JP2007265961A - Luminaire - Google Patents

Luminaire Download PDF

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JP2007265961A
JP2007265961A JP2006282933A JP2006282933A JP2007265961A JP 2007265961 A JP2007265961 A JP 2007265961A JP 2006282933 A JP2006282933 A JP 2006282933A JP 2006282933 A JP2006282933 A JP 2006282933A JP 2007265961 A JP2007265961 A JP 2007265961A
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lens
light emitting
light
emitting device
cover member
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JP4622985B2 (en
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Yoshiro Goto
芳朗 後藤
Kenichiro Tanaka
健一郎 田中
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Panasonic Electric Works Co Ltd
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Matsushita Electric Works Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a luminare improved light ejection efficiency. <P>SOLUTION: A light source unit A is contained in a lighting unit body 100. The light source unit A has an LED module 2 in which a plurality of light emission device 1 using an LED chip is arranged on the one side of a base substrate 200, and a cover member 3 provided with a lens 301 for controlling the direction of light emitted from the light emission device 1 to each portions opposite to the each light emission device 1. Each of the lenses 301 has a concave 302 staring at least a part of the light emission device 1. The each light source unit A has a reflection structure 5 for reflecting light leaked from the outside plane 301c of the one lens 301 of adjacent lenses 301 to the lens 301 side by preventing to extend to the other lens 301. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は、LEDチップを用いた発光装置を光源として備えた照明器具に関するものである。   The present invention relates to a lighting fixture including a light emitting device using an LED chip as a light source.

従来から、この種の照明器具として、図17に示すように、LEDチップを用いた複数の発光装置1’が回路基板からなるベース基板200’の一表面側に配置されたLEDモジュール2’と、ベース基板200’の上記一表面側において各発光装置1’を囲み且つ各発光装置1’に対向する各部位それぞれに発光装置1’から放射された光の配向を制御するレンズ301’を有するカバー部材3’とからなる光源ユニットA’を備えたものが提案されており、その適用例として、例えば、図18に示すように、光源ユニットA’を灯具本体100’の開口窓102’から後退して収納配置したダウンライトが提案されている(例えば、特許文献1参照)。なお、上記特許文献1には、LEDチップを用いた発光装置を光源として備えた照明器具の例として、ダウンライトに限らず、各種の照明器具(例えば、シーリングライト、スポットライトなど)が提案されている。   Conventionally, as this type of lighting fixture, as shown in FIG. 17, an LED module 2 ′ in which a plurality of light emitting devices 1 ′ using LED chips are arranged on one surface side of a base substrate 200 ′ made of a circuit board; In addition, a lens 301 ′ that controls the orientation of the light emitted from the light emitting device 1 ′ is provided in each of the portions that surround the light emitting devices 1 ′ on the one surface side of the base substrate 200 ′ and that face the light emitting devices 1 ′. A light source unit A ′ composed of a cover member 3 ′ has been proposed. As an application example thereof, for example, as shown in FIG. 18, the light source unit A ′ is connected to an opening window 102 ′ of the lamp body 100 ′. A downlight that has been retracted and stored has been proposed (see, for example, Patent Document 1). In Patent Document 1, various lighting fixtures (for example, ceiling lights, spotlights, etc.) are proposed as examples of lighting fixtures including a light emitting device using an LED chip as a light source. ing.

ところで、LEDチップを用いた発光装置を光源として備えた照明器具では、発光装置から放射された光の配光を制御するレンズの構造として、図19中に示すように発光装置1’の少なくとも一部(図示例では、全部)を収納する凹所302’が形成されたレンズ301’が提案されている(例えば、特許文献2〜4参照)。   By the way, in a lighting fixture provided with a light emitting device using an LED chip as a light source, as a lens structure for controlling the light distribution of light emitted from the light emitting device, at least one of the light emitting devices 1 ′ as shown in FIG. A lens 301 ′ having a recess 302 ′ for housing a portion (all in the illustrated example) is proposed (see, for example, Patent Documents 2 to 4).

ここにおいて、図19中に示したレンズ301’は、凹所302’の内底面302a’から入射した光を光出射面301b’に直接導く機能および凹所302’の内側面302b’から入射した光を外側面301c’で反射して光出射面301b’に導く機能を有している。なお、図19では、各レンズ301’をカバー部材3’と連続一体に形成してあるが、各レンズ301’をカバー部材3’とは別に形成したものも提案されている(例えば、特許文献5参照)。
特開2002−304904号公報 特開2005−149790号公報 特開2006−24381号公報 特開2005−183591号公報 特開2005−248461号公報
Here, the lens 301 ′ shown in FIG. 19 has a function of directly guiding the light incident from the inner bottom surface 302a ′ of the recess 302 ′ to the light exit surface 301b ′ and the inner surface 302b ′ of the recess 302 ′. It has a function of reflecting light to the light exit surface 301b ′ by reflecting it on the outer surface 301c ′. In FIG. 19, each lens 301 ′ is formed continuously and integrally with the cover member 3 ′. However, a lens in which each lens 301 ′ is formed separately from the cover member 3 ′ has been proposed (for example, Patent Literature 5).
JP 2002-304904 A JP 2005-149790 A JP 2006-24381 A JP 2005-183591 A JP 2005-248461 A

ところで、図18に示した構成の照明器具で図19のレンズ301’の構造を採用した場合、各発光装置1’を点灯させた点灯状態において、発光装置1’から放射され当該発光装置1’に対向するレンズ301’の外側面301c’から漏れて隣のレンズ301’の外側面301c’に入射した光の一部が灯具本体100’の内側面に照射されてしまう(図19,図20中の破線は光の伝搬経路を示している)ので、灯具本体100’からの光取り出し効率が低下してしまうという不具合があった。要するに、複数の発光装置1’ごとに光の配光を制御するレンズ301’を備えた照明器具においても、各レンズ301’の外側面301c’から漏れる光に起因して光取り出し効率が低下してしまうという不具合があった。なお、図18に示した構成の照明器具では、上述のように、発光装置1’から放射された光の一部がレンズ301’を通して灯具本体100’の内側面に照射されると、灯具本体100’の内側面に縞模様が現れて美観が損なわれてしまう(図19中のクロスハッチングを施した部位Bは縞模様が現れる領域を示している)。   By the way, when the structure of the lens 301 ′ in FIG. 19 is adopted in the lighting fixture having the configuration shown in FIG. 18, the light emitting device 1 ′ is radiated from the light emitting device 1 ′ in the lighting state in which each light emitting device 1 ′ is turned on. A part of the light leaking from the outer surface 301c ′ of the lens 301 ′ facing the lens and entering the outer surface 301c ′ of the adjacent lens 301 ′ is irradiated on the inner surface of the lamp body 100 ′ (FIGS. 19 and 20). Since the broken line in the middle indicates the light propagation path), the light extraction efficiency from the lamp body 100 ′ is reduced. In short, even in a lighting fixture including a lens 301 ′ that controls light distribution for each of the plurality of light emitting devices 1 ′, the light extraction efficiency is reduced due to light leaking from the outer surface 301c ′ of each lens 301 ′. There was a bug that it was. In the lighting fixture having the configuration shown in FIG. 18, as described above, when a part of the light emitted from the light emitting device 1 ′ is irradiated to the inner surface of the lamp body 100 ′ through the lens 301 ′, the lamp body A striped pattern appears on the inner surface of 100 'and the aesthetic appearance is impaired (the cross-hatched part B in FIG. 19 shows the region where the striped pattern appears).

本発明は上記事由に鑑みて為されたものであり、その目的は、光取り出し効率を高めることができる照明器具を提供することにある。   This invention is made | formed in view of the said reason, The objective is to provide the lighting fixture which can improve light extraction efficiency.

請求項1の発明は、LEDチップを用いた複数の発光装置がベース基板の一表面側に配置されたLEDモジュールと、ベース基板の前記一表面側において各発光装置を囲み且つ各発光装置に対向する各部位それぞれに発光装置から放射された光の配向を制御するレンズが設けられたカバー部材とを備え、各レンズは、発光装置に向かって凸となる形状に形成されるとともに先端部に発光装置の少なくとも一部を収納する凹所が形成され、LEDモジュールとカバー部材との間には、隣り合うレンズの一方のレンズの外側面から漏れた光が他方のレンズへ到達するのを阻止し前記一方のレンズ側へ反射する反射用構造体が設けられてなることを特徴とする。   According to a first aspect of the present invention, there is provided an LED module in which a plurality of light emitting devices using LED chips are arranged on one surface side of a base substrate, and each light emitting device is surrounded on the one surface side of the base substrate and faces each light emitting device. And a cover member provided with a lens for controlling the orientation of light emitted from the light emitting device. Each lens is formed in a convex shape toward the light emitting device and emits light at the tip. A recess for accommodating at least a part of the device is formed, and light leaking from the outer surface of one lens of an adjacent lens is prevented from reaching the other lens between the LED module and the cover member. A reflection structure that reflects toward the one lens side is provided.

この発明によれば、LEDモジュールとカバー部材との間には、隣り合うレンズの一方のレンズの外側面から漏れた光が他方のレンズへ到達するのを阻止し前記一方のレンズ側へ反射する反射用構造体が設けられているので、隣り合うレンズの一方のレンズの外側面から漏れた光が他方のレンズの外側面へ入射するのを阻止するとともに前記一方のレンズ側へ戻すことができ、その結果、光取り出し効率を高めることができる。   According to this invention, between the LED module and the cover member, the light leaking from the outer surface of one lens of the adjacent lenses is prevented from reaching the other lens and reflected to the one lens side. Since the reflecting structure is provided, light leaking from the outer surface of one lens of adjacent lenses can be prevented from entering the outer surface of the other lens and returned to the one lens side. As a result, the light extraction efficiency can be increased.

請求項2の発明は、請求項1の発明において、前記反射用構造体の光反射面は、前記レンズの前記外側面に沿った形状に形成されてなることを特徴とする。   According to a second aspect of the present invention, in the first aspect of the invention, the light reflecting surface of the reflecting structure is formed in a shape along the outer surface of the lens.

この発明によれば、光取り出し効率をより高めることができる。   According to this invention, the light extraction efficiency can be further increased.

請求項3の発明は、請求項1または請求項2の発明において、前記各レンズと前記カバー部材とが各別に形成されてなり、前記カバー部材は、前記各レンズそれぞれが前記反射用構造体を配置する一面側から挿入され前記各レンズの光出射面を露出させる複数のレンズ用窓孔を有し、前記反射用構造体は、前記各レンズそれぞれの前記発光装置側の端部が挿入される複数の開口部を有し、前記各レンズは、前記カバー部材と前記反射用構造体とで挟持されてなることを特徴とする。   According to a third aspect of the present invention, in the first or second aspect of the present invention, each of the lenses and the cover member are formed separately, and each of the lenses of the cover member includes the reflecting structure. A plurality of lens window holes that are inserted from one surface side to be disposed and expose a light emitting surface of each lens, and the reflecting structure is inserted with an end of each lens on the light emitting device side A plurality of openings are provided, and each of the lenses is sandwiched between the cover member and the reflecting structure.

この発明によれば、前記各レンズと前記カバー部材とが別部品なので、前記各レンズの成形が容易になって、前記各レンズの寸法精度を高めることが可能になるとともに、より複雑なレンズ形状にも対応可能になって光取り出し効率の向上を図れ、また、前記各レンズが、前記カバー部材と前記反射用構造体とで挟持されるので、前記各レンズを前記カバー部材や前記反射用構造体に接着したり溶着したりして固定する必要がなく、組み立てが容易になる。   According to this invention, since each lens and the cover member are separate parts, the molding of each lens is facilitated, the dimensional accuracy of each lens can be increased, and a more complicated lens shape can be obtained. And the lens can be sandwiched between the cover member and the reflecting structure, so that the lens is attached to the cover member or the reflecting structure. There is no need to fix it by gluing or welding to the body, and assembly is facilitated.

請求項4の発明は、請求項3の発明において、前記各発光装置への給電用の回路パターンが形成されるとともに各発光装置それぞれが挿通される複数の窓孔が形成され前記ベース基板の前記一表面側に配置された回路基板を備え、前記カバー部材が金属により形成され、前記反射用構造体は、絶縁材料により形成され、前記ベース基板の前記一表面側において回路基板を覆う形で配設されてなることを特徴とする。   According to a fourth aspect of the present invention, in the third aspect of the present invention, a circuit pattern for feeding power to each light emitting device is formed and a plurality of window holes through which each light emitting device is inserted are formed. A circuit board disposed on one surface side, wherein the cover member is made of metal, and the reflecting structure is made of an insulating material, and is arranged so as to cover the circuit board on the one surface side of the base substrate. It is characterized by being provided.

