JP3749828B2

JP3749828B2 - LED lighting

Info

Publication number: JP3749828B2
Application number: JP2000333092A
Authority: JP
Inventors: 範行小森; 裕司小泉; 弘明松原; 誠一佐藤
Original assignee: Hitachi Building Systems Co Ltd
Current assignee: Hitachi Building Systems Co Ltd
Priority date: 2000-10-31
Filing date: 2000-10-31
Publication date: 2006-03-01
Anticipated expiration: 2020-10-31
Also published as: JP2002141555A

Description

【０００１】
【発明の属する技術分野】
本発明は、通電によりそれぞれ発光する複数個のＬＥＤ体（すなわち発光ダイオード）を備えたＬＥＤ照明灯に関する。
【０００２】
【従来の技術】
図２３は一般的な蛍光灯を示す説明図である。
【０００３】
図２３に示す蛍光灯１００は、一般的な照明灯の光源として白熱電球（図示せず）と並んで広く利用されており、円筒状のガラス管１０１と、このガラス管１０１の両端内部に設けられ、熱電子放射性物質が塗布されるコイル状の電極フィラメント１０２と、ガラス管１０１の両端に固定される一対の口金１０３と、これらの口金１０３の外側面にそれぞれ固定される２組の電極ピン１０４、１０４Ａとを備えている。また、ガラス管１０１内に水銀やアルゴンガスが封入されるとともに、ガラス管１０１の内壁に蛍光物質が塗布されている。
【０００４】
【発明が解決しようとする課題】
ところで、上述した従来技術にあって、図２３に示す蛍光灯１００では次のような問題点がある。
【０００５】
（Ａ）ガラス管１０１内に水銀やアルゴンガスが封入されているため、ガラス管１０１が破損した場合、その破損したガラス管１０１を廃棄する人の人体や衣服に水銀が付着する危険性がある。
【０００６】
（Ｂ）蛍光灯１００の寿命等により新しいものに交換し、交換した蛍光灯１００を廃棄する際、ガラス管１０１を破砕するとガラス管１０１内に封入されていた水銀が周囲に放散してしまうので、ガラス管１０１を破砕する作業者に水銀が付着しないようにするため大掛かりな破砕装置を必要としている。また、破砕したガラス管１０１のガラス片には水銀が付着しているため、それらのガラス片は産業廃棄物としてそのまま地中に埋めた場合、土壌の汚染を生じるという問題がある。
【０００７】
（Ｃ）ガラス管１０１内に水銀やアルゴンガスを封入する必要があるため、ガラス管１０１と口金１０３との取付けを精度のよいものとし、気密性を十分に保持する必要がある。
【０００８】
（Ｄ）電極フィラメント１０２に高圧の交流を印加してその電極フィラメント１０２から多量の熱電子を放出させるため、消費電力が比較的大きい。
【０００９】
本発明は、上記のような従来技術における実情に鑑みてなされたもので、その目的は、安全かつ簡単に廃棄処理を行なうことができるとともに、消費電力の低減を図ることができ、また、細長管内の所定位置にプリント基板を簡単に保持し、細長管に口金具を容易に一体化することができ、既存する径の異なる各種の細長管と既存する径の異なる各種の口金具とを組み合わせて使用することができ、さらに、使用中にブッシングが高温状態になっても細長管を破損させることを防止でき、ブッシングを細長管に確実に固定することができるＬＥＤ照明灯を提供することにある。
【００１７】
【課題を解決するための手段】
上記目的を達成するため、本発明は、通電によりそれぞれ発光する複数個のＬＥＤ体を備えたＬＥＤ照明灯において、細長の剛性材からなり、前記複数個のＬＥＤが上面側に長手方向に沿って所定間隔をおいて配設されるプリント基板と、このプリント基板を収納し、透光性および保形性を有する細長管と、前記プリント基板の下面側に配設される全波整流ダイオードおよび複数個の電流制限抵抗を含む電気部品と、前記細長管の両端に取付けられ、前記プリント基板を前記細長管内に固定する絶縁材からなる一対のブッシングと、これらのブッシングの外周のそれぞれに装着される一対の口金具と、これらの口金具にそれぞれ設けられる一対の電極ピンと、一端を前記プリント基板に、他端を前記電極ピンにそれぞれ半田付けされるリード線である接続体とを備え、前記ブッシングは、前記細長管が嵌合するリング溝と、前記プリント基板の端縁部が載る台座と、前記リード線が貫通する貫通穴と、前記口金具が圧入嵌合する取付筒部とを有し、前記ブッシングのリング溝の内周壁径を前記細長管の内径より小さく設定することにより、前記ブッシングのリング溝の内周壁が熱により外方に膨出した場合の逃げ代となる隙間を、前記ブッシングのリング溝の内周壁と前記細長管の内壁との間に形成するとともに、熱で硬化することのない接着剤を前記隙間に介在させることにより、前記ブッシングのリング溝の内周壁に前記細長管の内壁を固定した構成にしてある。
【００１８】
このように構成した本発明では、ＬＥＤ体により低電流で比較的高い輝度の光を出射できるので、消費電力の低減を図ることができる。また、構成部品を収納する細長管が破損しても、蛍光燈のように水銀が封入されておらず破損した細長管に水銀が付着しないので、この細長管の廃棄処理を安全かつ簡単に行なえる。さらに、ブッシングを細長管の両端に装着することによって、これらのブッシングで細長管内の所定位置にプリント基板を簡単に保持できるとともに、細長管に電極ピンを設けた口金具を容易に一体化できる。
【００２０】
また、本発明は、リード線の両端をプリント基板および口金具に設けた電極ピンに半田付けすることにより、プリント基板と電極ピンとの電気的接続を簡便に行なうことができる。
【００２４】
また、本発明は、細長管が嵌合するリング溝の径および口金具が嵌合する取付筒部の径の異なる複数個のブッシングを簡単に用意することができ、それらブッシングを適宜変えることで、既存する径の異なる各種の細長管と既存する径の異なる各種の口金具とを組み合わせて使用できる。
【００２６】
また、本発明は、ブッシングが高温状態になってリング溝の内周壁が高熱により外方に膨出しても、このリング溝の内周壁と細長管の内壁との間の隙間が逃げ代となっており、しかも上記の隙間に介在する接着剤が熱で硬化しないので、上記の膨出による細長管の内壁に加わる力が小さくなる。これによって、使用中にブッシングが高温状態になっても細長管を破損させることを防止でき、ブッシングを細長管に確実に固定できる。
【００３４】
【発明の実施の形態】
以下、本発明のＬＥＤ照明灯の実施形態を図に基づいて説明する。
【００３５】
