JP2000100219A - Vehicular lamp using led as light source and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a vehicular lamp using LEDs as a light source that can uniformize the distance between LEDs and a lens plate with a simple structure and wherein the difference of luminance is hardly generated depending on a viewing direction from the outside. SOLUTION: Cross-sectionally U-shaped metal frames 40 serving as electrodes for an LED board 32 as well are fitted to both edge parts of the LED board 32 composed by mounting LEDs 1 on a flat board and forming bending lines 33 at predetermined positions, the LED board 32 and the metal frames 40 are bent with that form kept, the bent LED board 32 is fixed to boss parts 44 of a lamp housing with the metal frames 40, and thereby, the respective LED board 32 parts divided by the bending are arranged along and generally in parallel with the curved surface of a lens plate of the lamp housing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicular lamp using an LED (light emitting diode) as a light source, which is used for a tail lamp and a stop lamp of a vehicle, and a method of manufacturing the same.

[0002]

2. Description of the Related Art A vehicular lamp using an LED as a light source is known, for example, from Japanese Patent Application Laid-Open No. 6-349306. As shown in FIG. 7, the lamp described in the publication has an LED board 2 (2a to 2a) on which a large number of LEDs 1 as light sources are mounted.
2g) is housed in the lamp housing 3, and the lens plate 3 for transmitting the light of the LED 1 in the lamp housing 3 to the outside.
b is formed into a curved surface. In this case, since the lens plate 3b is formed in a curved surface, the housing main body 3a is formed in a stepped shape in accordance with the curved surface, and the divided LED boards 2a to 2g are arranged on each step of the step. Thus, the lens cut portions 4 formed on the lens plate 3b and the LEDs 1 are set so as to be at equal intervals. By setting the lens cut portions 4 and the LEDs 1 at equal intervals in this manner, it is possible to prevent unevenness in the brightness of the lens surface and improve the appearance.

[0003]

By the way, in the above-mentioned conventional example, in order to equalize the distance between the LED 1 and the lens plate 3b, the housing main body 3a is formed in a step shape and divided into respective steps. Each of the LED boards 2a to 2g was attached, but the structure was complicated and the attaching operation was troublesome. Further, since the optical axis directions of the LEDs 1 are all parallel, for example, when the curvature of the lens plate 3b is large, there is a possibility that a difference in luminance occurs depending on the direction viewed from the outside.

The present invention has been made in consideration of the above circumstances, and has a simple structure, whereby the distance between the LED and the lens plate can be made uniform, and furthermore, there is little difference in luminance depending on the viewing direction from the outside. It is an object of the present invention to provide a vehicular lamp as a light source and a method of manufacturing the same.

[0005]

According to a first aspect of the present invention, an LED board on which a plurality of LEDs as light sources are mounted is housed in a lamp housing, and the LED of the lamp housing is provided.
L having a curved lens plate for transmitting the light to the outside
In a vehicle lamp using an ED as a light source, the LED substrate is divided into a plurality of portions in a curved surface direction of the lens plate, and the divided LED substrates are arranged substantially in parallel along the curved surface of the lens plate. .

In this lamp, by fixing the divided LED board to the lamp housing in the same posture,
They can be arranged substantially parallel along the curved surface of the lens plate.

According to a second aspect of the present invention, there is provided a vehicular lamp using the LED according to the first aspect as a light source, wherein the divided LED boards are connected to each other behind the divided LED boards. A flexible substrate is arranged, and wiring between the divided LED substrates is performed by the flexible substrate.

In this lamp, wiring between the divided LED substrates is performed by a flexible substrate.

According to a third aspect of the present invention, there is provided a vehicular lamp using the LED according to the second aspect as a light source, wherein the flexible substrate and the LED substrate have the same color.

In this lamp, since there is a flexible board behind the LED board, when viewed from the front, the LED board and the flexible board appear alternately. However, since both are made the same color, they are viewed from the outside. It doesn't look like a striped pattern.

According to a fourth aspect of the present invention, an LED board on which a large number of LEDs as light sources are mounted is housed in a lamp housing, and a lens plate of the lamp housing for transmitting the light of the LEDs to the outside is provided with a curved surface. In a vehicular lamp using an LED formed in a shape as a light source, the LED substrate is bent into a plurality in the curved surface direction of the lens plate, and each of the LED substrate portions divided by the bending is substantially formed along the curved surface of the lens plate. It is characterized by being arranged in parallel.

In this lamp, the LED substrate can be arranged in a straight posture along the curved surface of the lens plate in the same posture by bending. The LED can be mounted on a flat substrate by soldering or the like.

