JP2013024966A - Optical component and lamp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent, even when light distribution of a plurality of LEDs is controlled, lowering of use efficiency of the LEDs while keeping light condensing performance.SOLUTION: A beam lamp optical component 46 is provided to an LED lamp 1 including a plurality of LEDs 15 as a light source and condenses and distributes light from the light source to a given range. The LEDs 15 each include condensation and distribution optical elements 47 integrally including condenser lenses 49 for collecting light incident from incident surfaces 49A and outputting the light from emission surfaces 49B and reflection surfaces 50 for reflecting the light deflected from the incident surfaces 49A to the emission surfaces 49B sides. Adjacent reflection surfaces 50 of the condensation and distribution optical elements 47 are overlapped with one another.

Description

  The present invention relates to a technique for improving the light condensing property and efficiency of a beam lamp having a light source such as an LED or an organic EL as a light source.

LED lamps are widely used as an alternative to light bulbs due to higher output and lower cost of LEDs. In recent years, light distribution has a light condensing property within a predetermined range (predetermined beam opening angle range). A beam lamp type LED lamp with concentrated light distribution is also implemented.
In the beam lamp type LED lamp, a configuration for concentrating the light distribution may be a configuration in which the light distribution is controlled by making the light emitted from the LED incident on an optical component separate from the LED.
On the other hand, as an optical component that improves the utilization efficiency and light condensing property of the LED, a lens for condensing the light emitted from the LED and irradiating it forward, and the light deflected from the incident surface of the lens is reflected forward. An optical component that is integrally provided with a reflecting surface is known (see, for example, Patent Document 1 and Patent Document 2).

JP 2007-266242 A JP 2007-142178 A

By using conventional optical components for light distribution control of a beam lamp type LED lamp, good light collection can be obtained with high utilization efficiency. However, when the LED lamp includes a plurality of LEDs as a light source, Such a problem arises.
That is, when a plurality of LEDs are provided in the light source, the optical component is provided in each LED. However, there is a limitation in the arrangement interval of the LEDs due to a demand for compact LED lamps, and interference between adjacent optical components is caused. In order to prevent this, the optical components are inevitably downsized. As a result, there is a problem that the use efficiency of the LED is reduced due to the downsizing of the optical component.

  The present invention has been made in view of the circumstances described above, and even when controlling the light distribution of a plurality of LEDs, an optical component that does not cause a decrease in the utilization efficiency of the LEDs while maintaining the light collecting property, And to provide a lamp.

  In order to achieve the above object, the present invention provides an optical component that is provided in a lamp having a plurality of light emitting elements in a light source and distributes the light from the light source in a predetermined range in a concentrated manner. Each of the light sources of the light source includes an optical element integrally including a lens that collects and outputs from the exit surface and a reflection surface that reflects light deflecting from the entrance surface to the exit surface side. The reflective surface of the optical element is wrapped.

  According to the present invention, in the above-described optical component, a plate-like light-transmitting member that integrally covers each of the optical elements is provided on the emission surface of each of the optical elements.

  In order to achieve the above object, the present invention provides a lamp having a plurality of light emitting elements as a light source, and includes an optical component that concentrates and distributes light from the light source in a predetermined range, and the optical component includes an incident surface. For each light emitting element of the light source, an optical element integrally including a lens that collects light incident from the light source and outputs the light from the exit surface and a reflection surface that reflects light that is deflected from the entrance surface to the exit surface side And a reflection surface of the adjacent optical element is wrapped.

According to the present invention, in an optical component that concentrates and distributes light from a light source having a plurality of light emitting elements within a predetermined range, a lens that collects light incident from the incident surface and outputs the light from the output surface, An optical element that integrally has a reflection surface that reflects reflected light to the emission surface side is provided for each light emitting element of the light source, and the reflection surfaces of adjacent optical elements are wrapped.
With this configuration, when the dimensional shape of the optical element is designed so that the light emitted from the light emitting element is sufficiently collected by the lens and the light that has not entered the lens is sufficiently reflected by the reflecting surface, Even when the arrangement interval of the light emitting elements is narrower than the dimension, the optical elements can be provided without downsizing, and the light condensing property and the use efficiency of the light emitting elements can be suppressed.

It is a figure which shows the LED lamp apparatus provided with the LED lamp which concerns on embodiment of this invention. It is a perspective view which shows the external appearance structure of an LED lamp, (A) is the external appearance perspective view seen from upper direction, (B) is the external appearance perspective view seen from the downward direction. It is a figure which shows the external appearance structure of an LED lamp, (A) is a top view, (B) is a side view, (C) is a bottom view. It is an upper perspective view which decomposes | disassembles and shows an LED lamp. It is a downward perspective view which decomposes | disassembles and shows an LED lamp. It is sectional drawing in the II line | wire of FIG. 3 (B). It is a figure which shows the structure of the optical component for beam lamps, (A) is a top view, (B) is a side view, (C) is a bottom view. It is a figure which shows the structure of a concentrated light distribution optical element. It is a light ray diagram which shows the effect | action of the adjacent concentrated light distribution optical element. It is a figure which shows the amount of lap | wrapping of the adjacent concentrated light distribution optical element. It is a figure which shows the amount of lap | wrapping of the adjacent concentrated light distribution optical element.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
In the following embodiments, an LED lamp having an LED as a light source is exemplified as a lamp having a light emitting element as a light source. However, the present invention is not limited to this, and other light emission such as an organic EL, for example. The present invention can also be applied to a lamp having an element as a light source.

