JP2012018865A - Led module and led lamp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an LED module which can be used by bending more greatly than a conventional LED module.SOLUTION: The LED module has a plurality of LEDs mounted on a flexible board 4, and at least one LED 20 out of the plurality of LEDs is mounted on a tab region 40 formed in the flexible board 4. The tab region 40 is a board part which is surrounded by a cut-out 40A cut into the flexible board 4 to surround the LED 20 exceeding its semicircle and a virtual line 40D connecting both end parts 40B, 40C of the cut-out 40A.

Description

  The present invention relates to an LED module and an LED lamp, and more particularly to an LED module or the like in which a plurality of LEDs are mounted on a flexible substrate.

  Compared with incandescent bulbs, fluorescent lamps and the like, they have a long life and consume less power. Therefore, lamps using LEDs as light sources, such as bulb-type LED lamps, have been put into practical use and are being further developed.

  Generally, a light bulb shaped LED lamp has a circuit unit for mounting a large number of LED chips on one mounting board and lighting the LED chips in a housing space between the back side of the mounting board and the base. It has the structure by which it is accommodated (patent document 1).

  Further, in order to use an alternative light source for an incandescent bulb, it is required to be as close as possible to the light distribution characteristics of the incandescent bulb. That is, for example, when it is attached downward, it is required to emit light not only downward but also laterally.

  In this respect, the light distribution of the LED exhibits Lambertian characteristics and its directivity is strong, and as such, the light distribution characteristics are such that the light distribution directly illuminates directly under and near the lamp.

  Therefore, it is conceivable to use an LED module in which LEDs are mounted (joined) in a row in the longitudinal direction of a strip-like flexible substrate as a light source of a lamp (prior art described in Patent Document 2). By using this LED module with a flexible substrate bent like a bow with the LED mounting surface facing outward, light can be emitted in the lateral direction.

  However, if the flexible substrate is greatly curved, the flatness of the LED mounting portion on the flexible substrate is lost, and thus there arises a problem that the bonding between the LED and the flexible substrate is peeled off.

  Therefore, in the inventions described in Patent Documents 2 and 3, the LED module has a configuration in which slits are provided in the width direction in the portion between adjacent LEDs of the flexible substrate having a belt shape as a whole. According to this, in the flexible substrate, the rigidity of the slit portion is lower than the rigidity of the LED mounting location. As a result, the flexible substrate bends only at the slitted portion, and the flatness of the LED mounting portion can be ensured, so that the bonding between the LED and the flexible substrate is difficult to peel off.

JP 2009-037995 A JP 2004-103993 A JP 2004-71342 A

  However, in the LED modules described in Patent Documents 2 and 3, since the portion that bends in the longitudinal direction of the flexible substrate is limited to the portion having the slits, the whole is not bent as a whole. Therefore, for example, there is a problem that it is not suitable for a bulb-shaped LED lamp that needs to be largely curved in a narrow space.

  In addition, the above-mentioned subject is a subject common to the LED module used as a light source not only in the LED module for light bulb-shaped LED lamps but in the illumination field where various light distribution characteristics are required.

  An object of this invention is to provide the LED module which can be bent and used more largely than the said conventional LED module in view of an above-described subject. Moreover, it aims at providing the LED lamp which has such an LED module in a light source.

(1) In order to achieve the above object, an LED module according to the present invention is an LED module in which a plurality of LEDs are mounted on a flexible substrate, and at least one of the plurality of LEDs is Mounted in a tab region formed on a flexible substrate, the tab region is an imaginary line connecting a notch put in the flexible substrate and surrounding both ends of the notch so as to surround the one LED over a half circumference. And a substrate portion surrounded by.
(2) Moreover, with respect to the LED module as described in (1), the said notch which creates the said tab area | region is put in U shape or U shape, It is characterized by the above-mentioned.
(3) or the LED module according to (1), wherein the flexible substrate has a strip shape, and the plurality of LEDs are arranged in at least one row in the longitudinal direction of the flexible substrate. Features.
(4) Moreover, with respect to the LED module according to (3), the tab region is formed so that the virtual line faces in the width direction of the flexible substrate.
(5) Or, in the LED module according to (3), the cutting direction from the virtual line is different between one tab area and another tab area.
(6) In this case, with respect to the LED module described in (5), each of the plurality of LEDs is mounted in the tab region, and the cutting direction of the tab region is different from the longitudinal center of the flexible substrate. Each of the cuts is cut from the imaginary line to the side closer to the flexible substrate.
(7) Or, for the LED module according to (5), each of the plurality of LEDs is mounted in a tab region, and the cutting direction of the tab region is different from the longitudinal center of the flexible substrate, Each cut is cut from the imaginary line to the center side.
(8) Moreover, with respect to the LED module according to (4), each of the plurality of LEDs is mounted in a tab region, and the cut direction from the imaginary line is the flexible substrate in all the tab regions. It is characterized by being directed to one end side.
(9) In order to achieve the above object, an LED lamp according to the present invention has the LED module according to (6) as a light source, and the LED module is in a curved state with the LED mounting side facing outward. It is installed in.
(10) Further, the LED lamp according to (9) has an extrusion member that is disposed on the back surface of the flexible substrate opposite to the LED mounting surface and pushes the tab region to the mounting surface side. It is characterized by.
(11) Further, with respect to the LED lamp according to (10), the extruded member is made of a heat-conductive material.
(12) In order to achieve the above object, an LED lamp according to the present invention has the LED module according to (7) as a light source, and the LED module is in a curved state with the LED mounting side inside. And an extrusion member that is disposed on the back surface of the flexible substrate opposite to the LED mounting surface and pushes the tab region to the mounting surface side.
(13) Moreover, the said extrusion member is formed with the heat conductive material with respect to the LED lamp as described in (12), It is characterized by the above-mentioned.
(14) In order to achieve the above object, the LED module according to (8) is provided as a light source, and the LED module is installed in a state of being bent in a circle with the LED mounting side facing outward. It is characterized by being.

