H bridge 59 on the flexible substrate 62. The position and arrangement order for mounting the electronic components may be arbitrary. In the second embodiment, the connector 51 and the DC / DC converter unit 52 are configured in order from the end of the flexible substrate 62 in accordance with the circuit configuration shown in FIG. The FET 53, the transformer 54, and the H bridge 59 constituting the inverter unit 58 are arranged to facilitate wiring.

After mounting the electronic component, each boundary portion between the region that becomes the bottom surface 11 of the plate-like member 10a and the region that becomes the four side surfaces 12 to 15 is bent together with the flexible substrate 62, and the region that becomes the side surface 13 and the partial top surface 16 become. Both the boundary with the region and the flexible substrate 62 are bent, and the concavo-convex shapes 19 a and 19 b are engaged with each other to form the housing 10. Since it is sufficient for the substrate to be flexible at least at the portion to be bent, a continuous flexible substrate 62 may be attached as in the illustrated example, or the side surface 15, the bottom surface 11, the side surface 13, and the partial top surface 16. Alternatively, a plate-like substrate may be attached to each of the regions to be connected, and the space between them may be connected with a flexible conductive wire or the like.

Since a power connector for connecting to an external power supply is inserted into and removed from the connector 51, stress is applied during insertion and removal. In the first embodiment, since the substrate 60 is a plate member, the plate-like member 10a is strengthened by the overlap of the substrate 60, and the connector 51 at the time of insertion / extraction can be sufficiently supported. 2 uses the thin flexible substrate 62, so that the connector 51 is substantially supported only by the plate-like member 10a. Therefore, in order to strengthen the support of the connector 51, in addition to the region serving as the wall surface of the housing 10 (that is, the bottom surface 11, the side surfaces 12 to 15, and the fixing member 20), the region where the connector 51 is disposed, that is, the partial ceiling. A surface 16 is provided. Further, in order to increase the strength of the partial top surface 16, the region to be the side surface 15 is engaged with the concave and convex shapes 19 a and 19 b. Furthermore, the area (connector mounting area) 64 of the flexible substrate 62 to be attached to the partial top surface 16 is made larger than the area necessary for mounting the connector 51, so that the connector 51 is firmly fixed.

As described in the first embodiment, when the light source lighting device 2 is not required to be waterproof, a hole such as a round hole 73 and a slit 74 is formed in a portion to be bent of the plate-like member 10a to facilitate the bending. And heat dissipation may be improved. Further, a large number of dimples may be formed on the outer wall surface in order to improve the heat dissipation of the housing 10.

The hole opened in the bent portion of the plate-like member 10a may have any shape. However, if a slit 74a longer than the width of the crossing substrate is opened in the bent portion crossed by the flexible substrate 62, the plate-like member 10a and the flexible substrate 62 are formed. When the two are bent together, the slit 74a becomes an allowance for slack in the flexible substrate 62. FIG. 13 is an enlarged view of a bent portion of the housing 10 and the flexible substrate 62. A slit 74a is formed in the bent portion, and the slack 63 of the bent portion of the flexible substrate 62 escapes into the slit 74a. Accordingly, the flexible substrate 62 can be bent naturally without applying excessive stress. Further, since the bending of the flexible substrate 62 is not hindered, no reaction force is generated by the flexible substrate 62, and the plate-like member 10a is easily bent.

On the other hand, it is not necessary to open the slit 74a. In this case, as shown in FIG. 10, the plate-like member 10a and the flexible substrate 62 are connected to each other while pulling the slack 63 of the bent portion of the flexible substrate 62 toward the inside of the housing 10. The work is complicated because it is necessary to bend. In this regard, if the slit 74a serving as a space in which the flexible substrate 62 sag is provided in advance, the plate member 10a can be easily bent without special consideration.

After the plate member 10a and the flexible substrate 62 are bent to form the housing 10, the starting circuit portion 90 is inserted from the top surface side of the housing 10 as shown in FIG. The fixing protrusions 92 and 92 are engaged with and fixed to the fixing holes 76 and 76 through the circuit through hole 75. Further, the discharge lamp 80 is inserted into an insertion hole 95 (shown in FIG. 9) provided in the seat surface 91 projecting outside the housing 10, and the terminal 81 of the discharge lamp 80 is connected to the high voltage terminal 93. The fixing member 82 is attached to the main part of the discharge lamp 80 and fixed to the starting circuit unit 90. In the illustrated example, fixing holes 76 and 76 are formed in the casing 10 and fixing protrusions 92 and 92 are formed in the starting circuit section 90 as fixing members for fixing the starting circuit section 90 and the casing 10. In addition, fixing protrusions 92 and 92 may be formed in the housing 10, and fixing holes 76 and 76 may be formed in the housing 10. Moreover, the fixing member 82 should just be a shape which fixes the discharge lamp 80 to the seat surface 91, and is not limited to the shape shown in FIG.