FIG. 1 is a diagram showing an LED lamp device 95 including the LED lamp 1 according to the present embodiment.
An LED lamp device 95 shown in the figure is an outdoor installation type lighting fixture used for outdoor signboard illumination and the like, and is attached to the LED lamp 1, a lamp holder 60 to which the LED lamp 1 is mounted, and the LED lamp 1. An annular waterproof packing 70 is provided.
The lamp holder 60 is a holder to which an existing light bulb can be mounted. The LED lamp 1 is configured to have substantially the same shape and optical characteristics as the existing light bulb, and is mounted on the lamp holder 60 instead of the existing light bulb. Can be used.

Specifically, the lamp holder 60 includes a cylindrical holder housing 62, and an arm mounting portion to which a support arm (not shown) is rotatably attached to a terminal portion 62 </ b> A of the holder housing 62. 64 is provided.
The front end 60B of the holder housing 62 opens with a diameter that engages with no gap on the surface of the glass bulb of the light bulb when the existing light bulb is mounted. Intrusion of water from the portion 66 is prevented. In the figure, a protrusion 68 provided at the tip 60B of the holder housing 62 is a member for fixing a net-like guard member (not shown) that covers and protects the LED lamp 1 or an existing light bulb. is there.

Inside the holder housing 62, a socket 65 into which the base of the existing bulb lamp and the base 3 of the LED lamp 1 are screwed is disposed. The socket 65 is connected to a power supply line drawn from outside, and power is supplied from the base 3 to the LED lamp 1 or the existing light bulb lamp through the socket 65.
The annular waterproof packing 70 is a rubber molding member, is detachably attached to a body portion 2 (described later) of the LED lamp 1, and closes the opening of the lamp holder 60 when the LED lamp 1 is attached to the lamp holder 60. Water intrusion from the gap between the holder 60 and the LED lamp 1 is prevented.
The annular waterproof packing 70 is used for the purpose of preventing water from entering the lamp holder 60. For example, the LED lamp 1 is attached to the lamp holder 60 installed indoors or a socket exposed to the outside. When waterproofing is not required, such as when used, it is not necessary to attach the annular waterproof packing 70. However, dust or the like can be prevented from entering by installing the annular waterproof packing 70 during indoor use.

Next, the configuration of the LED lamp 1 will be described in detail.
2A and 2B are perspective views showing the external configuration of the LED lamp 1 according to the present embodiment. FIG. 2A is an external perspective view seen from above, and FIG. 2B is an external perspective view seen from below. FIG. 3 is a diagram showing an external configuration of the LED lamp 1, FIG. 3A is a plan view, FIG. 3B is a side view, and FIG. 3C is a bottom view. 4 is an upper perspective view showing the LED lamp 1 in an exploded manner, and FIG. 5 is a lower perspective view showing the LED lamp 1 in an exploded manner. FIG. 6 is a cross-sectional view taken along the line II of FIG.

The LED lamp 1 according to the present embodiment is configured as a beam lamp type that has a condensing property for light distribution. A body portion 2 as a cylindrical portion that extends substantially perpendicularly downward from the center of the light source and has a base 3 at the end, and a plurality of heat radiation fins 25 provided on the back surface of the light emitting portion 12, and further includes a body portion 2. Is fitted with the annular waterproof packing 70.
The light emitting unit 12 emits light upward from substantially the entire upper surface 12A, and as shown in FIG. 4, a plurality of LEDs 15 serving as light sources and a substantially circular LED substrate mounted with these LEDs 15 in a plan view. 16, a beam lamp optical component 46, a cover 22, and a base plate 13 as a flat plate portion provided integrally with the distal end 2 </ b> C of the body portion 2.

The base plate 13 is a substantially disk-shaped member having a larger diameter than the body portion 2 when viewed from above, and the body portion 2 extends substantially vertically downward from a substantially central portion on the back surface of the base plate 13. Yes. As shown in FIG. 4, an insertion opening 14 connected to the body portion 2 is opened on the surface of the base plate 13, and an electric circuit board 8 on which a power source (power conversion device) and a driving circuit for lighting the LED 15 are mounted is an insertion opening. 14 is inserted into the body part 2.
The base plate 13 and the body portion 2 are integrally formed from the same material, that is, a resin molding using a mold from a thermally conductive resin material. The base plate 13, the body portion 2, and an insulating cylinder described later. The housing 10 of the LED lamp 1 is configured by the unit 10.

The LED 15 is formed, for example, by packaging an LED element. In this embodiment, a white LED is used as the LED 15. Needless to say, an LED having a light emitting color other than white may be used for the LED 15.
The LED board 16 is formed in a substantially disc shape as shown in FIGS. 4 and 5, and a plurality of LEDs 15 are mounted on the upper surface, and the upper surface of the base plate 13 as shown in FIGS. 4 to 6. It is fixed with screws 18 by screws.

  A lead wire lead-out opening 17 is opened substantially at the center of the LED substrate 16, and a lead wire for power supply (not shown) is drawn out from the electric circuit board 8 housed in the body 2 through the lead wire lead-out opening 17. Then, the LED 15 is electrically connected to the circuit pattern 80 formed on the upper surface of the LED substrate 16, and power is supplied to each LED 15 through the circuit pattern 80 to light up.