この発明によれば、前記反射用構造体が絶縁材料により形成され前記ベース基板の前記一表面側において回路基板を覆う形で配設されているので、前記カバー部材の材料として放熱性の高い金属を採用しながらも前記カバー部材と回路基板とを電気的に絶縁することができ、照明器具全体の薄型化を図れる。また、放熱性が向上することにより、前記各発光装置の温度上昇を抑制できるから、前記各発光装置への入力電力を大きくできて光出力の高出力化を図れるという利点がある。   According to the present invention, since the reflecting structure is formed of an insulating material and disposed on the one surface side of the base substrate so as to cover the circuit board, the metal having high heat dissipation as the material of the cover member The cover member and the circuit board can be electrically insulated while adopting the above, and the overall lighting fixture can be made thin. Further, since the heat dissipation is improved, the temperature rise of each light emitting device can be suppressed. Therefore, there is an advantage that the input power to each light emitting device can be increased and the light output can be increased.

請求項1の発明では、光取り出し効率を高めることができるという効果がある。   In the invention of claim 1, there is an effect that the light extraction efficiency can be increased.

(実施形態1)
以下、本実施形態の照明器具について図1〜図11を参照しながら説明する。
(Embodiment 1)
Hereinafter, the lighting fixture of this embodiment is demonstrated, referring FIGS.

本実施形態の照明器具は、ダウンライトであって、図1〜図3に示すように、LEDチップ10(図6〜図9参照)を用いた複数の発光装置1がベース基板200の一表面側(図1(a)の下面側)に配置されたLEDモジュール2と、ベース基板200の上記一表面側において各発光装置1を囲み且つ各発光装置1に対向する各部位それぞれに発光装置1から放射された光の配向を制御するレンズ301が設けられたカバー部材3と、LEDモジュール2とカバー部材3とを具備した光源ユニットAが収納配置される金属(例えば、Al,Cuなどの熱伝導率の高い金属)製の灯具本体100とを備えている。   The lighting fixture of this embodiment is a downlight, and as shown in FIGS. 1 to 3, a plurality of light emitting devices 1 using LED chips 10 (see FIGS. 6 to 9) are provided on one surface of the base substrate 200. The LED module 2 arranged on the side (the lower surface side of FIG. 1A) and the light emitting device 1 in each part surrounding the light emitting device 1 on the one surface side of the base substrate 200 and facing the light emitting device 1. A metal (for example, heat of Al, Cu, etc.) in which the light source unit A including the cover member 3 provided with the lens 301 for controlling the orientation of the light emitted from the LED module 2 and the cover member 3 is housed. And a lamp body 100 made of a metal having a high conductivity.

灯具本体100は、下面に円形状の開口窓102を有した箱状(つまり、一面開口した箱状)に形成されるとともに、下端部から外方へ外鍔部103が延設されており、造営材である天井材に貫設した取付孔に挿入され外鍔部103が取付孔の周部下面に当接する形で天井材に取り付けられる。なお、灯具本体100の底壁の中央部には光源ユニットAへの給電用の電線96,96を挿通する電線挿通孔104が貫設されている。ここで、各電線96,96における光源ユニットAの回路基板400に接続される一端側とは反対の他端側には、別置の電源ユニット(図示せず)の出力用の第1のコネクタに着脱自在に接続される第2のコネクタ97が設けられている。一方、回路基板400の中央部には、上記電線96,96を挿通する電線挿通孔401が形成されている。なお、灯具本体100の外側には、当該灯具本体100を天井材に取り付けるための板ばねからなる一対の取付ばね145を一体に設けたコ字状の保持部材140が取り付けられている。   The lamp body 100 is formed in a box shape having a circular opening window 102 on the lower surface (that is, a box shape having one surface opened), and an outer collar portion 103 is extended outward from the lower end portion. The outer flange portion 103 is inserted into an attachment hole penetrating the ceiling material, which is a construction material, and is attached to the ceiling material in such a manner that the outer flange portion 103 comes into contact with the lower surface of the peripheral portion of the attachment hole. An electric wire insertion hole 104 is inserted through the central portion of the bottom wall of the lamp body 100 for inserting electric wires 96 and 96 for supplying power to the light source unit A. Here, a first connector for output of a separate power supply unit (not shown) is provided on the other end side opposite to the one end side connected to the circuit board 400 of the light source unit A in each of the electric wires 96, 96. A second connector 97 that is detachably connected is provided. On the other hand, an electric wire insertion hole 401 through which the electric wires 96 are inserted is formed at the center of the circuit board 400. A U-shaped holding member 140 integrally provided with a pair of attachment springs 145 made of leaf springs for attaching the lamp body 100 to a ceiling member is attached to the outside of the lamp body 100.

灯具本体100は、内底面100aから離れるほど開口面積が徐々に大きくなっており、光源ユニットAにおけるベース基板200の他表面(図1(a)の上面)が内底面100aに当接する形で光源ユニットAが収納配置されている。ここにおいて、本実施形態の照明器具では、光源ユニットAの厚み寸法が灯具本体100の深さ寸法よりも小さくなっており、光源ユニットAが灯具本体100の開口窓102から後退する形で灯具本体100内に収納配置されている。   The lamp body 100 has an opening area that gradually increases with distance from the inner bottom surface 100a, and the other surface of the light source unit A (the upper surface in FIG. 1A) contacts the inner bottom surface 100a. Unit A is stored and arranged. Here, in the lighting fixture of this embodiment, the thickness dimension of the light source unit A is smaller than the depth dimension of the lamp body 100, and the lamp body is retreated from the opening window 102 of the lamp body 100. 100 is housed and arranged.

LEDモジュール2のベース基板200は、円板状の形状であり、熱伝導性材料(例えば、Al,Cuなどの熱伝導率の高い金属など)により形成されている。これに対して、LEDモジュール2の各発光装置1は、LEDチップ10と、LEDチップ10への給電用の一対のリードパターン23,23(図6参照)が設けられLEDチップ10が実装された実装基板20とを備えている。   The base substrate 200 of the LED module 2 has a disk shape and is formed of a heat conductive material (for example, a metal having high heat conductivity such as Al or Cu). On the other hand, each light emitting device 1 of the LED module 2 is provided with the LED chip 10 and a pair of lead patterns 23 and 23 (see FIG. 6) for supplying power to the LED chip 10, and the LED chip 10 is mounted. And a mounting board 20.

また、LEDモジュール2は、上述のベース基板200および各発光装置1の他に、各発光装置1の接続関係を規定する導体パターン(図示せず)が形成された円板状のガラスエポキシ(FR4)基板からなる回路基板400を備え、当該回路基板400には、各発光装置1それぞれに対応する部位に各発光装置1の一部を通す窓孔403(図1(b),図4,図6参照)が形成されている。なお、回路基板400の絶縁性基材の材料は、FR4のようなガラスエポキシ樹脂に限らず、例えば、ポリイミド系樹脂、フェノール樹脂などでもよい。   The LED module 2 includes a disk-shaped glass epoxy (FR4) in which a conductor pattern (not shown) that defines the connection relationship of each light emitting device 1 is formed in addition to the base substrate 200 and each light emitting device 1 described above. ) A circuit board 400 comprising a substrate is provided, and the circuit board 400 has a window hole 403 (FIG. 1B, FIG. 4 and FIG. 4) through which a part of each light-emitting device 1 passes through a portion corresponding to each light-emitting device 1. 6) is formed. In addition, the material of the insulating base material of the circuit board 400 is not limited to a glass epoxy resin such as FR4, and may be, for example, a polyimide resin or a phenol resin.

各発光装置1は、例えば、シリカやアルミナなどのフィラーからなる充填材を含有し加熱時に低粘度化する樹脂シート(例えば、溶融シリカを高充填したエポキシ樹脂シートのような有機グリーンシート)のような熱伝導性が高く加熱時の流動性が高い可塑性シート90をベース基板200の上記一表面との間に介在させた後で当該可塑性シート90を加熱して塑性変形させることによりベース基板200に固着されている。したがって、発光装置1とベース基板200との間にサーコン(登録商標)のようなゴムシート状の放熱シートなどを挟む場合や発光装置1とベース基板200とを単に接触させているだけの場合に比べて、各LEDチップ10からベース基板200までの熱抵抗を低減するとともに発光装置1ごとのLEDチップ10からベース基板200までの熱抵抗のばらつきを低減することができて放熱性が向上し、各LEDチップ10のジャンクション温度の温度上昇を抑制できるから、各LEDチップ10への入力電力を大きくできて光出力の高出力化を図れる。   Each light emitting device 1 is, for example, a resin sheet containing a filler made of a filler such as silica or alumina and having a low viscosity when heated (for example, an organic green sheet such as an epoxy resin sheet highly filled with fused silica). After the plastic sheet 90 having high thermal conductivity and high fluidity during heating is interposed between the one surface of the base substrate 200, the plastic sheet 90 is heated and plastically deformed to form the base substrate 200. It is fixed. Accordingly, when a rubber sheet-like heat dissipation sheet such as Sarcon (registered trademark) is sandwiched between the light emitting device 1 and the base substrate 200, or when the light emitting device 1 and the base substrate 200 are simply brought into contact with each other. In comparison, the thermal resistance from each LED chip 10 to the base substrate 200 can be reduced, and the variation in thermal resistance from the LED chip 10 to the base substrate 200 for each light emitting device 1 can be reduced, improving heat dissipation, Since the temperature rise of the junction temperature of each LED chip 10 can be suppressed, the input power to each LED chip 10 can be increased and the light output can be increased.

回路基板400は、各発光装置1それぞれに対応する部位に上述の窓孔403が形成されており、窓孔403の周部が実装基板20におけるLEDチップ10の実装面側における周部に重なる形でベース基板200の上記一表面から離間して配置される。なお、窓孔403の開口サイズは、後述の色変換部材70の外径よりも大きく且つ上述のレンズ301の一部を挿入可能となるように設定してある。   The circuit board 400 has the above-described window holes 403 formed in portions corresponding to the respective light emitting devices 1, and the peripheral portion of the window holes 403 overlaps the peripheral portion of the mounting substrate 20 on the mounting surface side of the LED chip 10. The base substrate 200 is disposed away from the one surface. The opening size of the window hole 403 is set so as to be larger than the outer diameter of the color conversion member 70 described later and to allow a part of the lens 301 to be inserted.

回路基板400における上記導体パターンは、複数の発光装置1の接続関係が直列接続の関係となるようにパターン設計されており、灯具本体100の電線挿通孔104およびベース基板200の中央部に形成された電線挿通孔204に挿通された給電用の一対の電線(図示せず)が電気的に接続されるようになっている。なお、回路基板400は、ベース基板200との対向面側に上記導体パターンが形成されており、他表面側には、金属層もしくは白色のレジスト層からなる光反射層(図示せず)が形成されている。   The conductor pattern in the circuit board 400 is designed so that the connection relationship of the plurality of light emitting devices 1 is a serial connection relationship, and is formed in the electric wire insertion hole 104 of the lamp body 100 and the central portion of the base substrate 200. A pair of power supply wires (not shown) inserted through the wire insertion holes 204 are electrically connected. The circuit board 400 has the conductor pattern formed on the side facing the base substrate 200, and a light reflecting layer (not shown) made of a metal layer or a white resist layer is formed on the other surface side. Has been.

なお、本実施形態では、複数の発光装置1を直列接続しているが、複数の発光装置1の接続関係は特に限定するものではなく、例えば、並列接続するようにしてもよいし、直列接続と並列接続とを組み合わせてもよい。   In the present embodiment, the plurality of light emitting devices 1 are connected in series. However, the connection relationship between the plurality of light emitting devices 1 is not particularly limited. For example, the light emitting devices 1 may be connected in parallel or connected in series. And parallel connection may be combined.

