JP2015041452A - Led module and cooling structure of vehicle light including led module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an LED module capable of eliminating heat conduction loss to improve radiation performance and facilitating replacement work.SOLUTION: An LED module 1 includes: a socket housing 2 detachably attached to a housing 21 (or a reflector) of a vehicle light 20; a heat sink (radiation member) 3 incorporated into the socket housing 2; and an LED chip 4 mounted on the heat sink 3, a duct portion 2C being integrally formed in the socket housing 2, and radiation fins 3B of the heat sink 3 being accommodated in the duct portion 2C.

Description

  The present invention relates to an LED module using an LED (light emitting diode) as a light source and a cooling structure for a vehicle lamp provided with the LED module.

  In recent years, LEDs having high luminance, low power consumption, and high durability tend to be used as light sources for vehicle lamps such as headlamps and tail lamps. In such a vehicular lamp, heat is generated when the LED emits light, and the temperature of the LED rises due to this heat. However, the light emission efficiency and the durability life of the LED decrease as the temperature rises.

  Therefore, a vehicular lamp requires a cooling structure that suppresses the temperature rise of the LED. However, in Patent Document 1, at least a part of a heat sink (heat radiating member) connected to a semiconductor light source (LED) is connected to an air duct. A configuration has been proposed in which the heat radiation performance of the heat sink is enhanced by an air flow induced in the air duct by a fan, and the temperature of the semiconductor light source connected to the heat sink is reduced by cooling the semiconductor light source. .

  In Patent Document 2, a heat dissipating member (heat sink) connected to the LED lamp unit is disposed in a through hole formed in a housing of a vehicle lamp, and the heating member is supplied by air supplied to the through hole by a fan. The structure which improves the heat dissipation performance of this and cools the said LED lamp unit connected to this heat radiating member, and suppresses the temperature rise is proposed.

JP 2009-070821 A Japanese Patent No. 4730717

  However, in the cooling structures proposed in Patent Documents 1 and 2, a substrate or a separate heat conduction structure (support) is disposed between the heat radiation member (heat sink) in contact with the air flow and the semiconductor light source (LED lamp unit). Therefore, there is a problem that heat conduction loss occurs between the heat conduction structure and the heat radiating member, and high heat radiation performance cannot be exhibited due to the heat conduction loss.

  In the cooling structures proposed in Patent Documents 1 and 2, since the semiconductor light source (LED lamp unit) is fixed, the semiconductor light source can be easily replaced when a failure occurs in the semiconductor light source. There is also a problem that it cannot be done.

  The present invention has been made in view of the above problems, and its object is to provide an LED module that can be easily replaced while improving heat dissipation performance and a cooling structure for a vehicle lamp including the LED module. .

  In order to achieve the above object, an invention according to claim 1 is mounted on a housing of a vehicle lamp or a socket housing that is detachable from a reflector, a heat dissipating member incorporated in the socket housing, and mounted on the heat dissipating member. In the LED module including the LED chip, a duct portion is integrally formed in the socket housing, and a part of the heat radiating member is accommodated in the duct portion.

  According to a second aspect of the present invention, there is provided a cooling structure for a vehicle lamp in which the LED module according to the first aspect is detachably mounted on a housing or a reflector, together with a duct portion formed in a socket housing of the LED module. An air duct constituting a continuous air passage and a blower for supplying cooling air to the air duct are provided.

  A third aspect of the invention is characterized in that, in the second aspect of the invention, a plurality of the LED modules are detachably attached to one air duct connected to one blower.

  According to the present invention, the heat radiation member of the LED module is forcibly air-cooled by the flow of air supplied from the blower to the air duct, so that the heat radiation performance of the heat radiation member is enhanced, and the LED chip mounted directly on the heat radiation member is efficient. Cools well. As a result, the temperature rise of the LED chip is suppressed, and the light emission efficiency and durability life are increased.

  According to the present invention, the LED module can be attached to and detached from the housing or reflector of the vehicular lamp. When the LED module is attached to the housing or reflector, the duct portion formed in the socket housing is the air duct. Since it constitutes a part, the LED module can be replaced without impairing the cooling performance.