図１は本発明の一実施形態に係わるＬＥＤ照明灯を示す斜視図、図２は本実施形態のＬＥＤ照明灯に設けられるプリント基板の平面図、図３は本実施形態のＬＥＤ照明灯の平面図、図４は本実施形態のＬＥＤ照明灯を下から見た図、図５は本実施形態のＬＥＤ照明灯の側面図、図６は図３のａ部を拡大して示す平面図、図７は図５のｂ部を拡大して示す側面図、図８は図４のｃ部を拡大して示す図、図９は図３のＸ−Ｘ線に沿う断面図、図１０は図３のＹ−Ｙ線に沿う断面図、図１１は本実施形態のＬＥＤ照明灯に設けられるＬＥＤ体の正面図、図１２は本実施形態のＬＥＤ照明灯の端部を拡大して示す断面図、図１３は本実施形態のＬＥＤ照明灯に設けられるブッシングを内側から見た側面図、図１４は図１３のブッシングのＺ−Ｚ線に沿う断面図、図１５は本実施形態のＬＥＤ照明灯に設けられるブッシングを外側から見た側面図、図１６は本実施形態のＬＥＤ照明灯が用いられる既設照明装置の説明図、図１７は本実施形態のＬＥＤ照明灯に設けられるプリント基板の電気回路図、図１８は本実施形態のＬＥＤ照明灯を製造する際の工程を示すフローチャートである。なお、図１ではＬＥＤ照明灯に設けられるプリント基板上の配線の図示を省略してある。
【００３６】
図１に示す本実施形態のＬＥＤ照明灯１は、透光性および保形性を有する円筒状の細長管２と、この細長管２内に設置される剛性材からなる細長のプリント基板３と、このプリント基板３の長手方向に沿ってプリント基板３の上面側３Ａに所定間隔をおいて配設される発光源としての複数個のＬＥＤ体（すなわち発光ダイオード）４と、プリント基板３の下面側３Ｂに配設される全波整流ダイオード５および複数個の電流制限抵抗６を含む電気部品７と、細長管２の両端に取付けられ、プリント基板３を細長管２内に固定する絶縁材からなる一対のブッシング８、９と、これらのブッシング８、９の外周のそれぞれに取付けられる一対の口金具１０、１１とを備えており、プリント基板３の両端に、図２に示すように、口金具１０、１１とプリント基板３との電気的接続を行なう接続体１２、１３がそれぞれ設けられている。
【００３７】
細長管２は、例えば、外径約３０ｍｍ×内径約２７ｍｍ×長さ約５６１ｍｍの透明ガラスからなる円管からなっており、プリント基板３、ＬＥＤ体４および電気部品７に塵埃が付着するのを阻止したりあるいは水滴が付着するのを阻止するようになっている。
【００３８】
プリント基板３は、例えば、長さ約５５９ｍｍ×横幅約２６．６ｍｍ×厚さ約１．５ｍｍの耐熱性の合成樹脂板からなっている。上記のようにプリント基板３の横幅を約２６．６ｍｍとするとともに、細長管２の内径を約２７ｍｍとして、プリント基板３の横幅寸法を細長管２の内径より僅かに小さな寸法としているので、細長管２内にプリント基板３を挿入する場合に細長管２の内壁が案内壁として機能する。
【００３９】
また、プリント基板３の上面側３Ａには、図１、図２、図３および図５に示すように、プリント基板３の長手方向に沿って等間隔をおいて１０個のＬＥＤ体４が一直線状に配設されている。ＬＥＤ体４間の間隔は、ＬＥＤ体４の取付中心から隣接するＬＥＤ体４の取付中心までの距離が約５４ｍｍとなるように設定するのが好ましい。プリント基板３の下面側３Ｂには、図１、図４および図５に示すように、そのプリント基板３の長手方向に沿って等間隔をおいて１０個の電流制限抵抗６が一直線状に配設させている。これらの電流制限抵抗６は１．６ｋΩのものが用いられ、かつＬＥＤ体４間の下方に位置するように配置されている。１個の全波整流ダイオード５は、プリント基板３の下面側３Ｂの一端側に配設されており、この全波整流ダイオード５は、電源が交流電流の場合は直流電流に変換してその直流電流をＬＥＤ体４に供給し、また電源が直流電流の場合はその直流電流をそのままＬＥＤ体４に供給する機能を有している。
【００４０】
複数個のＬＥＤ体４は、すべて同一形状で、かつ同一大きさのものが用いられるとともに、点灯時に緑色単色に発光する構造のものが用いられる。すべてのＬＥＤ体４は、図１１に示すように、エポキシ樹脂製の容器状のレンズ４Ａと、このレンズ４Ａ内に収納される半導体チップ４Ｂと、この半導体チップ４Ｂに約１０〜１５ｍＡの直流電流を印加する２本のピン状金属導線４Ｃ、４Ｄとを備えている。レンズ４Ａは、半導体チップ４Ｂからの光を一方向に指向させる狭指向レンズ構造にしてある。
【００４１】
ブッシング８、９は絶縁性、耐熱性および寸法安定性のすぐれた合成樹脂材、例えば、ポリブチレンテレフタレート材からなっている。例えば、ブッシング８は、図１２〜図１５に示すように、細長管２が圧入嵌合するリング溝８Ａと、プリント基板３の端縁部が載る台座８Ｂと、接続体１３が貫通する貫通穴８Ｃと、口金具１０が圧入嵌合する円筒状の取付筒部８Ｄと、この取付筒部８Ｄ内に設けられる受けリング体８Ｆとを有している。このブッシング８では、リング溝８Ａの内周壁８Ａ−１の径を細長管２の内径より小さく設定することにより、ブッシング８のリング溝８Ａの内周壁８Ａ−１が熱により外方に膨出した場合の逃げとなる隙間Ｇ１が、リング溝８Ａの内周壁８Ａ−１と細長管２の内壁との間に形成されている。隙間Ｇ１には、熱により硬化することのない接着剤を介在させることでリング溝８Ａの内周壁８Ａ−１に細長管２の内壁を固定させるようにしてあり、上記の接着剤は、細長管２をリング溝８Ａに接着させた状態でも柔軟性が保持される性質を有するシリコン系のものが用いられる。また、取付筒部８Ｄの外周壁８Ｄ−１には、高さが約０．５ｍｍで断面形状が半球状のリブ８Ｅをほぼ等間隔に複数個形成されている。
【００４２】
同様に、他のブッシング９もリング溝９Ａ、台座９Ｂ、貫通穴９Ｃ、取付筒部９Ｄおよび受けリング体９Ｆとを有しており、リング溝９Ａの内周壁９Ａ−１の径を細長管２の内径より小さく設定することにより、リング溝９Ａの内周壁９Ａ−１が熱により外方に膨出した場合の逃げとなる隙間Ｇ１が、リング溝９Ａの内周壁９Ａ−１と細長管２の内壁との間に形成されている。また、取付筒部９Ｄの外周壁９Ｄ−１に、高さが約０．５ｍｍで断面形状が半球状のリブ９Ｅをほぼ等間隔に複数個形成されている。
【００４３】
そして、プリント基板３は、そのプリント基板３の端縁部をブッシング８、９の台座８Ｂ、９Ｂに載置して、台座８Ｂ、９Ｂとプリント基板３の下面側端縁部とを接着剤で貼り付けることにより、ブッシング８、９に固定される。
【００４４】
口金具１０は、取付筒部８Ｄの外周に圧入される金属製胴体１０Ａと、後述する既設照明装置１４の電源回路部１５に電気的に接続する１本の電極ピン１０Ｂと、金属製胴体１０Ａの開口端縁に固定され、電極ピン１０Ｂを支持する絶縁物からなる絶縁円板１０Ｃとを有している。電極ピン１０Ｂは、導電性の材料からなり、例えば黄銅から作られている。口金具１０をブッシング８に取付ける際、口金具１０の金属製胴体１０Ａをブッシング８の取付筒部８Ｄに圧入すると、リブ８Ｅに金属製胴体１０Ａが案内されてその金属製胴体１０Ａが偏ることなく、ブッシング８の取付筒部８Ｄに金属製胴体１０Ａが円滑に嵌合するとともに、ブッシング８の取付筒部８Ｄのリブ８Ｅにより形成される凹部に接着剤が流れて金属製胴体１０Ａの外方に接着剤が流出しない。取付筒部８Ｄ内に設けられた受けリング体８Ｆは、絶縁円板１０Ｃが移動するなどの変形を阻止する機能を有している。また、他の口金具１１も同様であり、金属製胴体１１Ａ、１本の電極ピン１１Ｂ、および絶縁円板１１Ｃを有している。