Subsequently, the lid-like fixing member 20 is fitted and fixed to the partial top surface 16 side of the housing 10. As in the first embodiment, the fixing member 20 may be simply fitted into the housing 10, or the fixing member 20 may be provided with one uneven surface and the housing 10 provided with the other uneven surface to be engaged with each other. It may be.

By the above procedure, the light source lighting device 2 employing the simple housing 10 that can be formed by bending work can be realized. As in the first embodiment, the light source lighting device 2 effectively eliminates the space for fixing the flexible substrate 62 (the space necessary for screw or claw arrangement) and effectively uses the internal space of the housing 10. Since electronic parts can be mounted by using, miniaturization is possible. Further, since heat generated by the electronic component can be transmitted to the housing 10 via the flexible substrate 62, the heat radiation effect can be enhanced to reduce the thermal stress of the electronic component, thereby improving the reliability as the light source lighting device. can do.
In addition, since the electronic components are distributed and arranged on each surface of the housing 10, it is possible to avoid the concentration of heat generation, and the housing 10 having good heat dissipation without biasing the high temperature portion. realizable. In addition, when the discharge lamp 80 is used as a light source, there is a portion in the housing 10 where a high voltage terminal 93 and a terminal 81 are connected and a high voltage is applied. This prevents leakage (discharging) between the unit and the housing 10 and the fixing member 20.

When the light source lighting device 2 is used for an in-vehicle headlamp, the discharge lamp 80 is inserted into the light source installation portion 102 of the heat sink 100 shown in FIG. 6 so that the seating surface 91 is brought into contact with the back side of the light source installation portion 102. For example, the discharge lamp 80 can be fixed at a specified position of a lamp such as the reflecting mirror 101. That is, when the seating surface 91 is formed, the light emitting portion of the discharge lamp 80 may be aligned so as to be the focal point of the reflecting mirror 101. Thereby, the light source and light source lighting device which ensure the optical performance of a lamp are realizable.

As described above, according to the light source lighting device 2 according to the second embodiment, the flexible substrate 62 is used as the substrate, and the flexible substrate 62 is pasted across the plurality of inner wall surfaces of the housing 10 to bend the housing 10. It was comprised so that the site | part which crossed a part had flexibility. For this reason, it is not necessary to use a connector for connecting between the substrates affixed to the respective inner wall surfaces, and there is no need for a space for mounting the connector. An effective area can be widened, and thus a small light source lighting device 2 can be realized.

Further, similarly to the first embodiment, the discharge lamp 80 and the casing 10 that houses the lighting circuit section 50 and the starting circuit section 90 are integrally configured, so that the casing 10 does not need to have a waterproof structure. Therefore, the light source lighting device 2 for lighting the discharge lamp 80 using the simple housing 10 that can be formed by bending work can be realized at low cost. In addition, the space for fixing the flexible substrate 62 can be eliminated, and the components can be mounted using the internal space of the housing 10 effectively, and the compact light source lighting device 2 can be realized. Furthermore, by sticking the flexible substrate 62 to the inner wall surface of the housing 10, the wall surface can be used as a heat radiating surface to enhance the heat radiating effect, thereby reducing the stress due to heat applied to the electronic component, and the light source lighting device 2 reliability can be improved. Furthermore, since a non-waterproof casing can be used as the casing 10 of the light source lighting device 2, a method of manufacturing a light source lighting device that can be easily formed by bending the casing 10 can be provided.

Further, according to the second embodiment, the heat generating components such as the switching FET 53, the transformer 54, and the H bridge 59 constituting the lighting circuit unit 50 are provided in the respective portions of the flexible substrate 62 positioned on the plurality of inner wall surfaces of the housing 10. It was configured to be distributed. For this reason, it can avoid that heat_generation | fever concentrates, and the housing | casing 10 provided with favorable heat dissipation can be implement | achieved, without a high temperature part biasing.

Further, according to the second embodiment, since the slit 74a longer than the width of the flexible substrate 62 that crosses the bent portion is provided in the bent portion of the plate-like member 10a, the slack 63 that can be obtained by bending the flexible substrate 62 is provided. Since stress is not applied to the flexible substrate 62 so as to escape to the slit 74a, the reliability of the substrate is not impaired.
Further, by providing the round hole 73 and the slit 74 in the bent portion other than the slit 74a, the plate member 10a can be easily bent as in the first embodiment.

Further, according to the second embodiment, the plate-like member 10a is configured to provide the partial top surface 16 to which the connector mounting area 64 for mounting the connector 51 that receives power supply from the power source is provided. Can be supported, and the connector 51 can be firmly fixed.

Further, according to the second embodiment, the light source lighting device 2 is configured to include the high voltage terminal 93 that applies the high voltage generated by the starting circuit unit 90 to the discharge lamp 80 and the insulating member 94 that covers the terminal 81. Therefore, leakage due to high voltage can be suppressed. Therefore, the light source lighting device 2 having stable characteristics can be realized without failure.