According to a fifth aspect of the present invention, there is provided a vehicular lamp using the LED according to the fourth aspect as a light source, wherein a folding line for facilitating bending is formed on the LED substrate in advance. And

In this lamp, the LED board can be reliably bent at the designated position where the folding line is formed.

According to a sixth aspect of the present invention, there is provided a vehicular lamp using the LED according to the fourth or fifth aspect as a light source, wherein the LE is provided on both side edges of the LED board along the bending direction.
A metal frame having a U-shaped cross section that holds the bent shape of the D substrate and also serves as an electrode for the LED substrate is fitted.

In this lamp, the metal frame holds the bent shape of the LED substrate and also serves as an electrode for the LED substrate.

According to a seventh aspect of the present invention, there is provided a vehicular lamp using the LED according to the sixth aspect as a light source, wherein the metal frame is provided on the surface of both side edges of each of the LED substrate portions divided by the bending. A substrate-side electrode that is electrically connected to the metal frame when the metal frame is fitted.

In this lamp, the metal frame can be used as an electrode for the LED substrate by simply fitting the metal frame to both side edges of the LED substrate.

According to an eighth aspect of the present invention, there is provided a method of manufacturing a vehicular lamp using an LED as a light source according to the sixth or seventh aspect, wherein the LED is mounted on a flat substrate and the substrate is bent at a predetermined position. L formed with a fold line that facilitates
An ED substrate is prepared, and a metal frame having a U-shaped cross section, which also serves as an electrode for the LED substrate, is fitted to both side edges of the LED substrate along a direction in which the LED substrate is to be bent. Each of the LEs divided by bending is bent together at the position of the line and by fixing the bent LED board to the lamp housing via the metal frame.
The D-substrate portion is arranged substantially parallel to the curved surface of the lens plate of the lamp housing.

According to this manufacturing method, the LED can be mounted on the flat substrate having the folding line at the predetermined position, and the LED substrate can be bent at the folding line position.
This can be performed in a state where the metal frame is fitted to both side edges of the LED substrate in advance.

Even when the LED substrate is completely divided, the divided LED substrate portions can be interconnected by the metal frame.

[0022]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1A is a sectional view of a schematic configuration of a first embodiment of the present invention. This vehicular lamp 10 includes:
It includes a lamp housing 13 and an LED board 12 housed therein. The LED board 12 is divided into a large number, and a plurality of LEDs 1 are mounted on each of the divided LED boards 12 in a line.

The lamp housing 13 includes the housing body 1.
3a and a lens plate 13b. The lens plate 13b is entirely formed into a curved surface, and a lens cut portion (not shown) is provided corresponding to each LED1. Each of the LED boards 12 is arranged substantially parallel to the curved surface of the lens plate 13b.

As shown in FIG. 1B, the LED substrate 12
The wiring between them is performed by a wiring code 17, and each L
The ED substrate 12 is fixed to the housing body 13 by screws 15.
The boss portion 14 is fixed to the boss portion 14 protruding from a.

In the case of the lamp 10, since the divided LED substrates 12 are arranged substantially in parallel along the curved surface of the lens plate 13b, the luminance does not vary depending on the direction viewed from the outside. The LED substrate 12 is mounted on the housing body 13a while keeping the posture along the curved surface of the lens plate 13b.
, The housing main body 13a does not need to be formed in a stepped shape, so that the structure can be simplified and the mounting operation can be simplified.

FIG. 2 shows an enlarged part of a second embodiment of the present invention. In the vehicle lighting device 20, a flexible board 21 interconnecting the divided LED boards 12 is provided behind the divided LED boards (rigid boards) 12.
Are arranged, and wiring between the divided LED substrates 12 is performed by the flexible substrate 21. Therefore, like the lamp 10 of the first embodiment in FIG.
There is no need to connect the ED substrates 12, and the structure is simpler.

In this lamp 20, the LED substrate 12
There is a possibility that the LED substrate 12 and the flexible substrate 21 may appear alternately in a striped pattern when viewed from the front when viewed from the front, but when viewed from the outside by setting both to the same color. Even if it does not look like a striped pattern, it does not impair the appearance.

FIGS. 3 to 6 are explanatory views of the manufacturing process of the vehicle lamp 30 according to the third embodiment of the present invention. Again,
Ultimately, each of the divided LED substrate portions is arranged substantially parallel along the curved surface of the lens plate. Here, illustration of the lamp housing is omitted.