【００４５】
接続体１２は、一端１２Ａがプリント基板３に半田付けされ、他端１２Ｂがブッシング８の貫通穴８Ｃを通して口金具１０の電極ピン１０Ｂに半田付けされる一本の銅線からなるリード線から構成されている。また、他の接続体１３も同様であり、一端１３Ａがプリント基板３に半田付けされ、他端１３Ｂがブッシング９の貫通穴９Ｃを通して口金具１１の電極ピン１１Ｂに半田付けされ一本の銅線からなるリード線から構成されている。
【００４６】
図１６に示す既設照明装置１４は、ＬＥＤ照明灯１を所定の場所に脱着可能に取付ける第１の受具１６および第２の受具１７と、これらの第１の受具１６、第２の受具１７を取付部材１８に固定する取付金具１９、２０と、電源回路部１５に接続する電源コンセント２１と第１の受具１６とを接続する第１の配線コード２２と、電源コンセント２１と第２の受具１７とを接続する第２の配線コード２３とを有している。第１の受具１６と口金具１０との間、または第２の受具１７と口金具１１との間には、摩擦抵抗の大きなゴムやシリコンなどの弾性材からなり、ＬＥＤ照明灯１の回転を防止するドーナツ状の回転防止部材２４が設けられている。
【００４７】
図１７に示すように５個のＬＥＤ体４と５個の電流制限抵抗６とを交互に直列に接続した第１のＬＥＤ直列回路２５を形成し、他の５個のＬＥＤ体４と５個の電流制限抵抗６とを交互に直列に接続した第２のＬＥＤ直列回路２６を形成して、これらのＬＥＤ直列回路２５、２６を並列に接続することで並列回路を形成するとともに、この並列回路に対して１個の全波整流ダイオード５を直列に接続してある。これらのＬＥＤ直列回路２５、２６と全波整流ダイオード５とのプリント配線は、図３に示すように、プリント基板３に布設されている。
【００４８】
このように構成した実施形態のＬＥＤ照明灯１では、次のような効果が得られる。すなわち（１）ＬＥＤ照明灯１の環境温度が５０度Ｃの状態でＬＥＤ体４を点灯しても、細長管２内の温度を約６０度Ｃ以内に維持可能であることを本出願人による実験で確認できた。
【００４９】
（２）低電流で高い輝度が得られるＬＥＤ体４を採用することにより、ＬＥＤ照明灯１の消費電力が従来のものに比べて約１／４に低減することを本出願人による実験で確認できた。
【００５０】
（３）ＬＥＤ照明灯１の寿命が長くなり、ＬＥＤ照明灯１の交換を従来の約１年から約１４年に延長可能であることが本出願人による実験で確認できた。
【００５１】
（４）水銀やアルゴンガスが細長管２内に封入されていないので、万一、細長管２を破損しても、その破損した細長管２を廃棄する人の人体や衣服に水銀が付着する危険性がないので安全である。
【００５２】
（５）ＬＥＤ照明灯１の寿命等により新しいものに交換し、交換した古い細長管２を廃棄する際、細長管２を破砕しても水銀が周囲に放散するようなことがないので、細長管２を破砕する作業者に水銀が付着しないようにするため大掛かりな破砕装置を必要とせず、簡便に行なうことができる。また、破砕した細長管２のガラス片には水銀が付着していないため、産業廃棄物扱いとならず、容易に再利用することができる。
【００５３】
（６）細長管２内に水銀やアルゴンガスを封入する必要がないため、細長管２の成形や、細長管２とブッシング８、９および口金具１０、１１との取付けを簡単に行なうことができる。
【００５４】
（７）全波整流ダイオード５により、交流および直流のいずれの電源でも使用できる。
【００５５】
（８）第１のＬＥＤ直列回路２５と第２のＬＥＤ直列回路２６とが並列に接続されているので、第１のＬＥＤ直列回路２５のＬＥＤ体４が切れた場合（破損した場合）、あるいは第２のＬＥＤ直列回路２６のＬＥＤ体４が切れた場合でも、プリント基板３のＬＥＤ体４が交互に点灯消灯した状態となってプリント基板３のすべてのＬＥＤ体４が消灯せず、ＬＥＤ照明灯１として継続使用できる。
【００５６】
（９）プリント基板３の上面側に複数個のＬＥＤ体４のみがほぼ一直線状に整然と配設され、かつ、プリント基板３の下面側に複数個の電気部品７のみがほぼ一直線状に整然と配設されており、プリント基板３の上下両面がすっきりした形態となって見栄えのよいＬＥＤ照明灯１となるとともに、電流制限抵抗６から発生した熱はプリント基板３に遮られて細長管２の下半分およびプリント基板３の下面側に伝達し、ＬＥＤ体４が電流制限抵抗から発生した熱で直接温められることがないので、ＬＥＤ体４が電流制限抵抗６から発生した熱により高温になることを防止できる。
【００５７】
（１０）プリント基板３と電極ピン１０Ｂ、１１Ｂとの電気的接続をリード線からなる接続体１２、１３により簡便に行なうことができる。
【００５８】
（１１）ブッシング８、９により、細長管２内の所定の位置にプリント基板３を保持すること、および細長管２に電極ピン１０Ｂ、１１Ｂを設けた口金具１０、１１を一体化することを難なく行なえる。
【００５９】
（１２）細長管２が嵌合するリング溝８Ａ、９Ａの径および口金具１０、１１が嵌合する取付筒部８Ｄ、９Ｄの径の異なる複数個のブッシングを用意して、それらブッシングを適宜変えることで、既存する径の異なる各種の細長管と既存する径の異なる各種の口金具を適宜組み合わせ使用することができる。
【００６０】
（１３）ＬＥＤ照明灯１の使用中、ブッシング８、９が高温状態になってリング溝８Ａ、９Ａの内周壁８Ａ−１、９Ａ−１が外方に熱膨出してもリング溝８Ａ、９Ａの内周壁８Ａ−１、９Ａ−１と細長管２の内壁との間の隙間があるとともに接着剤が硬化しないので、この熱膨出による細長管２の内壁に加わる力が小さくなる。これによって、細長管２を破損させることなく、ブッシング８、９を細長管２に確実に固定することができる。
【００６１】
（１４）ブッシング８、９の取付筒部８Ｄ、９Ｄの外周壁８Ｄ−１、９Ｄ−１に接着剤を塗布すると半球状のリブ８Ｅ、９Ｅ間の凹部に十分な量の接着剤が付着し、しかも、ブッシング８、９の取付筒部８Ｄ、９Ｄの外周壁８Ｄ−１、９Ｄ−１に口金が複数個の半球状のリブ８Ｅ、９Ｅにより偏ることなく圧入されて、接着剤が口金１０、１１とブッシング８、９との間から外方に流出するのを最小限に食い止められるので、ブッシング８、９と口金１０、１１とが確実に、かつ見栄えよく固定される。
【００６２】
また、本実施形態のＬＥＤ照明灯１の製造方法は、図１８に示す一連の工程Ｓ１〜Ｓ４にしたがって行なわれる。すなわち、部品取付け工程Ｓ１として、１０個のＬＥＤ体４と、１個の全波整流ダイオード５および１０個の電流制限抵抗６からなる電気部品７と、接続体１２、１３とをプリント基板３に取付けた後、挿入工程Ｓ２として、プリント基板３を細長管２内に挿入し、ブッシング取付け工程Ｓ３として、プリント基板３を細長管２内に固定するブッシング８、９を細長管２の両端に取付け、次いで、口金具取付け工程Ｓ４として、口金具１０をブッシング８の外周に取付け、他の口金具１１をブッシング９の外周に取付けるとともに、口金具１０の電極ピン１０Ｂと接続体１３との電気的接続を行ない、他の口金具１１の電極ピン１１Ｂと接続体１２との電気的接続を行なうようになっている。
【００６３】