  According to the LED module having the above-described configuration, when the flexible substrate is entirely curved, the substrate portion other than the tab region (hereinafter referred to as “main body region”) is bent, but the tab region is based on the virtual line portion. Since it is an edge and is separated from the main body region with the notch as a boundary, the flatness is maintained. As a result, it is possible to prevent the LEDs mounted on the tab area from peeling off as much as possible. Moreover, since the overall flexibility of the flexible substrate is exhibited in the main body region, it can be bent largely as a whole.

1 is a perspective view illustrating a schematic configuration of an LED module according to Embodiment 1. FIG. It is a figure for demonstrating the effect | action of the said LED module. It is a figure which shows schematic structure of an example of a bulb-shaped LED lamp using the LED module as a light source. It is a figure which shows schematic structure of the other example of the light bulb-shaped LED lamp which used the said LED module for the light source. 6 is a plan view showing a schematic configuration of an LED module in Embodiment 2. FIG. It is a partial cross section figure which shows an example of the LED lamp which used the LED module of Embodiment 2 for the light source. It is a top view of the said LED lamp. It is a perspective view which shows schematic structure of the semi-cylindrical part which is a structural member of the said LED lamp. 6 is a plan view illustrating a schematic configuration of an LED module according to Embodiment 3. FIG. It is a partial cross section figure which shows an example of the LED lamp which used the LED module of Embodiment 3 for the light source. It is a figure which shows the modification of the LED module in Embodiment 3. FIG. 6 is a plan view showing a schematic configuration of an LED module according to Embodiment 4. FIG. It is a perspective view which shows the example of installation of the said LED module. It is a figure which shows the variation of the tab area | region in an LED module. It is a figure which shows the variation of the tab area | region in an LED module.

Embodiments according to the present invention will be described below with reference to the drawings.
<Embodiment 1>
(LED module)
FIG. 1 is a perspective view showing a schematic configuration of an LED module 2 in the first embodiment. In all the figures including this figure, the scales between the members are not necessarily unified.

  The LED module 2 includes a flexible substrate (flexible printed wiring board) 4 having a strip shape. The flexible substrate 4 is a wiring board in which conductor patterns 8 and 10 are formed on a flexible insulating film 6 such as polyester or polyimide. The thickness of the flexible substrate is about 0.3 to 0.5 [mm]. In addition, in what provided the heat dissipation structure in flexible substrate itself, thickness will increase a little and it is about 0.5-0.8 [mm].

  Both the conductor patterns 8 and 10 are directed from the main pattern portions 8A and 10A formed in parallel to the longitudinal direction along the edge of the insulating film 6 to the counterpart main pattern at predetermined intervals in the longitudinal direction from the main pattern portions 8A and 10A. And a plurality of branch pattern portions 8B and 10B extending in an L shape.

  Each of the tip portions of the pair of branch patterns 8A and 10B facing each other is formed on a mounting land (not shown). For example, a blue LED chip (not shown) is flip-chip mounted on the pair of mounting lands. Yes. That is, a single-sided electrode type LED chip in which both the p-side electrode and the n-side electrode are formed on one side is bonded to each of the pair of mounting lands via bumps (not shown). Thereby, all the blue LED chips are electrically connected in parallel by the two conductor patterns 8 and 10. Each of the one end portions of the two conductor patterns 8 and 10 is formed at the power supply terminals 8C and 10C.

  Each blue LED chip is covered with a yellow phosphor film, and the white LED 12, 14, 16, 18, 20, 22, 24, 26, 28, 30 is composed of the blue LED chip and the yellow phosphor film. (In FIG. 1, the white LEDs 16, 18, 24, and 26 are not shown).

  Each of the white LEDs 12,..., 30 (hereinafter simply referred to as “LED 12,..., 30”) is mounted on the tab region of the flexible substrate 4. The tab area will be described with reference to FIG.

  In FIG. 2A, the tab area of one LED 20 is taken up and described, and therefore other LEDs and their tab areas are not shown. Also, the conductor patterns 8 and 10 are not shown.

  The tab region 40 is a portion of the flexible substrate 4 surrounded by a notch 40A inserted into the flexible substrate 4 so as to surround the LED 20 over a half circumference and a virtual line 40D connecting both ends 40B and 40C of the notch 40A. . The tab region 40 and the flexible substrate 4 other than the tab region 40 are separated by a cut 40A and connected by a portion corresponding to the virtual line 40D. Here, the flexible substrate 4 part other than the tab area is referred to as “main body area 4A”. Here, with reference to the virtual line 40D, the direction of the cut 40A from the virtual line 40D is defined as “the direction of the tab region 40”. Therefore, as shown in FIG. 1, in this example, the tab regions 32,..., 50 are different in direction from the longitudinal center of the flexible substrate 4, and the tab regions 32,. , 48, and 50 are also directed toward the end side closer to the flexible substrate 4.

  For example, FIGS. 2B and 2C show a state where the LED module 2 having the above-described configuration is curved in a U-shape as a whole around the virtual line 40, for example. 2B is an external view seen from the side, and FIG. 2C is a longitudinal sectional view. In FIG. 2C, the LED 20 is not cut.

  Since the tab area 40 is separated from the main body area 4A by the notch 40A (FIG. 2A), the tab area 40 is separated from the main body area 4A as shown in FIGS. 2B and 2C. It does not follow the bending of, but keeps a substantially flat state before bending. At this time, the tab area 40 has a posture extending from the main body area 4A in the direction of the tangential line A of the main body area 4A in the portion corresponding to the virtual line 40D. That is, the tip of the tab region 40 is separated from the main body region 4A according to the degree of bending of the main body region 4A.