発光装置1は、図6〜図8に示すように、上述のLEDチップ10および実装基板20の他に、LEDチップ10から放射された光の配光を制御するドーム状の光学部材であって実装基板20との間にLEDチップ10を収納する形で実装基板20の一表面側(図7(b)における上面側)に固着された透光性材料からなる光学部材60と、光学部材60と実装基板20とで囲まれた空間でLEDチップ10および当該LEDチップ10に電気的に接続されたボンディングワイヤ14,14を封止した封止樹脂からなり透光性および弾性を有する封止部50と、LEDチップ10から放射され封止部50および光学部材60を透過した光によって励起されてLEDチップ10の発光色とは異なる色の光を放射する蛍光体および透光性材料により形成され実装基板20の上記一表面側で光学部材60の光出射面60bとの間に空隙80が形成される形で配設されるドーム状の色変換部材70とを備えている。   As shown in FIGS. 6 to 8, the light emitting device 1 is a dome-shaped optical member that controls the light distribution of the light emitted from the LED chip 10 in addition to the LED chip 10 and the mounting substrate 20 described above. An optical member 60 made of a translucent material fixed to one surface side (the upper surface side in FIG. 7B) of the mounting substrate 20 so as to house the LED chip 10 between the mounting substrate 20 and the optical member 60 A sealing portion made of a sealing resin that seals the LED chip 10 and the bonding wires 14 and 14 electrically connected to the LED chip 10 in a space surrounded by the mounting substrate 20. 50 and a phosphor and a translucent material that are excited by light emitted from the LED chip 10 and transmitted through the sealing portion 50 and the optical member 60 to emit light of a color different from the emission color of the LED chip 10. And a color conversion member 70 domed disposed in the form of gaps 80 are formed between the light exit surface 60b of the optical member 60 in the first surface side of the formed packaging substrate 20.

実装基板20は、熱伝導性材料からなりLEDチップ10が熱応力緩和用のサブマウント部材30を介して搭載される矩形板状の伝熱板21と、伝熱板21の一面側(図7(b)における上面側)に積層される配線基板22とで構成されている。上述の熱伝導性材料としては、Cuを採用しているが、Cuに限らず、例えば、Alなどを採用してもよい。   The mounting substrate 20 is made of a heat conductive material, and a rectangular plate-shaped heat transfer plate 21 on which the LED chip 10 is mounted via a submount member 30 for thermal stress relaxation, and one surface side of the heat transfer plate 21 (FIG. 7). The wiring board 22 is laminated on the upper surface side in (b). As the above-described heat conductive material, Cu is adopted, but not limited to Cu, for example, Al may be adopted.

配線基板22は、伝熱板21側とは反対の一表面側にLEDチップ10への給電用の一対のリードパターン23,23が形成されるとともにサブマウント部材30に対応する部位に厚み方向に貫通する矩形状の窓孔24が形成されたガラスエポキシ(FR4)基板により構成されており、LEDチップ10で発生した熱が配線基板22を介さずにサブマウント部材30および伝熱板21に伝熱できるようになっている。なお、配線基板22の絶縁性基材の材料は、FR4のようなガラスエポキシ樹脂に限らず、例えば、ポリイミド系樹脂、フェノール樹脂などでもよい。   The wiring board 22 is formed with a pair of lead patterns 23 and 23 for feeding power to the LED chip 10 on one surface side opposite to the heat transfer plate 21 side, and in a thickness direction at a portion corresponding to the submount member 30. It is composed of a glass epoxy (FR4) substrate in which a rectangular window hole 24 penetrating is formed, and heat generated in the LED chip 10 is transferred to the submount member 30 and the heat transfer plate 21 without passing through the wiring substrate 22. It can be heated. In addition, the material of the insulating base material of the wiring board 22 is not limited to a glass epoxy resin such as FR4, and may be, for example, a polyimide resin or a phenol resin.

配線基板22の各リードパターン23,23は、上記ガラスエポキシ基板の上記一表面側に形成されたCu膜とNi膜とAu膜との積層膜により構成されている。なお、配線基板22の他表面側には反り防止用金属膜(図示せず)が形成されており、伝熱板21と配線基板22とは、シート状の接着フィルム28(図7および図8参照)を用いて固着されている。また、上記反り防止用金属膜は、Cu膜により構成されている。   Each lead pattern 23, 23 of the wiring board 22 is composed of a laminated film of a Cu film, a Ni film, and an Au film formed on the one surface side of the glass epoxy board. A warp preventing metal film (not shown) is formed on the other surface side of the wiring board 22, and the heat transfer plate 21 and the wiring board 22 are made of a sheet-like adhesive film 28 (FIGS. 7 and 8). For fixing). The warp preventing metal film is composed of a Cu film.

また、配線基板22は、図9における左右両側縁それぞれの中央部から側方に突出する突出片22b,22bが延設されており、一方の突出片22bに、LEDチップ10へ過電圧が印加されるのを防止する過電圧防止用の表面実装型のツェナダイオード131(図6参照)を接続可能とするための一対のダイオード接続用ランド124,124が形成され、他方の突出片22bに、表面実装型のコンデンサ132(図6参照)を接続可能とするための一対のコンデンサ接続用ランド126,126が形成されている。ここにおいて、各ダイオード接続用ランド124,124および各コンデンサ接続用ランド126,126は、配線基板22においてリードパターン23,23と同一面上に形成されており、配線基板22には、ダイオード接続用ランド124,124とリードパターン23,23とを接続する第1の配線用導体パターン123,123(図9参照)が形成されるとともに、コンデンサ接続用ランド126,126とリードパターン23,23とを接続する第2の配線用導体パターン125,125(図9参照)が形成されている。   Further, the wiring board 22 is provided with protruding pieces 22b and 22b protruding laterally from the central portions of the left and right side edges in FIG. 9, and an overvoltage is applied to the LED chip 10 on one protruding piece 22b. A pair of diode-connecting lands 124 and 124 for connecting a surface-mounted Zener diode 131 (see FIG. 6) for preventing overvoltage is formed, and the other protruding piece 22b is surface-mounted. A pair of capacitor connection lands 126 and 126 for enabling connection of the capacitor 132 of the type (see FIG. 6) is formed. Here, the diode connection lands 124 and 124 and the capacitor connection lands 126 and 126 are formed on the same plane as the lead patterns 23 and 23 on the wiring board 22, and the wiring board 22 has a diode connection land. First wiring conductor patterns 123 and 123 (see FIG. 9) for connecting the lands 124 and 124 and the lead patterns 23 and 23 are formed, and the capacitor connecting lands 126 and 126 and the lead patterns 23 and 23 are connected to each other. Second wiring conductor patterns 125 and 125 (see FIG. 9) to be connected are formed.

また、配線基板22は、伝熱板21側とは反対の表面側に白色系の樹脂からなるレジスト層26が積層されており、レジスト層26は、各リードパターン23,23のインナーリード部23a,23aおよびアウターリード部23b,23b、各ダイオード接続用ランド124,124、各コンデンサ接続用ランド126,126それぞれが露出するように形成されている。ここで、回路基板400には、ツェナダイオード131に対応する部位にツェナダイオード131を挿通させる矩形状の窓孔408(図6参照)が設けられるとともに、コンデンサ132に対応する部位にコンデンサ132を挿通させる矩形状の窓孔409(図6参照)が設けられており、発光装置1としてLEDチップ10の静電破壊を防止するためのツェナダイオード131およびコンデンサ132を配線基板22に実装した構造を採用しながらも、ベース基板200と回路基板400との間の距離が長くなるのを防止でき、光源ユニットAの薄型化を図れる。   Further, the wiring board 22 has a resist layer 26 made of a white resin laminated on the surface side opposite to the heat transfer plate 21 side, and the resist layer 26 is an inner lead portion 23 a of each lead pattern 23, 23. , 23a and outer lead portions 23b, 23b, each of the diode connection lands 124, 124, and each of the capacitor connection lands 126, 126 are exposed. Here, the circuit board 400 is provided with a rectangular window hole 408 (see FIG. 6) through which the Zener diode 131 is inserted in a portion corresponding to the Zener diode 131, and the capacitor 132 is inserted in a portion corresponding to the capacitor 132. A rectangular window hole 409 (see FIG. 6) is provided, and a structure in which a Zener diode 131 and a capacitor 132 for preventing electrostatic breakdown of the LED chip 10 as the light emitting device 1 are mounted on the wiring board 22 is adopted. However, it is possible to prevent the distance between the base substrate 200 and the circuit board 400 from becoming long, and the light source unit A can be thinned.

LEDチップ10は、青色光を放射するGaN系青色LEDチップであり、結晶成長用基板としてサファイア基板に比べて格子定数や結晶構造がGaNに近く且つ導電性を有するn形のSiC基板からなる導電性基板11(図8参照)を用いており、導電性基板11の主表面側にGaN系化合物半導体材料により形成されて例えばダブルへテロ構造を有する積層構造部からなる発光部12(図8参照)がエピタキシャル成長法(例えば、MOVPE法など)により成長され、導電性基板11の裏面に図示しないカソード側の電極であるカソード電極(n電極)が形成され、発光部12の表面(導電性基板11の主表面側の最表面)に図示しないアノード側の電極であるアノード電極(p電極)が形成されている。要するに、LEDチップ10は、一表面側にアノード電極が形成されるとともに他表面側にカソード電極が形成されている。上記カソード電極および上記アノード電極は、Ni膜とAu膜との積層膜により構成してあるが、上記カソード電極および上記アノード電極の材料は特に限定するものではなく、良好なオーミック特性が得られる材料であればよく、例えば、Alなどを採用してもよい。   The LED chip 10 is a GaN-based blue LED chip that emits blue light, and is a conductive substrate made of an n-type SiC substrate that has a lattice constant and a crystal structure close to GaN as a crystal growth substrate and has conductivity compared to a sapphire substrate. The light emitting unit 12 (see FIG. 8) is used, which is formed of a GaN-based compound semiconductor material on the main surface side of the conductive substrate 11 and has, for example, a double structure. ) Is grown by an epitaxial growth method (for example, MOVPE method), a cathode electrode (n electrode) which is a cathode side electrode (not shown) is formed on the back surface of the conductive substrate 11, and the surface of the light emitting unit 12 (conductive substrate 11). An anode electrode (p electrode), which is an electrode on the anode side (not shown), is formed on the outermost surface on the main surface side. In short, the LED chip 10 has an anode electrode formed on one surface side and a cathode electrode formed on the other surface side. The cathode electrode and the anode electrode are composed of a laminated film of a Ni film and an Au film, but the material of the cathode electrode and the anode electrode is not particularly limited, and a material capable of obtaining good ohmic characteristics For example, Al or the like may be employed.

なお、本実施形態では、LEDチップ10の発光部12が導電性基板11よりも伝熱板21から離れた側となるように伝熱板21に搭載されているが、LEDチップ10の発光部12が導電性基板11よりも伝熱板21に近い側となるように伝熱板21に搭載するようにしてもよい。光取り出し効率を考えた場合には、発光部12を伝熱板21から離れた側に配置することが望ましいが、本実施形態では導電性基板11と発光部12とが同程度の屈折率を有しているので、発光部12を伝熱板21に近い側に配置しても光の取り出し損失が大きくなりすぎることはない。   In the present embodiment, the light emitting unit 12 of the LED chip 10 is mounted on the heat transfer plate 21 so as to be on the side farther from the heat transfer plate 21 than the conductive substrate 11. The heat transfer plate 21 may be mounted so that 12 is closer to the heat transfer plate 21 than the conductive substrate 11. In consideration of the light extraction efficiency, it is desirable to arrange the light emitting unit 12 on the side away from the heat transfer plate 21, but in this embodiment, the conductive substrate 11 and the light emitting unit 12 have the same refractive index. Therefore, even if the light emitting unit 12 is disposed on the side closer to the heat transfer plate 21, the light extraction loss does not become too large.

また、LEDチップ10は、LEDチップ10のチップサイズよりも大きなサイズの矩形板状に形成されLEDチップ10と伝熱板21との線膨張率の差に起因してLEDチップ10に働く応力を緩和する上述のサブマウント部材30を介して伝熱板21に搭載されている。   Further, the LED chip 10 is formed in a rectangular plate shape larger than the chip size of the LED chip 10, and stress acting on the LED chip 10 due to the difference in linear expansion coefficient between the LED chip 10 and the heat transfer plate 21. It is mounted on the heat transfer plate 21 via the above-described submount member 30 to be relaxed.