As shown in FIGS. 4 to 6, the base plate 13 forms a tray shape having a side wall 19 along the periphery of the flat disk, and serves as a glove that covers the LED substrate 16 on the inner peripheral surface of the side wall 19. A cover 22 is attached by screwing. An O-ring 26 is provided between the cover 22 and the base plate 13, and the O-ring 26 is sandwiched between the cover 22 and the base plate 13 as the cover 22 is screwed into the side wall 19. As described above, the mounting structure of the cover 22 to the base plate 13 is a screw structure, and the waterproofness of the light emitting unit 12 is enhanced by sandwiching the O-ring 26 between the cover 22 and the base plate 13.
Although not shown, the cover 22 is provided with the name of the LED lamp 1 on the inner surface by printing, engraving, or the like. Thereby, even if the LED lamp 1 is exposed to wind and rain, the nameplate does not disappear and does not disappear due to rubbing.

  The beam lamp optical component 46 is an optical component that controls the light distribution of the light emitting unit 12 of the LED lamp 1, and is formed as one member that covers each of the LEDs 15, and controls the light distribution of each LED 15. By radiating from the upper surface 12A of the cover 22, a beam lamp type light distribution, that is, a concentrated light distribution within a predetermined beam opening angle range is realized. The detailed configuration of the beam lamp optical component 46 will be described later.

  The radiating fins 25 are provided radially around the body portion 2 when viewed from the back surface of the base plate 13. Each radiating fin 25 is provided so as to extend along the body part 2 from the back surface of the base plate 13, and radiates heat generated by the LED substrate 16 placed on the base plate 13. Each radiating fin 25 is formed integrally with the body portion 2 when the casing 35 is injection molded.

By the way, the above-mentioned LED substrate 16 is made of a metal material such as an aluminum material having high thermal conductivity, so that the heat generated by the LED 15 can be efficiently transmitted to the base plate 13 and radiated from the radiation fins 25. However, when the LED substrate 16 is a metal substrate, there is a problem that the electrical insulation performance is deteriorated.
Therefore, in this embodiment, a resin substrate having electrical insulation is used for the LED substrate 16, and the thickness thereof is set to such a degree that the same insulation performance as that of a so-called double insulation structure can be obtained, thereby realizing high insulation performance. .
However, the LED substrate 16 made of a resin material has a low heat dissipation performance compared to a metal substrate unless any countermeasure is taken, and thus hinders an increase in light output.
Therefore, in the present embodiment, the heat dissipation of the LED substrate 16 is enhanced by covering the front and back surfaces of the LED substrate 16 with a copper foil as a heat dissipation layer.

  Specifically, as shown in FIGS. 3 to 5, a substantially circular copper foil 83 is provided on each of the front and back surfaces of the LED substrate 16 as a heat dissipation layer having conductivity and thermal conductivity so as to cover the surface. ing. Each copper foil 83 is insulated between the gap surrounding the LED substrate 16 and the side wall 19 of the base plate 13 so as to be electrically insulated, and between the screw 18 when the LED substrate 16 is screwed. The LED board 16 is formed to a size that covers the front and back surfaces of the LED board 16 as much as possible, except for the notch 83A.

Among the front and back surfaces of the LED substrate 16, a plurality of LEDs 15 are mounted concentrically on the LED mounting surface of the LED 15, and the circuit pattern 80 of each LED 15 is formed using the copper foil 83.
That is, on the LED mounting surface, as shown in FIGS. 3 and 4, a plurality of slits 84 are formed radially on the copper foil 83, and the copper foil 83 is formed into a plurality of substantially fan-shaped conductive areas 85 by each slit 84. Divided (partitioned). Each slit 84 has a sufficient width to obtain electrical insulation between the conductive areas 85, and each slit 84 is adjacent to a positive electrode terminal and a negative electrode terminal (not shown) provided on the back surface of the LED 15. The LED 15 is provided across the slit 84 so as to connect to the matching conductive area 85. Of these conductive areas 85, at least two adjacent conductive areas 85 are electrically connected to the power supply circuit of the electric circuit board 8, so that each LED 15 is connected by each conductive area 85. A series circuit connected in series is formed.

In this way, the copper foil 83 covering the LED mounting surface is partitioned by the slit 84 into a planar conductive area 85 that is electrically connected to the power supply circuit, and the LED 15 is electrically connected to each conductive area 85 across the slit 84. Since the circuit pattern 80 for lighting the LED 15 is configured by connecting to the LED 15, high heat dissipation is obtained on the LED mounting surface.
In particular, since the slits 84 are provided radially in the copper foil 83, each conductive area 85 is formed in a substantially fan shape, and in each conductive area 85, the heat resistance decreases toward the outside in the radial direction. Can be efficiently transmitted to the outside and diffused.

On the back surface side of the LED substrate 16, as shown in FIG. 5, an exposed portion 16 </ b> A in which a portion of the copper foil 83 corresponding to the insertion opening 14 of the body portion 2 is cut out to expose the insulating resin LED substrate 16. Is provided. Thereby, since the location which opposes the electric circuit board 8 inserted in the insertion opening 14 becomes the exposed part 16A, the electrical insulation between the electric circuit boards 8 is maintained.
At this time, although the heat radiation performance is lowered by the amount of the exposed portion 16A provided on the copper foil 83, the electric circuit board 8 is pressed against the exposed portion 16A by the LED substrate 16 mounted and fixed on the base plate 13. A fixing bush 27 (described later) that presses against the bottom of the body portion 2 is configured to be in close contact. The fixed bush 27 is integrally formed with a cooling piece 27A that is in close contact with the body portion 2, and the heat of the exposed portion 16A is transferred to the body portion 2 through the cooling piece 27A of the fixed bush 27 and exposed. The excessive temperature rise of the part 16A can be prevented.