  Thus, even if the strip-shaped flexible substrate 4 is curved, the tab region 40 on which the LED 40 is mounted is separated from the main body region 4A with the notch 40A as a boundary, with the phantom line 40D being the base end. The mounting surface is kept substantially flat, and it is possible to prevent the LED 40 from being peeled off from the flexible substrate 4 due to bending.

Moreover, since the overall flexibility of the flexible substrate 4 is exhibited in the main body region 4A (because it is ensured in the main body region 4A), it can be bent largely as a whole.
Returning to FIG. 1, the other LEDs 12, 14,..., 20, 22,..., 28, 30 are also mounted in the tab areas 32, 34,. Therefore, any of the LEDs 12,..., 30 can be prevented from being peeled off from the flexible substrate 4 by bending the flexible substrate 4 as much as possible.
(LED lamp)
An embodiment in which the LED module 2 is used for a bulb-type LED lamp will be described with reference to FIG.

FIG. 3 is a cross-sectional view illustrating a schematic configuration of a bulb-shaped LED lamp 52 according to the embodiment. The LED lamp 52 is preferably used as an LED lamp instead of an incandescent bulb.
As shown in FIG. 3, the LED lamp 52 has a holder 54 made of an insulating material such as synthetic resin. The cross section of the holder 54 is substantially circular, and has a shape in which a small cylindrical portion 56 and a large cylindrical portion 60 are connected by a tapered cylindrical portion 58.

  The small cylindrical part 56 of the holder 54 is provided with a base part 66 including a shell 62 and an eyelet 64. The base part 66 conforms to the standard of E26 base specified in JIS (Japanese Industrial Standard), for example, and is attached to a socket (not shown) for a general incandescent lamp.

  A disk-shaped first circuit board 68 is attached in the large cylindrical portion 60 of the holder 54. In addition, a support plate 70 that is a support member is attached so as to overlap the first circuit board 68. The support plate 70 is made of an insulating material such as a synthetic resin and has a disk shape. The support plate 70 has a large-diameter portion 70A and a small-diameter portion 70B, and a step portion 70C is formed.

  On the opposite side of the support plate 70 from the first circuit board 68, a second circuit board 72 is attached in a standing state. A plurality of electronic components 74 are mounted on the second circuit board 72, and a lighting circuit that converts the power supplied from the commercial power source via the base 66 to the power necessary for lighting the LEDs. Is configured. The second circuit board 72 and the base part 66 are electrically connected via a first lead wire 76 connected to the shell 62 and a second lead wire 78 connected to the eyelet 64. The first lead wire 76 and the second lead wire 78 are inserted through a through hole 80 that communicates the support plate 70 and the first circuit board 68.

  The support plate 70 is provided with a pair of elongated holes 82 and 84 that are slightly longer than the width of the flexible substrate 2 (FIG. 1). Although not shown in FIG. 3, the support plate 70 is provided with another pair of long holes in the direction perpendicular to the paper surface. Therefore, a total of four long holes are formed, and these long holes are formed along the periphery of the support plate 70 at intervals of 90 degrees around the center of the support plate 70.

  Silicone bushings 86 and 88 each having a slit slightly smaller than the cross-sectional shape of the flexible substrate 2 (FIG. 1) are fixed to the long holes 82 and 84, respectively. In addition, through holes 90 and 92 that are in communication with the slits of the bushes 86 and 88 and that are larger than the cross-sectional shape of the flexible substrate 2 (FIG. 1) are formed in the first circuit board 68.

  Two LED modules 2 are supported on the support plate 70. When distinguishing these two LED modules, it is set as the 1st LED module 2A and the 2nd LED module 2B.

  The first LED module 2A is supported by the support plate 70 in a state in which the flexible substrate 4 is bent in a substantially U shape with the LEDs 12,. Specifically, until both ends of the flexible substrate 4 protrude from the corresponding through holes 90 and 92, both end portions thereof are press-fitted into the slits of the corresponding bushes 86 and 88.

The second LED module 2B is three-dimensionally crossed with the first LED module 2A and is supported on the support plate 70 in the same manner as the first LED module 2A.
Note that the support plate 70 and the flexible substrate 4 may be fixed with an adhesive, thereby improving heat dissipation through the support plate 70. Therefore, as the adhesive to be used, it is preferable to use an adhesive having a high thermal conductivity containing a filler.

  The power supply terminal 8C of the first LED module 2A is electrically connected to the printed wiring (not shown) of the first circuit board 72 via the internal wiring 94 (note that the first power supply terminal 10C and the first power supply terminal 10C are connected to the first power supply terminal 10C. (Internal wiring connecting the printed wiring (not shown) of the circuit board 72 does not appear in the figure.) Similarly to the power supply terminals of the first LED module 2A, the power supply terminals 8C and 10C of the second LED module 2B are also electrically connected via the printed wiring (not shown) and the internal wiring (not shown) of the first circuit board 72. Has been.

The second circuit board 72 is electrically connected to the first circuit board 68 via the internal wirings 96 and 98.
The second circuit board 72 and the first LED module 2A and the second LED module 2B are connected to each other by internal wirings 96 and 98 and a printed wiring (not shown) of the first circuit board 82, respectively. Illuminated by the power supplied from.

  As described above, since the flexible substrate 4 is used by being bent in a substantially U shape, the LEDs 12, 14, 28, 30 among the LEDs mounted in a line in the longitudinal direction of the flexible substrate 4 are: Light is emitted in a direction substantially orthogonal to the central axis X of the LED lamp 52, light is emitted from the LEDs 36, 38, 44, 46 in a direction obliquely intersecting the central axis X, and the LEDs 40, 42 are centered. Light is emitted in a direction substantially parallel to the axis X, and a wide light distribution characteristic is obtained. The central axis X is an axis including the center of the cylindrical portion 66 having a substantially cylindrical shape.