サブマウント部材30は、上記応力を緩和する機能だけでなく、LEDチップ10で発生した熱を伝熱板21においてLEDチップ10のチップサイズよりも広い範囲に伝熱させる熱伝導機能を有している。本実施形態では、サブマウント部材30の材料として熱伝導率が比較的高く且つ絶縁性を有するAlNを採用しており、LEDチップ10は、上記カソード電極がサブマウント部材30におけるLEDチップ10側の表面に設けられ上記カソード電極と接続される導体パターン31(図10参照)および金属細線(例えば、金細線、アルミニウム細線など)からなるボンディングワイヤ14を介して一方のリードパターン23と電気的に接続され、上記アノード電極がボンディングワイヤ14を介して他方のリードパターン23と電気的に接続されている。なお、LEDチップ10とサブマウント部材30とは、例えば、SnPb、AuSn、SnAgCuなどの半田や、銀ペーストなどを用いて接合すればよいが、AuSn、SnAgCuなどの鉛フリー半田を用いて接合することが好ましい。   The submount member 30 has not only a function of relieving the stress but also a heat conduction function of transferring heat generated in the LED chip 10 to a range wider than the chip size of the LED chip 10 in the heat transfer plate 21. Yes. In the present embodiment, AlN having a relatively high thermal conductivity and insulation is used as the material of the submount member 30, and the LED chip 10 has the cathode electrode on the LED chip 10 side of the submount member 30. A conductive pattern 31 (see FIG. 10) provided on the surface and connected to the cathode electrode and electrically connected to one lead pattern 23 via a bonding wire 14 made of a fine metal wire (for example, a gold fine wire, an aluminum fine wire, etc.) The anode electrode is electrically connected to the other lead pattern 23 via the bonding wire 14. The LED chip 10 and the submount member 30 may be bonded using, for example, solder such as SnPb, AuSn, SnAgCu, or silver paste, but may be bonded using lead-free solder such as AuSn, SnAgCu. It is preferable.

また、サブマウント部材30は、図10に示すように、導体パターン31の周囲に、LEDチップ10から放射された光を反射する反射膜32が形成されている。サブマウント部材30の厚み寸法は、反射膜32の表面が配線基板22の上記一表面(レジスト層26の表面)よりも伝熱板21から離れるように設定してある。したがって、LEDチップ10の側面から放射された光がサブマウント部材30や配線基板22に吸収されるのを防止することができて外部への光取り出し効率の向上による光出力の向上を図れる。なお、反射膜32は、Ni膜とAg膜との積層膜により構成してある。また、反射膜32には、両ボンディングワイヤ14、14が接触したときにLEDチップ10の両電極間が反射膜32を介して短絡されるのを防止するために反射膜32を2つの領域に絶縁分離するスリット33,33が形成されている。   Further, as shown in FIG. 10, the submount member 30 is formed with a reflective film 32 that reflects light emitted from the LED chip 10 around the conductor pattern 31. The thickness dimension of the submount member 30 is set so that the surface of the reflective film 32 is farther from the heat transfer plate 21 than the one surface of the wiring board 22 (the surface of the resist layer 26). Therefore, the light emitted from the side surface of the LED chip 10 can be prevented from being absorbed by the submount member 30 and the wiring board 22, and the light output can be improved by improving the light extraction efficiency to the outside. The reflective film 32 is composed of a laminated film of a Ni film and an Ag film. Further, the reflective film 32 is divided into two regions in order to prevent the two electrodes of the LED chip 10 from being short-circuited via the reflective film 32 when the bonding wires 14 and 14 are in contact with each other. Insulating and separating slits 33 are formed.

ここにおいて、LEDチップ10およびサブマウント部材30は、それぞれ平面形状が矩形状(本実施形態では、正方形状)であり、LEDチップ10は、平面視における各辺それぞれがサブマント部材30の一対の対角線のいずれか一方の対角線に交差する形でサブマウント部材30の中央部に配置されているので、LEDチップ10の各側面それぞれからサブマウント部材30側へ放射された光を反射膜32により効率良く反射することができ、外部への光取り出し効率の向上による光出力の向上を図れる。なお、本実施形態では、LEDチップ10とサブマント部材30とを厚み方向に沿った中心軸が略一致し、且つ、LEDチップ10の平面視における各辺それぞれがサブマウント部材30の上記一方の対角線と略45度の角度をなすように配置してある。   Here, the LED chip 10 and the submount member 30 each have a rectangular planar shape (in this embodiment, a square shape), and the LED chip 10 has a pair of diagonal lines of the submant member 30 on each side in plan view. Is disposed at the central portion of the submount member 30 so as to intersect one of the diagonal lines, the light emitted from each side surface of the LED chip 10 to the submount member 30 side is efficiently reflected by the reflective film 32. The light output can be reflected and the light output can be improved by improving the light extraction efficiency to the outside. In the present embodiment, the LED chip 10 and the submant member 30 have substantially the same center axis along the thickness direction, and each side in the plan view of the LED chip 10 is the one diagonal line of the submount member 30. And an angle of about 45 degrees.

サブマウント部材30の材料はAlNに限らず、線膨張率が導電性基板11の材料である6H−SiCに比較的近く且つ熱伝導率が比較的高い材料であればよく、例えば、複合SiC、Siなどを採用してもよい。本実施形態では、LEDチップ10がサブマウント部材30を介して伝熱板21に搭載されているので、LEDチップ10で発生した熱をサブマウント部材30および伝熱板21を介して効率良く放熱させることができるとともに、LEDチップ10と伝熱板21との線膨張率差に起因してLEDチップ10に働く応力を緩和することができる。   The material of the submount member 30 is not limited to AlN, and any material may be used as long as the linear expansion coefficient is relatively close to 6H—SiC that is the material of the conductive substrate 11 and the heat conductivity is relatively high. Si or the like may be employed. In this embodiment, since the LED chip 10 is mounted on the heat transfer plate 21 via the submount member 30, the heat generated by the LED chip 10 is efficiently radiated via the submount member 30 and the heat transfer plate 21. In addition, the stress acting on the LED chip 10 due to the difference in linear expansion coefficient between the LED chip 10 and the heat transfer plate 21 can be reduced.

上述の封止部50の材料である封止樹脂としては、シリコーン樹脂を用いているが、シリコーン樹脂に限らず、例えばアクリル樹脂などを用いてもよい。   As the sealing resin that is the material of the sealing portion 50 described above, a silicone resin is used. However, the sealing resin is not limited to the silicone resin, and for example, an acrylic resin may be used.

光学部材60は、透光性材料(例えば、シリコーン樹脂など)の成形品であってドーム状に形成されている。ここで、本実施形態では、光学部材60をシリコーン樹脂の成形品により構成しているので、光学部材60と封止部50との屈折率差および線膨張率差を小さくすることができる。なお、封止部50の材料がアクリル樹脂の場合には、光学部材60もアクリル樹脂により形成することが好ましい。   The optical member 60 is a molded product of a translucent material (for example, silicone resin) and is formed in a dome shape. Here, in this embodiment, since the optical member 60 is formed of a silicone resin molded product, the difference in refractive index and the linear expansion coefficient between the optical member 60 and the sealing portion 50 can be reduced. In addition, when the material of the sealing part 50 is an acrylic resin, it is preferable to form the optical member 60 also with an acrylic resin.

ところで、光学部材60は、光出射面60bが、光入射面60aから入射した光を光出射面60bと上述の空隙80との境界で全反射させない凸曲面状に形成されている。ここで、光学部材60は、光出射面60bが球面の一部により形成されており、当該球面の中心がLEDチップ10の厚み方向に沿った発光部12の中心線上に位置するように配置されている。言い換えれば、光学部材60は、当該光学部材60の光軸がLEDチップ10の厚み方向に沿った発光部12の中心線上に位置するように配置されている。したがって、LEDチップ10から放射され光学部材60の光入射面60aに入射された光が光出射面60bと空隙80との境界で全反射されることなく色変換部材70まで到達しやすくなり、全光束を高めることができる。なお、LEDチップ10の側面から放射された光は封止部50および光学部材60および空隙80を伝搬して色変換部材70まで到達し色変換部材70の蛍光体を励起したり蛍光体には衝突せずに色変換部材70を透過したりする。また、光学部材60は、位置によらず法線方向に沿って肉厚が一様となるように形成されており、上述の封止部50は、半球状の形状に形成されている。   By the way, the optical member 60 has a light emitting surface 60b formed in a convex curved surface shape that does not totally reflect light incident from the light incident surface 60a at the boundary between the light emitting surface 60b and the gap 80 described above. Here, the optical member 60 is formed such that the light emitting surface 60b is formed by a part of a spherical surface, and the center of the spherical surface is located on the center line of the light emitting unit 12 along the thickness direction of the LED chip 10. ing. In other words, the optical member 60 is disposed so that the optical axis of the optical member 60 is located on the center line of the light emitting unit 12 along the thickness direction of the LED chip 10. Therefore, the light emitted from the LED chip 10 and incident on the light incident surface 60a of the optical member 60 can easily reach the color conversion member 70 without being totally reflected at the boundary between the light emitting surface 60b and the gap 80. The luminous flux can be increased. The light emitted from the side surface of the LED chip 10 propagates through the sealing portion 50, the optical member 60, and the gap 80 to reach the color conversion member 70 to excite the phosphor of the color conversion member 70 or to the phosphor. The color conversion member 70 is transmitted without colliding. Moreover, the optical member 60 is formed so that thickness may become uniform along a normal direction irrespective of a position, and the above-mentioned sealing part 50 is formed in the hemispherical shape.

色変換部材70は、シリコーン樹脂のような透光性材料とLEDチップ10から放射された青色光によって励起されてブロードな黄色系の光を放射する粒子状の黄色蛍光体とを混合した混合物の成形品により構成されている(つまり、色変換部材70は、透光性材料および蛍光体により形成されている)。したがって、本実施形態における発光装置1は、LEDチップ10から放射された青色光と黄色蛍光体から放射された光とが色変換部材70の外面70bを通して放射されることとなり、白色光を得ることができる。なお、色変換部材70の材料として用いる透光性材料は、シリコーン樹脂に限らず、例えば、アクリル樹脂、ガラス、有機成分と無機成分とがnmレベルもしくは分子レベルで混合、結合した有機・無機ハイブリッド材料などを採用してもよい。また、色変換部材70の材料として用いる透光性材料に混合する蛍光体も黄色蛍光体に限らず、例えば、赤色蛍光体と緑色蛍光体とを混合しても白色光を得ることができる。   The color conversion member 70 is a mixture of a translucent material such as a silicone resin and a particulate yellow phosphor that emits broad yellow light when excited by the blue light emitted from the LED chip 10. It is comprised by the molded article (that is, the color conversion member 70 is formed with the translucent material and fluorescent substance). Therefore, in the light emitting device 1 in the present embodiment, the blue light emitted from the LED chip 10 and the light emitted from the yellow phosphor are emitted through the outer surface 70b of the color conversion member 70 to obtain white light. Can do. The translucent material used as the material of the color conversion member 70 is not limited to a silicone resin, but an organic / inorganic hybrid in which, for example, an acrylic resin, glass, an organic component and an inorganic component are mixed and combined at the nm level or the molecular level. Materials etc. may be adopted. Further, the phosphor mixed with the translucent material used as the material of the color conversion member 70 is not limited to the yellow phosphor. For example, white light can be obtained by mixing a red phosphor and a green phosphor.

ここで、色変換部材70は、当該色変換部材70の内面70aの曲率半径を光学部材60の光出射面60bの曲率半径よりもやや大きく設定してあり、色変換部材70の頂部と光学部材60の光出射面60bとが近接し、当該頂部から離れるにつれて光学部材60の光出射面60bとの間の距離が徐々に大きくなっている。なお、色変換部材70の頂部と光学部材60の光出射面60bとが近接とは、色変換部材70の頂部と光学部材60の光出射面60bとが接している場合、色変換部材70の頂部と光学部材60の光出射面60bとを接しない程度に近づけてある場合の両方を含む概念であり、図示例では、前者の場合を示してある。また、色変換部材70は、位置によらず法線方向に沿った肉厚が一様となるように成形されている。   Here, in the color conversion member 70, the radius of curvature of the inner surface 70a of the color conversion member 70 is set to be slightly larger than the radius of curvature of the light emitting surface 60b of the optical member 60, and the top of the color conversion member 70 and the optical member The distance between the light emitting surface 60b of the optical member 60 and the light emitting surface 60b of the optical member 60 gradually increases as the distance from the apex portion increases. The proximity of the top of the color conversion member 70 and the light emitting surface 60b of the optical member 60 means that the top of the color conversion member 70 and the light emitting surface 60b of the optical member 60 are in contact with each other. This is a concept including both of the case where the top part and the light emitting surface 60b of the optical member 60 are not close to each other. In the illustrated example, the former case is shown. The color conversion member 70 is formed so that the thickness along the normal direction is uniform regardless of the position.

