JP2011113879A - Method for manufacturing heat dissipation member for self-ballasted led lamp - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method having superior moldability of a low-cost heat dissipation member for a self-ballasted LED lamp which is superior in heat dissipation performance and has superior productivity with a simple structure. <P>SOLUTION: From an Al alloy-made columnar material having an alloy composition containing 0.01 to 2.0% Fe, 0.01 to 1.5% Si, further containing one or more kinds out of 1.5% or less Mn, 1.0% or less Mg, 0.4% or less Zn, 0.3% or less Cu, 0.2% or less Cr, and 0.1% or less Ti, and then having the balance Al with inevitable impurities, a cylinder with a wall thickness of 0.3 to 1 mm, having a plurality of numbers of ribs integrally on the outer wall face is obtained by a pressurized type molding process at a temperature of 300°C or less. The obtained cylinder is expanded and worked into a tapered shape using a metal mold for expanding the cylinder heated to 150 to 300°C, thereby forming the heat dissipation member for the self-ballasted LED lamp. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a heat-dissipating member for a light bulb-shaped LED lamp, and particularly relates to a method for advantageously manufacturing a heat-dissipating member for a light-bulb-shaped LED lamp excellent in characteristics such as heat dissipation. is there.

  In recent years, with the improvement in performance of LEDs (light emitting diodes), it has been studied to use a lamp (LED lamp) using such LEDs as a light source as a next-generation lighting device. Various LED lamps are conceivable as such LED lamps, and a bulb-shaped LED lamp that can be replaced with an incandescent lamp that is widely used in general households, a so-called LED bulb is particularly noted. Some of them have become commercially available. This LED bulb has a surprising characteristic that its life span is about 40 times that of a conventional incandescent bulb and power consumption is about 1/8. This is because it is an excellent product that meets the requirements for energy saving.

  By the way, the LED element used for such an LED bulb generally has a light output that decreases as the temperature rises, and when the environmental temperature increases, the light output over time is lower than when it is low. It is known that the decrease is large and the lifetime is shortened. For this reason, in an LED bulb, a heat radiating member or a heat radiating holder is provided on the body, and measures have been taken to promote the heat dissipation of heat generated from the LED element. As shown, various types of structures have been proposed. Among them, Patent Document 1 discloses a trumpet-shaped metal heat dissipating part, and Patent Documents 2 and 3 disclose a heat dissipating part in which heat dissipating fins are radially formed. Further, in Patent Documents 4 and 5, the heat radiation portion of the heat radiation fin structure stacked in the axial direction is clarified, and in Patent Document 6, a trumpet shape similar to that of Patent Document 1 is formed on the outer periphery of the base. A structure provided with a heat dissipating member has been clarified.

  However, these proposed conventional heat dissipating members have some inherent problems in performance. For example, the trumpet-shaped metal heat dissipating portion disclosed in Patent Document 1 is not always sufficient. There is a problem that the heat dissipation effect cannot be obtained. Moreover, the heat radiation part disclosed in Patent Documents 2 to 6 has a complicated structure in which a plurality of parts are combined, or uses a cast or die-cast product such as aluminum, and has a high productivity. The problem is that it is low, heavy and expensive. For example, when an aluminum die cast product is used as such a heat radiating member, it is difficult to technically reduce the thickness (generally, the thickness is 2.0 mm or more), and therefore In addition, it is inevitable that the product weight increases, and the Al-Si alloy generally used in aluminum die casting has a low thermal conductivity, so it also improves heat dissipation. There was a limit and it was hard to say that it was excellent as a molding method of a heat dissipation member.

Japanese Patent Laid-Open No. 2001-243809 JP-A-2005-93097 Utility Model Registration No. 3151497 JP 2005-166578 A JP 2008-186758 A JP 2008-311022 A

  Here, the present invention has been made in the background as described above, and the problem to be solved is an excellent heat dissipation performance, a simple structure, and a low productivity. The object is to provide a manufacturing method with excellent moldability of a heat-radiating member for a light-bulb LED lamp at low cost, and also provide a method by which a heat-dissipating member having such excellent characteristics can be produced industrially advantageously. There is to do.

  And, in order to solve the above-mentioned problems, the present invention can be suitably implemented in various aspects as listed below, but each aspect described below is in any combination, It can be adopted. It should be noted that the aspects and technical features of the present invention are not limited to those described below, and can be recognized based on the description of the entire specification and the inventive concept disclosed in the drawings. Should be understood.