  Even if the flexible substrate 4 is curved in this way, as described above, the LEDs 12,..., 30 are all mounted on the tab regions 32,. For the reason, the joint is not peeled off.

The LED lamp 52 includes a globe 100 that covers the first LED module 2A and the second LED module 2B. The globe 100 has a substantially oval shape with one end cut off, and an opening periphery is fitted into a stepped portion 70 </ b> C existing in the large cylindrical portion 60 of the holder 54. The step portion 70 </ b> C is filled with a heat-resistant adhesive 102, whereby the support plate 70, the globe 100, and the first circuit board 68 are fixed to the holder 54.
(Modification of LED lamp)
Another embodiment of a bulb-shaped LED lamp will be described with reference to FIG.

  FIG. 4A is a cross-sectional view showing a schematic configuration of an LED lamp 104 according to another embodiment. The LED lamp 104 has basically the same configuration as the LED lamp 52 (FIG. 3) except that it has a heat sink. Therefore, different parts will be mainly described below. In FIG. 4, the same components as those shown in FIG. 3 are denoted by the same reference numerals, and the description thereof is omitted.

  The LED lamp 104 is provided upright from the support plate 70 and has an upright portion 106 provided corresponding to the first LED module 2A and the second LED module 2B. The standing portion 106 is substantially U-shaped, and the first arch portion 108 corresponding to the first LED module 2A and the second arch portion 110 corresponding to the second LED module 2B intersect at the center portion in the longitudinal direction (plane intersection). (Here, the intersecting portion is the shared portion 112 of the first and second arch portions 108, 110. Therefore, the shared portion 112 belongs to both the arch portions 108, 110).

  The support plate 70 and the standing portion 106 are integrally formed. The support plate 70 and the standing portion 106 are made of, for example, aluminum and are manufactured by casting. In addition, you may form not only aluminum but another metal material.

Since the first and second arch portions 108 and 110 have basically the same configuration, the first arch portion 108 will be described as an example.
The first arch portion 108 has push-out portions 116,..., 134 at positions corresponding to the tab regions 32,.

FIG. 4B is a perspective view of the extruded portions 126 and 128 corresponding to the tab regions 42 and 44 and the vicinity thereof in the first arch portion 108.
The extruding portions 126 and 128 are portions protruding from the outer peripheral surface of the main body portion 108A of the first arch portion 108, and the protruding end surfaces 126A and 128A are slightly similar to the corresponding tab regions 42 and 44. It is formed on a flat surface.

  When the first LED module 2A is attached to the first arch portion 108 having such extruded portions 116,..., 134 so as to be wound from the central portion in the longitudinal direction, each of the extruded portions 116,. The tab areas 32,... Therefore, desired light distribution characteristics can be obtained in the LED lamp 104 by appropriately setting the angle formed by the projecting end faces 126A and 128A and the central axis X. Since the projecting end surfaces 126A and 128A are formed in a flat surface, the flatness of the tab regions 42 and 44 is not impaired, and thus the LEDs 22 and 24 are not easily peeled off from the flexible substrate 4 as in the past. Thus, the 1st arch part 108 containing extrusion part 116, ..., 134 functions as an extrusion member with respect to a tab area | region.

  Further, the upright portion 106 including the first arch portion 108 and the support plate 70 integrally formed therewith are made of a highly heat conductive material (aluminum), and a protruding end surface that contacts the tab region is formed in a flat surface. Therefore, the heat generated in each LED 12,..., 30 is conducted through the tab regions 32,.

In this manner, the standing portion 106 including the first arch portion 108 and the support plate 70 integrally formed therewith are formed of a metal material or other highly heat conductive material, thereby functioning as a heat sink.
<Embodiment 2>
(LED module)
FIG. 5 shows a plan view of the LED module 140 in the second embodiment. In FIG. 5, the conductor pattern is not shown.

  The LED module 140 includes a flexible substrate 142 and LEDs 144, 146, 148, 150 mounted on the flexible substrate 142. The material of the flexible substrate 142 is the same as that of the first embodiment, and the LEDs 144,..., 150 have the same configuration as the LED of the first embodiment.

The LEDs 144, 146, 148, 150 are mounted on the tab regions 152, 154, 156, 158.
In the LED module 2 (FIG. 1) of the first embodiment, each of the tab regions 32,..., 50 is a flexible corresponding to each of the tab regions on both sides from the imaginary line with the longitudinal center of the flexible substrate 4 as a boundary. The LED module 140 according to the second embodiment is extended to the end portion side of the substrate 4, but the tab regions 152 and 154 and the tab regions 156 and 158 on both sides are separated from the longitudinal center of the flexible substrate 142. , Extending from the virtual line toward the center. That is, all the tab regions 152, 154, 156, 158 face the center in the longitudinal direction of the flexible substrate 142.

In the LED module 2, the lengths of the tab regions in the longitudinal direction of the flexible substrate 4 are all equal. However, in the LED module 140, the lengths of the tab regions 154 and 156 near the center of the flexible substrate 142 are the end. It is longer than the length of the tab regions 152 and 158 near the portion.
(LED lamp)
An embodiment in which the LED module 140 is used in an LED lamp in the form of a halogen bulb with a reflector will be described with reference to FIGS.

  6 is a cross-sectional view of the LED lamp 160 according to Embodiment 1 as viewed from the front, and FIG. 7 is a plan view thereof. In addition, the 1st LED module 140A mentioned later in FIG. 6 is not cut | disconnected. Further, FIG. 7 is drawn with a module mounting ring 168 described later removed, and internal wirings 212 and 214 described later are omitted.