ところで、色変換部材70は、図11に示すような形状であって、実装基板20側の端縁から実装基板20側へ突出し先端部に外方へ突出した係止爪71aを有する複数(本実施形態では、4つ)の取付脚71が上記端縁の周方向に離間して設けられ、実装基板20は、上記一表面側に各取付脚71それぞれが挿入される複数の凹所であってそれぞれ係止爪71aが係止される係止面を有する複数の凹所27が形成されている。要するに、発光装置1は、色変換部材70における実装基板20側の端縁から実装基板20側へ突出した複数の取付脚71の先端部に設けられた係止爪71aが、実装基板20の上記一表面に形成された凹所27の上記係止面に係止されている。ここで、凹所27は、配線基板22において窓孔24の周囲で厚み方向に貫設された矩形状の貫通孔27aと、伝熱板21の上記一面側に形成されて貫通孔27aに連通し且つ貫通孔27aよりも開口面積が大きな円形状の凹溝27bとで構成され、配線基板22において凹溝27bに臨む面が上記係止面を構成している。したがって、本実施形態の発光装置1では、実装基板20における凹所27を容易に形成することが可能である。   By the way, the color conversion member 70 has a shape as shown in FIG. 11, and has a plurality of (this book) having locking claws 71 a protruding from the edge on the mounting substrate 20 side to the mounting substrate 20 side and protruding outward at the tip portion. In the embodiment, four mounting legs 71 are provided apart from each other in the circumferential direction of the edge, and the mounting substrate 20 is a plurality of recesses into which the mounting legs 71 are inserted on the one surface side. A plurality of recesses 27 having locking surfaces to which the locking claws 71a are locked are formed. In short, in the light emitting device 1, the locking claws 71 a provided at the tip ends of the plurality of mounting legs 71 projecting from the edge of the color conversion member 70 on the mounting substrate 20 side to the mounting substrate 20 side have the above-mentioned of the mounting substrate 20. It is locked to the locking surface of the recess 27 formed on one surface. Here, the recess 27 is formed on the wiring substrate 22 in the thickness direction around the window hole 24 in the thickness direction and on the one surface side of the heat transfer plate 21 and communicates with the through hole 27a. In addition, a circular concave groove 27b having an opening area larger than that of the through hole 27a is formed, and a surface of the wiring board 22 facing the concave groove 27b constitutes the locking surface. Therefore, in the light emitting device 1 of this embodiment, the recess 27 in the mounting substrate 20 can be easily formed.

なお、本実施形態における発光装置1では、サブマウント部材30の厚み寸法を、上述のように反射膜32の表面が配線基板22の上記一表面(レジスト層26の表面)よりも伝熱板21から離れるように設定してあるが、当該厚み寸法を、反射膜32の表面が色変換部材70における実装基板20側の端縁よりも伝熱板21から離れて位置するように設定することにより、色変換部材70の端縁と実装基板20の上記一表面との間に隙間が形成されている場合でもLEDチップ10から側方に放射された光が色変換部材70と実装基板20との隙間を通して出射されるのを防止することができる(つまり、LEDチップ10から放射された青色光が色変換部材70を通らずに外部へ出射されるのを防止することができる)。   In the light emitting device 1 according to the present embodiment, the thickness of the submount member 30 is set so that the surface of the reflective film 32 is more heat-conductive plate 21 than the one surface of the wiring substrate 22 (the surface of the resist layer 26) as described above. The thickness dimension is set so that the surface of the reflective film 32 is positioned farther from the heat transfer plate 21 than the edge of the color conversion member 70 on the mounting substrate 20 side. Even when a gap is formed between the edge of the color conversion member 70 and the one surface of the mounting substrate 20, the light emitted from the LED chip 10 to the side is between the color conversion member 70 and the mounting substrate 20. The light emitted from the gap can be prevented (that is, the blue light emitted from the LED chip 10 can be prevented from being emitted outside without passing through the color conversion member 70).

上述の発光装置1では、色変換部材70が実装基板20の上記一表面側において光学部材60の光出射面60bとの間に空隙80が形成される形で配設されているので、色変換部材70に外力が作用したときに色変換部材70に発生した応力がLEDチップ10やボンディングワイヤ14,14に伝達されるのを抑制でき、LEDチップ10の発光特性の変動や各ボンディングワイヤ14,14の断線が起こりにくくなるから信頼性が高くなり、また、色変換部材70の頂部が光学部材60の光出射面60bに接しており、色変換部材70における実装基板20側の端縁から実装基板20側へ突出した複数の取付脚71の先端部に設けられた係止爪71aが実装基板20の上記一表面に形成された凹所27の上記係止面に係止されているので、LEDチップ10などの発熱に起因してゲル状の封止部50が軟化しても光学部材60および色変換部材70が落下するのを防止することができ、信頼性が高くなる。   In the light emitting device 1 described above, since the color conversion member 70 is disposed in a form in which a gap 80 is formed between the light emitting surface 60b of the optical member 60 on the one surface side of the mounting substrate 20, color conversion is performed. The stress generated in the color conversion member 70 when an external force is applied to the member 70 can be suppressed from being transmitted to the LED chip 10 and the bonding wires 14, 14. 14 is less likely to occur, and the reliability is increased. Further, the top of the color conversion member 70 is in contact with the light emitting surface 60b of the optical member 60, and the color conversion member 70 is mounted from the edge on the mounting substrate 20 side. Since the locking claws 71 a provided at the distal ends of the plurality of mounting legs 71 projecting toward the substrate 20 are locked to the locking surfaces of the recesses 27 formed on the one surface of the mounting substrate 20. Due to the heat generation, such as an LED chip 10 can be an optical member 60 and the color conversion member 70 is also gelatinous sealing portion 50 is softened to prevent the falling, is reliable.

ところで、回路基板400の窓孔403は、上述の発光装置1の色変換部材70を挿通可能な開口サイズの円形状に形成されており、回路基板400は、各窓孔403の周部において、当該回路基板400の上記導体パターンと発光装置1の各アウターリード部23bとを電気的に接続するためのスルーホール配線407(図6参照)が形成されている。なお、各スルーホール配線407は、回路基板400の厚み方向に貫通したスルーホールの内面と回路基板400の両面における当該スルーホールの周部とに跨って形成されており、回路基板400の上記一表面側において上記導体パターンと接続されている。   By the way, the window hole 403 of the circuit board 400 is formed in a circular shape having an opening size through which the color conversion member 70 of the light-emitting device 1 can be inserted. A through-hole wiring 407 (see FIG. 6) for electrically connecting the conductor pattern of the circuit board 400 and each outer lead portion 23b of the light emitting device 1 is formed. Each through-hole wiring 407 is formed across the inner surface of the through-hole penetrating in the thickness direction of the circuit board 400 and the periphery of the through-hole on both surfaces of the circuit board 400. The conductor pattern is connected to the surface side.

ここで、回路基板400において各窓孔403それぞれの周部に形成された各一対のスルーホール配線407の形成位置は、実装基板20のアウターリード部23bの投影領域からずらしてある。具体的には、各一対のスルーホール配線407の形成位置は、発光装置1の配線基板22の四隅のうちの2箇所に重なるように設計してある。   Here, the formation position of each pair of through-hole wirings 407 formed in the peripheral part of each window hole 403 in the circuit board 400 is shifted from the projection region of the outer lead part 23 b of the mounting board 20. Specifically, the formation positions of each pair of through-hole wirings 407 are designed to overlap two of the four corners of the wiring board 22 of the light emitting device 1.

また、本実施形態における発光装置1は、実装基板20と回路基板400との間に配置されリードパターン23,23と上記導体パターンとの間の電路となる配線パターン151,151が形成された一対のフレキシブルプリント配線板150,150を備えている。   In addition, the light emitting device 1 according to the present embodiment includes a pair of wiring patterns 151 and 151 that are disposed between the mounting substrate 20 and the circuit substrate 400 and serve as an electric path between the lead patterns 23 and 23 and the conductor pattern. Flexible printed wiring boards 150, 150.

各フレキシブルプリント配線板150,150の配線パターン151,151には、アウターリード部23b,23bに重なる部位にU字状の第1の接合用パターン部151aが形成され、スルーホール配線407に重なる部位に円形状の第2の接合用パターン部151bが形成されており、アウターリード部23bと第1の接合用パターン部151aとが半田からなる第1の接合部(図示せず)を介して接合されて電気的に接続され、スルーホール配線407と第2の接合用パターン部151bとが半田からなる第2の接合部(図示せず)を介して接合されて電気的に接続されている。なお、各フレキシブルプリント配線板150,150の平面形状は、湾曲した形状に形成されている。   In the wiring patterns 151 and 151 of the flexible printed wiring boards 150 and 150, U-shaped first bonding pattern portions 151 a are formed in portions overlapping the outer lead portions 23 b and 23 b, and portions overlapping the through-hole wiring 407. A circular second bonding pattern portion 151b is formed on the outer lead portion 23b, and the outer lead portion 23b and the first bonding pattern portion 151a are bonded via a first bonding portion (not shown) made of solder. Thus, the through-hole wiring 407 and the second bonding pattern portion 151b are bonded and electrically connected via a second bonding portion (not shown) made of solder. In addition, the planar shape of each flexible printed wiring board 150, 150 is formed in a curved shape.

本実施形態におけるLEDモジュール2では、各フレキシブルプリント配線板150,150が、ベース基板200と回路基板400との線膨張率差に起因してリードパターン23と上記導体パターンとの間の接合部に働く応力を緩和する応力緩和手段として機能するので、各発光装置1と回路基板400との間の接続信頼性を高めることができる。   In the LED module 2 in the present embodiment, the flexible printed wiring boards 150 and 150 are formed at the joint between the lead pattern 23 and the conductor pattern due to the difference in linear expansion coefficient between the base substrate 200 and the circuit substrate 400. Since it functions as a stress relaxation means for relaxing the working stress, the connection reliability between each light emitting device 1 and the circuit board 400 can be enhanced.

また、上述のカバー部材3は、透光性材料(例えば、アクリル樹脂、ガラスなど)の成形品により構成されており、ベース基板200の上記一表面側においてベース基板200から離間して配置される前板部3aと、前板部3aの周縁からベース基板200の上記一表面側へ連続一体に突出した円環状の側板部3bとを備えている。ここにおいて、ベース基板200には、カバー部材3を固定するための固定ねじ119を挿通する2つのねじ挿通孔217が形成されており、カバー部材3には、ベース基板200の上記他面側からベース基板200のねじ挿通孔217に挿通された固定ねじ119の先端部が螺合するねじ孔3dを有する2つのボス部3cが連続一体に形成されている。なお、カバー部材3は、上述の前板部3aに各レンズ301が連続一体に形成されており、各レンズ301が各発光装置1の光軸に一致する形でベース基板200の上記一表面側に配置される。   Further, the above-described cover member 3 is formed of a molded product of a translucent material (for example, acrylic resin, glass, etc.), and is disposed apart from the base substrate 200 on the one surface side of the base substrate 200. A front plate portion 3a and an annular side plate portion 3b that protrudes continuously and integrally from the periphery of the front plate portion 3a toward the one surface side of the base substrate 200 are provided. Here, the base substrate 200 is formed with two screw insertion holes 217 through which a fixing screw 119 for fixing the cover member 3 is inserted, and the cover member 3 is formed from the other surface side of the base substrate 200. Two boss portions 3c having a screw hole 3d into which a tip end portion of a fixing screw 119 inserted through the screw insertion hole 217 of the base substrate 200 is screwed are integrally formed. In the cover member 3, each lens 301 is continuously formed integrally with the above-described front plate portion 3 a, and the one surface side of the base substrate 200 is formed such that each lens 301 coincides with the optical axis of each light-emitting device 1. Placed in.

