JP2014096237A - Method of manufacturing led line lamp, led protection tube for led line lamp, and led line lamp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make an LED line lamp lightweight and long in lifetime while providing sufficient heat radiation characteristics, and to improve the productivity.SOLUTION: A heat radiation part 2a is made of a first heat-conductive resin, and a diffusion part 2b is made of a resin which transmits and diffuses irradiation light of an LED element 4b. An outer cylinder part 2 comprising the heat radiation part 2a and diffusion part 2b is molded in one body. Mutually facing guide parts 2b-1, 2b-1' provided at both front and rear ends of the diffusion part 2b are formed in a length direction respectively to be sectioned in a channel shape including the heat radiation part 2a as one side, and an LED substrate 4 is slid and inserted so as to have both front and rear ends held at the channel-sectioned part. A grooved part 2a-2 is formed in the length direction at a substantially center part of the heat radiation part 2a. A second heat-conductive resin 5 is charged between the opposite surface 2a-1 of the heat radiation part 2a including the grooved part 2a-2, and the side of a substrate part 4a where the LED element 4b is not mounted.

Description

  The present invention relates to a manufacturing method of an LED line lamp in which a heat radiating portion and a diffusion portion for an LED are integrally formed, an LED protective tube and an LED line lamp according to the manufacturing method.

  In particular, the present invention relates to an LED protective tube, an LED line lamp, and the like that can achieve weight reduction while ensuring sufficient heat dissipation characteristics and further improve productivity.

  In this specification, if necessary, the longitudinal direction of the LED line lamp is the “left and right” direction, the sealing lid portion 1 side described later is “left”, the sealing lid portion 1 ′ side is “right”, Describe each. The front and back indicate the front side (front) and back side (rear) when the LED output light irradiation side is “down” and the opposite side is “up” with respect to the “left” and “right”, respectively. Yes.

  2. Description of the Related Art Conventionally, an LED line lamp has been proposed in which an LED illumination unit is rotatably attached to a fixed base set on the power supply side (for example, Patent Document 1). In this LED line lamp, the rotation axis of the illumination board (LED board) on which the LED element is mounted is attached in a form that can be frictionally engaged with the fixed base, and the rotation of the illumination board that is arbitrarily set with respect to the fixed base. The moving position is held by frictional engagement between the rotating shaft of the illumination board and its receiving side (fixed base).

  In the conventional LED line lamp in which the LED illumination unit is mounted on the power supply side fixed base, the arbitrary rotation state of the LED illumination unit is maintained by the frictional action between the illumination unit side and the receiving side. Therefore, there is a problem that it is difficult to continuously hold the rotation position of the LED illumination unit, that is, the irradiation position of the LED output light, at a desired position continuously.

  Therefore, an LED line in which the fixed base and the rotatable LED illumination unit are moderately engaged, and thereby the LED illumination unit can be continuously stabilized in a state where the LED illumination unit is rotated to an arbitrary position. A lamp has been devised (for example, Patent Document 2).

JP 2007-122933 A

Utility Model Registration No. 3176594

The LED line lamp to which the technology described in Patent Document 2 is applied is as follows.
A fixed base arranged in a pair of left and right,
A pair of left and right sheath caps attached to each of the fixed bases in a rotatable manner;
An annular holding member incorporated in the annular space inside the fixed base to hold the sheath-like cap in its arbitrary rotational position;
A diffuser plate with a C-shaped cross section that exhibits a diffusion action and a whitening action of LED output light;
A heat sink whose left and right ends are attached to a sheath cap in a state integrated with the diffuser,
It is configured to include an LED substrate having a plurality of LED elements fixed to the heat sink and mounted in-line.

  As the fixed base, the annular holding member, the sheath cap, the diffusion plate, and the LED substrate, for example, those made of synthetic resin such as polycarbonate are used. And the thing made from metals, such as aluminum, is used for the heat sink, for example.

  A member in which the diffusion plate and the heat radiating plate are integrated constitutes a linear cylindrical portion. That is, a metal (aluminum) heat radiating plate is attached to a C-shaped notch portion of a diffusion plate made of synthetic resin and having a C-shaped cross section, thereby forming a cylindrical portion. The heat radiating plate has an opposing guide portion for attaching the LED board inside the cylinder, and holds the LED board by caulking.

In the LED line lamp to which the technology described in Patent Document 2 described above is applied, the work of attaching the LED substrate to the heat sink of the cylindrical portion is as follows.
(11) Insert the LED board into the opposite guide part of the heat sink from the longitudinal direction.
(12) Crush the required portion (that is, the crimped portion) of the facing guide portion, and fix and hold it so that the back surface of the LED substrate is in close contact with the heat sink.
(13) The heat sink is inserted into the C-shaped notch of the diffusion plate from the longitudinal direction to form a cylindrical portion.