In addition, although copper foil 83 was illustrated as a thermal radiation layer, it is not restricted to this, Arbitrary things can be used if it is the material which has heat conductivity and the electroconductivity which can function as an electrical wiring. Further, the material of the heat dissipation layer on the front and back surfaces of the LED substrate 16 need not be the same.
Furthermore, the circuit pattern 80 is not limited to the series circuit of the LEDs 15 and may be an arbitrary circuit such as a parallel circuit.

Next, the configuration of the base 3 of the body part 2 will be described.
The end 2A of the body portion 2 is provided with a cylindrical insulating tube portion 10 made of an insulating material in order to insulate the base 3 and the body portion 2, as shown in FIG. The base 3 is attached to the terminal end 10A of the insulating cylinder 10. The electric circuit board 8 is accommodated from the body part 2 to the insulating cylinder part 10, and is electrically connected to the base 3 through a lead wire (not shown) at an end part on the insulating cylinder part 10 side.

The base 3 includes a cylindrical shell 5 that is threaded into a socket 65 (for example, an E26 type socket) of an existing lamp holder 60, and an insulating portion 6 at the top of the end of the shell 5. The shell 5 and the eyelet 7 are configured to have a shape and size that can be attached to an existing socket. Thereby, the said LED lamp 1 can be mounted | worn with the socket 65 of the said lamp holder 60 which mounts and uses the existing socket and the existing light bulb, and can use it as an alternative of the existing light bulb.
Since the shell 5 and the body portion 2 are electrically insulated by the insulating cylinder portion 10 as described above, even if the shell 5 and the body portion 2 are made of a conductive material to improve the heat dissipation of the body portion 2, The insulation between the shell 5 and the body part 2 is maintained well.

By the way, although a high heat dissipation performance can be obtained by using a metal material such as aluminum for the body part 2, the casing 35 including the body part 2 becomes heavy, so that the existing socket may have insufficient strength. Since the body portion 2 is a metal material and the insulating cylinder portion 10 is a non-metal material, there is also a problem that the bonding between the body portion 2 and the insulating cylinder portion 10 is weak.
Therefore, in the present embodiment, a heat conductive resin is used as the material of the body portion 2, and an insulating resin is used as the material of the insulating cylinder portion 10, and the body portion 2 and the insulating cylinder portion 10 are formed by insert molding.

  By forming the body portion 2 from a heat conductive resin, the LED lamp 1 can be lighter than when the housing 35 is formed of a metal material such as aluminum, and the LED lamp 1 can be replaced with an existing socket as an alternative to a light bulb. Even when it is mounted on the existing lamp holder 60, there is no need to reinforce the existing socket or the existing lamp holder 60 in order to support the weight of the LED lamp 1, and it can be used as it is. Moreover, since the number of the radiation fins 25 can be increased by reducing the weight, the surface area can be increased and the heat dissipation can be improved more efficiently. As such a heat conductive resin, a resin material having a heat conductivity of 2 W / mK or more and excellent heat conductivity is preferable. For example, a highly heat conductive carbon fiber (in this embodiment, Lahima manufactured by Teijin Ltd. (registered) A polycarbonate resin mixed with a trademark)) can be suitably used.

The body part 2 and the insulating cylinder part 10 are integrally formed by insert molding of a resin material, so that the joining becomes strong, but due to aging deterioration, the joining surface (the mating face) between the body part 2 and the insulating cylinder part 10 ) May cause a gap and may impair waterproofness.
Therefore, as shown in FIG. 6, the end 2 </ b> A of the body part 2 is formed with an engagement convex part 2 </ b> B protruding radially inward of the body part 2, and on the outer peripheral surface in front of the opening end of the insulating cylinder part 10. Is formed with an annular engaging recess 10B that is recessed on the inner surface side, and an abutting portion 10C that contacts the inner peripheral surface of the body portion 2 and the engaging protrusion 2B is formed at the opening end of the insulating cylinder portion 10. ing.
The engaging convex portion 2B engages with the engaging concave portion 10B and the abutting portion 10C abuts on the trunk portion 2, so that the joint portion between the trunk portion 2 and the insulating cylinder portion 10 is formed in a so-called labyrinth shape. In addition, the area of the joint is increased and the joint strength is increased. With this labyrinth-like configuration, waterproofness is maintained even when a gap occurs in the insert molding surface due to cracks due to aging, etc. at the joint between the body portion 2 and the insulating cylinder portion 10, and durability corresponding to the life of the LED 15 Is obtained.
The shape of the joint surface between the terminal end 2A of the body portion 2 and the opening end (insertion end) of the insulating cylinder portion 10 is not limited to the labyrinth shape, and may be any shape that can improve waterproofness and joint strength. It can be any shape such as a wedge shape.

Next, a structure for housing the electric circuit board 8 in the body portion 2 will be further described.
As shown in FIG. 6, the electric circuit board 8 is formed to have a length extending from the distal end 2C of the body part 2 to the insulating cylinder part 10, and as shown in FIGS. It is formed to have a shape that engages with the internal shape of the cylindrical portion 10.
That is, the upper diameter R (FIG. 6) of the body part 2 is formed to be approximately the same as the upper lateral width of the electric circuit board 8, and when the electric circuit board 8 is inserted into the body part 2, the insulating cylinder part The lower end of the electric circuit board 8 is inserted into a holding part (not shown) formed inside the electric circuit board 8, and the electric circuit board 8 is fixed in the body part 2.