上述のカバー部材3における各レンズ301は、発光装置1に向かって凸となる形状に形成されるとともに先端部に発光装置1の少なくとも一部(本実施形態では、色変換部材70)を収納する凹所302が形成されており、凹所302の内底面302aから入射した光を当該レンズ301の光出射面301bに直接導く機能と、凹所302の内側面302bから入射した光を当該レンズ301の外側面301cで反射して当該レンズ301の光出射面301bに導く機能とを有するように設計してあり、カバー部材3の前板部3aにおけるベース基板200との対向面を含む平面からベース基板200に近づくにつれて外径が徐々に小さくなる形状となっている。また、各レンズ301の光出射面301bは、中央部が凸曲面状に形成され周部が平面状に形成されている。なお、発光装置1の構造によっては、レンズ301の凹所302に発光装置1の全部を収納するようにしてもよい。   Each lens 301 in the cover member 3 described above is formed in a convex shape toward the light emitting device 1 and houses at least a part of the light emitting device 1 (in this embodiment, the color conversion member 70) at the tip. A recess 302 is formed, and a function of directly guiding light incident from the inner bottom surface 302 a of the recess 302 to the light exit surface 301 b of the lens 301, and light incident from the inner surface 302 b of the recess 302. It is designed to have a function of reflecting on the outer surface 301c of the lens and guiding it to the light emitting surface 301b of the lens 301, and from the plane including the surface facing the base substrate 200 in the front plate portion 3a of the cover member 3. The outer diameter gradually decreases as it approaches the substrate 200. Further, the light exit surface 301b of each lens 301 has a central portion formed in a convex curved surface shape and a peripheral portion formed in a flat shape. Depending on the structure of the light emitting device 1, the entire light emitting device 1 may be stored in the recess 302 of the lens 301.

ところで、本実施形態における光源ユニットAは、隣り合うレンズ301の一方のレンズ301の外側面301cから漏れた光が他方のレンズ301へ到達するのを阻止し上記一方のレンズ301側へ反射する白色の反射用構造体5がLEDモジュール2の回路基板400とカバー部材3とで囲まれた空間内に設けられている(なお、図1(b)中の破線は隣り合うレンズ301の一方のレンズ301の外側面301cから漏れた光の伝搬経路を示している)。   By the way, the light source unit A in the present embodiment prevents the light leaking from the outer surface 301c of one lens 301 of the adjacent lenses 301 from reaching the other lens 301 and reflects it to the one lens 301 side. The reflecting structure 5 is provided in a space surrounded by the circuit board 400 and the cover member 3 of the LED module 2 (note that a broken line in FIG. 1B indicates one lens of the adjacent lenses 301). 301 shows a propagation path of light leaking from the outer surface 301c of 301).

反射用構造体5は、例えば、テフロン(登録商標)のようなフッ素樹脂を材料とした成形品であって、円板状に形成されており、ベース基板200側に突出する4つの柱状の脚部500aが周方向に略等間隔で離間して形成されるとともに、カバー部材3の各レンズ301それぞれが挿入される複数の円形状の開口部501が設けられ、当該開口部501の内側面がレンズ301の外側面301cから漏れた光を反射する光反射面を構成している。なお、反射用構造体5の周部においてカバー部材3の各ボス部3cそれぞれに対応する部位には、切欠部503(図4参照)が形成されている。また、光源ユニットAのベース基板200には灯具本体100の底壁に挿通された2本の取付ねじ(図示せず)それぞれが螺合する2つのねじ孔215(図4参照)を設けてあり、反射用構造体5の周部においてベース基板200の各ねじ孔215それぞれに対応する部位には、切欠部504が形成されている。また、反射用構造体5の中央部には、貫通孔502が形成されている。また、回路基板400において反射用構造体5の各脚部500aそれぞれに対応する部位には、切欠部405(図1(a)および図4参照)が形成されている。   The reflecting structure 5 is, for example, a molded product made of a fluororesin such as Teflon (registered trademark), is formed in a disc shape, and has four columnar legs protruding toward the base substrate 200 side. The portions 500a are formed at substantially equal intervals in the circumferential direction, and a plurality of circular openings 501 into which the respective lenses 301 of the cover member 3 are inserted are provided, and the inner surface of the openings 501 is A light reflecting surface that reflects light leaking from the outer surface 301 c of the lens 301 is configured. Note that notches 503 (see FIG. 4) are formed at portions corresponding to the respective boss portions 3 c of the cover member 3 in the peripheral portion of the reflecting structure 5. In addition, the base substrate 200 of the light source unit A is provided with two screw holes 215 (see FIG. 4) into which two mounting screws (not shown) inserted through the bottom wall of the lamp body 100 are screwed. A cutout portion 504 is formed in a portion corresponding to each screw hole 215 of the base substrate 200 in the peripheral portion of the reflecting structure 5. Further, a through hole 502 is formed in the central portion of the reflecting structure 5. Further, a notch 405 (see FIGS. 1A and 4) is formed in a portion of the circuit board 400 corresponding to each leg 500a of the reflecting structure 5.

以上説明した本実施形態の照明器具では、光源ユニットAに、隣り合うレンズ301の一方のレンズ301の外側面301cから漏れた光が他方のレンズ301へ到達するのを阻止し上記一方のレンズ301側へ反射する反射用構造体5が設けられているので、隣り合うレンズ301の一方のレンズ301の外側面301cから漏れた光が他方のレンズ301へ入射して灯具本体100の内側面に照射されるのを抑制することができ(図1(b)中の破線は一方のレンズ301の外側面301cから漏れた光の伝搬経路を示している)、しかも一方のレンズ201側へ戻すことができ、その結果、点灯状態での美観を高めることができ、且つ、灯具本体100からの光取り出し効率を高めることができる。   In the lighting fixture of the present embodiment described above, light leaking from the outer surface 301 c of one lens 301 of the adjacent lens 301 is prevented from reaching the other lens 301 in the light source unit A, and the one lens 301 described above. Since the reflecting structure 5 that reflects to the side is provided, the light leaking from the outer surface 301c of one lens 301 of the adjacent lenses 301 enters the other lens 301 and irradiates the inner surface of the lamp body 100. (A broken line in FIG. 1B indicates a propagation path of light leaking from the outer surface 301c of one lens 301) and can be returned to the one lens 201 side. As a result, the aesthetics in the lighting state can be enhanced, and the light extraction efficiency from the lamp body 100 can be enhanced.

ここにおいて、図12に示すように、反射用構造体5の開口部501の内側面からなる光反射面を、レンズ301の外側面301cに沿った形状に形成すれば、灯具本体100からの光取り出し効率をより高めることができる。また、反射用構造体5の材料としてフッ素樹脂のような耐熱性および電気絶縁性に優れた絶縁材料を用いているので、信頼性を高めることができる。なお、本実施形態では、1つの反射用構造体5で各レンズ301それぞれの外側面301cから漏れた光を反射することができるが、各レンズ301ごとに枠状の反射用構造体5を設け、当該枠状の反射用構造体5の内側面を光反射面としてもよい。また、本実施形態では、反射用構造体5の材料としてフッ素樹脂を用いているが、反射用構造体5の材料はフッ素樹脂以外の材料でもよい。   Here, as shown in FIG. 12, if the light reflecting surface formed by the inner surface of the opening 501 of the reflecting structure 5 is formed in a shape along the outer surface 301 c of the lens 301, the light from the lamp main body 100 can be obtained. The extraction efficiency can be further increased. Moreover, since the insulating material excellent in heat resistance and electrical insulation, such as a fluororesin, is used as the material of the reflecting structure 5, the reliability can be improved. In the present embodiment, the light leaked from the outer surface 301c of each lens 301 can be reflected by one reflecting structure 5, but a frame-like reflecting structure 5 is provided for each lens 301. The inner surface of the frame-like reflecting structure 5 may be a light reflecting surface. Moreover, in this embodiment, although the fluororesin is used as the material of the reflective structure 5, the material of the reflective structure 5 may be a material other than the fluororesin.

(実施形態2)
以下、本実施形態の照明器具について、図13〜図16を参照しながら説明するが、実施形態1と同様の構成要素には同一の符号を付して説明を適宜省略する。
(Embodiment 2)
Hereinafter, although the lighting fixture of this embodiment is demonstrated, referring FIGS. 13-16, the same code | symbol is attached | subjected to the component similar to Embodiment 1, and description is abbreviate | omitted suitably.

本実施形態の照明器具は、シーリングライトであり、ベース基板200およびカバー部材3の形状が実施形態1とは相違し、LEDモジュール2のベース基板200とカバー部材3とを複数本(本実施形態では、4本)の固定ねじ119により結合することによって、天井材のような造営材180に直付けされる器具本体(灯具本体)を構成している。   The lighting fixture of the present embodiment is a ceiling light, the shapes of the base substrate 200 and the cover member 3 are different from those of the first embodiment, and a plurality of the base substrate 200 and the cover member 3 of the LED module 2 (this embodiment). Then, the fixture main body (lamp main body) directly attached to the construction material 180 like a ceiling material is comprised by couple | bonding with the four fixing screws 119.

ここにおいて、ベース基板200は、各発光装置1が配置される一表面側(図13(b)における下面側)とは反対側の他表面(図13(b)における上面)の中央部に、造営材180に形成された円形状の取付孔181に挿入される円柱状の埋込部203が突設されており、回路基板400への給電用の電線96,96を器具本体内へ導入するための電線挿通孔204(図13(b)参照)が、埋込部203の上端面とベース基板200の上記一表面との間に貫設されている。   Here, the base substrate 200 is arranged at the center of the other surface (upper surface in FIG. 13B) opposite to the one surface side (the lower surface side in FIG. 13B) on which each light emitting device 1 is arranged. A cylindrical embedding portion 203 to be inserted into a circular mounting hole 181 formed in the construction material 180 is protruded, and electric wires 96 and 96 for feeding power to the circuit board 400 are introduced into the instrument body. A wire insertion hole 204 (see FIG. 13B) is provided between the upper end surface of the embedded portion 203 and the one surface of the base substrate 200.

また、ベース基板200には、固定ねじ119を挿通するねじ挿通孔217が4箇所に形成されており、カバー部材3には、ベース基板200の上記他表面側からベース基板200のねじ挿通孔217に挿通された固定ねじ119の先端部が螺合するねじ孔3d(図16参照)が4箇所に形成されている。また、ベース基板200には、器具本体を造営材180に直付けするための複数本(本実施形態では、2本)の取付ねじ185(図13(c)参照)それぞれを挿通するねじ挿通孔205が形成されており、カバー部材3には、当該カバー部材3とベース基板200とが結合された状態において取付ねじ185をドライバにより操作可能とするための操作孔303が形成されている。   The base substrate 200 has four screw insertion holes 217 through which the fixing screws 119 are inserted. The cover member 3 has screw insertion holes 217 in the base substrate 200 from the other surface side. Screw holes 3d (see FIG. 16) are formed at four locations into which the distal end portions of the fixing screws 119 inserted through are screwed. Further, a screw insertion hole through which a plurality of (two in this embodiment) mounting screws 185 (see FIG. 13C) for directly attaching the tool body to the construction material 180 is inserted into the base substrate 200. 205 is formed, and an operation hole 303 is formed in the cover member 3 so that the mounting screw 185 can be operated by a driver in a state where the cover member 3 and the base substrate 200 are coupled.

カバー部材3は、円盤状に形成され、厚み方向の一面(図13(b)における上面)にベース基板200が収納される凹所311が形成され、さらに凹所311の内底面に、回路基板400および反射用構造体5を収納する収納凹所312が形成されている。ここにおいて、本実施形態では、ベース基板200の外周形状が円形状であるのに対して、反射用構造体5および回路基板400それぞれの外周形状が矩形状であり、凹所311はベース基板200の外周形状に対応した円形状に開口され、収納凹所312は反射用構造体5の外周形状に対応した矩形状に開口されている。また、カバー部材3における凹所311の内底面には、複数(本実施形態では、2つ)の位置決め凸部313が突設されており、ベース基板200には位置決め凸部313が嵌合される位置決め凹部213が形成されている。なお、カバー部材3の周部は、当該カバー部材3の外周縁に近づくにつれて厚みが薄くなっており、器具本体を造営材180に取り付けた状態において、カバー部材3の周部と造営材180との間に隙間190(図13(b)参照)が形成されるので、放熱性を高めることができる。   The cover member 3 is formed in a disc shape, and a recess 311 in which the base substrate 200 is accommodated is formed on one surface in the thickness direction (upper surface in FIG. 13B), and a circuit board is formed on the inner bottom surface of the recess 311. A storage recess 312 for storing 400 and the reflecting structure 5 is formed. Here, in the present embodiment, the outer peripheral shape of the base substrate 200 is a circular shape, whereas the outer peripheral shapes of the reflecting structure 5 and the circuit board 400 are rectangular, and the recess 311 is the base substrate 200. The housing recess 312 is opened in a rectangular shape corresponding to the outer peripheral shape of the reflecting structure 5. In addition, a plurality (two in the present embodiment) of positioning protrusions 313 project from the inner bottom surface of the recess 311 in the cover member 3, and the positioning protrusions 313 are fitted into the base substrate 200. A positioning recess 213 is formed. The peripheral portion of the cover member 3 becomes thinner as it approaches the outer peripheral edge of the cover member 3, and the peripheral portion of the cover member 3, the construction material 180, and the like are attached to the construction material 180. Since a gap 190 (see FIG. 13B) is formed between them, heat dissipation can be improved.