  As shown in FIG. 6, the LED lamp 160 includes a base portion 162, a lighting circuit unit 164, a heat sink 166, a module mounting ring 168, two LED modules 140, and the like. In addition, when distinguishing two LED modules 140, it is set as the 1st LED module 140A and the 2nd LED module 140B, respectively.

  The base part 162 has a main body part 170 made of an electrically insulating material. One end portion of the main body 170 is formed in a substantially cylindrical shape, and a shell 172 is fitted into the cylindrical portion. Further, one end side of the cylindrical portion is formed in a substantially truncated cone shape, and an eyelet 174 is fixed to the top portion of the truncated cone. The base part 162 conforms to a standard (for example, JIS standard) that can be attached to a socket of an existing lighting fixture for a light bulb.

  The other end portion of the cylindrical portion of the main body 170 is formed in a hollow shape in which the internal space is widened away from the eyelet 174, and the lighting circuit unit 164 is accommodated in the hollow portion.

  The lighting circuit unit 164 includes a circuit board 176 and a plurality of electronic components 178 mounted on the circuit board 176. The lighting circuit unit 164 and the eyelet 174 are electrically connected by a first lead wire 180, and the lighting circuit unit 164 and the shell 172 are electrically connected by a second lead wire 182, respectively. The lighting circuit unit 164 converts commercial AC power supplied via the eyelet 174 and the shell 172, the first lead wire 180, and the second lead wire 182 into power for lighting the two LED modules 140. Power is supplied to the two LED modules 140.

  The heat sink 166 is made of a highly heat conductive material such as aluminum, and has a neck portion 184 and a hook-like portion 186 that is connected to the neck portion 184. 6 and 7, the central axis X of the neck portion 184 and the collar portion 186 is indicated by a one-dot chain line.

  The neck portion 184 has a substantially cylindrical shape, and is inserted into the opening portion of the main body portion 170 of the base portion 162 and fixed to the main body portion 170. For this fixing, an adhesive, among them, a silicone resin, an adhesive having good thermal conductivity (for example, an adhesive containing thermal grease) (all not shown), or the like can be used.

The heat sink 166 is a combination of two plane-symmetric members (first member 166A and second member 166B).
FIG. 8 is a perspective view of the first member 166A. 8 also shows the central axis X (of the heat sink 166) when the first member 166A and the second member 166B are combined. Each part of the first member 166A is given an alphabet “A”, and the letter “A” is omitted when the corresponding part of the heat sink 166 in which the first member 166A and the second member 166B are combined is shown. However, it shall be indicated only by numbers.

The first member 166A includes a semi-cylindrical portion 184A that becomes the neck portion 184 (FIG. 1) and a semi-cylindrical portion 186A that is connected to the semi-cylindrical portion 186A (FIG. 1).
Extruded portions 190A, 192A, 194A, 196A, 198, and 200 are provided so as to project inward (toward the central axis X) from the inner peripheral surface 188A of the semi-cylindrical portion 186A.

  An insertion hole 208 for internal wirings 212 and 214 (described later) for electrically connecting the LED module 140 and the lighting circuit unit 164 is formed in the bottom portion 206A of the semi-cylindrical portion 186A.

Further, the first member 166A has a mating surface 210A with the second member 166B.
The extruding portions 198 and 200 have a U shape in a plan view (viewed from the direction of the central axis X), and an upper surface thereof is formed in a plane. Further, the upper surface of the extruded portion 198 is slightly smaller than the tab regions 152 and 158, and the upper surface of the extruded portion 200 is slightly smaller than the tab regions 154 and 156.

Further, the first member 166A has a mating surface 210A with the second member 166B.
When the first member 166A and the second member 166B are combined and their mating surfaces are combined, the extrusion part 190A and the extrusion part 196A of the first member 166A are respectively the extrusion parts 190B and 196B corresponding to the second member 166B (FIG. 7) and the same shape as the extruded portion 198. Further, the extruded portion 192A and the extruded portion 194A of the first member 166A are integrated with the corresponding extruded portions 192B and 194B (FIG. 7) of the second member 166B, respectively, and have the same shape as the extruded portion 200.

Further, in the second member 166B, the same pushing portions 204 and 202 (FIG. 7) are provided at positions facing the pushing portion 198 and the pushing portion 200 of the first member 166A, respectively.
Accordingly, when the first member 166A and the second member 166B are viewed in plan with their mating surfaces being combined, the extruded portions 190, 192, 194, and 196 intersect the central axis X as shown in FIG. The extruded portions 198, 200, 202, and 204 are arranged in a line on the straight line and in a direction orthogonal to the straight line.

  In addition, in the state where the first member 166A and the second member 166B are combined with their mating surfaces aligned, the outer shape is the outer shape of the reflector part in the halogen lamp with a reflector having the same size as the base part 162. And approximate. In other words, the reflector portion of the halogen light bulb with a reflector is generally bowl-shaped. Therefore, by setting the bowl-shaped portion 186 to have the same size as the bowl-shaped portion of the reflecting mirror, the bowl-shaped portion 186 approximates the outer shape of the reflecting mirror portion. Therefore, the LED lamp 160 is suitable as an alternative light source for the halogen lamp with a reflector.

  The first LED module 140 </ b> A is installed along the inner peripheral surface of the hook-shaped portion 186 in the direction in which the extruded portions 190,. At this time, each of the extrusion portions 190, 192, 194, 196 forcibly pushes the corresponding tab regions 152, 254, 156, 158 from the main body region of the flexible substrate 142. Therefore, desired light distribution characteristics can be obtained in the LED lamp 160 by appropriately setting the angle formed by the upper surface of the extruded portions 190, 192, 194 and 196 with the central axis X. In this example, since the upper surface is in a relationship orthogonal to the central axis X, each of the LEDs 144, 146, 148, 150 emits light in the central axis X direction.