It is a perspective view of the LED module which concerns on this invention. It is a disassembled perspective view of the LED module which concerns on this invention. It is a side view (figure of the arrow A direction of FIG. 1) of the LED module which concerns on this invention. It is a top view (figure of the arrow B direction of FIG. 3) of the LED module which concerns on this invention. It is CC sectional view taken on the line of FIG. It is a plane sectional view of a vehicular lamp provided with the cooling structure concerning the present invention. It is a rear view of a vehicular lamp provided with the cooling structure concerning the present invention. It is a back side perspective view of a vehicular lamp provided with the cooling structure concerning the present invention. It is a fragmentary perspective view which shows the state before mounting | wearing with the LED module of the cooling structure part of a vehicle lamp provided with the cooling structure which concerns on this invention.

Embodiments of the present invention will be described below with reference to the accompanying drawings.
[LED module]
1 is a perspective view of an LED module according to the present invention, FIG. 2 is an exploded perspective view of the LED module, FIG. 3 is a side view of the LED module (a view in the direction of arrow A in FIG. 1), and FIG. FIG. 5 is a cross-sectional view taken along the line CC in FIG. 3. FIG. 5 is a plan view of the module (a view in the direction of arrow B in FIG. 3).

  An LED module 1 according to the present invention incorporates an aluminum heat sink 3 as a heat radiating member in a socket housing 2 integrally formed of resin, and a plurality of LED chips are arranged at the center of a rectangular top surface 3 a of the heat sink 3. 4 is directly mounted.

  Here, in the present embodiment, the central axis of the socket housing 2 coincides with the optical axis of the LED module 1, and the LED chip 4 is rotationally symmetric with respect to the central axis of the top surface 3 a of the heat sink 3. Is arranged.

  Thus, as shown in FIG. 5, the insulating layer 5 is deposited on the top surface 3 a of the heat sink 3 except for the portion where the LED chip 4 is mounted. A copper pattern 6 (not shown) is formed. As shown in FIGS. 1 and 2, a resin potting ring 7 is formed around the LED chip 4 and a copper pattern (not shown). Further, as shown in FIG. 2, three rectangular copper patterns 8 are formed on one side of the top surface 3 a of the heat sink 3.

  As shown in FIGS. 1 to 5, the socket housing 2 includes a circular block-shaped main body portion 2A, a rectangular cylindrical socket portion 2B and a duct portion 2C extending integrally from a position offset from the center of the main body portion 2A. It has. Here, the outer periphery of the duct portion 2C is formed in an arcuate curved shape along the outer shape of the ring-shaped flange 2a formed in the main body portion 2A. 1 to 4, four engagement claws 2b (only three are shown in the figure) are integrally formed on the outer periphery of the main body 2A of the socket housing 2.

  The heat sink 3 is an aluminum extrusion-molded product, which includes a rectangular block-shaped main body portion 3A and a plurality of rectangular thin pieces (eight in the illustrated example) extending vertically from the main body portion 3A. The heat radiating fins 3B are integrally formed.

  Thus, the socket housing 2 and the heat sink 3 are integrally formed by insert molding, and the main body 3A of the heat sink 3 is embedded in the main body 2A of the socket housing 2 as shown in FIG. The heat dissipating fins 3B of the heat sink 3 are disposed in a space (flow path) in the duct portion 2C of the socket housing 2, and their tip portions are embedded and supported in the duct portion 2C (see FIG. 5). .

Further, as shown in FIG. 5, the socket housing 2 is formed with a board storage space 2c extending to the socket portion 2B, and a rectangular plate-like circuit board 9 is fixed to the board storage space 2c. It is stored in a state. As shown in FIG. 2, a plurality of control elements 10 such as resistors and diodes for controlling the drive current to the LED chip 4 are arranged on the circuit board 9, and one end thereof (the front side in FIG. 5). Are provided with three terminals 11 bent in an L shape, and three terminals 12 are also provided at the other end (the back side in FIG. 5). When the circuit board 9 is fixed to the socket housing 2 as shown in FIG. 5, the three terminals 11 provided at one end of the circuit board 9 are provided on the top surface 3 a of the heat sink 3. The three terminals 12 electrically connected to the two copper patterns 6 (see FIG. 2) and provided at the other end of the circuit board 9 are connected to a space (in the socket portion 2B of the socket housing 2 as shown in FIG. Facing the channel).
[Vehicle lamp cooling structure]
Next, the cooling structure of the vehicular lamp 20 including the LED module 1 configured as described above will be described below with reference to FIGS.