Further, according to the second embodiment, the light source lighting device 2 is provided with the fixing holes 76 and 76 and the fixing convex portions 92 and 92 for fixing the starting circuit unit 90 and the housing 10. The discharge lamp 80 is fixed and has a seat surface 91 for positioning the light source lighting device 2 by being seated at a predetermined position of the lamp. For this reason, the light emission part of the discharge lamp 80 can be fixed to a specified position with respect to the lamp, and thus a light source that ensures the optical performance of the lamp can be realized.

In addition, in the second embodiment, similarly to the first embodiment, it is easy to handle using the fixing member 20, and the housing 10 having a stable dimension is formed, or the dimples are provided on the surface of the plate-like member 10a. The heat dissipation effect of the body 10 can also be enhanced.

In addition, the lighting circuit unit 50 of the discharge lamp 80 described in the second embodiment is replaced with the flexible substrate 62 using a plate-like substrate as shown in the first embodiment, and the bottom surface 11 of the housing 10. It is also possible to affix to.
Conversely, the lighting circuit unit 50 of the light emitting diode 30 described in the first embodiment is configured using a flexible substrate having flexibility as shown in the second embodiment instead of the plate-like substrate 60, and It is also possible to disperse and mount heat generating components such as the switching FET 53 and the transformer 54 on the respective portions of the flexible substrate located on the plurality of inner wall surfaces of the housing 10.

In addition to these configurations, the present invention is within the scope of the invention, and can be freely combined with each embodiment, or any modification of any component in each embodiment, or any component in each embodiment. Can be omitted.

As described above, in the light source lighting device and the manufacturing method thereof according to the present invention, the unfolded plate member is bent to form the casing for the lighting circuit, and the light source is integrated into the casing. It is suitable for use in a light source attached to a lamp in a waterproof in-vehicle headlamp case and a light source lighting device thereof.

Claims (16)

A lighting circuit unit that receives supply of power from a power source, converts the power source voltage into a voltage for a light source by a converter unit and supplies power to the light source, and the light source, and is a light source that can be attached to and detached from the lamp A lighting device,
A substrate on which components constituting the lighting circuit section are mounted;
A light source lighting device comprising: a casing or a part of a casing that is formed by bending an unfolded plate-like member to which the substrate is attached, and that houses the lighting circuit portion therein. The light source lighting according to claim 1, wherein the substrate is affixed across a plurality of inner wall surfaces of the housing, and at least a portion of the substrate crossing a bent portion of the housing has flexibility. apparatus. The plate-like member is a metal member,
The light source lighting device according to claim 1, further comprising an insulating member that insulates the plate-like member and the substrate. 3. The light source lighting device according to claim 2, wherein the heat-generating parts constituting the lighting circuit unit are dispersed in each part of the substrate located on a plurality of inner wall surfaces of the casing. The light source lighting device according to claim 1, wherein at least one of a hole and a slit is provided in a bent portion of the plate-like member. 3. The light source lighting device according to claim 2, wherein a slit longer than the width of the substrate crossing the bent portion is provided in the bent portion of the plate-like member. The light source lighting device according to claim 1, wherein the plate-like member has a region to which a substrate portion on which a connector that receives power supply from a power source is mounted is pasted. The light source lighting device according to claim 1, further comprising a fixing member that fixes the casing formed by bending the plate-like member. The light source lighting device according to claim 8, wherein the fixing member constitutes a part of an outer wall of the housing. The light source lighting device according to claim 1, wherein unevenness is provided on a surface of the plate-like member. The light source lighting device according to claim 1, wherein the light source is a light emitting diode. The light source lighting device according to claim 11, further comprising a heat transfer member that absorbs heat generated by the light emitting diode and transmits the heat to an external heat dissipation member. The light source is a discharge lamp;
The casing internally includes an inverter unit that converts a DC voltage output from the converter unit into an alternating current and supplies electric power to the discharge lamp, and a starting circuit unit that starts by applying a high voltage to the discharge lamp. The light source lighting device according to claim 1, wherein the light source lighting device is housed. The light source lighting device according to claim 13, further comprising an insulating member that covers a portion where a high voltage generated in the starting circuit unit is applied to the discharge lamp. A fixing member for fixing the casing and the starting circuit unit;
A part of the starter circuit portion has a shape that penetrates the housing and protrudes to the outside, is seated at a predetermined position of the lamp and positions the light source lighting device, and the release on the seat surface. The light source lighting device according to claim 13, further comprising a fixing member that fixes the electric lamp. A lighting circuit unit that receives supply of power from a power source, converts the power source voltage into a voltage for a light source by a converter unit and supplies power to the light source, and the light source, and is a light source that can be attached to and detached from the lamp A method of manufacturing a lighting device,
A substrate pasting step of pasting the substrate on a plate member in an unfolded state that forms a housing or a part of the housing by bending;
A component mounting step for mounting a component constituting the lighting circuit section on the substrate attached to the plate-shaped member;
A method of manufacturing a light source lighting device, comprising: a case processing step of bending the plate-like member to form a case or a part of the case.

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