At this time, if the upper diameter R of the body portion 2 is reduced to about the upper width of the electric circuit board 8 to achieve compactness, the electric circuit board 8 comes close to the body section 2 and the body section 2 and the electric circuit are connected. The electrical insulation performance with the substrate 8 deteriorates. Therefore, an insulating sheet 28 wound around the electric circuit board 8 is provided in the body part 2, and the entire inner surface of the body part 2 is covered with the insulating sheet 28, so that the electric circuit board 8 and the body part are covered. The insulation performance between the two is to be improved.
The insulating sheet 28 is formed by forming a single sheet having flexibility and insulation into a strip shape. When the insulating sheet 28 is attached to the body portion 2, the insulating sheet 28 extends along the extending direction of the body portion 2. After the concave portion 28C (FIG. 4) extending by bending is formed by bending, the belt-like sheet is wound in an annular shape so as to overlap each other, and the concave portion 28C is engaged with an engagement piece (not shown) inside the body portion 2. Inserted from the insertion opening 14 of the base plate 13.
When inserted into the body part 2, the insulating sheet 28 is expanded by rewinding, and is mounted so as to cover the inner surface of the body part 2 by the rewinding force at this time.
In this way, the insulating sheet 28 is formed in a band shape, inserted into the insertion opening 14 of the base plate 13 in a wound state, and mounted in the body part 2 by rewinding the insulating sheet 28, so that the body part 2 The insulating sheet 28 can be easily attached so as to cover the entire inner surface of the cover.

As shown in FIG. 6, the electric circuit board 8 housed in the body part 2 is firmly fixed by pressing the upper end part 8 </ b> C by the LED board 16 through the fixing bush 27. As described above, the fixed bush 27 is integrally formed with a cooling piece 27A that is in close contact with the body portion 2. Heat from the exposed portion 16A is transferred to the body portion 2 through the cooling piece 27A of the fixed bush 27. Thus, an excessive temperature rise of the exposed portion 16A is prevented.
Further, the heat generated in the electric circuit board 8 is also transferred to the body portion 2 through the fixed bush 27 to be radiated.

As described above, the insulating sheet 28 covers the inner side surface of the body portion 2, and the insulating sheet 28 is made of a material having high thermal conductivity, and the body portion 2 extends from the cooling piece 27 </ b> A of the fixed bush 27. It is designed not to impede heat transfer to.
As described above, the insulating sheet 28 has high thermal conductivity, and the cooling piece 27 </ b> A is provided between the circuit component of the electric circuit board 8 and the insulating sheet 28 as a heat conductive member that thermally connects them. Both the insulation and heat dissipation of the electric circuit board 8 can be enhanced.
Further, since the cooling piece 27A is formed integrally with the fixing bush 27, the electric circuit board 8 can be fixed and cooled easily.

As described above, the housing 35 including the body portion 2 and the base plate 13 is provided with a plurality of heat radiation fins 25 so as to maintain heat dissipation.
The radiating fins 25 each have a thin plate shape, and a large number of the radiating fins 25 are provided in a radial manner with the axis of the body portion 2 as the center when viewed from the back surface of the base plate 13. These radiating fins 25 have fin base portions 25B, which are the base portions, connected to the back surface 13A of the base plate 13, and the radiating fins 25, the body portion 2 and the base plate 13 are molded from the above-described thermally conductive resin. It is integrally formed by the resin molding used. Thus, by integrally molding the base plate 13 and the heat radiating fins 25, the thermal resistance between the base plate 13 and the heat radiating fins 25 is suppressed, the amount of heat transfer to the heat radiating fins 25 is increased, and high heat radiating performance is achieved. can get.

As shown in FIG. 1, the radiating fins 25 are formed in a substantially fan shape in a side view that draws a gentle arc from the back surface 13 </ b> A (FIG. 2) of the base plate 13 toward the opening edge 66 of the holder housing 62. When the LED lamp 1 is mounted on the lamp holder 60, the design is enhanced by enhancing the sense of unity with the lamp holder 60.
As shown in FIG. 6, the fin tips 25 </ b> A of the respective radiation fins 25 are formed horizontally (perpendicular to the axis of the body part 2), and the annular waterproof packing 70 attached to the body part 2 contacts.

  As shown in FIGS. 1 to 6, the annular waterproof packing 70 has a substantially truncated cone shape (substantially trapezoidal shape in cross section) that is continuous with an arc drawn by the outer shape 25 </ b> D of the radiating fin 25 when viewed from the side. In addition, the contour shape composed of the heat radiation fins 25 and the annular waterproof packing 70 is formed so as to be equal to the contour shape of the glass bulb of the existing light bulb, and prevents problems caused by the difference in shape when replacing the existing light bulb. Is planned.

Here, a resin material mixed with carbon fiber having high thermal conductivity (hereinafter referred to as “thermal conductive fiber”) is used as the material of the body portion 2. It is known that anisotropy occurs in thermal conductivity depending on the orientation of conductive fibers.
In the present embodiment, the heat radiation capacity of the body portion 2 is increased by orienting the heat conductive fibers so that the heat conductivity from the body portion 2 and the base plate 13 to the heat radiation fins 25 is increased. The orientation of the heat conducting fibers is controlled by the direction in which the resin flows during resin injection molding.