  6 is a cross-sectional plan view of a vehicular lamp having a cooling structure according to the present invention, FIG. 7 is a rear view of the vehicular lamp, FIG. 8 is a rear perspective view of the vehicular lamp, and FIG. 9 is a vehicular lamp. It is a fragmentary perspective view which shows the state before mounting | wearing with the LED module of the cooling structure part.

  A vehicular lamp 20 according to the present embodiment is a headlamp disposed on the left and right of the front portion of the vehicle, and as shown in FIG. And the three elliptical curved reflectors 23 are stored in the lamp chamber S defined by the arcuate curved transparent outer lens 22 covering the opening and arranged in the lateral direction, and the rear surface of the housing 21 A total of three LED modules 1 are detachably mounted at locations corresponding to the reflector 23. The inner surface of each reflector 23 is subjected to a reflection process such as aluminum vapor deposition in order to increase the reflectance. Further, depending on the vehicular lamp, the LED module 1 is detachably attached to the reflector.

  Also, as shown in FIG. 9, circular mounting holes 24 are formed at three locations (only two locations are shown in FIG. 9) where the LED module 1 on the rear surface of the housing 21 is mounted. In the inner periphery of the hole 24 (four locations corresponding to the four engaging claws 2b protruding from the socket housing 2 of the LED module 1), there are notched engaging grooves 24a (three in FIG. 9). Only shown).

  By the way, one blower 25 is installed at one lateral end of the rear surface of the housing 21, and a rectangular cylindrical air duct 26 extends horizontally from the discharge side of the blower 25 along the rear surface of the housing 21. Has been. As shown in FIG. 9, a duct portion 2 </ b> C formed in the socket housing 2 of the LED module 1 is provided at a location where the LED module 1 of the air duct 26 is mounted (a location where the mounting hole 24 of the housing 21 is formed). A total of three notches 26a (only two are shown in FIG. 9) are formed.

  Thus, as shown in FIG. 9, each LED module 1 includes the four engaging claws 2 b (FIG. 1 and FIG. 1) formed on the front end of the main body 2 </ b> A of the socket housing 2 from the back side of the housing 21. 2) is inserted into the mounting hole 24 in a state aligned with the engaging groove 24a (see FIG. 9) of the mounting hole 24 of the housing 21, and each LED module 1 is rotated in the direction of the arrow in FIG. The LED module 1 is mounted on the housing 21 by engaging 2b with the peripheral edge of the mounting hole 24 of the housing 21. When the LED module 1 is mounted in the mounting hole 24 of the housing 21 in this way, the duct portion 2C formed in the socket housing 2 of each LED module 1 is fitted into each notch 26a of the air duct 26, and the duct 26 and the LED A flow path is continuously formed inside the duct portion 2 </ b> C of the module 1. Note that the LED module 1 mounted on the housing 21 as described above can be easily detached from the housing 21 by a procedure reverse to the above. That is, as shown in FIGS. 6 to 8, if the LED module 1 mounted on the housing 21 is rotated in the reverse direction (the direction opposite to the arrow direction in FIG. 9), the main body 2A of the socket housing 2 of the LED module 1 is used. Since the engagement of the engaging claw 2b formed on the peripheral edge of the mounting hole 24 of the housing 21 is released, the LED module 1 can be taken out to the front side and easily removed from the housing 21. In the present embodiment, the outer shape of the duct portion 2C of the socket housing 2 and the shape of the notch 26a of the air duct 26 are circular or circular, so that the LED module 1 can be easily attached and detached, and the duct portion 2C Generation of a gap between the notches 26a is prevented.

  Although not shown, a power plug is attached to an end of a power cord that extends from a battery mounted on the vehicle, and has a rectangular cylindrical shape formed in the socket housing 2 of the LED module 1 that is attached to the housing 21. By inserting a power plug into the socket portion 2B, the LED 4 (see FIGS. 1, 2, and 5) as the light source of the LED module 1 is electrically connected to the battery via the terminal 11, the circuit board 9, the terminal 12, and the power cord. Connected to.