(1) A cylindrical portion, a funnel-shaped expanded tubular portion that extends integrally from one end in the axial direction of the cylindrical portion and gradually increases in diameter outward in the axial direction, and an outer wall surface of the cylindrical portion and the expanded tubular portion Provided as a method of manufacturing a heat dissipation member for a light bulb shaped LED lamp having a plurality of ribs that are integrally provided and continuously extend from the cylindrical portion to the expanded cylindrical portion and parallel to each other in the axial direction,
Fe: 0.01-2.0 mass% and Si: 0.01-1.5 mass%, Mn: 1.5 mass% or less, Mg: 1.0 mass% or less, Zn: 0 4% by mass or less, Cu: 0.3% by mass or less, Cr: 0.2% by mass or less, Ti: 0.1% by mass or less, and the balance is inevitable with Al. A step of preparing a columnar material made of Al alloy having an alloy composition composed of mechanical impurities;
From such an Al alloy cylindrical material, a wall thickness of 0.3-1 mm is integrally formed by a plurality of parallel ribs extending in the axial direction on the outer wall surface by pressure molding at a temperature of 300 ° C. or less. Forming a cylindrical body of
One of the openings of the cylindrical body is expanded into a tapered shape having a large diameter toward the outside in the axial direction by an expansion mold heated to 150 to 300 ° C., and the funnel-shaped expansion cylinder Forming a portion and leaving the cylindrical portion other than the expanded portion as the cylindrical portion;
The manufacturing method of the heat radiating member for bulb-type LED lamps characterized by including these.
(2) The manufacturing method of the heat radiating member for bulb-type LED lamps according to the above aspect (1), wherein the pressure mold forming process is a cold mold process.
(3) The manufacturing method of the heat radiating member for a bulb-shaped LED lamp according to the above aspect (2), wherein the cold die processing is backward extrusion processing, impact molding processing, or forging processing.
(4) The above aspect (1), wherein the expansion die has a conical shape portion, and the expansion processing is performed by press-fitting the conical shape portion into one opening of the cylindrical body. The manufacturing method of the heat radiating member for bulb-type LED lamps as described in any one of thru | or (3).
(5) The manufacturing method of the heat radiating member for bulb-type LED lamps according to any one of the above aspects (1) to (4), wherein the cylindrical body has a bottomed cylindrical shape.
(6) The above aspects (1) to (1), wherein the cylindrical body has an outer diameter: r, a height: r-5r, a rib thickness: 0.5-5 mm, and a rib height: 0.5-15 mm. The manufacturing method of the heat radiating member for bulb-type LED lamps as described in any one of (5).
(7) When the outer diameter of the cylindrical portion is r, the outer diameter at the open end of the expanded cylindrical portion is 1.1r to 3r, according to any one of the above aspects (1) to (6). Manufacturing method of heat dissipation member for bulb-type LED lamp.

  Thus, according to the manufacturing method of the heat radiating member for a bulb-type LED lamp according to the present invention, from a specific Al alloy material having a good thermal conductivity, in a temperature range of 300 ° C. or less where it is not completely recrystallized. A thin-walled cylindrical body in which a plurality of ribs are integrally formed on the outer wall surface is obtained by pressure molding, and the tape is formed into a taper shape by using an expansion mold heated to a predetermined temperature. By performing the expansion process, it is possible to easily and easily obtain a thin heat-dissipating member having sufficient work hardening characteristics and sufficient strength imparted with good molding processability. In addition to its simple structure, it can be made to be excellent in productivity, so that it can advantageously provide a heat-dissipating member for a bulb-type LED lamp at low cost, and high Inexpensive and inexpensive bulb-shaped LED run The realization of is the advantageous obtained aim.

  In particular, in the present invention, as a pressure mold forming process for obtaining a cylindrical body that gives a target heat radiating member, a cold mold process, particularly a backward extrusion process, an impact molding process, or a forging process is advantageous. By adopting such cold mold processing, it is possible to produce a cylindrical body with a thin wall and having high strength, with high productivity. It can perform better.

  And, in the heat radiating member for a light bulb shaped LED lamp obtained by the method according to the present invention, an Al alloy having a high thermal conductivity made of a specific alloy composition is used as a material, and pressure molding processing The cylindrical wall having a wall thickness of 0.3 to 1 mm obtained by the above and having a plurality of ribs integrally on the outer wall surface is used to improve the heat dissipation characteristics. Therefore, the reduction in the thickness of the heat radiating member and the improvement in the thermal conductivity can be effectively achieved. Therefore, compared with the heat radiating member made of a conventional casting or die-cast product, the heat radiating characteristic is It could be greatly improved, and at the same time its weight reduction could be realized.