  In addition, since the flat surfaces of the tab regions 152, 154, 156, and 158 are not impaired because the upper surfaces of the extruded portions 190, 192, 194, and 196 are flat, the LEDs 144, 146, 148, and 150 are flexible substrates. The point that it is difficult to peel off from 142 is the same as before.

  The second LED module 140B is placed on the first LED module 140A in the direction in which the extruded portions 198,..., 204 are aligned, and is installed on the bowl-shaped portion 186 in the same manner as the first LED module 140A.

Thus, the heat sink 166 including the extruding portions 190,..., 204 functions as an extruding member for the tab region.
The LED module 140 is fixed to the hook-shaped portion 186 with both ends thereof being restrained by the module mounting ring 168. The module mounting ring 168 has a circular groove 168A, and both ends of the flexible substrate 142 are fitted into the groove 168A. The module mounting ring 168 pushes the flexible substrate 142 back to the inner surface of the hook-shaped portion 186 against the restoring force, so that the flexible substrate 142 curved in a bow shape tries to return to the original state by the restoring force. (LED module 140) is fixed to the hook-shaped portion 186.

The module mounting ring 168 is fixed to the hook-shaped portion 186 with an adhesive (not shown). In the first LED module 140A, the power supply terminal (not shown) of the flexible substrate 142 and the circuit substrate 176 of the lighting circuit unit 164 are electrically connected by internal wirings 212 and 214. Similarly, the second LED module 140B is connected to the lighting circuit unit 164 by internal wiring (not shown).
<Embodiment 3>
(LED module)
FIG. 9 shows a plan view of the LED module 220 in the third embodiment. In FIG. 9, the conductor pattern is not shown.

  The LED module 220 includes a flexible substrate 222 and LEDs 224, 226, 228,..., 242 and 244 mounted thereon. The material of the flexible substrate 222 is the same as that of the first embodiment, and the LEDs 224,..., 244 also have the same configuration as the LED of the first embodiment.

The LEDs 224, 226, 228,..., 242 and 244 are mounted on the tab regions 246, 248, 250,.
Unlike the LED modules of the first and second embodiments, the LED module 220 of the third embodiment has all the tab regions 246,. That is, all of the tab regions 246,... 266 are directed to one end portion of the flexible substrate 222.

Attachment holes 268 and 270 are formed in both end portions of the flexible substrate 222.
(LED lamp)
An embodiment in which the LED module 220 is used in an LED lamp having an annular fluorescent lamp shape will be described with reference to FIG.

  FIG. 10 is a sectional view of the LED lamp 278 according to the third embodiment. FIG. 10 is a cross-sectional view of an annular glass tube 280 having a circular cross section cut along a plane including the tube axis. In FIG. 10, the LED module 220 is not cut.

The glass tube 280 has an annular shape as described above, and for example, a glass tube for an annular fluorescent lamp can be used.
The LED module 220 is inserted into the glass tube 280 from the opening 280A of the glass tube 280 so that the LEDs 224,. In the LED module 220, the mounting holes 268 and 278 of the flexible substrate 222 are fitted into the mounting pins 284 and 286 of the base part 282 and fixed to the glass tube 280. In this state, the flexible substrate 222 is slightly tensioned in the longitudinal direction, so that both side edges of the flexible substrate 222 are in contact with the inner peripheral surface of the glass tube 280 as shown in the cross-sectional view. It is in a state.

  Thus, even if the LED module 220 is curved in a circular shape, the tab regions 246,..., 266 are spaced apart from the flexible substrate 222 part (main body region) other than the tab region to maintain flatness. .., 244 can be prevented from being peeled off from the flexible substrate 222 as much as possible.

  The base portion 282 is a combination of the first member 288 and the second member 230 having a semi-cylindrical shape. Both the first member 288 and the second member 230 are made of an insulating material such as synthetic resin. The mounting pins 284 and 286 are erected from the bottom of the first member 288. Base pins 292 and 294 are implanted in the second member 290. The base pins 292 and 294 and the power supply terminals (not shown) of the flexible substrate 222 are electrically connected by internal wirings 296 and 298.

The LED lamp 278 is used by being attached to a lighting fixture (not shown) having a lighting circuit.
In addition, by coating a white light diffusing material such as silica particles on the inner surface of the glass tube 280, light can be emitted from a wider range of the glass tube 280. It can be approximated by an annular fluorescent lamp.

In addition, when a blue light emitting LED is used and a yellow phosphor is applied to the inner surface of the glass tube 280, white light can be obtained by mixing light.
Furthermore, if a reflecting member or the like is used, light emitted in the lateral direction can be irradiated onto a desired irradiation surface such as the lower side.
(Modification of LED module)
FIG. 11A shows a plan view of a modification of the LED module. In addition, illustration of a conductor pattern is abbreviate | omitted also in Fig.11 (a).

  The LED module 279 can emit light downward (in the width direction of the strip-shaped flexible substrate 281) without providing the reflection member. In FIG. 11, for convenience, the same reference numerals are assigned to the tab area and the LED.