上記の口金具取付け工程Ｓ４では、ブッシング取付け工程Ｓ３の終了後にブッシング８、９の外周に接着剤を塗布した後、ブッシング８、９の外周にそれぞれ口金具１０、１１を圧入固定するとともに、電極ピン１０Ｂ、１１Ｂと接続体１２、１３との電気的接続を行なうようにしてもよい。また、ブッシング取付け工程Ｓ３では、予めブッシング８、９側に接着剤を塗布するようにしてもよい。
【００６４】
このように構成した本実施形態のＬＥＤ照明灯１の製造方法によれば、ＬＥＤ照明灯１を工程Ｓ１〜Ｓ２にしたがって円滑に流れ作業で組み立てることができるので、ＬＥＤ照明灯１の生産性を向上できる。
【００６５】
なお、本実施形態のＬＥＤ照明灯１では、細長管２が透明ガラス製であるが、これに限定されるものではなく、光を通過させ、かつ保形性および難燃性を有するものであれば合成樹脂製であってもよい。
【００６６】
図１９はＬＥＤ照明灯に設けられるブッシングの変形例を示す説明図、図２０はＬＥＤ照明灯に設けられる支持材の一例を示す断面図、図２１はＬＥＤ照明灯に設けられる支持材の変形例を示す断面図、図２２はＬＥＤ照明灯に設けられる支持材の他の変形例を示す断面図である。
【００６７】
図１９に示すブッシング８、９は、それぞれブッシング８、９と一体的に形成されるプリント基板押え部８Ｈ、９Ｈを有しており、その他の構造はブッシング８、９と基本的に同一である。各プリント基板押え部８Ｈ、９Ｈは、ＬＥＤ照明灯１を製造する際のブッシング取付け工程Ｓ３で、細長管２内に挿入されるプリント基板３がブッシング８、９の台座８Ｂ、９Ｂに押えられた状態を維持させる機能を有している。したがって、プリント基板押え部８Ｈ、９Ｈによりプリント基板３と台座８Ｂ、９Ｂとが離れることがないので、これらのプリント基板３と台座８Ｂ、９Ｂとを接着剤によって確実に固定できる。
【００６８】
また、図２０に示す細長管２内の下方には絶縁材からなる支持材、例えば支持ピン２７が立設されるとともに、プリント基板３の下面側３Ｂの中央部に当接しており、支持ピン２７でプリント基板３の中央部を支持することにより、細長管２内に挿入したプリント基板３の反りを抑えることができる。
【００６９】
また、図２１に示す細長管２内には絶縁材からなる支持材、例えば支持ピン２８が上下方向に立設されるとともに、プリント基板３の中央部を貫通しており、支持ピン２８でプリント基板３の中央部を支持することにより、細長管２内に挿入したプリント基板３の反りを抑えることができる。
【００７０】
また、図２２に示すプリント基板３の幅方向両辺に、絶縁材からなるＵ字型の支持材２９が取付けられており、これらの支持材２９でプリント基板３の幅方向両辺をそれぞれ支持することにより、細長管２内に挿入したプリント基板３の反りを抑えることができる。
【００７１】
【発明の効果】
以上説明したように、本発明は、ＬＥＤ体により低電流で比較的高い輝度の光を出射できるので、消費電力の低減を図ることができる。また、構成部品を収納する細長管が破損しても、蛍光燈のように水銀が封入されておらず破損した細長管に水銀が付着しないので、この細長管の廃棄処理を安全かつ簡単に行なえる。さらに、細長管の両端に装着したブッシングで細長管内の所定位置にプリント基板を簡単に保持できるとともに、細長管に電極ピンを設けた口金具を容易に一体化できる。
【００７２】
また、リード線からなる接続体の両端をプリント基板および口金具に設けた電極ピンに半田付けすることにより、プリント基板と電極ピンとの電気的接続を簡便に行なうことができる。
【００７４】
また、細長管が嵌合するリング溝の径および口金具が嵌合する取付筒部の径の異なる複数個のブッシングを簡単に用意することができ、それらブッシングを適宜変えることで、既存する径の異なる各種の細長管と既存する径の異なる各種の口金具とを組み合わせて使用できる。
【００７５】
また、ブッシングが高温状態になってリング溝の内周壁が高熱により外方に膨出しても、このリング溝の内周壁と細長管の内壁との間の隙間が逃げ代となっており、しかも上記の隙間に介在する接着剤が熱で硬化しないので上記の膨出による細長管の内壁に加わる力が小さくなる。したがって、使用中にブッシングが高温状態になっても細長管を破損させることを防止でき、ブッシングを細長管に確実に固定できる。
【図面の簡単な説明】
【図１】本発明の一実施形態に係わるＬＥＤ照明灯を示す斜視図である。
【図２】本実施形態のＬＥＤ照明灯に設けられるプリント基板の平面図である。
【図３】本実施形態のＬＥＤ照明灯の平面図である。
【図４】本実施形態のＬＥＤ照明灯を下から見た図である。
【図５】本実施形態のＬＥＤ照明灯の側面図である。
【図６】図３のａ部を拡大して示す平面図である。
【図７】図５のｂ部を拡大して示す側面図である。
【図８】図４のｃ部を拡大して示す図である。
【図９】図３のＸ−Ｘ線に沿う断面図である。
【図１０】図３のＹ−Ｙ線に沿う断面図である。
【図１１】本実施形態のＬＥＤ照明灯に設けられるＬＥＤ体の正面図である。
【図１２】本実施形態のＬＥＤ照明灯の端部を拡大して示す断面図である。
【図１３】本実施形態のＬＥＤ照明灯に設けられるブッシングを内側から見た側面図である。
【図１４】図１３のブッシングのＺ−Ｚ線に沿う断面図である。
【図１５】本実施形態のＬＥＤ照明灯に設けられるブッシングを外側から見た側面図である。
【図１６】本実施形態のＬＥＤ照明灯が用いられる既設照明装置の説明図である。
【図１７】本実施形態のＬＥＤ照明灯に設けられるプリント基板の電気回路図である。
【図１８】本実施形態のＬＥＤ照明灯を製造する際の工程を示すフローチャートである。
【図１９】ＬＥＤ照明灯に設けられるブッシングの変形例を示す説明図である。
【図２０】ＬＥＤ照明灯に設けられる支持材の一例を示す断面図である。
【図２１】ＬＥＤ照明灯に設けられる支持材の変形例を示す断面図である。
【図２２】ＬＥＤ照明灯に設けられる支持材の他の変形例を示す断面図である。
【図２３】一般的な蛍光灯を示す説明図である。
【符号の説明】
１ＬＥＤ照明灯
２細長管
３プリント基板
４ＬＥＤ体（発光源）
５全波整流ダイオード
６電流制限抵抗
７電気部品
８、９ブッシング
８Ｈ、９Ｈプリント基板押え部
１０、１１口金具
１０Ｂ、１１Ｂ電極ピン
１２、１３接続体
１４既設照明装置
１５電源回路部
２４回転防止部材
２５第１のＬＥＤ直列回路
２６第２のＬＥＤ直列回路
２７支持ピン（支持材）
２８支持ピン（支持材）
２９支持材[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an LED illumination comprising a plurality of LED bodies (that is, light emitting diodes) each emitting light when energized. In the light Related.
[0002]
[Prior art]
FIG. 23 is an explanatory view showing a general fluorescent lamp.