  Thus, in the conventional LED line lamp, the heat radiation part of the LED protective tube is made of metal (aluminum), so it is heavy, such as reducing the burden on the equipment to be attached, improving safety when falling, and facilitating transportation. Therefore, the weight reduction of the heat radiating part has been demanded.

  Further, in the LED line lamp to which the technology described in Patent Document 2 described above is applied, the diffusion plate and the heat radiating plate are assembled after the LED substrate is attached to the heat radiating plate, and the productivity is poor. It is also difficult to provide a sufficient airtightness between the diffuser plate and the heat radiating plate, which are greatly different in material, and the oxidation of the solder portion due to the influence of the heat generated by the LED and oxygen in the air hinders the extension of the life.

Therefore, the present invention provides
(21) A cylindrical LED protective tube is an integrally molded product made of a synthetic resin heat radiating portion and a diffusion portion, and the LED protective tube is mounted in the left-right direction (longitudinal direction) when the LED substrate is attached. Left and right direction (longitudinal direction) groove-like parts that are the supply target parts of the thermally conductive resin filled between the LED substrate and the LED protective tube heat radiation part are provided to ensure sufficient heat dissipation characteristics of the LED protective tube. However, to reduce the weight and extend the life of LED line lamps,
(22) By simplifying the structure of the LED protective tube, the manufacturing cost of the LED line lamp is reduced and the productivity is improved.
For purposes.

  The present invention solves the above problems as follows.

(1) An LED substrate (for example, a later-described LED substrate 4) on which an LED element (for example, a later-described LED element 4b) is mounted is disposed inside a straight tubular LED protective tube (for example, a later-described outer cylinder portion 2). In the manufacturing method of the shaped LED line lamp,
A heat dissipating part (for example, a heat dissipating part 2a described later) made of a first heat conductive resin having a contact surface (for example, a facing surface 2a-1 described later) with the LED substrate, and transmitting the irradiation light of the LED element. A resin-made diffusing portion (for example, a diffusing portion 2b described later) and an opposing guide portion (for example, an opposing guiding portion 2b described later) for guiding and holding the LED substrate between the contact surface. -1, 2b-1 '), the LED protective tube is integrally molded,
The LED board is slid and inserted into the integrally formed LED protective tube from the opening end portion along the opposing guide portion.
(2) In (1) above,
When the LED board is slid and inserted along the opposing guide portion,
Supplying a second thermal conductive resin (for example, thermal conductive resin 5 described later) to the contact surface;
By this supply, the second thermally conductive resin is filled in a space region between the LED substrate and the contact surface that is formed as the slide is inserted.
(3) In (2) above,
The second thermally conductive resin is
It is made to supply to the groove-shaped part (for example, groove-shaped part 2a-2 mentioned later) formed in the slide insertion direction of the said contact surface.
(4) In (1) and (2) above,
An interlocking member (for example, a driving unit for slidingly inserting the LED substrate and an injection unit (for example, a later-described dropping port 6a) for supplying the second thermal conductive resin to the contact surface (for example, By the action of the hook 8) described later,
The second thermally conductive resin is supplied to the front portion in the slide insertion direction from the tip position of the LED substrate.
(5) In a straight tubular LED protective tube (for example, an outer cylinder portion 2 to be described later) that accommodates an LED board (for example, an LED substrate 4 to be described later) on which an LED element (for example, an LED element 4b described later) is mounted,
A heat dissipating part (for example, a heat dissipating part 2a described later) made of a first heat conductive resin having a contact surface (for example, a facing surface 2a-1 described later) with the LED substrate;
A resin-made diffusion part that transmits and diffuses the light emitted from the LED element (for example, a diffusion part 2b described later);
An opposing guide portion (for example, an opposing guide portion 2b-1, 2b-1 ′ described later) for guiding and holding the LED substrate between the contact surface,
The heat radiating part, the diffusing part, and the entire opposing guide part are integrally formed.
(6) In (5) above,
The contact surface is
A groove-shaped portion (for example, a groove-shaped portion 2a-2 described later) in the insertion direction of the LED substrate that is slidably inserted along the opposing guide portion is provided.
(7) In the LED line lamp,
The LED substrate is held by the opposing guide portion of the LED protective tube for the LED line lamp of (5) and (6).
(8) In (7) above,
A space region between the heat radiation part and the contact surface of the LED substrate is filled with a second heat conductive resin (for example, heat conductive resin 5 described later).
(9) In the above (7) and (8),
A lid portion (for example, a sealing lid portion 1, 1 ′ described later) for sealing an end portion of the LED protective tube is provided,
An internal space between the LED protective tube and the lid is filled with an inert gas.