  Further, for example, as shown in FIG. 1, the radiating fin 25 is provided with a wire hole 89 through which a wire for preventing fall is passed, and heat conduction is performed so that the strength of the radiating fin 25 is not lowered by the wire hole 89. The orientation of the conductive fiber may be changed.

Next, manufacture of the housing 35 will be described.
As described above, the housing 35 is manufactured by resin molding. However, a heat conductive resin is used for a portion including the base plate 13, the heat radiating fins 25, and the body portion 2, and the insulating resin is applied to the insulating cylinder portion 10. Since it is used, the resin molding of the housing 35 is formed by two-color molding or insert molding.

After the resin molding of the housing 35, a paint or a chemical is applied to the surface in order to improve weather resistance and designability. In this coating process, in the conventional LED lamp having a general configuration, the radiation fins 25 extend radially from the body 2, and the end of the radiation fin 25 on the base plate 13 side is connected to the back surface of the base plate 13. Since it is a structure, there is a problem that paint is hard to enter at the joint portion between the body portion 2 and the radiating fins 25 and the base plate 13 and that sagging occurs on the front side of the fins when the application amount is increased. For this reason, in the application process, it is necessary to apply a small amount of paint or the like divided into a plurality of times, which increases the number of applications and leads to an increase in cost.
This problem can be solved to some extent by separating the radiating fins 25 from the back surface of the base plate 13 to provide a gap, but in this case, the heat radiating performance of the base plate 13 that receives the heat generated by the LED substrate 16 is reduced. Since it falls, a high output type LED15 cannot be used.

Therefore, in the LED lamp 1 of this embodiment, all the heat radiation fins 25 are separated from the body portion 2 to solve the problem of liquid accumulation in the coating process without impairing the heat radiation performance of the base plate 13.
That is, as shown in FIG. 6, between all the radiation fins 25 and the trunk | drum 2, it extends from fin base part 25B which is a root part of the radiation fin 25 which is a connection location with the base board 13, to fin front-end | tip 25A. By providing the separating portion 91 that separates the heat radiation fin 25 and the body portion 2, a gap is provided between the heat radiation fin 25 and the body portion 2.

Thereby, in the coating application process to the housing 35, no liquid pool is generated between the radiating fins 25 and the body part 2, so that the amount of liquid applied per time is increased to reduce the number of times of application. Thus, the paint can be easily applied to the casing 35 without unevenness. In particular, by spraying the paint using a spray or the like, the paint wraps around the body portion 2 through the separating portion 91, and the paint can be applied evenly over a wide range by one application.
Furthermore, by providing the separation part 91, the housing 35 can be reduced in weight and the material cost can be suppressed. Further, when the LED lamp 1 is used, rainwater or the like does not collect between the heat radiating fins 25 and the body portion 2.
Further, in the conventional configuration in which the radiating fins 25 are provided radially from the body part 2, the number of radiating fins 25 that can be installed is equal to the outer peripheral length of the body part 2, with the minimum moldable thickness of the fin base part 25 </ b> B of the radiating fins 25. Although it is limited to the number obtained by dividing, by separating the radiating fins 25 from the body portion 2, a larger number of radiating fins 25 can be provided, and the heat radiation performance can be improved.

By the way, when it is set as the structure which isolate | separates the radiation fin 25 from the trunk | drum 2, the intensity | strength of the radiation fin 25 falls compared with the structure connected with the trunk | drum 2.
In addition, when the resin is mixed with the heat conductive fibers used in the present embodiment, the material flow from the body portion 2 to the heat radiating fins 25 is eliminated and the material flows only from the base plate 13 at the time of injection molding. The flow of the resin is worse than that without mixing, and it is difficult to control the injection pressure for solid molding without insufficient filling up to the thin fin-shaped tip. Further, if the number of the heat radiating fins 25 is increased in order to improve the heat dissipation, the contact area between the mold and the resin increases at the time of molding. As a result, the mold release of the molded product becomes worse, the molding cycle time increases, and the moldability deteriorates.
Therefore, in this embodiment, as shown in FIGS. 1 to 5, all the radiation fins 25 are provided with reinforcing ribs 92 extending from the fin base portions 25 </ b> B of the radiation fins 25 to the fin tips 25 </ b> A. By providing the reinforcing ribs 92 on the heat radiating fins 25, it is possible to achieve the same strength as when the heat radiating fins 25 are attached to the body portion 2, and the flow of the resin is improved and the moldability is improved. Furthermore, since it is possible to press the protruding pin of the mold against the rib end portion 93 of the reinforcing rib 92 when taking out the product from the mold, the product can be reliably taken out from the mold, Product damage can be prevented.

Next, the configuration of the beam lamp optical component 46 will be described in detail.
As described above, the LED lamp 1 includes the beam lamp optical component 46 in the light emitting unit 12, and the irradiation light is concentrated and distributed within a predetermined beam opening angle range by the beam lamp optical component 46.
As shown in FIGS. 3 to 6, the beam lamp optical component 46 is configured as one optical component that covers all of the LEDs 15 included in the light emitting unit 12, and is attached to the base plate 13 together with the LED substrate 16 by screws 18. It is fixed with screws.