When manufacturing the lamp 30 of the third embodiment, first, as shown in FIG. 3A, a flat rigid substrate having perforations or grooves formed as folding lines 33 at predetermined positions as shown in FIG. The LED substrate 32 is manufactured by mounting a plurality of LEDs 1 in a predetermined arrangement on 32a. In this case, each substrate portion to be divided is provided with an LED 1 and, if necessary, a resistor and a diode. LED board 3
As shown in FIG. 3 (b), electrodes 34 for energizing each LED 1 are provided on the back surface of both side edges along the direction in which the second LED 1 is to be bent. Up to this point, the rigid substrate 32a in the form of a flat plate is used as in the normal case, so that it can be manufactured as it is by the conventional process.

Next, as shown in FIGS. 4 and 5, metal frames 40 having a U-shaped cross section are fitted to both side edges of the LED board 32 along the direction in which the LED board 32 is to be bent. This metal frame 40 is LE
It has a notch 41 for facilitating bending at a position corresponding to the fold line 33 of the D board 32, and has terminal sections 42 with holes at both ends in the length direction, and is fitted to both side edges of the LED board 32. By being pressed into contact with the press, it is integrated with the LED substrate 32, conducts to the electrode 34 on the back surface of the LED substrate 32, and becomes the electrode for the LED substrate 32 as it is.

Then, after the metal frame 40 is fitted in this manner, as shown in FIG.
Are bent together at the position of the fold line 33, and the holed terminal portion 42 of the metal frame 40 is screwed 45 to the boss portion 4
4, the bent LED substrate 32 can be arranged in a predetermined form.

That is, each L divided by bending
The ED substrate 32 can be disposed substantially parallel to the curved surface of the lens plate of the lamp housing.

In this manufacturing method, the LED 1 is first placed on a rigid plate 32a having a folding line 33 at a predetermined position.
Can be mounted, so that the LED substrate 32 can be manufactured as it is by a conventional manufacturing process. Further, since the LED board 32 is bent at the position of the fold line 33 in a state where the metal frame 40 is fitted to both side edges of the LED board 32 in advance, excessive force is applied to the LED board 32.
The bent shape of the LED substrate 32 can be reliably held at a predetermined angle with little involvement of the substrate 32.

Further, since the metal frame 40 is present at the time of bending, even if the LED substrate 32 is completely divided, the divided LED substrate 32 portions should be interconnected by the metal frame 40. Can be.

In the lamp 30 manufactured as described above, since the LED substrate 32 divided by bending is arranged substantially in parallel along the curved surface of the lens plate, similar to the lamp of the previous embodiment, the luminance depends on the viewing direction. There will be no variation.

Further, since the folding line 33 is formed on the LED board 32 in advance, it can be easily and reliably bent at a designated position at the time of mounting. Further, since the LED board 32 can be attached to the lamp housing by the metal frame 40 also serving as an electrode for the LED board 32, the attachment can be simplified, and the terminal 5 at the tip of the power cord 50 can be attached.
The wiring connection of the LED board 32 can be completed only by fastening the 1 together with the screw 45.

[0038]

As described above, according to the first aspect of the present invention, since the divided LED substrates are arranged substantially in parallel along the curved surface of the lens plate, the luminance does not vary depending on the viewing direction. . Further, since it is not necessary to form the housing in a step shape, the structure can be simplified, and the LED can be used.
The work of mounting the substrate can be easily performed.

According to the second aspect of the present invention, a flexible substrate is arranged behind the divided LED substrate, and the wiring between the divided LED substrates is performed by the flexible substrate. Is unnecessary, and the structure becomes simpler.

According to the third aspect of the present invention, since the LED substrate and the flexible substrate have the same color, the LED substrate and the flexible substrate do not look like a stripe even when viewed from the outside.
Does not impair the appearance.

According to the fourth aspect of the present invention, since the LED substrates divided by bending are arranged substantially in parallel along the curved surface of the lens plate, the luminance does not vary depending on the viewing direction. Further, since it is not necessary to form the housing in a stepped shape, the structure is simplified and the installation is not troublesome. In addition, since it is only necessary to bend the LED board and attach it later, it is sufficient to mount the LED on the flat board at the beginning and perform soldering or the like, and the conventional manufacturing process can be used as it is.

According to the fifth aspect of the present invention, since the folding line is formed on the LED substrate in advance, it is possible to easily and reliably bend at the designated position when mounting.

According to the sixth aspect of the present invention, since the metal frames are fitted to both side edges of the LED board, the LED board can be securely mounted on the lamp housing in a stable posture. In addition, since the metal frame also serves as an electrode for the LED board, when attaching the metal frame to the lamp housing with a screw, for example, simply tighten the terminal at the end of the power cord together with a screw, and the wiring connection of the LED board is made. Can be completed.

According to the seventh aspect of the present invention, the metal frame can be used as an electrode for the LED substrate without fitting any special wiring by merely fitting the metal frame to both side edges of the LED substrate. Can be.