1 shows an example of a tool and a material used in manufacturing a heat-radiating member for a light bulb shaped LED lamp according to the present invention, and (a) is a perspective explanatory view of a die used for pressure molding, and (b). These are perspective explanatory views of an Al alloy columnar material used for manufacturing a cylindrical body. A process of manufacturing a cylindrical body in which a plurality of ribs are integrally provided on the outer wall surface by impact molding processing using the die shown in FIG. 1 and a columnar material made of an Al alloy is shown in FIG. It is process explanatory drawing shown by the AA cross section in a). FIG. 2 shows a cylindrical body obtained in FIG. 2 and an expansion mold that is a jig for expanding the cylindrical body, and (a) is a perspective explanatory view of such a cylindrical body, (B) is a perspective explanatory view of an expansion mold. It is process explanatory drawing which shows the process which manufactures the heat radiating member according to this invention using the cylindrical body and expansion die jig | tool shown by FIG. 3 in the BB cross section in Fig.3 (a). An example of the heat radiating member obtained by the expansion process of the cylindrical body according to FIG. 4 is shown, Comprising: (a) is the half-rod cross-sectional explanatory drawing, (b) is CC cross-sectional description in (a). FIG. It is a semi-cylindrical cross-section explanatory drawing which shows an example of the lightbulb-type LED lamp incorporating the heat radiating member according to this invention.

  By the way, in order to form the heat-dissipating member for a bulb-shaped LED lamp with an Al material, in the present invention, 0.01 to 2.0% Fe and 0.01 to 1.5 on a mass basis % Si, and 1.5% or less Mn, 1.0% or less Mg, 0.4% or less Zn, 0.3% or less Cu, 0.2% or less Cr, And 0.1% or less of Ti, containing one or more of Ti, and the balance is to use an Al alloy having an alloy composition consisting of Al and unavoidable impurities. It can be improved effectively and can contribute advantageously to the improvement of the heat dissipation characteristics of the heat dissipation member obtained.

  In addition, in the alloy composition of such an Al alloy, when the Fe content is less than 0.01% (mass basis; the same applies hereinafter), in addition to the insufficient strength as the heat dissipation member, the Fe content Therefore, it is necessary to use an expensive high-purity aluminum ingot, which is not practical from the viewpoint of cost. Further, when the Fe content exceeds 2.0%, the thermal conductivity becomes too small, and in addition to the problem that the heat dissipation performance required for the heat dissipation member is not sufficient, The problem that the taper-shaped widening work becomes difficult is caused.

  Further, Si, which is one other major component in the alloy component of the Al alloy according to the present invention, adversely affects the strength of the heat radiating member when its content is less than 0.01%, as in the case of Fe described above. In addition to being brought about, there is a problem that is not practical due to cost. On the other hand, if the content exceeds 1.5%, the heat radiation performance is adversely affected, and the molding operation of the heat radiation member is difficult. This is not desirable because it causes problems such as.

  Furthermore, in the alloy composition of the Al alloy according to the present invention, Mn, Mg, Zn, Cu, Cr, and Ti are contained in at least one or more of them. Is too much, that is, if the Mn content exceeds 1.5%, the Mg content exceeds 1.0%, the Zn content exceeds 0.4%, or the Cu content If the Cr content exceeds 0.3%, and if the Cr content exceeds 0.2% or the Ti content exceeds 0.1%, in any case, the thermal conductivity of the Al alloy increases. When it becomes too small, the problem that the heat dissipation characteristic requested | required of a heat radiating member will fall will be brought about, and the problem of making the shaping | molding process operation | work for obtaining a heat radiating member difficult will be caused.

  And in order to manufacture the heat radiating member for bulb-type LED lamps according to the present invention, first, a columnar material made of an Al alloy having the above alloy composition is prepared. Such a columnar material can be obtained according to various known techniques, for example, punching a plate material obtained from an Al alloy having the above-described alloy composition, cutting the extruded material, It can be easily obtained according to a technique such as cutting or punching from an ingot obtained by continuous casting. Further, it is desirable that such a columnar material is recrystallized, whereby a subsequent molding process can be easily performed, and a desired cylindrical body can be advantageously obtained. It is.

  In the present invention, a plurality of parallel ribs extending in the axial direction are integrally formed on the outer wall surface by pressure molding (primary molding) using the Al alloy cylindrical material thus obtained. The cylindrical body which has is manufactured as a primary molded article. Here, the pressure mold forming process uses a mold having an inner wall surface shape that gives an outer wall surface shape of a target cylindrical body, and the above-described Al alloy columnar material is set in this mold. This is a technique in which a cylindrical body having a desired shape is formed by pressurizing with a punch or the like and plastically flowing, and is generally completely recrystallized by a forming operation in a temperature range of 300 ° C. or lower. The target cylindrical body is formed as a molded body that has not been formed. On the other hand, when a molding operation in a temperature range exceeding 300 ° C. is adopted, the obtained cylindrical body is completely recrystallized, so that the effect of work hardening based on the pressure molding process is reduced. Therefore, the strength as the heat radiating member cannot be sufficiently provided.

  In the present invention, as such a pressure mold forming process, advantageously, a cold mold process is employed, and as the cold mold process, for example, backward extrusion process, impact molding process, forging process, etc. However, since the impact molding process is excellent in terms of productivity and the like, it is advantageously employed in the present invention.