  In the description of the first thermal conductive resin and the second thermal conductive resin described above, “first” and “second” are different portions of the respective thermal conductive resins (the first is the heat radiating part itself, The second indicates that it is used in a space area between the LED substrate and the heat dissipation portion. It is arbitrary whether the two heat conductive resins are made of different materials or the same material.

  The LED protective tube, the LED line lamp, and the method for manufacturing the LED line lamp having the configurations (1) to (9) are the objects of the present invention.

The present invention provides the above problem solving means.
(31) Since the LED protective tube will be lighter, we will reduce the burden on the equipment to which the LED line lamp is attached, improve safety when dropped, and facilitate transportation.
(32) Since the LED protective tube (heat radiation part + transmission / diffusion part) is integrally molded, it becomes easy to obtain airtightness when the LED line lamp is filled with an inert gas, and the service life is extended.
(33) Since the structure of the LED protection tube is simplified, the production cost of the LED line lamp is reduced and the productivity is improved.
You can do that.

It is explanatory drawing which shows the whole external appearance of a LED line lamp. It is explanatory drawing which shows the cross-sectional shape of the AA 'direction of FIG. It is an experimental result which shows the relationship between the mixing | blending ratio of each of the thermal radiation resin and polycarbonate which comprises a thermal radiation part, and the thermal radiation part performance at that time. It is explanatory drawing about the assembly method of a LED line lamp. It is explanatory drawing about the assembly method of a LED line lamp.

  With reference to FIGS. 1-5, the form for implementing this invention is demonstrated.

  The components with reference numbers with alphabets (for example, the heat radiating portion 2a) used in each figure are shown to be part of the components (for example, the outer cylinder portion 2) with the numeral portions of the reference numbers in principle. In addition, a constituent element (for example, the groove-like part 2a-2) in which a hyphen (-) and a number are further described after the reference number with alphabet is one of the constituent elements of the reference number with alphabet (for example, the heat radiating part 2a). It shows that it is a part.

In FIG. 1, FIG. 2, FIG. 4, and FIG.
1 and 1 'are arranged in a pair of left and right shapes, and sealing lid portions that seal both left and right ends of the outer cylinder portion 2 configured by a heat radiating portion 2a and a diffusion portion 2b, which will be described later,
1a and 1a ′ are a pair of connection terminals formed on the respective outer end surface portions of the sealing lid portion,
2 is a straight tubular outer tube portion (LED protective tube) that is integrally molded and includes a heat radiating portion 2a and a diffusion portion 2b, which will be described later.
2a is formed of a mixture of a heat-dissipating resin described later and a synthetic resin such as polycarbonate, and a heat-dissipating part that dissipates heat generated by the LED substrate 4 described later to the outside,
2a-1 is formed in the longitudinal direction at the substantially central portion of the heat radiating portion so as to be inside the outer cylinder portion, and the heat absorption opposite to the back surface (upper side) of the LED element 4a mounting surface of the LED substrate 4 described later. Facing surface (contact surface),
2a-2 is a groove-shaped portion formed in the center in the longitudinal direction of the facing surface,
2b is a C-shaped linear diffusion section having a cross-sectional shape that is produced from a synthetic resin such as polycarbonate and exhibits LED light diffusing action and whitening action;
2b-1 and 2b-1 ′ are respectively formed in the front and rear end portions (longitudinal direction) on the rectangular bottom surface side of the diffusion portion so as to have a U-shaped cross section with the heat radiation portion 2a as one side thereof. A pair of opposing guide portions for slidingly holding the LED substrate 4 therein is shown.

And
3 is a driving element for driving the LED element 4b of the LED substrate 4 to be described later, an LED driving circuit unit equipped with a power supply circuit unit, etc.
4 is an LED substrate disposed between the opposing surface (contact surface) 2a-1 in a state of being held by the opposing guide portions 2b-1, 2b-1 ′ of the diffusing portion 2b.
4a is mounted with a later-described LED element 4b, and a board portion on which a conductor pattern for supplying current from the LED drive circuit unit 3 to each LED element 4b is set,
4b is a plurality of LED elements mounted in-line downward on the substrate part 4a,
4c, in the LED substrate, a solder connection portion for connecting the conductor pattern of the substrate portion 4a and each of the LED elements 4b,
4d shows holes for slide insertion operation formed at the ends in the longitudinal direction of the LED substrate.