7A and 7B are diagrams showing the configuration of the optical component 46 for the beam lamp. FIG. 7A is a plan view, FIG. 7B is a side view, and FIG. 7C is a bottom view.
As shown in the figure, the beam lamp optical component 46 is provided for each LED 15 mounted on the LED substrate 16 and is arranged so as to be positioned directly above each LED 15. A light transmissive plate portion 48 that covers the concentrated light distribution optical element 47 and is connected to the emission surface 47B of each concentrated light distribution optical element 47 is provided. In the surface of the light projecting member 48, a through hole 90 is provided substantially at the center (that is, a position corresponding to the lead wire extraction opening 17 of the LED substrate 16).

FIG. 8 is an enlarged view showing one concentrated light distribution optical element 47.
As shown in FIG. 8, the concentrated light distribution optical element 47 is arranged coaxially with the optical axis K of the LED 15, condenses light emitted from the LED 15 so as to be within a predetermined opening angle, and outputs the light along the coaxial. The condensing lens 49 and the reflecting surface 50 are integrally formed of a transparent resin material.
The condenser lens 49 is a plano-convex lens having a spherical incident surface 49A and a flat exit surface 49B. The condenser lens 49 is disposed coaxially with the optical axis K with the incident surface 49A positioned directly above the LED 15, condenses the light H1 of the LED 15 incident from the incident surface 49A, and emits the light from the output surface 49B.
The reflecting surface 50 is formed in a rotating curved surface (for example, a rotating paraboloid or rotating ellipsoid), and is provided coaxially with the optical axis K so as to include the condensing lens 49 and the LED 15 therein. The light H2 of the LED 15 that warps from the incident surface 49A of 49 is reflected toward the exit surface 49B.

  With this configuration, most of the light emitted from the LED 15 is incident on either the condensing lens 49 and the reflecting surface 50 and is output from the exit surface 49B. Since the light distribution is controlled by each of the reflecting surfaces 50, a good light collecting property can be obtained.

The shape of the concentrated light distribution optical element 47 will be described. The concentrated light distribution optical element 47 has an external shape obtained by cutting off the bottom of the reflecting surface 50 substantially horizontally. A concave portion 50A for accommodating the LED 15 is formed at the bottom of the reflecting surface 50, and the bottom surface (surface facing the LED 15) of the concave portion 50A is formed in a substantially spherical shape to form the incident surface 49A of the condenser lens 49.
In the present embodiment, as shown in FIG. 8, the lens focal point P1 of the condenser lens 49 and the reflective surface focal point P2 of the reflective surface 50 are at different positions on the optical axis K outside the recess 50A. Thus, the reflecting surface focal point P2 is designed to be closer to the recess 50A than the lens focal point P1.

At this time, the size and shape of the reflecting surface 50 of the concentrated light distribution optical element 47 and the incident surface 49A of the condensing lens 49 are such that most of the light emitted from the light emitting surface of the LED 15 is directed to the reflecting surface 50 and the condensing lens 49. It is defined on the premise that it can be incident and that the incident light can be sufficiently condensed and emitted with a high degree of parallelism.
However, since the LED lamp 1 is provided with a plurality of LEDs 15, if the LEDs 15 are arranged adjacent to each other, the dimensional shape of the concentrated light distribution optical element 47 cannot be a prescribed shape. .

  On the other hand, for example, if the arrangement interval of the LEDs 15 is increased, the concentrated light distribution optical element 47 can be made to have a prescribed size and shape, but the light emitting portion 12 of the LED lamp 1 is increased in size, and the material cost of the housing 35 is also increased. To increase. In addition, although the concentrated light distribution optical element 47 can be provided in each LED 15 by downsizing each of the concentrated light distribution optical elements 47, the dimensional shape deviates from the specified value. There is a problem of deterioration.

  Therefore, in this embodiment, as shown in FIGS. 7 and 9, the reflecting surfaces 50 of the adjacent concentrated light distribution optical elements 47 are connected by being wrapped. Accordingly, the concentrated light distribution optical element 47 can be provided in each LED 15 without downsizing each of the concentrated light distribution optical elements 47, and deterioration of utilization efficiency and light condensing property of the LEDs 15 can be suppressed. Further, by connecting the concentrated light distribution optical elements 47, they can be handled as an integrated beam lamp optical component 46, which can be handled easily and can be increased in structural strength. In particular, since the light transmitting plate portion 48 is integrally provided on the exit surface 49B of each concentrated light distribution optical element 47, the structural strength is further enhanced.

However, when wrapping the reflecting surface 50, if the wrap amount α (FIG. 9) is increased to the extent that the reflecting surface 50 of another concentrated light distributing optical element 47 enters the condensing lens 49 of the concentrated light distributing optical element 47, Since the wrap region Ra is greatly increased and the light condensing performance of the concentrated light distribution optical element 47 is excessively deteriorated, the wrap amount α of the reflecting surface 50 is, as shown in FIG. It is 49B or less and is limited to about ½ of the height A of the reflecting surface 50.
If the light condensing property is not a problem, the lamp amount α may exceed about ½ of the height A of the reflecting surface 50 and enter the condensing lens 49. However, as shown in FIGS. 9 and 10, the light H3 that enters the wrap region Ra wrapped by the reflection surface 50 travels straight without being reflected by the reflection surface 50. Light distribution is emitted without being controlled, causing stray light. Therefore, the wrap amount α (about 3/4 of the height A of the reflecting surface 50 as shown in FIG. 11 in the configuration of the present embodiment) in a range where stray light due to light passing through the wrap region Ra is not significant. It is preferable to do.