ところで、実施形態1にて説明した照明器具はダウンライトであったが、本実施形態の照明器具のように造営材180に器具本体を直付けして用いるシーリングライトでは、造営材180側からの放熱性が低くなるので、各発光装置1で発生した熱をカバー部材3側からも放熱させることで各発光装置1の温度上昇を抑制することが考えられる。しかしながら、実施形態1の照明器具のようにカバー部材3と各レンズ301とが各レンズ301の材料(例えば、アクリル樹脂、ガラスなど)により一体成形されている場合には、カバー部材3の熱伝導率が低いので、カバー部材3側からの放熱をほとんど期待できない。また、実施形態1の照明器具のように、カバー部材3と各レンズ301とが一体成形されている場合、レンズ301のレンズ形状として複雑なレンズ形状に対応するのが難しく寸法精度が低くなる懸念がある。また、成形用の金型が高価になるとともに、レンズ301の数やカバー部材3の形状が異なる製品ごとに高価な金型が必要となってしまう。   By the way, although the lighting fixture demonstrated in Embodiment 1 was a downlight, in the ceiling light used by attaching a fixture main body directly to the construction material 180 like the lighting fixture of this embodiment, it is from the construction material 180 side. Since heat dissipation becomes low, it is conceivable to suppress the temperature rise of each light emitting device 1 by dissipating the heat generated in each light emitting device 1 from the cover member 3 side. However, when the cover member 3 and each lens 301 are integrally formed of the material of each lens 301 (for example, acrylic resin, glass, etc.) as in the lighting fixture of Embodiment 1, the heat conduction of the cover member 3 is performed. Since the rate is low, almost no heat dissipation from the cover member 3 side can be expected. Further, when the cover member 3 and each lens 301 are integrally formed as in the lighting fixture of the first embodiment, it is difficult to cope with a complicated lens shape as the lens shape of the lens 301, and the dimensional accuracy may be lowered. There is. Further, the mold for molding becomes expensive, and an expensive mold is required for each product in which the number of lenses 301 and the shape of the cover member 3 are different.

そこで、本実施形態では、カバー部材3と各レンズ301とを別部品として、カバー部材3を金属により形成し、各レンズ301を透光性材料(例えば、アクリル樹脂、ガラスなど)により形成してある。   Therefore, in this embodiment, the cover member 3 and each lens 301 are separate parts, the cover member 3 is formed of metal, and each lens 301 is formed of a light-transmitting material (for example, acrylic resin, glass, etc.). is there.

しかして、本実施形態の照明器具では、各発光装置1で発生した熱を、各レンズ301の材料に比べて熱伝導率の高い金属により形成されたカバー部材3を通して放熱させることができて放熱面積が大きくなるので、放熱性が向上し、各発光装置1の温度上昇を抑制できるから、各発光装置1への入力電力を大きくできて光出力の高出力化を図れるという利点があり、しかも、カバー部材3と各レンズ301とが別部品なので、各レンズ301の成形が容易になって、各レンズ301の寸法精度を高めることが可能になるとともに、より複雑なレンズ形状にも対応可能になって光取り出し効率の向上を図れる。また、レンズ301の数やカバー部材3の形状が異なる製品でレンズ301を共通部品として流用することができるので、部品の共通化による低コスト化を図れるという利点や金型を安くできるという利点もある。   Thus, in the lighting fixture of the present embodiment, the heat generated in each light emitting device 1 can be dissipated through the cover member 3 formed of a metal having a higher thermal conductivity than the material of each lens 301, and the heat is dissipated. Since the area is increased, the heat dissipation is improved and the temperature rise of each light emitting device 1 can be suppressed. Therefore, there is an advantage that the input power to each light emitting device 1 can be increased and the light output can be increased. Since the cover member 3 and each lens 301 are separate parts, the molding of each lens 301 is facilitated, the dimensional accuracy of each lens 301 can be increased, and more complex lens shapes can be accommodated. Thus, the light extraction efficiency can be improved. In addition, since the lens 301 can be used as a common component in a product having a different number of lenses 301 or the shape of the cover member 3, there is an advantage that the cost can be reduced by sharing the components, and that the mold can be reduced. is there.

また、反射用構造体5は、各レンズ301それぞれにおける発光装置1側の端部が挿入(嵌挿)される複数の円形状の開口部501を有する矩形板状に形成され、外周縁から全周に亘ってベース基板200側へ突出片503が突設されており、突出片503の先端縁がベース基板200の上記一表面に当接しベース基板200の上記一表面側において回路基板400を覆う形で配設されている。   Further, the reflecting structure 5 is formed in a rectangular plate shape having a plurality of circular openings 501 into which the end portions on the light emitting device 1 side of the respective lenses 301 are inserted (inserted), and is entirely formed from the outer periphery. A protruding piece 503 protrudes toward the base substrate 200 over the circumference, and the leading edge of the protruding piece 503 contacts the one surface of the base substrate 200 to cover the circuit board 400 on the one surface side of the base substrate 200. Arranged in a shape.

したがって、本実施形態の照明器具では、カバー部材3の材料として放熱性の高い金属を採用しながらもカバー部材3と回路基板400とをフッ素樹脂などの絶縁材料により形成された反射用構造体5によって電気的に絶縁することができ、照明器具全体の薄型化を図れる。ここにおいて、本実施形態では、器具本体の薄型化を図るために、カバー部材3の上記一面にベース基板200を収納する凹所311を形成するとともに、当該凹所311の内底面に、回路基板400および反射用構造体5を収納する収納凹所312を形成し、反射用構造体5の外周縁よりも外側でカバー部材3とベース基板200とを結合してある。また、反射用構造体5における回路基板400側の表面には、発光装置1の実装基板20や回路基板400に実装されている電子部品(例えば、実施形態1にて説明したツェナダイオード131やコンデンサ132など)それぞれに対応する位置に凹部504(図16参照)が形成されており、反射用構造体5と回路基板400とを厚み方向において当接させることで器具本体の薄型化を図りながらも、電子部品に外力がかからないようにしてある。なお、反射用構造体5において、突出片503の代わりに、実施形態1と同様に複数の脚部500a(図1(a)参照)を設けてもよい。   Therefore, in the lighting fixture of this embodiment, the reflective structure 5 in which the cover member 3 and the circuit board 400 are formed of an insulating material such as a fluororesin while adopting a metal with high heat dissipation as the material of the cover member 3. Therefore, the entire lighting fixture can be reduced in thickness. Here, in this embodiment, in order to reduce the thickness of the instrument body, a recess 311 for housing the base substrate 200 is formed on the one surface of the cover member 3, and a circuit board is formed on the inner bottom surface of the recess 311. A housing recess 312 for housing 400 and the reflecting structure 5 is formed, and the cover member 3 and the base substrate 200 are coupled to each other outside the outer peripheral edge of the reflecting structure 5. Further, on the surface of the reflecting structure 5 on the circuit board 400 side, the mounting substrate 20 of the light emitting device 1 and the electronic components mounted on the circuit board 400 (for example, the Zener diode 131 and the capacitor described in the first embodiment). 132) (see FIG. 16), the recesses 504 (see FIG. 16) are formed, and the reflection structure 5 and the circuit board 400 are brought into contact with each other in the thickness direction, thereby reducing the thickness of the instrument body. The external force is not applied to the electronic component. In the reflecting structure 5, a plurality of legs 500 a (see FIG. 1A) may be provided in the same manner as in the first embodiment, instead of the protruding pieces 503.

ところで、本実施形態におけるカバー部材3は、各レンズ301それぞれが上記一面側から挿入され各レンズ301の光出射面301bを露出させる複数の円形状のレンズ用窓孔314が形成されている。   By the way, the cover member 3 in the present embodiment is formed with a plurality of circular lens window holes 314 in which each lens 301 is inserted from the one surface side and the light emitting surface 301b of each lens 301 is exposed.

一方、レンズ301は、外側面301cを囲む枠状であって反射用構造体5側の端縁が反射用構造体5に当接する枠状部303が連続一体に形成されており(枠状部303は、反射用構造体5側とは反対側の端部がレンズ301の外側面301cに連続一体に連結されている)、枠状部303の反射用構造体5側の端部には反射用構造体5に当接する鍔片304が全周に亘って外方へ突設されている。一方、カバー部材3の上記一面側の収納凹所312の内底面においてレンズ用窓孔314の周部には鍔片304が当接する凹部315が形成されており、レンズ301は、カバー部材3におけるレンズ用窓孔314の周部(凹部315の内底面)と反射用構造体5との間に鍔片304が挟持されている。要するに、各レンズ301は、カバー部材3と反射用構造体5とで挟持されている。また、反射用構造体5は、カバー部材3側の表面における開口部501の周部から全周に亘って反射用突起502が突設されており、当該反射用突起502がレンズ301の外側面301cと枠状部303との間の隙間に挿入されている。ここで、反射用構造体5は、開口部501の内側面と反射用突起502の内側面とが滑らかに連続し、各内側面がレンズ301の外側面301cに沿った形状に形成されており、各内側面が、レンズ301の外側面301cから漏れた光を反射する光反射面を構成している。   On the other hand, the lens 301 has a frame shape surrounding the outer surface 301c, and a frame-shaped portion 303 whose end on the reflective structure 5 side is in contact with the reflective structure 5 is formed integrally (frame-shaped portion). 303 is connected to the outer surface 301c of the lens 301 continuously and integrally with the end opposite to the reflecting structure 5 side), and is reflected at the reflecting structure 5 end of the frame-like portion 303. A flange 304 that abuts against the structural member 5 is provided so as to protrude outward over the entire circumference. On the other hand, on the inner bottom surface of the housing recess 312 on the one surface side of the cover member 3, a concave portion 315 with which the flange 304 abuts is formed on the peripheral portion of the lens window hole 314. A flange 304 is sandwiched between the periphery of the lens window hole 314 (the inner bottom surface of the recess 315) and the reflecting structure 5. In short, each lens 301 is sandwiched between the cover member 3 and the reflecting structure 5. Further, the reflecting structure 5 has a reflecting projection 502 protruding from the periphery of the opening 501 on the surface on the cover member 3 side, and the reflecting projection 502 is formed on the outer surface of the lens 301. It is inserted into a gap between 301c and the frame-like portion 303. Here, in the reflecting structure 5, the inner surface of the opening 501 and the inner surface of the reflecting protrusion 502 are smoothly continuous, and each inner surface is formed in a shape along the outer surface 301 c of the lens 301. Each inner surface constitutes a light reflecting surface that reflects light leaking from the outer surface 301 c of the lens 301.

以上説明した本実施形態の照明器具の組立時には、カバー部材3の上記一面側から各レンズ用窓孔314それぞれにレンズ301を挿入してから、反射用構造体5を収納凹所312に収納し、その後、LEDモジュール2をカバー部材3に重ね合わせてLEDモジュール2のベース基板200とカバー部材3とを複数本の固定ねじ119により結合すれば、レンズ301に連続一体に形成された枠状部303の鍔部304がカバー部材3と反射用構造体5との間に挟持されることとなる。しかして、本実施形態の照明器具では、各レンズ301がカバー部材3と反射用構造体5とで挟持されるので、各レンズ301を個別にカバー部材3や反射用構造体5に接着したり溶着したりして固定する必要がなく、組み立てが容易になる。   When assembling the lighting fixture of the present embodiment described above, the lens 301 is inserted into each lens window hole 314 from the one surface side of the cover member 3, and then the reflecting structure 5 is stored in the storage recess 312. Then, if the LED module 2 is overlapped with the cover member 3 and the base substrate 200 of the LED module 2 and the cover member 3 are joined by a plurality of fixing screws 119, the frame-shaped portion formed integrally with the lens 301 continuously. The flange 304 of 303 is sandwiched between the cover member 3 and the reflecting structure 5. Thus, in the lighting fixture of the present embodiment, each lens 301 is sandwiched between the cover member 3 and the reflecting structure 5, so that each lens 301 is individually bonded to the cover member 3 or the reflecting structure 5. There is no need for welding and fixing, and assembly is facilitated.