And
5 is a heat conductive resin (see FIG. 2) filled between the heat radiation part 2a and the LED substrate 4.
6 is a pipe for dripping the heat conductive resin 5 to be filled onto the groove-like portion 2a-2 (see FIGS. 4 and 5),
6a is one end of the pipe, provided on the side different from the connection end of the liquid supply pipe 7 to be described later, a dropping port for dropping the heat conductive resin 5 on the groove-like portion 2a-2,
7 is a liquid supply pipe connected to the pipe 6 for supplying the heat conductive resin 5 into the pipe,
8, the end of which is in the shape of a key around 90 degrees, for example, so that the LED board 4 can be slid along the opposing guide portions 2b-1, 2b-1 '. Each of the hooks has a shape into which the end can be inserted.

  The LED line lamp includes an outer cylinder portion 2 (LED protective tube) composed of a sealing lid portion 1, 1 ′, a heat radiating portion 2 a and a diffusion portion 2 b, an LED drive circuit portion 3, an LED substrate 4, and a heat conductive resin 5. It consists of components such as.

  For the sealing lid portions 1 and 1 ′ and the diffusion portion 2 b, for example, those made of synthetic resin such as polycarbonate are used. For the heat radiating part 2a, a mixture of a heat radiating resin, which is a synthetic resin containing a high thermal conductivity filler and having high thermal conductivity, and a synthetic resin such as polycarbonate is used. For the substrate portion 4a, an aluminum substrate, a glass epoxy substrate, or the like is used. The heat conductive resin 5 is made of a resin having high heat conductivity. In addition, the resin used for the heat conductive resin 5 preferably has not only high heat conductivity but also adhesiveness.

  Examples of the polycarbonate used for the sealing lid portions 1 and 1 ', the heat radiating portion 2a, and the diffusing portion 2b include grade name: EKD2108U manufactured by Mitsubishi Engineering Plastics. In the heat radiating part 2a, examples of the heat radiating resin mixed with the above-described polycarbonate and the like include grade name: TPN1121 of Mitsubishi Engineering Plastics Co., Ltd. The TPN 1121 has a thermal conductivity of 7 to 8 W / m / K, whereas a general polycarbonate has a thermal conductivity of about 0.2 W / m / K. In addition, as the heat conductive resin 5, for example, silicone high heat conductive heat radiation adhesive TC-2030 manufactured by Toray Dow Corning Co., Ltd. can be used. This TC-2030 is a two-component mixed-curing type adhesive, which, after mixing, cures from a liquid state to a rubber-like shape, and therefore needs to be dropped and filled before curing.

  FIG. 1 is a diagram showing an overall appearance of an LED line lamp.

  The outer cylinder part 2 composed of the heat radiating part 2a and the diffusing part 2b is a straight tube, and the LED drive circuit part 3 can be mounted inside one end (left side in FIG. 1). ing. The LED drive circuit unit 3 is electrically connected to the connection terminals 1a and 1a ′, and can receive control signals such as lighting and extinguishing and power supply. The outer cylinder part 2 composed of the heat radiating part 2a and the diffusing part 2b is provided with an LED drive circuit part 3 and an LED substrate 4 (see FIG. 2) inside and filled with an inert gas such as nitrogen gas. The both ends of the sealing lid portions 1 and 1 'are hermetically sealed.

  Here, the sealing lid portion 1, 1 ′ rotates the outer cylinder portion 2 composed of the heat radiating portion 2 a and the diffusing portion 2 b, for example, by applying the technology described in Utility Model Registration No. 3176594. It is preferred that it can be gripped as possible.

  In the illustrated LED line lamp, a blue light emitting element covered with a yellow phosphor is used as the LED element 4b. The white light obtained by the blue and yellow color mixing action can be output as white irradiation light from the diffusion portion 2b containing the diffusing agent.

  FIG. 2 is a diagram showing a cross-sectional shape in the AA ′ direction of FIG. 1.

  Opposing guide portions 2b-1 and 2b-1 'are provided at both upper ends of the diffusing portion 2b, that is, in a longitudinal direction portion in contact with the heat radiating portion 2a. The opposing guide portions 2b-1, 2b-1 'are each formed to have a U-shaped cross section with the heat radiating portion 2a as one side. The LED substrate 4 is slid and inserted into a U-shaped portion formed by the heat radiating portion 2a and the opposing guide portions 2b-1, 2b-1 'so that both front and rear end portions thereof are held.

  That is, the height of the U-shaped portion of the cross section is determined to be a size that allows the LED substrate 4 to be stably held by sliding the LED substrate 4 into the opposing guide portions 2b-1, 2b-1 ′. .

  The LED board 4 is mounted inline with the LED element 4b mounted on the board part 4a and the board part 4a on which the conductor pattern for supplying the current from the LED drive circuit unit 3 to each LED element 4b is drawn. The plurality of LED elements 4b, the conductor pattern of the board part 4a and the solder connection part 4c for connecting each of the LED elements 4b, and the plurality of LED elements 4b based on the drive control of the LED drive circuit part 3 Is turned on and off.