According to the embodiment described above, the following effects can be obtained.
That is, in this embodiment, the LED board 16 on which the LED 15 as the light emitting element is mounted, the base plate 13 as a flat plate portion on which the LED board 16 is placed, and the base 2 extends from the back surface 13A of the base plate 13 to the terminal 2A. 3 is provided with a plurality of heat radiation fins 25 extending along the body portion 2 on the back surface 13A of the base plate 13, and the heat radiation fins 25. Between each of the above and the body portion 2, a gap is provided from the fin base portion 25 </ b> B, which is the root portion of the radiation fin 25, to the fin tip 25 </ b> A.
According to this configuration, in the coating process on the casing 35 including the base plate 13, the body portion 2, and the heat radiation fin 25, no liquid pool is generated between the heat radiation fin 25 and the body portion 2. The number of times of application can be increased by increasing the amount of liquid applied per time, and the paint can be easily applied to the casing 35 without unevenness. In particular, by spraying the paint using a spray or the like, the paint wraps around the body portion 2 through the separating portion 91, and the paint can be applied evenly over a wide range by one application.
Furthermore, by providing the separation part 91, the housing 35 can be reduced in weight and the material cost can be suppressed. Further, when the LED lamp 1 is used, rainwater or the like does not collect between the heat radiating fins 25 and the body portion 2.
Further, in the conventional configuration in which the radiating fins 25 are provided radially from the body part 2, the number of radiating fins 25 that can be installed is equal to the outer peripheral length of the body part 2, with the minimum moldable thickness of the fin base part 25 </ b> B of the radiating fins 25. Although it is limited to the number obtained by dividing, by separating the radiating fins 25 from the body portion 2, a larger number of radiating fins 25 can be provided, and the heat radiation performance can be improved.

Further, according to the present embodiment, the reinforcing rib 92 is provided from the fin base portion 25B of the radiating fin 25 to the fin tip 25A.
By providing the reinforcing ribs 92 on the heat radiating fins 25, it is possible to achieve the same strength as when the heat radiating fins 25 are attached to the body portion 2, and the flow of the resin is improved, thereby improving the moldability. Furthermore, since it is possible to press the protruding pin of the mold against the rib end portion 93 of the reinforcing rib 92 when taking out the product from the mold, the product can be reliably taken out from the mold, Product damage can be prevented.

  In addition, according to the present embodiment, the beam lamp optical component 46 that concentrates and distributes the light of the light emitting unit 12 including the plurality of LEDs 15 within a predetermined range condenses the light incident from the incident surface 49A and exits from the output surface 49B. Each of the LEDs 15 of the light emitting unit 12 is provided with a concentrated light distribution optical element 47 integrally including an output condensing lens 49 and a reflection surface 50 that reflects the light deflecting from the incident surface 49A to the emission surface 49B side. The reflecting surface 50 of the concentrated light distribution optical element 47 is configured to wrap.

  According to this configuration, the light from the LED 15 is sufficiently condensed by the condenser lens 49 and the light that has not entered the condenser lens 49 is sufficiently reflected by the reflecting surface 50 so that the concentrated light distribution optical element 47 can be reflected. When designing the size and shape, even if the arrangement interval of the LEDs 15 is narrower than the size of the concentrated light distribution optical element 47, the concentrated light distribution optical element 47 can be provided in each LED 15 without downsizing, and the light collecting is performed. And a decrease in utilization efficiency of the LED 15 can be suppressed.

Further, according to the present embodiment, the plate-shaped light transmitting plate portion 48 that integrally covers each of the concentrated light distribution optical elements 47 is provided on the emission surface 49B of each of the concentrated light distribution optical elements 47.
Thereby, each concentrated light distribution optical element 47 can be firmly connected.

  The above-described embodiment is merely an aspect of the present invention, and can be arbitrarily modified and applied without departing from the spirit of the present invention.

DESCRIPTION OF SYMBOLS 1 LED lamp 2 Body part 12 Light emission part 13 Base board 15 LED (light emitting element)
16 LED substrate 25 Radiation fin 35 Case 46 Optical component for beam lamp (optical component)
47 Concentrated light distribution optical element (optical element)
47B Outgoing surface 48 Translucent plate 49 Condensing lens (lens)
49A Incident surface 49B Outgoing surface 50 Reflective surface 50A Concave portion 95 LED lamp device K Optical axis Ra Wrap region P1 Lens focus P2 Reflective surface focus

Claims (3)

An optical component that is provided in a lamp including a plurality of light emitting elements as a light source, and concentrates and distributes light from the light source in a predetermined range,
The light emitting element of the light source includes an optical element that integrally includes a lens that collects light incident from the incident surface and outputs the light from the output surface, and a reflective surface that reflects light that is warped from the incident surface toward the output surface. An optical component characterized in that a reflection surface of the adjacent optical element is wrapped.   The optical component according to claim 1, wherein a plate-like translucent member that integrally covers each of the optical elements is provided on an emission surface of each of the optical elements. A lamp comprising a plurality of light emitting elements as a light source,
An optical component that concentrates and distributes the light of the light source within a predetermined range,
The optical component includes an optical element integrally including a lens that collects light incident from an incident surface and outputs the light from the output surface, and a reflective surface that reflects light that is deflected from the incident surface to the output surface side. A lamp provided for each light emitting element of the light source, wherein a reflecting surface of the adjacent optical element is wrapped.

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