  Here, FIGS. 1 and 2 illustrate one embodiment for obtaining a target cylindrical body by impact molding, which is one of pressure molding processes. That is, FIG. 1 (a) shows a die used for impact molding, and FIG. 1 (b) shows a slag as an Al alloy cylindrical material formed with such a die. Further, FIG. 2 is a process explanatory view showing a process of manufacturing a target cylindrical body using the dice and slag shown in FIG.

  In these drawings, a die 10 used for impact molding has a bottomed molding cavity 12 opened on the upper surface of the die, as shown in FIG. The molding cavity 12 has a cylindrical portion molding portion 14 having an inner diameter corresponding to the outer diameter of the cylindrical portion of the primary molded product, which is a target cylindrical body, and extends radially outward from the cylindrical portion molding portion 14. And a plurality of rib forming portions 16 (here, 8 pieces) each having a size corresponding to the rib in the target cylindrical body. Then, the slag 18 having a size accommodated in the molding cavity 12 is formed of an aluminum alloy having an alloy composition according to the present invention in a cylindrical shape as shown in FIG. 1 (b). .

  Further, the impact molding process using the die 10 and the slag 18 shown in FIGS. 1A and 1B is performed, for example, as shown in FIG. That is, as shown in the drawing, after the slag 18 is put into the molding cavity 12 of the die 10 and accommodated, the punch 20 disposed above is rapidly lowered in the same manner as in the prior art, and the slag 18 Impact molding is performed by pressing and pressing 18. By this impact molding operation, the slag 18 is pressed by the punch 20 in the molding cavity 12 of the die 10, so that the slag 18 is plastically deformed and flows, and each rib molding portion 16 of the molding cavity 12 has a flow. And is allowed to extend upward in an outer shape corresponding to the cross-sectional outer shape of the molding cavity 12 by flowing upward in which pressure is released. Next, after the bottom surface of the punch 20 is stopped at a predetermined height from the bottom surface of the molding cavity 12, the punch 20 is lifted and removed, thereby forming a hollow portion inside. A cylindrical primary molded product 22 is thus obtained. Then, when the primary molded product 22 is taken out from the die 10, as shown in the drawing, a plurality of pieces (in parallel to each other in the axial direction) extending radially outward around the cylindrical tubular portion 24, respectively. Here, eight ribs 26 are obtained in a bottomed cylindrical body formed integrally.

  In the impact molding process for obtaining such a primary molded product 22, the Al alloy material (18) to be processed is not completely recrystallized so that the process is performed in a temperature range of 300 ° C. or lower. In other words, it is desirable to perform the impact molding process so that the temperature of the slag 18 does not become higher than 300 ° C. even if the process generates heat, thereby advantageously ensuring the characteristics realized by work hardening. Thus, the primary molded product 22 having excellent strength can be obtained, and the desired heat radiating member can be advantageously obtained while maintaining the excellent strength of the primary molded product 22. .

  And in the primary molded product 22 obtained in this way, it is comprised so that the thickness (wall thickness) of the cylindrical wall of the cylindrical part 24 may be 0.3-1 mm, and thereby Therefore, it is possible to effectively contribute to the improvement of heat dissipation. The wall thickness of the cylindrical portion 24 in such a primary molded product 22 can be easily determined by selecting the difference between the inner diameter of the cylindrical portion molding portion 14 and the outer diameter of the punch 20 in the molding cavity 12 of the die 10. Can be realized. When the wall thickness of the cylindrical portion 24 exceeds 1 mm, the tube portion becomes a thick cylindrical wall portion and thermal conductivity deteriorates, so that sufficient heat dissipation characteristics cannot be obtained. When the thickness is less than 3 mm, the wall thickness becomes too thin, causing a problem that the molding operation becomes difficult.

  By the way, in the primary molded product 22, the outer diameter (r) of the cylindrical portion 24 is appropriately selected according to the size of the product (LED lamp) used for the heat dissipation member. , About 5 to 500 mm, and practically within a range of about 10 to 50 mm. The larger the outer diameter (r), the more the device is applied to a large illuminating device, where the number of LEDs used is increased, and thus higher heat dissipation is required. In addition, the height (length in the axial direction) of the primary molded product 22 is generally appropriately selected within the range of r to 5r. On the other hand, when the height is less than r, since the height with respect to the outer diameter (r) is low, there is a problem that the surface area as the heat radiating member becomes small and sufficient heat dissipation characteristics cannot be obtained. In addition, when the height exceeds 5r, the height of the primary molded product 22 with respect to the diameter becomes too large, which causes a problem that the primary molding operation (pressure mold processing) becomes difficult.