  And groove-like part 2a-2 is formed in the longitudinal direction in the approximate center part of the thermal radiation part 2a. The heat conductive resin 5 is filled between the heat radiating part 2a including the groove part 2a-2 and the side on which the LED element 4b of the substrate part 4a is not mounted. By forming the groove-shaped part 2a-2, the heat conductive resin 5 is sufficiently distributed between the LED substrate and the heat dissipation part. Thereby, the heat | fever generate | occur | produced by lighting of the LED board 4 can be thermally radiated from the thermal radiation part 2a efficiently. Further, for example, a copper plate is preferably attached to the contact surface of the substrate portion 4a with the heat conductive resin 5 in order to further improve the heat conductivity.

  Here, the opposing guide portions 2b-1 and 2b-1 'are formed in a U-shaped cross section with the heat radiating portion 2a as one side at the front and rear ends of the diffusing portion 2b, that is, at the portion in contact with the heat radiating portion 2a. However, the opposing guide portions 2b-1 and 2b-1 'are formed in the outer cylinder portion 2 at least at two locations so as to have a U-shaped cross section in the longitudinal direction. For example, it may be formed so as to have a U-shaped cross section in the longitudinal direction in the vicinity of the front and rear ends of the diffusion portion 2b, or two or more opposing guide portions 2b are formed, You may enable it to mount the LED board of a different magnitude | size.

  FIG. 3 is an explanatory view showing the blending experiment result of the heat radiation resin and the polycarbonate regarding the heat radiation portion 2a.

  The reason why the heat dissipating part 2a is a mixture of a heat dissipating resin and a resin such as polycarbonate is to improve moldability, adhesion, surface finish, etc., which are not satisfied with the heat dissipating resin alone. FIG. 3 shows the mixing ratio of polycarbonate (for example, grade name: EKD2108U manufactured by Mitsubishi Engineering Plastics Co., Ltd.) and a heat radiation resin (for example, grade name: TPN1121 etc. of Mitsubishi Engineering Plastics Co., Ltd.), elasticity, and heat dissipation. It shows the relationship between the properties, formability, adhesion, and surface finish.

  According to this relationship, when the heat dissipation part 2a in which the mixing ratio of the heat dissipation resin and the synthetic resin such as polycarbonate is in the range of 30% to 70% is used, the elasticity, heat dissipation, moldability, and adhesion of the heat dissipation part are concerned. A certain level of quality can be obtained for each of the surface finish.

  Since the heat radiating part 2a generated with the resin mixture having such a mixing ratio has sufficient adhesion, the heat radiating part 2a and the diffusing part 2b are integrally formed (two-color molding) using the extruded material as a necessary material. It is possible to form the outer cylinder portion 2 by cutting it into a long length. Thereby, it is possible to eliminate the need to separately produce a metal heat radiating member, to reduce the man-hours, and to reduce the weight of the outer cylinder portion 2. Moreover, what sealed the outer cylinder part 2 integrally molded by the sealing lid parts 1 and 1 'is excellent in airtightness, For example, inert gas, such as nitrogen gas, can be inject | poured. Accordingly, it is possible to prevent deterioration of the LED element 4b, the solder connection portion 4c, and the like due to temperature rise due to oxidation, and it is possible to extend the life of the LED line lamp.

That is, the basic features of the LED line lamp described with reference to FIGS. 1, 2 and 3 are as follows:
(41) The heat dissipating part 2a is made of a synthetic resin having high thermal conductivity,
(42) The heat radiating portion 2a and the diffusing portion 2b are integrally formed,
(43) On the upper end side of the diffusing portion 2b, opposed guide portions 2b-1, 2b-1 'in the longitudinal direction of the diffusing portion are formed so as to have a U-shaped cross section together with the heat radiating portion 2a. Is that the end portion in the front-rear direction is sandwiched and held by the U-shaped section formed by the heat radiation portion 2a and the opposing guide portions 2b-1, 2b-1 ′,
It is.

Further basic features are
(44) A groove-like portion 2a-2 in the longitudinal direction of the heat radiating portion is formed at a substantially central portion of the lower surface of the heat radiating portion 2a.
(45) The heat conductive resin 5 is filled in the gap between the facing surface 2a-1 of the heat radiating portion 2a including the groove-shaped portion 2a-2 and the surface of the substrate portion 4a where the LED element 4b is not mounted. Being
(46) An inert gas (for example, nitrogen gas) is injected into the inside of the outer cylinder portion 2 composed of the heat radiating portion 2a and the diffusing portion 2b sealed with the sealing lid portions 1 and 1 '. It is.