The LED module 279 has basically the same configuration as that of the LED module 220 (FIG. 9) except that the shape of the tab region is different.
A tab region 285 provided for each LED 283 in the LED module 279 has an L shape as shown in FIG. When the tab region 285 formed in this way is bent in the direction perpendicular to the paper surface from the base end portion thereof, the mounting surface of the LED 283 is oriented in a direction intersecting the width direction of the flexible substrate 281, so the width of the flexible substrate 281 from the LED 283 is Light is emitted in the direction. FIG. 11B shows a view of one tab region 285 (LED 283) viewed from the side in this state. FIG. 11B shows an example in which the tab region 285 is bent at a substantially right angle with respect to the main body region 281A (a portion of the flexible substrate 281 other than the tab region 285) from the base end thereof. As shown in FIG. 11B, the main surface (LED mounting surface) of the tab region 285 is substantially orthogonal to the width direction of the flexible substrate 281 (direction perpendicular to the paper surface). Light is emitted in the width direction 281. In FIG. 11A, reference numerals 287 and 289 indicate attachment holes similar to the attachment holes 268 and 270 (FIG. 9) of the LED module 220.

When the LED module 279 having the above configuration is replaced with the LED module 220 shown in FIG. 10 to form an LED lamp, light can be emitted downward (in a direction perpendicular to the paper surface).
<Embodiment 4>
FIG. 12 is a plan view of the LED module 300 according to the fourth embodiment.

The LED module 300 has a flexible substrate 302. The material of the flexible substrate 302 is the same as that of the first embodiment.
The flexible substrate 302 has a substantially trapezoidal shape in which a part of a square substrate material is cut out in an isosceles triangle shape from its four corners toward the center, and is connected via a central square portion. It is divided into four parts. Hereinafter, each of the trapezoidal substrate portions will be referred to as trapezoidal portions 304.306, 308, 310.

  Since the configurations of the trapezoidal portions 304, 306, 308, and 310 are all the same, the trapezoidal portion 304 will be described as a representative, and the components of the other trapezoidal portions 306, 308, and 310 that are common to the trapezoidal portion 304 are necessary. Accordingly, the same reference numerals as those of the trapezoidal portion 304 are attached, and the description thereof is omitted.

The trapezoidal portion 304 is formed with one tab region 312 near the upper base of the trapezoid and three tab regions 314, 316, and 318 along the lower base near the lower base.
LEDs 320, 322, 324, and 326 are mounted on each of the tab areas 312, 314, 316, and 318. LEDs 320,..., 326 are the same as the LEDs of the first embodiment.

  The trapezoidal portion 304 has a conductor pattern 328 that electrically connects the LEDs 312, 314, 316, and 318 in this order in series, and both end portions of the conductor pattern 328 are formed at power supply terminals 328 A and 328 B.

  Each of the four LEDs mounted for each of the trapezoidal portions 304, 306, 308, and 310 is independently wired by a conductor pattern 328. As a result, the LEDs 312, 314, 316 and 318 can be turned on and off for each of the trapezoidal portions 304, 306, 308 and 310.

  A usage example of the LED module 300 configured as described above will be described with reference to FIG. In FIG. 13A, the conductor pattern of the LED module 300 is not shown.

The LED module 330 is attached to a lighting fixture having a base 330 having a truncated regular quadrangular pyramid shape.
Each inclined surface 332 of the pedestal 330 is provided with an extruding portion 334 as needed in correspondence with each of the tab regions (FIG. 13B). Since the purpose and function of the extruding part are the same as those described above, a detailed description thereof will be omitted.

In this example, an extrusion portion 334 is provided corresponding to the tab regions 314 and 318.
When the trapezoidal portions 304, 306, 308, and 310 are respectively combined with the four inclined surfaces of the pedestal 330 and installed as shown in FIG. 13, the tab regions 314 and 318 are pushed out by the pushing portion 334 to be inclined 332. With a predetermined angle. Since the tab regions 312 and 316 are not provided with the pushing portion 334, the tab regions 312 and 316 are parallel to the inclined surface 332.

In this way, by providing the push-out portion 334 and setting the angle of the tab region in various ways, it is possible to realize an illumination device having various light distribution characteristics.
Of course, all the angles of the tab regions 312, 314, 316, and 318 can be made different, or all the angles can be made uniform.

In addition, in this example, since the LED module 300 is not curved as a whole, it is not used in a mode in which the problem of the present invention occurs. However, since the LED module is configured as described above, a new usage is provided. This is shown as an example in which (use) is possible. That is, even when the LED module according to the present embodiment is installed in a flat place, various light distribution characteristics can be realized by appropriately setting the angle of the tab region according to the purpose of use. is there.
<Variations such as tab area shape>
Variations of the tab area shape and the like will be described with reference to FIGS.

In FIGS. 14 and 15, all the LEDs are denoted by the same reference numeral “340”.
In the first, second, and third embodiments, the tab regions all face the longitudinal direction of the strip-shaped flexible substrate. However, as shown in FIG. 14A, the tab regions 346 are arranged in the width direction of the flexible substrate 342. You may be facing. Alternatively, as illustrated in FIG. 14B, the tab region 350 may face a direction that obliquely intersects the longitudinal direction of the flexible substrate 348.

  Up to this point, the tab region has been substantially U-shaped, but in addition to this, a U-shaped tab region 356 (FIG. (C)), a substantially circular tab region 358 (FIG. (D)), A trapezoidal tab region 360 (FIG. (E)), a polygonal (regular hexagonal in this example) tab region 362 (FIG. (F)), and an elliptical tab region 364 (FIG. (G)). You can also.

  Further, as shown in FIG. 14 (h), through holes 367 and 369 may be opened at both ends of the notch 365 for creating the tab region 363. The through holes 367 and 369 are formed by punching out the flexible substrate portions near the both ends so as to overlap a part of the both ends. By providing such through holes 367 and 369, when the tab region 363 is bent in the thickness direction with respect to the main body region, it is possible to prevent the flexible substrate from tearing starting from the end portion of the notch 365.