ところで、上述の実施形態1では、照明器具としてダウンライトを例示し、実施形態2では、照明器具としてシーリングライトを例示したが、本発明の技術思想はダウンライトやシーリングライトに限らず、他の照明器具にも適用できる。   By the way, in above-mentioned Embodiment 1, although the downlight was illustrated as a lighting fixture and the ceiling light was illustrated as a lighting fixture in Embodiment 2, the technical idea of this invention is not restricted to a downlight or a ceiling light, Other It can also be applied to lighting equipment.

また、上述の各実施形態1,2では、LEDチップ10として、発光色が青色の青色LEDチップを採用しており、導電性基板11としてSiC基板を採用しているが、SiC基板の代わりにGaN基板を用いてもよく、SiC基板やGaN基板を用いた場合には結晶成長用基板として絶縁体であるサファイア基板を用いている場合に比べて、結晶成長用基板の熱伝導率が高く結晶成長用基板の熱抵抗を小さくできる。また、LEDチップ10の発光色は青色に限らず、例えば、赤色、緑色などでもよい。すなわち、LEDチップ10の発光部12の材料はGaN系化合物半導体材料に限らず、LEDチップ10の発光色に応じて、GaAs系化合物半導体材料やGaP系化合物半導体材料などを採用してもよい。また、導電性基板11もSiC基板に限らず、発光部12の材料に応じて、例えば、GaAs基板、GsP基板などから適宜選択すればよい。また、LEDチップ10と実装基板20との線膨張率の差が比較的小さい場合にはサブマウント部材30は必ずしも設ける必要はない。また、LEDチップ10単体で白色光が得られる場合には、蛍光体および透光性材料により形成された色変換部材70の代わりに、透光性材料により形成されたドーム状の保護部材を採用すればよい。   In the first and second embodiments described above, a blue LED chip whose emission color is blue is employed as the LED chip 10 and a SiC substrate is employed as the conductive substrate 11, but instead of the SiC substrate. A GaN substrate may be used. When a SiC substrate or a GaN substrate is used, the crystal growth substrate has a higher thermal conductivity than the case where a sapphire substrate, which is an insulator, is used as the crystal growth substrate. The thermal resistance of the growth substrate can be reduced. Further, the light emission color of the LED chip 10 is not limited to blue, and may be, for example, red or green. That is, the material of the light-emitting portion 12 of the LED chip 10 is not limited to the GaN-based compound semiconductor material, and a GaAs-based compound semiconductor material, a GaP-based compound semiconductor material, or the like may be employed according to the emission color of the LED chip 10. Further, the conductive substrate 11 is not limited to the SiC substrate, and may be appropriately selected from, for example, a GaAs substrate and a GsP substrate according to the material of the light emitting unit 12. Further, when the difference in linear expansion coefficient between the LED chip 10 and the mounting substrate 20 is relatively small, the submount member 30 is not necessarily provided. In addition, when white light can be obtained with the LED chip 10 alone, a dome-shaped protective member made of a translucent material is used instead of the color conversion member 70 made of phosphor and the translucent material. do it.

また、上述の発光装置1では、LEDチップ10としてチップサイズが1mm□のものを用いサブマウント部材30上に1個のLEDチップ10を配置しているが、LEDチップ10のチップサイズや数は特に限定するものではなく、例えば、LEDチップ10としてチップサイズが0.3mm□のものを採用するようにして、1個のサブマウント部材30上に複数個(図示例では、8個)のLEDチップ10を配置し、これら複数個のLEDチップ10を導体パターン31および図示しないボンディングワイヤを介して直列接続するようにしてもよい。   Further, in the light emitting device 1 described above, the LED chip 10 having a chip size of 1 mm □ is used and one LED chip 10 is arranged on the submount member 30, but the chip size and number of the LED chips 10 are different. There is no particular limitation, and for example, a plurality of (eight in the illustrated example) LEDs are provided on one submount member 30 by adopting an LED chip 10 having a chip size of 0.3 mm □. The chip 10 may be disposed, and the plurality of LED chips 10 may be connected in series via the conductor pattern 31 and a bonding wire (not shown).

また、上述の各実施形態1,2では、発光装置1が一対のフレキシブルプリント配線板150,150を備えているが、一対のフレキシブルプリント配線板150,150を設けずに、端子板などを用いて回路基板400と電気的に接続するようにしてもよい。また、ツェナダイオード131やコンデンサ132を実装基板20ではなく、回路基板400に実装するようにしてもよい。   In each of the first and second embodiments described above, the light-emitting device 1 includes the pair of flexible printed wiring boards 150 and 150. However, a terminal board or the like is used without providing the pair of flexible printed wiring boards 150 and 150. The circuit board 400 may be electrically connected. Further, the Zener diode 131 and the capacitor 132 may be mounted on the circuit board 400 instead of the mounting board 20.

実施形態1の照明器具を示し、(a)は要部概略断面図、(b)は動作説明図である。The lighting fixture of Embodiment 1 is shown, (a) is principal part schematic sectional drawing, (b) is operation | movement explanatory drawing. 同上の照明器具の概略斜視図である。It is a schematic perspective view of a lighting fixture same as the above. 同上の照明器具の概略下面図である。It is a schematic bottom view of a lighting fixture same as the above. 同上の照明器具における光源ユニットの概略分解斜視図である。It is a general | schematic disassembled perspective view of the light source unit in a lighting fixture same as the above. 同上の照明器具における光源ユニットの概略斜視図である。It is a schematic perspective view of the light source unit in a lighting fixture same as the above. 同上の照明器具におけるLEDモジュールの要部分解斜視図である。It is a principal part disassembled perspective view of the LED module in a lighting fixture same as the above. 同上の照明器具における発光装置を示し、(a)は概略平面図、(b)は(a)のA−B−C−D−E概略断面図である。The light-emitting device in a lighting fixture same as the above is shown, (a) is a schematic plan view, (b) is an A-B-C-D-E schematic sectional view of (a). 同上の照明器具におけるLEDモジュールの要部概略断面図である。It is a principal part schematic sectional drawing of the LED module in a lighting fixture same as the above. 同上の照明器具における発光装置の要部概略平面図である。It is a principal part schematic plan view of the light-emitting device in a lighting fixture same as the above. 同上の照明器具における発光装置のサブマウント部材の概略斜視図である。It is a schematic perspective view of the submount member of the light-emitting device in the lighting fixture same as the above. 同上の照明器具における発光装置の色変換部材を示し、(a)は一部破断した正面図、(b)は下面図である。The color conversion member of the light-emitting device in a lighting fixture same as the above is shown, (a) is a partially broken front view, and (b) is a bottom view. 同上の照明器具における光源ユニットの他の構成例を示す要部概略断面図である。It is a principal part schematic sectional drawing which shows the other structural example of the light source unit in a lighting fixture same as the above. 実施形態2の照明器具を示し、(a)は概略上面図、(b)は一部破断した概略正面図、(c)は一部破断した概略側面図である。The lighting fixture of Embodiment 2 is shown, (a) is a schematic top view, (b) is a schematic front view partly broken, (c) is a schematic side view partly broken. 同上の照明器具の概略下面図である。It is a schematic bottom view of a lighting fixture same as the above. 同上の照明器具の概略分解斜視図である。It is a general | schematic disassembled perspective view of a lighting fixture same as the above. 同上の照明器具の概略分解斜視図である。It is a general | schematic disassembled perspective view of a lighting fixture same as the above. 従来例を示す照明器具における光源ユニットの概略分解斜視図である。It is a schematic exploded perspective view of the light source unit in the lighting fixture which shows a prior art example. 従来例を示す照明器具の概略斜視図である。It is a schematic perspective view of the lighting fixture which shows a prior art example. 同上の照明器具の動作説明図である。It is operation | movement explanatory drawing of a lighting fixture same as the above. 同上の照明器具の動作説明図である。It is operation | movement explanatory drawing of a lighting fixture same as the above.

符号の説明Explanation of symbols

1 発光装置
2 LEDモジュール
3 カバー部材
5 反射用構造体
100 灯具本体
102 開口窓
200 ベース基板
301 レンズ
301b 光出射面
301c 外側面
302 凹所
302b 内側面
314 レンズ用窓孔
400 回路基板
403 窓孔
501 開口部
A 光源ユニット
DESCRIPTION OF SYMBOLS 1 Light-emitting device 2 LED module 3 Cover member 5 Reflective structure 100 Lamp main body 102 Opening window 200 Base substrate 301 Lens 301b Light emission surface 301c Outer side surface 302 Recessed portion 302b Inner side surface 314 Lens window hole 400 Circuit board 403 Window hole 501 Opening A Light source unit

Claims (4)

LEDチップを用いた複数の発光装置がベース基板の一表面側に配置されたLEDモジュールと、ベース基板の前記一表面側において各発光装置を囲み且つ各発光装置に対向する各部位それぞれに発光装置から放射された光の配向を制御するレンズが設けられたカバー部材とを備え、レンズは、発光装置の少なくとも一部を収納する凹所が形成され、LEDモジュールとカバー部材との間には、隣り合うレンズの一方のレンズの外側面から漏れた光が他方のレンズへ到達するのを阻止し前記一方のレンズ側へ反射する反射用構造体が設けられてなることを特徴とする照明器具。   An LED module in which a plurality of light emitting devices using LED chips are arranged on one surface side of a base substrate, and each light emitting device that surrounds each light emitting device on the one surface side of the base substrate and faces each light emitting device And a cover member provided with a lens for controlling the orientation of the light emitted from the lens, the lens is formed with a recess for accommodating at least a part of the light emitting device, and between the LED module and the cover member, An illumination fixture comprising: a reflecting structure that prevents light leaking from an outer surface of one lens of adjacent lenses from reaching the other lens and reflects the light toward the one lens side. 前記反射用構造体の光反射面は、前記レンズの前記外側面に沿った形状に形成されてなることを特徴とする請求項1記載の照明器具。
の照明器具。
The lighting apparatus according to claim 1, wherein the light reflecting surface of the reflecting structure is formed in a shape along the outer surface of the lens.
Lighting fixtures.
前記各レンズと前記カバー部材とが各別に形成されてなり、前記カバー部材は、前記各レンズそれぞれが前記反射用構造体を配置する一面側から挿入され前記各レンズの光出射面を露出させる複数のレンズ用窓孔を有し、前記反射用構造体は、前記各レンズそれぞれの前記発光装置側の端部が挿入される複数の開口部を有し、前記各レンズは、前記カバー部材と前記反射用構造体とで挟持されてなることを特徴とする請求項1または請求項2記載の照明器具。   Each of the lenses and the cover member are formed separately, and the cover member is inserted from one surface side where each of the lenses arranges the reflecting structure and exposes the light emitting surface of each lens. And the reflecting structure has a plurality of openings into which the light emitting device side ends of the respective lenses are inserted, and each of the lenses includes the cover member and the The lighting fixture according to claim 1 or 2, wherein the lighting fixture is sandwiched between the reflecting structures. 前記各発光装置への給電用の回路パターンが形成されるとともに各発光装置それぞれが挿通される複数の窓孔が形成され前記ベース基板の前記一表面側に配置された回路基板を備え、前記カバー部材が金属により形成され、前記反射用構造体は、絶縁材料により形成され、前記ベース基板の前記一表面側において回路基板を覆う形で配設されてなることを特徴とする請求項3記載の照明器具。   A circuit pattern for supplying power to each light emitting device, a plurality of window holes through which each light emitting device is inserted, and a circuit board disposed on the one surface side of the base substrate; 4. The member according to claim 3, wherein the member is made of metal, and the reflecting structure is made of an insulating material, and is disposed so as to cover the circuit board on the one surface side of the base board. lighting equipment.
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