  Conventionally, the heat radiating part of the LED line lamp has been made of metal such as aluminum, whereas the heat radiating part 2a shown in FIGS. 1 and 2 is shown in the basic feature (41). As described above, it is made of a synthetic resin having high thermal conductivity. Thereby, it can reduce in weight with respect to the conventional one, and reduction of the instrument burden of attachment object, safety improvement at the time of dropping, easy transportation, etc. can be achieved.

  In addition, conventionally, since the heat radiation part of the LED line lamp has been made of metal such as aluminum, the heat radiation part and the diffusion part have been formed separately, but the basic feature (42) As shown, the outer tube portion 2 including the heat radiating portion 2a and the diffusing portion 2b can be integrally formed. Thereby, the man-hour for outer cylinder part 2 formation can be reduced.

  Conventionally, the LED board has been fixed by caulking of the metal part. However, since the outer cylinder part 2 composed of the heat radiating part 2a and the diffusing part 2b is made of resin, a similar fixing method is used. I can't. On the other hand, as shown in the basic feature (43), since the opposing guide portions 2b-1, 2b-1 'are formed, the LED substrate 4 includes the heat radiating portion 2a and the opposing guide portion 2b-. It is slid and inserted so that the front and rear end portions are sandwiched and held by the U-shaped section formed by 1 and 2b-1 ′ (see FIGS. 4 and 5 for details of the process). Will be described later). Thereby, it becomes possible to arrange | position the LED board 4 in the predetermined position inside the outer cylinder part 2, without using a metal member.

  Further, as shown in the basic features (44) and (45), the opposing surface 2a-1 including the groove-like portion 2a-2 formed in the longitudinal direction of the heat radiating portion and the LED element 4b of the substrate portion 4a are provided. Since the heat conductive resin 5 is filled in the gap between the surface on which the LED board 4 is not mounted, the heat generated by the lighting of the LED substrate 4 can be efficiently radiated from the heat radiation portion 2a. Moreover, when the heat conductive resin 5 has adhesiveness, since the LED board 4 is fixed more stably, it is suitable.

  Moreover, since the airtightness of the outer cylinder part 2 comprised by the thermal radiation part 2a and the spreading | diffusion part 2b is high, as shown in the said basic characteristic (43), the outer cylinder part 2 is made into sealing lid part 1,1. It becomes possible to fill the inside sealed with ′ with an inert gas. Accordingly, it is possible to prevent deterioration of the LED element 4b, the solder connection portion 4c, and the like due to temperature rise due to oxidation, and it is possible to extend the life of the LED line lamp.

  Next, with reference to FIG. 4 and FIG. 5, a process of attaching the LED substrate 4 to the outer cylinder portion 2 composed of the heat radiating portion 2 a and the diffusing portion 2 b and filling the thermally conductive resin 5 will be described.

  As described above, since all the mounting portions of the LED substrate 4 are made of resin, the LED substrate 4 cannot be fixed inside the outer cylinder portion 2 by caulking for metal. Further, since the integrally formed outer cylinder portion 2 becomes a thin cylindrical long member, the work for attaching the LED board 4 which is also a long member inside is very difficult in the same manner as the conventional attachment work. It becomes difficult. For this reason, the LED substrate 4 is attached from the longitudinal direction, and simultaneously with the insertion, the heat conductive resin 5 is poured into a place immediately before the LED substrate 4 is inserted.

  As shown in FIG. 4, the filling process of the heat conductive resin 5 first fixes the pipe 6 and the hook 8 longer than the length in the longitudinal direction of the outer cylinder part 2 so as to form one bar-like member. When the pipe 6 and the hook 8 are pulled out from the right side in the drawing in the left direction, the pipe 6 is pulled out from the hooked portion of the tip of the hook 8 (left side in the drawing: when FIG. 4 is horizontally long). And the position is determined so that the dripping port 6a is located above the groove-like portion 2a-2. The hook 8 has a cross section in which the LED substrate 4 is composed of the opposing guide portions 2b-1, 2b-1 'and the heat radiating portion 2a when the pipe 6 and the hook 8 are pulled out from the right side in the drawing in the left direction. The position of the tip is determined so as to be inserted into the U-shaped portion and slid.

  The LED board 4 has the LED element 4b of the board | substrate part 4a, the solder connection part 4c, and the hole part 4d in the longitudinal direction edge part which does not have a conducting wire pattern. The hole 4d is preferably provided at at least one end in the longitudinal direction of the LED substrate 4. The LED substrate 4 is prepared on the tip side of the hook 8.