According to the invention of claim 8, the LED substrate can be manufactured as it is by the conventional manufacturing process. In addition, since the LED frame is bent after fitting the metal frame to both side edges of the LED substrate, an excessive force is less likely to be applied to the LED substrate, and the bent shape of the LED substrate can be held at a predetermined angle. . Therefore, the LED substrate can be fixed in an appropriate posture along the lens plate. Further, even when the LED substrate is completely divided by bending, the LED substrate portions divided by the metal frame can be connected to each other, so that there is little trouble in mounting.

[Brief description of the drawings]

FIG. 1 is a schematic configuration diagram of a first embodiment of the present invention, in which (a)
Is a sectional view, and (b) is an enlarged perspective view of a main part.

FIG. 2 is an enlarged perspective view of a main part of a second embodiment of the present invention.

FIGS. 3A and 3B are explanatory views of a third embodiment of the present invention, wherein FIG. 3A is a perspective view showing a front surface of an LED substrate before bending, and FIG.

FIG. 4 is an explanatory view of the third embodiment of the present invention, and is a perspective view showing a state where metal frames are about to be fitted to both side edges of the LED board before bending.

FIG. 5 is an explanatory view of the third embodiment of the present invention, and is a side view showing a state where metal frames are fitted to both side edges of the LED board before bending.

FIG. 6 is an explanatory view of the third embodiment of the present invention, and is a perspective view showing a state in which an LED board on which a metal frame is fitted is bent.

FIG. 7 is a sectional view of a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 LED 10 Vehicle lamp 12 LED board 13 Lamp housing 13b Lens plate 20 Vehicle lamp 21 Flexible substrate 30 Vehicle lamp 32 LED substrate 33 Folding line 34 Electrode 40 Metal frame

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3K080 AA01 AB01 AB16 AB17 BA07 BB02 BE07 CC06 CC17 5F041 AA31 DB08 DC07 DC22 DC25 DC75 DC83 EE11 FF16

Claims (8)

[Claims] An LED having a plurality of LEDs mounted thereon as a light source is housed in a lamp housing, and an LED having a curved lens plate for transmitting the light of the LEDs of the lamp housing to the outside is used as a light source. In the vehicle lamp described above, the LED substrate is divided into a plurality of parts in a curved surface direction of the lens plate, and the divided LED substrates are arranged substantially in parallel along the curved surface of the lens plate. Vehicle lighting device. 2. A vehicular lamp using the LED according to claim 1 as a light source, wherein the divided LE is provided behind the divided LED substrate.
A vehicular lamp using an LED as a light source, wherein a flexible substrate that connects the D substrates is arranged, and wiring between the divided LED substrates is performed by the flexible substrate. 3. A vehicular lamp using the LED according to claim 2 as a light source, wherein the flexible substrate and the LED substrate have the same color. 4. An LED having a plurality of LEDs as a light source mounted in a lamp housing, and an LED having a curved lens plate for transmitting the light of the LEDs of the lamp housing to the outside. In the vehicle lighting device, the LED substrate is bent into a plurality of pieces in the curved surface direction of the lens plate, and the LED board portions divided by the bending are arranged substantially in parallel along the curved surface of the lens plate. A vehicle lamp using an LED as a light source. 5. A vehicular lamp using the LED according to claim 4 as a light source, wherein a fold line for facilitating bending is formed on the LED substrate in advance. Vehicle lighting fixtures. 6. A vehicular lamp using the LED according to claim 4 or 5 as a light source, wherein the LED board holds the bent shape of the LED board at both side edges of the LED board along the bending direction. A vehicular lamp using an LED as a light source, wherein a metal frame having a U-shaped cross section serving also as an electrode for a substrate is fitted. 7. A vehicular lamp using the LED according to claim 6 as a light source, wherein the metal frame is fitted to surfaces of both side edges of each of the LED substrate portions divided by the bending. A vehicular lamp using an LED as a light source, comprising a substrate-side electrode that is electrically connected to a metal frame. 8. A method of manufacturing a vehicular lamp using an LED as a light source according to claim 6 or 7, wherein the LED is mounted on a flat substrate and a folding line for facilitating bending of the substrate is provided at a predetermined position. A prepared LED substrate is prepared, and a metal frame having a U-shaped cross section, which also serves as an electrode for the LED substrate, is fitted to both side edges of the LED substrate along a direction in which the LED substrate is to be bent. The metal frame is folded together at the position of the folding line, and the folded L
By fixing the ED substrate to the lamp housing via the metal frame, each of the LED substrate portions divided by bending is arranged substantially parallel to the curved surface of the lens plate of the lamp housing. A method for manufacturing a vehicle lamp using an LED as a light source.