[0003]
A fluorescent lamp 100 shown in FIG. 23 is widely used along with an incandescent bulb (not shown) as a light source of a general illumination lamp. A cylindrical glass tube 101 and both ends of the glass tube 101 are provided. A coiled electrode filament 102 to which a thermionic radioactive material is applied, a pair of caps 103 fixed to both ends of the glass tube 101, and two sets of electrode pins fixed to the outer surfaces of these caps 103, respectively. 104, 104A. Further, mercury or argon gas is sealed in the glass tube 101 and a fluorescent material is applied to the inner wall of the glass tube 101.
[0004]
[Problems to be solved by the invention]
By the way, in the prior art mentioned above, the fluorescent lamp 100 shown in FIG. 23 has the following problems.
[0005]
(A) Since mercury or argon gas is enclosed in the glass tube 101, when the glass tube 101 is damaged, there is a risk that mercury adheres to the human body or clothes of the person who discards the damaged glass tube 101. .
[0006]
(B) When replacing the fluorescent lamp 100 with a new one due to the lifetime of the fluorescent lamp 100 and discarding the replaced fluorescent lamp 100, if the glass tube 101 is crushed, the mercury enclosed in the glass tube 101 will diffuse to the surroundings. In order to prevent mercury from adhering to an operator who crushes the glass tube 101, a large crushing device is required. Further, since mercury is attached to the glass pieces of the crushed glass tube 101, there is a problem that when these glass pieces are buried as industrial waste in the ground as they are, soil contamination occurs.
[0007]
(C) Since it is necessary to enclose mercury or argon gas in the glass tube 101, it is necessary to attach the glass tube 101 and the base 103 with high accuracy and to maintain sufficient airtightness.
[0008]
(D) Since a high-voltage alternating current is applied to the electrode filament 102 to discharge a large amount of thermoelectrons from the electrode filament 102, power consumption is relatively large.
[0009]
The present invention has been made in view of the actual situation in the prior art as described above. Eyes In general, the disposal process can be performed safely and easily, and the power consumption can be reduced, and the printed circuit board can be easily held at a predetermined position in the elongated tube, and the metal fittings can be easily attached to the elongated tube. Integrate But Can Various existing elongated tubes with different diameters can be used in combination with existing fittings with different diameters, and even if the bushing becomes hot during use, the elongated tube is prevented from being damaged. The bushing can be securely fixed to the elongated tube The object is to provide an LED lighting.
[0017]
[Means for Solving the Problems]
Up Note In order to achieve Tomorrow In an LED illuminating lamp comprising a plurality of LED bodies that emit light when energized, the print is made of an elongated rigid material, and the plurality of LEDs are arranged on the upper surface side at predetermined intervals along the longitudinal direction. A board, an elongated tube that accommodates the printed board and has translucency and shape retention, an electric component including a full-wave rectifier diode and a plurality of current limiting resistors disposed on the lower surface side of the printed board; A pair of bushings made of an insulating material attached to both ends of the elongated tube and fixing the printed circuit board in the elongated tube, a pair of fittings attached to the outer circumferences of these bushings, and these fittings A pair of electrode pins, respectively, A connection body which is a lead wire soldered to the printed circuit board at one end and the electrode pin at the other end, and the bushing includes a ring groove into which the elongated tube is fitted, and an edge of the printed circuit board A pedestal on which the portion is mounted, a through hole through which the lead wire passes, and an attachment tube portion into which the fitting is press-fitted, and the inner peripheral wall diameter of the ring groove of the bushing is set smaller than the inner diameter of the elongated tube By doing so, a clearance is formed between the inner peripheral wall of the bushing ring groove and the inner wall of the elongated tube when the inner peripheral wall of the ring groove of the bushing bulges outward due to heat. In addition, the inner wall of the elongated tube is fixed to the inner peripheral wall of the ring groove of the bushing by interposing an adhesive that does not cure with heat in the gap. It is configured.
[0018]
In this way In the light Since the LED body can emit light with relatively high luminance at a low current, the power consumption can be reduced. In addition, even if the elongated tube that houses the components is damaged, mercury is not enclosed like the fluorescent lamp and mercury does not adhere to the damaged elongated tube, so the disposal of the elongated tube can be performed safely and easily. The Furthermore, by attaching the bushings to both ends of the elongated tube, the printed circuit board can be easily held at a predetermined position in the elongated tube by these bushings, and the mouthpiece provided with the electrode pins on the elongated tube can be easily integrated.
[0020]
In addition, the present invention Can easily perform electrical connection between the printed circuit board and the electrode pins by soldering both ends of the lead wires to the electrode pins provided on the printed circuit board and the fitting.
[0024]
In addition, the present invention Can easily prepare a plurality of bushings with different diameters of the ring groove in which the elongated tube is fitted and the diameter of the mounting cylinder part in which the fitting is fitted, and the existing diameter can be changed by appropriately changing the bushings. It is possible to use a combination of various elongated tubes with different diameters and various fittings with different diameters.
[0026]
In addition, the present invention Even if the bushing becomes hot and the inner peripheral wall of the ring groove bulges outward due to high heat, the clearance between the inner peripheral wall of the ring groove and the inner wall of the elongated tube is an escape allowance. Since the adhesive interposed in the gap is not cured by heat, the force applied to the inner wall of the elongated tube due to the bulge is reduced. This prevents the elongated tube from being damaged even when the bushing becomes hot during use, and allows the bushing to be securely fixed to the elongated tube.
[0034]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the LED lighting of the present invention Light Embodiments will be described with reference to the drawings.
[0035]
FIG. 1 is a perspective view showing an LED illumination lamp according to an embodiment of the present invention, FIG. 2 is a plan view of a printed circuit board provided in the LED illumination lamp of this embodiment, and FIG. 3 is a plan view of the LED illumination lamp of this embodiment. FIG. 4 is a view of the LED illumination lamp of this embodiment as viewed from below, FIG. 5 is a side view of the LED illumination lamp of this embodiment, and FIG. 6 is an enlarged plan view showing a part a of FIG. 7 is an enlarged side view showing the portion b in FIG. 5, FIG. 8 is an enlarged view showing the portion c in FIG. 4, FIG. 9 is a sectional view taken along line XX in FIG. 3, and FIG. FIG. 11 is a front view of an LED body provided in the LED illumination lamp of the present embodiment, and FIG. 12 is an enlarged sectional view showing an end portion of the LED illumination lamp of the present embodiment. FIG. 13 is a side view of the bushing provided in the LED illumination lamp of this embodiment as viewed from the inside, and FIG. 14 is along the ZZ line of the bushing of FIG. FIG. 15 is a side view of the bushing provided in the LED illumination lamp of this embodiment as viewed from the outside, FIG. 16 is an explanatory diagram of an existing illumination device in which the LED illumination lamp of this embodiment is used, and FIG. FIG. 18 is a flowchart showing a process for manufacturing the LED illumination lamp of this embodiment. In FIG. 1, illustration of wiring on a printed circuit board provided in the LED lighting is omitted.
[0036]
An LED illuminating lamp 1 according to the present embodiment shown in FIG. 1 includes a cylindrical elongated tube 2 having translucency and shape retention, and an elongated printed board 3 made of a rigid material installed in the elongated tube 2. A plurality of LED bodies (that is, light emitting diodes) 4 as light emitting sources arranged at predetermined intervals on the upper surface side 3A of the printed circuit board 3 along the longitudinal direction of the printed circuit board 3, and the lower surface of the printed circuit board 3 An electrical component 7 including a full-wave rectifier diode 5 and a plurality of current limiting resistors 6 disposed on the side 3B, and an insulating material attached to both ends of the elongated tube 2 and fixing the printed circuit board 3 in the elongated tube 2 2 and a pair of fittings 10 and 11 attached to the outer peripheries of these bushings 8 and 9, respectively. As shown in FIG. Metal fittings 10 and 11 Connectors 12 and 13 for electrical connection between the cement board 3, respectively.