  Further, the rib 26 integrally provided on the outer wall surface of the cylindrical portion 24 of the primary molded product 22 is advantageously provided so as to extend radially outward at a thickness of 0.5 to 5 mm. It is done. This is because if the rib thickness is too thick, the heat dissipation is not sufficient, while if it is too thin, the molding becomes difficult. Furthermore, as the height which is the protruding length of the rib 26 in the radial direction, a value in the range of 0.5 to 15 mm is advantageously employed. If the rib height is less than 0.5 mm, the surface area of the heat radiating member is reduced, and sufficient heat dissipation cannot be obtained. On the other hand, if the rib height exceeds 15 mm, the rib 26 is formed on the cylindrical portion 24. This is because it becomes too high with respect to the diameter (r), so that the Al alloy material is difficult to flow to the rib portion during the pressure molding process, and the molding process operation becomes difficult. The ribs 26 having such a size are generally equidistant in the circumferential direction of the cylindrical portion 24 at a rate of about 4 to 80, preferably at a rate of about 8 to 40. And it will be arranged radially and integrally.

  Next, the cylindrical body composed of the primary molded product 22 as shown in FIG. 3A obtained as described above is shown in FIG. 4 by using a mold 28 for expanding cylinders as shown in FIG. 3B. Thus, the taper-shaped widening process is performed on one of the openings. At that time, the cylinder-expansion mold 28 is heated to a temperature of 150 to 300 ° C., and such cylinder expansion is performed. An expansion molding operation using the mold 28 can be easily performed. In addition, when the heating temperature of the expansion cylinder mold 28 is less than 150 ° C., it cannot sufficiently contribute to the effect of facilitating the expansion expansion operation, and a heating temperature exceeding 300 ° C. is adopted. In such a case, since the obtained molded article material is completely recrystallized, there arises a problem that the strength of the heat radiating member obtained by expanding the cylinder is deteriorated.

  Further, the taper-shaped widening process according to the present invention for the primary molded product 22 is specifically performed as shown in the process diagram shown in FIG. 4, in which the opening of the primary molded product 22 is formed. On the other hand, the conical portion 28a of the expansion mold 28 heated to a predetermined temperature is adapted to be plunged or press-fitted coaxially from the tip portion. Then, the cylinder-expansion mold 28 plunged into the opening of the primary molded product 22 presses the primary molded product 22 in the axial direction, so that the heating effect from the cylinder-expansion mold 28 also acts. The primary molded product 22 is easily deformed, and the opening side portion of the primary molded product 22 is expanded into a shape corresponding to the conical portion 28a of the cylindrical expansion mold 28 (secondary molding). Thus, the taper-shaped expansion process is performed, and the secondary molded product 30 is formed.

  As is apparent from FIG. 5, the secondary molded product 30 obtained in this way is a portion of the cylindrical portion 24 on the bottom side left in the primary molded product 22 without being subjected to the taper expansion process. The cylindrical portion 32 and the tapered or funnel-shaped cylindrical portion 24 opening side portion which is formed by being subjected to a taper-shaped widening process and gradually increases in diameter outward in the axial direction. It is comprised integrally from the expanded cylinder part 34. FIG. Then, on the outer wall surfaces of the cylindrical portion 32 and the expanded cylinder portion 34, the ribs 26 are bent and deformed at the connecting portion between the cylindrical portion 32 and the expanded cylinder portion 34 by a taper-shaped expanding process. The cylindrical portion 32 is positioned so as to extend in parallel to each other in the axial direction and radially outward from the cylindrical portion 32 along the outer wall surface thereof.

  Therefore, by the secondary molded product 30 having such a configuration, the cylindrical portion 32 corresponding to the bottom side portion of the primary molded product 22 and the axially outward portion extending integrally from one axial end of the cylindrical portion 32. Are provided integrally with the outer wall surface of the cylindrical portion 32 and the expanded cylindrical portion 34, and extends continuously from the cylindrical portion 32 to the expanded cylindrical portion 34. The heat dissipation member having a plurality of ribs 26 parallel to each other in the axial direction is provided as a so-called heat dissipation holder in the LED bulb.

  In the secondary molded product 30, the angle of the funnel shape or taper shape of the expanded tube portion 34 depends on the design characteristics of the heat dissipation member in the target LED lamp and the taper-shaped widening workability of the primary molded product 22. The maximum outer diameter (R) of the expanded cylindrical portion 34 is determined based on the outer diameter (r) of the cylindrical portion 32 (tubular portion 24). Usually, the value is in the range of 1.1r to 3r. This is because when the maximum outer diameter (R) of the expanded cylindrical portion 34 is less than 1.1r, it becomes a cylindrical shape, looks bad, and becomes inferior in design, and when larger than 3r, At the time of the taper-shaped widening process on the molded product 22, there arises a problem that cracks are easily caused. Furthermore, even in the axial length (height) of the cylindrical portion 32 and the expanded tube portion 34, in addition to the design properties as a product, the axial length of the primary molded product 22 and the maximum outer diameter of the expanded tube portion 34. It is determined appropriately according to the degree of (R).

  And the heat radiating member comprising the secondary molded product 30 obtained in this way is obtained in a state where the strength imparted by work hardening in the pressure molding process or the like related to the primary molding is effectively maintained. Therefore, while maintaining sufficient strength as a heat radiating member for a light bulb shaped LED lamp, it can be used as a heat radiating member in a light bulb shaped LED lamp in the same manner as in the past. This is shown in FIG.