  The pipe 6 and the hook 8 fixed to each other are inserted into the outer cylinder part 2 from one end (left side in the figure) of the outer cylinder part 2, and the hook-shaped portion of the hook 8 is connected to the other part of the outer cylinder part 2. It is arranged so as to come out from the end (right side in the figure). A liquid supply pipe 7 is attached to the other end (left side in the figure) of the pipe 6, and the thermally conductive resin 5 is sent to the pipe 6. When the hole 4d of the LED substrate 4 is provided at one end in the longitudinal direction of the LED substrate 4, the LED substrate is arranged so that the hole 4d is on the outer cylinder 2 side (left side in the figure). 4 is preferably arranged.

  When the hole 4d of the LED substrate 4 is inserted into the key-shaped portion of the pipe 6 and the hook 8 is pulled out from the right to the left in the drawing, the LED substrate 4 is opposed to each other as shown in FIG. It is inserted into the U-shaped section formed by the guide portions 2b-1, 2b-1 'and the heat radiating portion 2a and is slid. At that time, the heat conductive resin 5 is dripped onto the upper part of the groove-shaped portion 2a-2 from the dropping port 6a on the traveling direction side (left side in the figure) from the slide insertion position of the LED substrate 4. The dripping amount of the heat conductive resin 5 is larger than the volume of the groove-shaped portion 2a-2, and is sufficient to fill the gap between the LED substrate 4 and the heat radiation portion 2 including the groove-shaped portion 2a-2. Adjusted to

  In this way, the LED board 4 which is also a long member can be easily attached to the outer cylinder part 2 which is a thin cylindrical long member. Further, in the same process, The heat conductive resin 5 can be filled in a gap between the heat radiation part 2 including the groove part 2a-2. When the heat conductive resin 5 not only has high heat conductivity but also adhesiveness, the LED substrate 4 is more stably fixed, which is preferable.

  Even when a heat conductive resin having no adhesiveness is used, the LED substrate 4 slidably inserted into the outer cylinder portion 2 is positioned in the longitudinal direction by the sealing lid portions 1 and 1 ′ at both ends of the LED line lamp. Secured.

  Further, the vertical direction and the front-rear direction of the LED substrate 4 are positioned by the holding action between the opposing guide portions 2b-1, 2b-1 'and the heat radiating portion 2a.

The manufacturing process of the LED line lamp is as follows, for example.
(51) A mixture of a heat radiating resin constituting the heat radiating portion 2a and a synthetic resin such as polycarbonate and a synthetic resin such as polycarbonate constituting the diffusing portion 2b are integrally molded (two-color molding) as an extrusion material, and necessary. The outer cylinder part 2 is formed by cutting into lengths.
(52) Insert the rod-shaped part composed of the pipe 6 and the hook 8 into the outer cylinder part 2.
(53) The hole 4d of the LED substrate 4 is hooked on the hook-like portion of the hook 8.
(54) While dripping an appropriate amount of the heat conductive resin 5 into the groove-like part 2a-2, the rod-like part composed of the pipe 6 and the hook 8 is driven to be pulled out from the outer cylinder part 2, and the LED substrate 4 is moved to the heat radiating part. 2a and the opposing guide portions 2b-1, 2b-1 ′ are slid and inserted so that the end portions in the front-rear direction are sandwiched between the U-shaped portions formed by the cross-section and pulled to a predetermined position.
(55) The LED drive circuit unit 3 is attached to the LED substrate 4 or the like.
(56) An inert gas is injected into the outer cylinder portion 2 and filled, and the sealing lid portions 1 and 1 'are attached.

In the case of this LED line lamp manufacturing process,
(61) By adjusting the mixing ratio of the heat-dissipating resin and the synthetic resin such as polycarbonate, the adhesion of the heat-dissipating part 2a is improved, and the outer cylinder part 2 composed of the heat-dissipating part 2a and the diffusing part 2b can be integrally formed. Therefore, it is not necessary to separately produce a metal heat radiating member, and the man-hour for forming the outer cylinder part 2 is reduced.
(62) The LED board 4 is slid and inserted so that the front and rear end portions are sandwiched between U-shaped sections formed by the heat radiating portion 2a and the opposing guide portions 2b-1, 2b-1 '. So, easily attach the LED board 4 which is a long member to the outer cylinder part 2 which is a thin cylindrical long member,
(63) Since the thermal conductive resin 5 can be filled in the same process as the slide insertion of the LED substrate 4, no additional process is required and the productivity is improved.
It has the advantages such as.