[0037]
The elongated tube 2 is formed of a circular tube made of transparent glass having an outer diameter of about 30 mm × an inner diameter of about 27 mm × a length of about 561 mm, for example, and dust adheres to the printed circuit board 3, the LED body 4, and the electrical component 7. It is designed to prevent or prevent water droplets from adhering.
[0038]
The printed circuit board 3 is made of, for example, a heat-resistant synthetic resin plate having a length of about 559 mm, a width of about 26.6 mm, and a thickness of about 1.5 mm. As described above, the width of the printed circuit board 3 is about 26.6 mm, the inner diameter of the elongated tube 2 is about 27 mm, and the width of the printed circuit board 3 is slightly smaller than the inner diameter of the elongated tube 2. When the printed circuit board 3 is inserted into the tube 2, the inner wall of the elongated tube 2 functions as a guide wall.
[0039]
Further, as shown in FIGS. 1, 2, 3, and 5, 10 LED bodies 4 are aligned on the upper surface side 3 </ b> A of the printed circuit board 3 at regular intervals along the longitudinal direction of the printed circuit board 3. It is arranged in a shape. The interval between the LED bodies 4 is preferably set so that the distance from the mounting center of the LED body 4 to the mounting center of the adjacent LED body 4 is about 54 mm. On the lower surface side 3B of the printed circuit board 3, ten current limiting resistors 6 are arranged in a straight line at equal intervals along the longitudinal direction of the printed circuit board 3, as shown in FIGS. It is set up. These current limiting resistors 6 are 1.6 kΩ, and are arranged so as to be positioned below the LED bodies 4. One full-wave rectifier diode 5 is disposed on one end side of the lower surface side 3B of the printed circuit board 3, and this full-wave rectifier diode 5 converts the direct current into a direct current when the power source is an alternating current. A current is supplied to the LED body 4, and when the power source is a direct current, the direct current is supplied to the LED body 4 as it is.
[0040]
A plurality of LED bodies 4 having the same shape and the same size are used, and those having a structure that emits light in a green color when turned on are used. As shown in FIG. 11, all LED bodies 4 are made of an epoxy resin container-shaped lens 4A, a semiconductor chip 4B housed in the lens 4A, and a direct current of about 10 to 15 mA in the semiconductor chip 4B. Are provided with two pin-shaped metal conductors 4C and 4D. The lens 4A has a narrow directional lens structure that directs light from the semiconductor chip 4B in one direction.
[0041]
The bushings 8 and 9 are made of a synthetic resin material having excellent insulation, heat resistance and dimensional stability, for example, polybutylene terephthalate material. For example, as shown in FIGS. 12 to 15, the bushing 8 includes a ring groove 8 </ b> A into which the elongated tube 2 is press-fitted, a pedestal 8 </ b> B on which an edge of the printed circuit board 3 is placed, and a through hole through which the connecting body 13 passes. 8C, a cylindrical mounting tube portion 8D into which the fitting 10 is press-fitted, and a receiving ring body 8F provided in the mounting tube portion 8D. In this bushing 8, by setting the diameter of the inner peripheral wall 8A-1 of the ring groove 8A to be smaller than the inner diameter of the elongated tube 2, the inner peripheral wall 8A-1 of the ring groove 8A of the bushing 8 bulges outward due to heat. A gap G1 serving as a clearance in this case is formed between the inner peripheral wall 8A-1 of the ring groove 8A and the inner wall of the elongated tube 2. In the gap G1, the inner wall of the elongated tube 2 is fixed to the inner peripheral wall 8A-1 of the ring groove 8A by interposing an adhesive that is not cured by heat. A silicon-based material having the property of maintaining flexibility even when 2 is bonded to the ring groove 8A is used. In addition, a plurality of ribs 8E having a height of about 0.5 mm and a hemispherical cross section are formed on the outer peripheral wall 8D-1 of the mounting cylinder portion 8D at substantially equal intervals.
[0042]
Similarly, the other bushing 9 also has a ring groove 9A, a pedestal 9B, a through hole 9C, a mounting cylinder portion 9D, and a receiving ring body 9F, and the diameter of the inner peripheral wall 9A-1 of the ring groove 9A is the elongated tube 2 By setting the inner diameter of the ring groove 9A smaller than the inner diameter wall of the ring groove 9A, the gap G1 is a clearance between the inner peripheral wall 9A-1 of the ring groove 9A and the elongated tube 2. It is formed between the inner walls. A plurality of ribs 9E having a height of about 0.5 mm and a hemispherical cross section are formed at substantially equal intervals on the outer peripheral wall 9D-1 of the mounting cylinder portion 9D.
[0043]
And the printed circuit board 3 mounts the edge part of the printed circuit board 3 on the bases 8B and 9B of the bushings 8 and 9, and attaches the bases 8B and 9B and the lower surface side edge part of the printed circuit board 3 with an adhesive. By pasting, the bushings 8 and 9 are fixed.
[0044]
The metal fitting 10 includes a metal body 10A that is press-fitted into the outer periphery of the mounting cylinder portion 8D, one electrode pin 10B that is electrically connected to a power supply circuit portion 15 of an existing lighting device 14 described later, and a metal body 10A. And an insulating disc 10C made of an insulator that supports the electrode pin 10B. The electrode pin 10B is made of a conductive material, and is made of, for example, brass. When the metal fitting 10A of the metal fitting 10 is press-fitted into the attachment cylinder portion 8D of the bushing 8 when the fitting 10 is attached to the bushing 8, the metal fuselage 10A is guided to the rib 8E, and the metal fuselage 10A is not biased. The metal body 10A smoothly fits into the mounting cylinder portion 8D of the bushing 8, and an adhesive flows into the recess formed by the rib 8E of the mounting cylinder portion 8D of the bushing 8 to the outside of the metal body 10A. Adhesive does not flow out. The receiving ring body 8F provided in the mounting cylinder portion 8D has a function of preventing deformation such as the movement of the insulating disk 10C. The other end fitting 11 is the same, and has a metal body 11A, one electrode pin 11B, and an insulating disk 11C.
[0045]
The connection body 12 is composed of a lead wire made of a single copper wire having one end 12A soldered to the printed circuit board 3 and the other end 12B soldered to the electrode pin 10B of the fitting 10 through the through hole 8C of the bushing 8. Has been. The other connecting body 13 is also the same, and one end 13A is soldered to the printed circuit board 3, and the other end 13B is soldered to the electrode pin 11B of the fitting 11 through the through hole 9C of the bushing 9. It is comprised from the lead wire which consists of.
[0046]
The existing illumination device 14 shown in FIG. 16 includes a first receiver 16 and a second receiver 17 that detachably attach the LED illumination lamp 1 to a predetermined place, and the first receiver 16 and the second receiver 16. Mounting brackets 19, 20 for fixing the receiver 17 to the mounting member 18, a power outlet 21 connected to the power supply circuit section 15, a first wiring cord 22 connecting the first receiver 16, and a power outlet 21 A second wiring cord 23 for connecting the second receiver 17 is provided. Between the 1st receptacle 16 and the fitting 10, or between the 2nd receptacle 17 and the fitting 11, it consists of elastic materials, such as rubber | gum and silicon with a large frictional resistance, A donut-shaped anti-rotation member 24 for preventing rotation is provided.