  That is, in FIG. 6, a light bulb shaped LED lamp 40 has an external shape similar to that of a conventional incandescent light bulb. It can be connected to a power source. A heat radiator 44 made of a heat radiating member according to the present invention is attached to the base 42 at the cylindrical portion 32, while an LED substrate 46 and glass or resin are provided on the opening side of the expanded tube portion 34. A hemispherical translucent cover 48 made of a transparent material such as the like is attached and configured. Here, the heat radiating body 44 is obtained by processing the above-mentioned secondary molded product 30 so as to be adapted to the bulb-type LED lamp structure, and by the lighting circuit 50 disposed inside the heat radiating body 44. The LED element 52 provided on the substrate 46 can emit light. The lighting circuit 50 is electrically connected to the base 42 through a connection hole 44 a provided at the bottom of the radiator 44, whereby power is supplied from the base 42 to the lighting circuit 50. To get.

  Thus, by using the heat radiating member according to the present invention as the heat radiating body 44 in the light bulb shaped LED lamp 40, the heat generated by the LED element 52 is transferred to the heat radiating body 44 through the substrate 46 due to its excellent heat radiating performance. Then, heat can be effectively radiated from the heat radiating body 44 to the outside, so that the original light emitting performance and life of the LED element 52 can be advantageously ensured.

  The exemplary embodiments of the present invention have been described in detail above. However, these are merely examples, and the present invention is not limited in any way by specific descriptions according to such embodiments. It should be understood that this is not to be construed as a matter of course.

  For example, in the illustrated specific example, the LED lamp 40 shown in FIG. 6 is used by using a bottomed heat dissipating member (30) obtained by primary molding (pressure molding process) and secondary molding (expansion process). The lighting circuit 50 can be advantageously housed and held there, but it can also be configured as a heat radiator that does not have such a bottom, and further as a heat radiation member. Is possible.

  Further, in the above-described embodiment, the explanation is mainly made in relation to the impact molding process. However, in the present invention, a pressure mold molding process such as a known backward extrusion process or forging process is similarly employed. It can be done.

  Furthermore, the heat radiating member (30) according to the present invention is not only used as the heat radiating body 44 in the shape or configuration of the LED lamp 40 shown in FIG. In general, the LED element (52) is supplied with power through the base 42, and the LED element (52) is covered in various shapes. It has a structure in which a light cover is provided or the light from the LED element (52) is irradiated to the outside through a lens.

  In addition, although not listed one by one, the present invention can be carried out in a mode to which various changes, modifications, improvements, etc. are added based on the knowledge of those skilled in the art, and such a mode can be applied to the present invention. It goes without saying that all of them belong to the category of the present invention without departing from the spirit of the present invention.

  Hereinafter, representative examples of the present invention will be shown to clarify the present invention more specifically, but the present invention is not limited by the description of such examples. That should also be understood.

Example 1
First, various aluminum alloys (No. 1 to No. 24) containing the alloy components shown in Table 1 below, the balance being Al and inevitable impurities, are each agglomerated by a known DC casting method, Each of the obtained ingots was subjected to a homogenization treatment at 500 ° C. for 6 hours, and then immediately hot-rolled to obtain a hot-rolled plate having a thickness of 12 mm corresponding to each Al alloy. Respectively. Then, a disk-shaped slag (18) having a diameter of 19.9 mm was cut out from each of the obtained hot-rolled sheets by cutting to obtain a primary forming sample.

  Next, for the slag (18) corresponding to each of the Al alloys (No. 1 to No. 24) thus obtained, a primary molding operation is performed as a pressure molding process by an impact molding operation using a crank press. did. Specifically, impact molding was performed using a die (10) and a slag (18) shown in FIG. 1 as shown in FIG. In addition, although the temperature of slag (18) which is material temperature was 25 degreeC before impact shaping | molding, after impact shaping | molding, it became material temperature of about 200 degreeC by process heat_generation | fever. The shape of the primary molded product (22: cylindrical body) is as shown in FIG. 3 (a), and the dimensions are: diameter (r): 20 mm, height: 50 mm (2.5r), cylindrical wall Thickness: 0.3 mm, rib (26) height: 2 mm, and rib (26) thickness: 1 mm. Furthermore, in the impact molding described above, the stroke of the punch (20) was adjusted so that the bottom thickness of the bottomed cylindrical primary molded product (22) was 6.4 mm.

  Thereafter, the Al alloy No. obtained as described above was obtained. 1-No. When each of the primary molded products (22) corresponding to 24 is subjected to secondary molding, an expansion mold (28) shown in FIG. 3B is used and heated to 200 ° C. As shown in FIG. 4, the conical portion (28a) of the expansion die (28) is press-fitted into the opening portion, thereby performing a secondary forming operation which is a taper-shaped expansion process. Secondary molded articles (30) as shown in FIG. In addition, the angle of the conical portion (28a) of the used expansion cylinder mold (28) is 60 °, and the maximum outer diameter (R) of the opening after expansion is 50 mm (2.5r). The length of the expanded slope was 30 mm, and the height of the non-expanded primary molded part (32) was 20 mm.