The embodiments of the present invention are not limited to the above-described embodiments, and various modifications are possible without departing from the spirit of the present invention.
(71) providing a plurality of dropping ports 6a;
(72) providing a plurality of groove-like portions 2a-2,
(73) A plurality of hole portions 4d of the LED substrate 4 are provided.
(74) Provide a plurality of hook-like portions of the hook 8;
(75) The pipe 6 and the hook 8 are also used, the dropping port 6a is provided at the tip of the hook 8, and the heat conductive resin 5 is dropped from the hole 4d of the LED substrate 4 onto the contact surface.
(76) The opposing end portions of the opposing guide portions 2b-1, 2b-1 ′ are narrowed toward the contact surface so that the LED board 4 inserted by sliding is biased to the contact surface.
(77) The insertion direction end portion (front-rear direction edge portion) of the LED substrate 4 has a concave or convex arc shape when viewed from above in FIGS.
(78) The LED board 4 is formed with an end portion (edge portion in the front-rear direction) in the insertion direction with a tapered surface that becomes thinner toward the tip end.
(79) The heat dissipating part 2a and the diffusing part 2b are integrally molded with the same resin having translucency and heat conductivity.
(80) As a resin forming the heat radiation part 2a, an acrylonitrile / butadiene / styrene resin (ABS resin) mixed with a heat conductive filler, a polyester resin, or the like is used.
(81) The diffusion part 2b uses an acrylic resin, a polystyrene resin, or the like as a resin to be formed.
(82) As the heat conductive resin 5, an epoxy resin, a polyester resin, or the like mixed with a heat conductive filler is used.
(83) As the heat conductive resin 5, a resin having curable properties such as thermosetting, anaerobic curable, and thermoplasticity is used.
(84) Carbon, alumina, aluminum nitride, silicon carbide, boron nitride, or the like is used as the heat conductive filler for each of the resin (80) and the heat conductive resin 5;
(85) As an inert gas, carbon dioxide, argon gas, helium gas, etc. are used.
You may do it.

1, 1 ′: Sealing lid 1a, 1a ′: Power supply terminal,
2: Outer cylinder (LED protective tube)
2a: Heat radiation part 2a-1: Opposing surface 2a-2: Grooved part 2b: Diffusion parts 2b-1, 2b-1 ′: Opposing guide part 3: LED drive circuit part 4: LED substrate 4a: Substrate part 4b: LED Element 4c: Solder connection part 4d: Hole part 5: Thermally conductive resin 6: Pipe 6a: Drip port 7: Liquid supply pipe 8: Hook

Claims (9)

In the manufacturing method of the LED line lamp of the form in which the LED substrate on which the LED element is mounted is disposed inside the straight tubular LED protective tube,
The LED is disposed between the heat radiating portion made of the first heat conductive resin having a contact surface with the LED substrate, the resin diffusion portion that transmits and diffuses the irradiation light of the LED element, and the contact surface. The LED protective tube having an opposing guide portion for guiding and holding the substrate is integrally formed,
Into the integrally formed LED protective tube, the LED substrate is slid and inserted along the opposing guide portion from the opening end portion thereof.
A method for manufacturing an LED line lamp. When the LED board is slid and inserted along the opposing guide portion,
Supplying a second thermally conductive resin to the contact surface;
By this supply, the second thermally conductive resin is filled in a space area between the LED substrate and the contact surface formed with the slide insertion.
The method of manufacturing an LED line lamp according to claim 1. The second thermally conductive resin is
Supplied to the groove-shaped part formed in the slide insertion direction of the contact surface,
The method of manufacturing an LED line lamp according to claim 2. By the action of the interlocking member that integrates the driving part for slidingly inserting the LED substrate and the injection part for supplying the second thermal conductive resin to the contact surface,
The second thermally conductive resin is supplied to the front portion in the slide insertion direction from the tip position of the LED substrate,
The method of manufacturing an LED line lamp according to claim 1 or 2, In the straight tubular LED protective tube that houses the LED substrate on which the LED element is mounted,
A heat radiating portion made of a first heat conductive resin having a contact surface with the LED substrate;
A resin-made diffusion part that transmits and diffuses the light emitted from the LED element;
An opposing guide portion for guiding and holding the LED substrate between the contact surface,
The entirety of the heat dissipating part, the diffusing part and the opposing guide part are integrally formed,
An LED protective tube for an LED line lamp. The contact surface is
A groove-like portion in the insertion direction of the LED substrate that is slidably inserted along the opposing guide portion;
The LED protective tube for an LED line lamp according to claim 5. The LED substrate is held in the opposing guide portion of the LED protective tube for the LED line lamp according to claim 5 or 6,
LED line lamp characterized by that. The space region between the heat dissipation part and the contact surface of the LED substrate is filled with a second thermally conductive resin,
The LED line lamp according to claim 7. A lid for sealing the end of the LED protective tube;
The LED line lamp according to claim 7 or 8, wherein an inner space between the LED protective tube and the lid is filled with an inert gas.

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