[0047]
As shown in FIG. 17, a first LED series circuit 25 in which five LED bodies 4 and five current limiting resistors 6 are alternately connected in series is formed, and the other five LED bodies 4 and five are formed. The second LED series circuit 26 in which the current limiting resistors 6 are alternately connected in series is formed, and the LED series circuits 25 and 26 are connected in parallel to form a parallel circuit. In contrast, one full-wave rectifier diode 5 is connected in series. The printed wiring between the LED series circuits 25 and 26 and the full-wave rectifier diode 5 is laid on the printed circuit board 3 as shown in FIG.
[0048]
In the LED illumination lamp 1 of the embodiment configured as described above, the following effects can be obtained. That is, (1) The present applicant states that the temperature in the elongated tube 2 can be maintained within about 60 ° C. even if the LED body 4 is turned on when the environmental temperature of the LED lighting lamp 1 is 50 ° C. It was confirmed by experiment.
[0049]
(2) By adopting the LED body 4 that can obtain high brightness at a low current, it has been confirmed by experiments by the present applicant that the power consumption of the LED lighting lamp 1 is reduced to about 1/4 compared with the conventional one. did it.
[0050]
(3) It has been confirmed by an experiment by the present applicant that the life of the LED lighting lamp 1 is extended and the replacement of the LED lighting lamp 1 can be extended from about 1 year to about 14 years.
[0051]
(4) Since mercury or argon gas is not enclosed in the elongated tube 2, even if the elongated tube 2 is damaged, mercury adheres to the human body or clothes of the person who discards the damaged elongated tube 2. It is safe because there is no danger.
[0052]
(5) When replacing the old elongated tube 2 with a new one due to the life of the LED lighting lamp 1 and discarding the old elongated tube 2, mercury is not diffused to the surroundings even if the elongated tube 2 is crushed. In order to prevent mercury from adhering to an operator who crushes the tube 2, a large crushing device is not required and can be easily performed. Moreover, since mercury does not adhere to the crushed glass tube 2, it is not handled as industrial waste and can be easily reused.
[0053]
(6) Since it is not necessary to enclose mercury or argon gas in the elongated tube 2, it is possible to easily form the elongated tube 2 and attach the elongated tube 2 to the bushings 8 and 9 and the fittings 10 and 11. it can.
[0054]
(7) The full-wave rectifier diode 5 can be used for both AC and DC power supplies.
[0055]
(8) Since the first LED series circuit 25 and the second LED series circuit 26 are connected in parallel, when the LED body 4 of the first LED series circuit 25 is cut (damaged), or Even when the LED body 4 of the second LED series circuit 26 is cut off, the LED bodies 4 of the printed circuit board 3 are alternately turned on and off, and all the LED bodies 4 of the printed circuit board 3 are not turned off, and LED lighting is performed. The lamp 1 can be used continuously.
[0056]
(9) Only the plurality of LED bodies 4 are arranged in a substantially straight line on the upper surface side of the printed circuit board 3 and only the plurality of electrical components 7 are arranged in a substantially straight line on the lower surface side of the printed circuit board 3. The upper and lower surfaces of the printed circuit board 3 are clean and the LED lighting lamp 1 has a good appearance, and the heat generated from the current limiting resistor 6 is blocked by the printed circuit board 3 and below the elongated tube 2. Since the LED body 4 is not directly warmed by the heat generated from the current limiting resistor 6 because the LED body 4 is not directly warmed by the heat generated from the current limiting resistor 6. Can be prevented.
[0057]
(10) The electrical connection between the printed circuit board 3 and the electrode pins 10B and 11B can be easily performed by the connecting bodies 12 and 13 made of lead wires.
[0058]
(11) Holding the printed circuit board 3 at a predetermined position in the elongated tube 2 by the bushings 8 and 9, and integrating the fittings 10 and 11 provided with the electrode pins 10B and 11B on the elongated tube 2 It can be done without difficulty.
[0059]
(12) Prepare a plurality of bushings having different diameters of the ring grooves 8A and 9A into which the elongated pipe 2 is fitted and the diameters of the mounting cylinder portions 8D and 9D into which the fittings 10 and 11 are fitted. By changing, it is possible to appropriately combine and use various kinds of elongated tubes having different diameters and various kinds of end fittings having different diameters.
[0060]
(13) Even when the bushings 8 and 9 are in a high temperature state during use of the LED lighting lamp 1 and the inner peripheral walls 8A-1 and 9A-1 of the ring grooves 8A and 9A are thermally expanded outward, the ring grooves 8A and 9A Since there is a gap between the inner peripheral walls 8A-1 and 9A-1 and the inner wall of the elongated tube 2 and the adhesive is not cured, the force applied to the inner wall of the elongated tube 2 due to this thermal expansion is reduced. Accordingly, the bushings 8 and 9 can be securely fixed to the elongated tube 2 without damaging the elongated tube 2.
[0061]
(14) When an adhesive is applied to the outer peripheral walls 8D-1 and 9D-1 of the mounting cylinders 8D and 9D of the bushings 8 and 9, a sufficient amount of adhesive adheres to the recesses between the hemispherical ribs 8E and 9E. In addition, the base is press-fitted to the outer peripheral walls 8D-1 and 9D-1 of the bushing portions 8D and 9D of the bushings 8 and 9 by the plurality of hemispherical ribs 8E and 9E without being biased, and the adhesive is applied to the base 10. , 11 and the bushings 8, 9 are prevented from flowing out to the minimum, so that the bushings 8, 9 and the bases 10, 11 are securely and securely fixed.
[0062]
Moreover, the manufacturing method of the LED lighting lamp 1 of this embodiment is performed according to a series of processes S1-S4 shown in FIG. That is, as the component mounting step S1, ten LED bodies 4, one full-wave rectifier diode 5 and ten electric current limiting resistors 6 and connection bodies 12 and 13 are connected to the printed circuit board 3. After the attachment, as an insertion step S2, the printed circuit board 3 is inserted into the elongated tube 2, and as the bushing attachment step S3, bushings 8, 9 for fixing the printed circuit board 3 in the elongated tube 2 are attached to both ends of the elongated tube 2. Next, as a fitting attachment step S4, the fitting 10 is attached to the outer periphery of the bushing 8, the other fitting 11 is attached to the outer periphery of the bushing 9, and the electrical connection between the electrode pin 10B of the fitting 10 and the connection body 13 is performed. The connection is performed, and the electrode pins 11B of the other metal fittings 11 and the connection body 12 are electrically connected.
[0063]
In the fitting attachment step S4, after the bushing attachment step S3 is finished, an adhesive is applied to the outer periphery of the bushings 8, 9, and then the fittings 10, 11 are press-fitted and fixed to the outer periphery of the bushings 8, 9, respectively. The pins 10B and 11B and the connection bodies 12 and 13 may be electrically connected. In the bushing attachment step S3, an adhesive may be applied in advance to the bushings 8 and 9 side.
[0064]
According to the manufacturing method of the LED lighting lamp 1 of the present embodiment configured as described above, the LED lighting lamp 1 can be smoothly assembled according to the steps S1 to S2, so that the productivity of the LED lighting lamp 1 can be increased. It can be improved.
[0065]
In the LED illumination lamp 1 of the present embodiment, the elongated tube 2 is made of transparent glass, but is not limited to this, and may be one that allows light to pass and has shape retention and flame retardancy. For example, it may be made of synthetic resin.
[0066]
19 is an explanatory view showing a modified example of the bushing provided in the LED lighting, FIG. 20 is a cross-sectional view showing an example of the supporting material provided in the LED lighting, and FIG. 21 is a modified example of the supporting material provided in the LED lighting. FIG. 22 is a cross-sectional view showing another modification of the support member provided in the LED illumination lamp.