  And when manufacturing the target heat radiating member (secondary molded product 30) by such primary molding and secondary molding, the test No. corresponding to each of the above-mentioned Al alloys (No. 1 to No. 24). 1-No. 24, the primary formability, the secondary formability, the strength (hardness) and heat dissipation of the molded product were evaluated, and the results are shown in Table 2 below.

  Regarding the evaluation of moldability, regarding the possibility of molding in primary molding, the presence or absence of cracks in the primary molded product (22) is visually observed, and the possibility of molding in cylinder expansion molding (secondary molding) is as follows: The presence or absence of cracks in the expanded tube opening (opened portion in the expanded tube portion 34) is visually observed. Further, regarding the evaluation of the strength (hardness) of the secondary molded product (30), the conical slope of the expanded tube product The cross-sectional Vickers hardness (Hv) was evaluated, and here, when the value was 40 or more, it was regarded as acceptable.

  In addition, the evaluation of heat dissipation was performed by using a rib-shaped conical or funnel-shaped sample (secondary molded product 30) that could be formed by the above-described impact molding and tube expansion molding as a heat dissipation holder as follows. Then, an LED bulb was produced, and the heat dissipation was evaluated by measuring the temperature in the vicinity of the LED element. Specifically, a disc-shaped lid that can be fitted into the opening of the radiator (44) in the LED bulb (40) shown in FIG. 6 and sealed using a pure aluminum material of JIS A1050 having a thickness of 2 mm. The body is manufactured by cutting, and the four LED elements (52) and the control unit are arranged on the upper surface of the obtained lid, and a hemispherical dome-shaped cover ( The LED bulb (40) was produced by covering 48). The LED element (52) is a type of white LED element having a heat generation temperature of 85 ° C. Moreover, as a heat dissipation evaluation method, a method was adopted in which a thermocouple for temperature measurement was fixed to the surface of the lid in the vicinity of the LED element of the LED bulb, and the temperature 120 minutes after the energized light emission was measured. In addition, all start temperature was room temperature (25 degreeC). Then, the case where the measurement temperature after 120 minutes was 55 ° C. or less was evaluated as ◎, and the case where the measurement temperature was higher than 55 ° C. and 65 ° C. or less was evaluated as ◯. And the case where measurement temperature exceeded 65 degreeC was set as x, and it was evaluated as heat dissipation defect.

  As is apparent from the results in Table 2, when a heat radiating member was manufactured by primary molding (impact molding) and secondary molding (expanded cylinder molding) using an Al alloy having an alloy composition according to the present invention (Test No. 1). 1) to 16), the moldability is good and the Vickers hardness (Hv) of the slag (18) before impact molding is about 25, whereas the two after the cylinder expansion molding. The hardness (Hv) of the next molded product (30) is 40 or more, and the strength is greatly improved. As a heat dissipation holder, practically useful strength is obtained, Excellent results in heat dissipation were shown. In contrast, when primary molding and secondary molding were performed using an Al alloy having an alloy composition outside the scope of the present invention (test Nos. 17 to 24), cracks occurred, and the intended heat dissipation. Even when a member could not be obtained and a heat radiating member could be obtained, the heat dissipation was insufficient.

-Example 2-
Alloy No. 1 in Table 1 above. Using an Al alloy having the alloy component according to No. 1, DC casting, homogenization treatment, and hot rolling were performed in the same manner as in Example 1 to obtain a hot rolled plate having a plate thickness of 12 mm. Then, a disk-shaped slag (18) having a diameter of 19.9 mm was cut out from the hot-rolled sheet to obtain a sample for primary forming.

  Next, using the obtained primary molding sample, a primary molding (impact molding) operation was performed in the same manner as in Example 1 to produce a primary molded product (22). In this primary molding, the temperature of the sample was adjusted by heating as necessary so that the material temperature after primary molding was as shown in Table 3 below. Thereafter, with respect to the obtained various primary molded articles (22), Example 1 and Example 1 were used, respectively, by using an expansion mold (28) heated to various temperatures shown in Table 3 below. A similar expansion molding operation was carried out to produce the intended secondary molded product (30).

  And while evaluating the possibility of the shaping | molding in such primary shaping | molding and cylinder expansion shaping | molding (secondary shaping | molding), also about the hardness (cross-section Vickers hardness of a funnel-shaped part) of Example 1. The results are shown in Table 4 below.

  As is apparent from the results of Tables 3 and 4, the test temperature in which the material temperature after the primary molding and the heating temperature of the expansion mold (28) are within the range defined by the present invention. . In the secondary molded product (30) of 25-27 and 30-31, the primary moldability and the expansion moldability are high, and the hardness (strength) is excellent, and the overall evaluation is also good. It became a thing.