  Further, the notch for creating the tab area may be a slit-like notch 368 as in the tab area 366 of FIG. Also in this case, the through holes 367 and 369 may be provided corresponding to both ends of the cut 368.

  In the above embodiment, one LED is mounted in one tab area. However, the present invention is not limited to this. As shown in FIGS. 15A and 15B, a plurality of LEDs are provided in one tab area 370 and 372. Individual (four in this example) LEDs 340 may be mounted.

As described above, the present invention has been described based on the embodiment. However, the present invention is not limited to the above-described form, and for example, the following form may be adopted.
(1) In the above embodiment, the tab area is provided for all the LEDs mounted on the flexible substrate. However, it is not always necessary to provide the tab area for all the LEDs (all the LEDs are not necessarily mounted in the tab area). Not necessary).

  For example, in the case of Embodiment 1 shown in FIG. 3, the first LED module 2A is largely curved in a substantially U shape as a whole, but when viewed partially, the LEDs 12, 14, 16, 26 , 28 and 30 are almost not bent and substantially flat. Therefore, it is not always necessary to provide a tab region for the LEDs 12, 14, 16, 26, 28, and 30 for the purpose of preventing peeling of the joints.

  In short, when the flexible substrate is bent and used, it is sufficient to provide a tab region for the LED to be mounted on a portion that is bent to such a degree that bonding peeling may occur. Therefore, in the case where one LED is mounted on a bent portion of a plurality of LEDs mounted on a flexible substrate, there is a need to provide at least a tab region for the LED. When two or more LEDs are mounted on such a portion, it is necessary to provide a tab region for each of them.

In addition, although it is not mounted on the bent portion, it is necessary to provide a tab region for the LED mounted on the portion where the light emission direction is adjusted by the pushing portion (for example, pushing portions 120 and 130 (FIG. 4)). It goes without saying that there is.
(2) In LED module 2 (FIG. 1), LED module 140 (FIG. 5), and LED module 220 (FIG. 9) of the first to third embodiments, LEDs are mounted in one row in the longitudinal direction of a strip-shaped flexible substrate. However, the present invention is not limited to this, and two or more rows may be mounted side by side.
(3) You may form a metal layer in a tab area | region at least among the back surfaces on the opposite side to the LED mounting surface of a flexible substrate. The metal layer may be, for example, a metal film formed by vapor deposition of aluminum, or may be an aluminum foil or a thin plate. The metal is not limited to aluminum but may be copper, gold (Au), or other good heat conductive metal.

By doing in this way, even if it is not provided with a heat sink, a certain heat dissipation property can be obtained.
(4) In the above embodiment, the LED is composed of the LED chip and the phosphor, but it is also possible to use only the LED chip. In this case, the LED chip to be used can be appropriately selected according to the desired emission color. Further, a plurality of types of LED chips having different emission colors may be used, and a desired color of emitted light may be obtained by mixing these colors.

  The LED module according to the present invention can be suitably used, for example, as a light source in the illumination field that requires various light distribution characteristics.

2,140,220,279,300 LED module 4,142,220,281,302 Flexible substrate 12,14,16,18,20,22,24,26,28,30,144,146,148,150, 224,226,228,230,232,234,236,238,240,242,244,283,320,322,324,326 LED
32,34,36,38,40,42,44,46,48,50,152,154,156,158,246,248,250,252,254,256,258,260,262,264,266 285, 312, 314, 316, 318 Tab area 52, 104, 160, 278 LED lamp

Claims (14)

An LED module in which a plurality of LEDs are mounted on a flexible substrate,
Among the plurality of LEDs, at least one LED is mounted on a tab region formed on the flexible substrate,
The tab region is a substrate portion surrounded by a cut formed in the flexible substrate so as to surround the one LED over a half circumference and an imaginary line connecting both ends of the cut. LED module.   2. The LED module according to claim 1, wherein the notch for creating the tab region is formed in a U-shape or a U-shape. The flexible substrate has a strip shape,
The LED module according to claim 1, wherein the plurality of LEDs are arranged in at least one row in the longitudinal direction of the flexible substrate.   The LED module according to claim 3, wherein the tab region is formed so that the imaginary line faces in a width direction of the flexible substrate.   The LED module according to claim 3, wherein the cutting direction from the virtual line is different between one tab region and another tab region. Each of the plurality of LEDs is mounted in a tab area,
The cutting direction of the tab region is different from the longitudinal center of the flexible board as a boundary, and each cutting is cut from the imaginary line to an end portion closer to the flexible board. 5. The LED module according to 5. Each of the plurality of LEDs is mounted in a tab area,
6. The LED according to claim 5, wherein the cut direction of the tab region is different with respect to the center in the longitudinal direction of the flexible substrate, and each cut is cut from the virtual line toward the center. module. Each of the plurality of LEDs is mounted in a tab area,
The LED module according to claim 4, wherein a direction of the cut from the imaginary line is directed to one end side of the flexible substrate in all tab regions. The LED module according to claim 6 as a light source,
The LED module is installed in a curved state with the LED mounting side facing outward.   The LED lamp according to claim 9, further comprising an extrusion member that is disposed on a back surface of the flexible substrate opposite to the mounting surface of the LED and pushes the tab region toward the mounting surface.   The LED lamp according to claim 10, wherein the extruded member is made of a highly heat conductive material. The LED module according to claim 7 as a light source,
The LED module is installed in a curved state with the LED mounting side inside,
An LED lamp, comprising: an extrusion member that is disposed on a back surface of the flexible substrate opposite to the LED mounting surface and pushes the tab region toward the mounting surface.   The LED lamp according to claim 12, wherein the extruded member is made of a highly heat conductive material. The LED module according to claim 8 as a light source,
The LED lamp is characterized in that the LED module is installed in a state of being bent in a circle with the LED mounting side facing outward.

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