[0067]
The bushings 8 and 9 shown in FIG. 19 have printed circuit board pressing portions 8H and 9H formed integrally with the bushings 8 and 9, respectively, and the other structures are basically the same as the bushings 8 and 9. . The printed circuit board pressing portions 8H and 9H are pressed by the pedestals 8B and 9B of the bushings 8 and 9 in the bushing mounting step S3 when manufacturing the LED lamp 1 in the bushing attachment process S3. It has a function to maintain the state. Accordingly, since the printed circuit board 3 and the bases 8B and 9B are not separated by the printed circuit board pressing portions 8H and 9H, the printed circuit board 3 and the bases 8B and 9B can be reliably fixed by the adhesive.
[0068]
Further, a support material made of an insulating material, for example, a support pin 27 is provided below the elongated tube 2 shown in FIG. 20 and is in contact with the center portion of the lower surface side 3B of the printed circuit board 3, so that the support pin By supporting the central portion of the printed board 3 with 27, the warp of the printed board 3 inserted into the elongated tube 2 can be suppressed.
[0069]
Further, in the elongated tube 2 shown in FIG. 21, a support material made of an insulating material, for example, a support pin 28 is erected in the vertical direction and penetrates through the central portion of the printed circuit board 3. By supporting the central portion of the substrate 3, it is possible to suppress warping of the printed substrate 3 inserted into the elongated tube 2.
[0070]
Further, U-shaped support materials 29 made of an insulating material are attached to both sides in the width direction of the printed circuit board 3 shown in FIG. 22, and both width direction sides of the printed circuit board 3 are supported by these support materials 29. Thus, warping of the printed circuit board 3 inserted into the elongated tube 2 can be suppressed.
[0071]
【The invention's effect】
As explained above, Tomorrow Since the LED body can emit light with relatively high luminance at a low current, the power consumption can be reduced. In addition, even if the elongated tube that houses the components is damaged, mercury is not enclosed like the fluorescent lamp and mercury does not adhere to the damaged elongated tube, so the disposal of the elongated tube can be performed safely and easily. The Furthermore, the bushing attached to both ends of the elongated tube can easily hold the printed circuit board at a predetermined position in the elongated tube, and can easily integrate a fitting provided with electrode pins on the elongated tube.
[0072]
Also , By soldering both ends of the connection body made of the lead wires to the electrode pins provided on the printed circuit board and the mouth metal fitting, electrical connection between the printed circuit board and the electrode pins can be easily performed.
[0074]
Also , Thin A plurality of bushings with different diameters of the ring groove into which the long pipe is fitted and the diameter of the mounting cylinder part into which the fitting is fitted can be easily prepared. By appropriately changing these bushings, the existing diameters are different. It can be used in combination with various elongated tubes and various types of fittings with different diameters.
[0075]
Also The Even if the shing becomes hot and the inner peripheral wall of the ring groove bulges outward due to high heat, the clearance between the inner peripheral wall of the ring groove and the inner wall of the elongated tube is a clearance, and the above-mentioned Since the adhesive interposed in the gap is not cured by heat, the force applied to the inner wall of the elongated tube due to the bulge is reduced. Therefore, even if the bushing becomes hot during use, the elongated tube can be prevented from being damaged, and the bushing can be securely fixed to the elongated tube.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an LED illumination lamp according to an embodiment of the present invention.
FIG. 2 is a plan view of a printed circuit board provided in the LED illumination lamp of the present embodiment.
FIG. 3 is a plan view of the LED illumination lamp of the present embodiment.
FIG. 4 is a view of the LED illumination lamp of the present embodiment as viewed from below.
FIG. 5 is a side view of the LED illumination lamp of the present embodiment.
6 is an enlarged plan view showing a part a of FIG. 3;
7 is an enlarged side view showing a part b of FIG. 5. FIG.
8 is an enlarged view of a portion c in FIG.
9 is a cross-sectional view taken along line XX of FIG.
10 is a cross-sectional view taken along line YY of FIG.
FIG. 11 is a front view of an LED body provided in the LED illumination lamp of the present embodiment.
FIG. 12 is an enlarged cross-sectional view showing an end portion of the LED illumination lamp of the present embodiment.
FIG. 13 is a side view of a bushing provided in the LED illumination lamp of the present embodiment as viewed from the inside.
14 is a cross-sectional view of the bushing of FIG. 13 taken along the line ZZ.
FIG. 15 is a side view of a bushing provided in the LED illumination lamp of the present embodiment as viewed from the outside.
FIG. 16 is an explanatory diagram of an existing illumination device in which the LED illumination lamp of the present embodiment is used.
FIG. 17 is an electric circuit diagram of a printed circuit board provided in the LED illumination lamp of the present embodiment.
FIG. 18 is a flowchart showing a process for manufacturing the LED illumination lamp of the present embodiment.
FIG. 19 is an explanatory view showing a modified example of the bushing provided in the LED illumination lamp.
FIG. 20 is a cross-sectional view showing an example of a support member provided in the LED illumination lamp.
FIG. 21 is a cross-sectional view showing a modified example of the support member provided in the LED lighting.
FIG. 22 is a cross-sectional view showing another modification of the support member provided in the LED illumination lamp.
FIG. 23 is an explanatory view showing a general fluorescent lamp.
[Explanation of symbols]
1 LED lighting
2 Elongated pipe
3 Printed circuit board
4 LED body (light source)
5 Full-wave rectifier diode
6 Current limiting resistor
7 Electrical parts
8,9 bushing
8H, 9H Printed circuit board retainer
10, 11 metal fittings
10B, 11B electrode pin
12, 13 connection body
14 Existing lighting equipment
15 Power supply circuit
24 Anti-rotation member
25 1st LED series circuit
26 Second LED series circuit
27 Support pin (support material)
28 Support pin (support material)
29 Support material

Claims

In an LED illumination lamp including a plurality of LED bodies that emit light when energized,
A printed circuit board made of an elongated rigid material, in which the plurality of LEDs are arranged on the upper surface side at predetermined intervals along the longitudinal direction, and accommodates the printed circuit board, and has translucency and shape retention. An elongated tube, a full wave rectifier diode disposed on the lower surface side of the printed circuit board and a plurality of current limiting resistors, and attached to both ends of the elongated tube, the printed circuit board is fixed in the elongated tube. A pair of bushings made of insulating material, a pair of fittings attached to the outer periphery of each of these bushings, a pair of electrode pins respectively provided on these fittings, one end on the printed circuit board, and the other end A connection body that is a lead wire to be soldered to each of the electrode pins,
The bushing includes a ring groove into which the elongated tube is fitted, a pedestal on which an end edge portion of the printed circuit board is placed, a through hole through which the lead wire passes, and an attachment tube portion into which the fitting is press fitted. Have
By setting the inner peripheral wall diameter of the ring groove of the bushing to be smaller than the inner diameter of the elongated tube, the bushing has a clearance as a clearance when the inner peripheral wall of the ring groove of the bushing bulges outward due to heat. The elongated tube is formed between the inner circumferential wall of the ring groove of the bushing and the inner wall of the elongated tube, and an adhesive that is not cured by heat is interposed in the gap, thereby forming the elongated tube on the inner circumferential wall of the ring groove of the bushing. LED lighting characterized by fixing the inner wall of the LED.

The plurality of LED bodies are arranged in a substantially straight line on the upper surface side of the printed circuit board, and the electrical components are arranged in a substantially straight line on the lower surface side of the printed circuit board and below the LED bodies. The LED illumination lamp according to claim 1, wherein

2. The LED illumination lamp according to claim 1, wherein a plurality of ribs having a hemispherical cross section are formed on an outer peripheral wall of the mounting cylinder portion of the bushing.

It said elongated tube, LED lighting lamp according to any one of claims 1 to 3, characterized in that a supporting member for supporting the predetermined position of the printed circuit board.