-Example 3-
Alloy No. shown in Table 1 above. Using the Al alloy according to No. 1, DC casting, homogenization treatment, and hot rolling were performed in the same manner as in Example 1 to produce a hot rolled plate having a thickness of 12 mm, and this hot rolled plate From this, a disk-shaped slag (18) having a diameter of 19.9 mm (test No. 34, 35, 38, 39) or a diameter of 39.9 mm (test No. 36, 37) is cut out by cutting, A sample for primary molding was obtained.

  Then, using the obtained two samples for primary molding, primary molding and secondary molding were performed in the same manner as in Example 1, and secondary molded products having dimensional specifications as shown in Table 5 below, respectively. The test (No. 34-39) which gives was carried out.

  And about the secondary molded article (30) which concerns on each obtained test example, it carries out similarly to Example 1, evaluates hardness (Hv) and heat dissipation, and also performs comprehensive evaluation, The result is obtained. The results are shown in Table 6 below.

  As is apparent from the results of Table 6, when the thickness of the cylindrical wall portion (24) in the secondary molded product (30) exceeds 1 mm (Test No. 38), the heat dissipation becomes insufficient. Also, from the viewpoint of heat dissipation, it is considered effective to increase the height of the rib (26) or to increase the maximum diameter of the expanded tube opening, and to further increase the thickness of the wall portion. When the thickness is too thin (Test No. 39), primary molding becomes difficult, and the intended secondary product (heat dissipating member) cannot be obtained.

DESCRIPTION OF SYMBOLS 10 Dies 12 Molding cavity 14 Cylindrical part molding part 16 Rib molding part 18 Slag 20 Punch 22 Primary molding product 24 Cylindrical part 26 Rib 28 Expansion mold 30 Secondary molding product 32 Cylindrical part 34 Expansion part 40 Light bulb type LED Lamp 42 Base 44 Radiator 44a Connection hole 46 LED substrate 48 Translucent cover 50 Lighting circuit

Claims (7)

A cylindrical portion, a funnel-shaped expanded tubular portion that extends integrally from one end in the axial direction of the cylindrical portion, and that gradually increases in diameter outward in the axial direction, and the cylindrical portion and the outer wall surface of the expanded tubular portion integrally A method of manufacturing a heat-dissipating member for a bulb-type LED lamp having a plurality of ribs that are provided and continuously extend from the cylindrical portion to the expanded cylindrical portion and parallel to each other in the axial direction,
Fe: 0.01-2.0 mass% and Si: 0.01-1.5 mass%, Mn: 1.5 mass% or less, Mg: 1.0 mass% or less, Zn: 0 4% by mass or less, Cu: 0.3% by mass or less, Cr: 0.2% by mass or less, Ti: 0.1% by mass or less, and the balance is inevitable with Al. A step of preparing a columnar material made of Al alloy having an alloy composition composed of mechanical impurities;
From such an Al alloy cylindrical material, a wall thickness of 0.3-1 mm is integrally formed by a plurality of parallel ribs extending in the axial direction on the outer wall surface by pressure molding at a temperature of 300 ° C. or less. Forming a cylindrical body of
One of the openings of the cylindrical body is expanded into a tapered shape having a large diameter toward the outside in the axial direction by an expansion mold heated to 150 to 300 ° C., and the funnel-shaped expansion cylinder Forming a portion and leaving a portion of the cylindrical body other than the expanded portion as the cylindrical portion;
The manufacturing method of the heat radiating member for bulb-type LED lamps characterized by including these.   The method for manufacturing a heat-dissipating member for a bulb-shaped LED lamp according to claim 1, wherein the press-molding process is a cold mold process.   The method for manufacturing a heat-radiating member for a bulb-type LED lamp according to claim 2, wherein the cold die processing is backward extrusion processing, impact molding processing, or forging processing.   The said expansion mold is implemented by the said mold for cylinder expansion having a cone-shaped part, and press-fitting this cone-shaped part in one opening part of the said cylindrical body. The manufacturing method of the heat radiating member for bulb-type LED lamps of any one of Claims 1.   The manufacturing method of the heat radiating member for bulb-type LED lamps according to any one of claims 1 to 4, wherein the cylindrical body has a bottomed cylindrical shape.   6. The cylindrical body according to claim 1, wherein the cylindrical body has an outer diameter: r, a height: r to 5r, a rib thickness: 0.5 to 5 mm, and a rib height: 0.5 to 15 mm. The manufacturing method of the heat radiating member for bulb-type LED lamps of Claim 1. The light bulb-shaped LED lamp according to any one of claims 1 to 6, wherein an outer diameter at an opening end of the expanded cylindrical portion is 1.1r to 3r, where r is an outer diameter of the cylindrical portion. Manufacturing method of heat dissipation member.

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