  Therefore, when the driver supplies power to each LED module 1 from the battery by a switch operation, the current from the battery is supplied to the LED chip 4 of each LED module 1 through the power cord, the terminal 12, the circuit board 9, and the terminal 11. Each LED chip 4 is activated to emit light. Then, the light emitted from each LED chip 4 is reflected by the reflector 23, passes through the outer lens 22, and is emitted toward the front of the vehicle (upward in FIG. 6).

  When the LED chip 4 emits light as described above, the LED chip 4 generates heat, but the heat is cooled by the cooling structure according to the present invention provided in the vehicular lamp 10.

  That is, the blower 25 is driven when the vehicular lamp 20 is turned on, and the cooling air discharged from the blower 25 is continuously formed inside the air duct 26 and the duct portion 2C of the LED module 1 provided in the middle thereof. The heat radiation performance of the heat radiation fins 3B is enhanced by flowing through the flow path and passing through the plurality of heat radiation fins 3B of the heat sink 3 accommodated in the duct portion 2C of each LED module 1. For this reason, the heat conducted from the LED chip 4 of each LED module 1 to the heat sink 3 is efficiently dissipated from the heat radiating fins 3B and discharged outside the air duct 26 by the cooling air.

  In the present embodiment, in each LED module 1, since the LED chip 4 is directly mounted on the top surface 3a of the main body 3A of the heat sink 3, the heat generated in the LED chip 4 is applied to the LED substrate as in the related art. It conducts directly to the heat sink 3 without going through. For this reason, a conduction loss is suppressed small, heat is efficiently transmitted to the heat sink 3, and heat is efficiently radiated from the radiation fins 3 </ b> B formed on the heat sink 3.

  Therefore, according to the cooling structure according to the present invention, an increase in the temperature of the LED chip 4 of each LED module 1 is suppressed, and an effect that high luminous efficiency and durable life are ensured for the LED chip 4 is obtained.

  Further, the LED module 1 according to the present invention can be attached to and detached from the housing 21 of the vehicular lamp 20. When the LED module 1 is mounted on the housing 21, the duct portion 2 </ b> C formed in the socket housing 2 is an air duct 26. Therefore, the LED module 1 can be easily replaced without impairing the cooling performance.

In the present invention, the rear combination lamp other than the headlamp, DRL (Daytime Running
Lamp), fog lamp, back lamp, side turn lamp, rear fog lamp, high-mount stop lamp, license plate lamp and other arbitrary vehicle lamp cooling structure and LED module which is detachably mounted on any vehicle lamp Of course, the same applies to the above.

DESCRIPTION OF SYMBOLS 1 LED module 2 Socket housing 2A Socket housing main body 2B Socket housing socket 2C Socket housing duct 2a Socket housing flange 2b Socket housing engagement claw 2c Socket housing board storage space 3 Heat sink (heat dissipation member)
3A Heat sink body 3B Heat sink fin 3a Heat sink top surface 4 LED chip 5 Insulating layer 6 Copper pattern 7 Ring 8 Copper pattern 9 Circuit board 10 Control element 11, 12 Terminal 20 Vehicle lamp 21 Housing 22 Outer lens 23 Reflector 24 Housing mounting hole 24a Mounting hole engaging groove 25 Blower 26 Air duct 26a Air duct notch S Light chamber

Claims (3)

In an LED module including a socket housing detachable with respect to a housing or reflector of a vehicle lamp, a heat dissipation member incorporated in the socket housing, and an LED chip mounted on the heat dissipation member,
An LED module, wherein a duct part is formed integrally with the socket housing, and a part of the heat radiating member is accommodated in the duct part. A cooling structure for a vehicle lamp, wherein the LED module according to claim 1 is detachably attached to a housing or a reflector,
A cooling structure for a vehicular lamp, comprising: an air duct that forms a continuous air passage with a duct portion formed in a socket housing of the LED module; and a blower that supplies cooling air to the air duct. The cooling structure for a vehicle lamp according to claim 2, wherein a plurality of the LED modules are detachably attached to one air duct connected to one blower.

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