JP2015135825A - Light emitting diode lamp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a light emitting diode lamp which maintains an inner pressure of a glass bulb at the atmospheric pressure.SOLUTION: A light emitting diode lamp includes: a light emitting diode unit 10 on which light emitting diodes 11 are mounted; a glass bulb 21 in which the light emitting diode unit 10 is disposed; and a mouth piece 23 attached to the glass bulb 21. The glass bulb 21 has an opening part 231, which allows atmospheric air to pass, in the mouth piece 23. The light emitting diode lamp includes a narrow tube such as an exhaust tube 221 which allows the interior of the glass bulb 21 and the interior of the mouth piece 23 to communicate with each other and protrudes from the glass bulb 21 into the mouth piece 23. The opening part 231 is formed in a tip part of the narrow tube.

Description

  The present invention relates to a street light LED (light emitting diode element) bulb, for example. In particular, the present invention realizes an LED light bulb having a wide light distribution close to an HID lamp (High Intensity Discharge lamp) used for a street light or a security light.

(1) Conventional HID lamp:
A. Since the luminous flux is large and wide and can be illuminated far, it has been widely used in outdoor applications such as street lights and security lights. It has also been used for base-down and base-up equipment.
B. High power consumption and short life (about 10,000 hours).
C. Since light is emitted by mercury discharge, it takes time until the mercury in the arc tube evaporates and the brightness is stabilized.

(2) Light bulb shaped LED:
A. The directivity of light is high, and it is suitable for irradiation in a certain direction such as improvement of the illuminance directly below the bottom surface (Patent Document 1: JP 2009-4130 A).
In this case, several arrangements are sufficient, the amount of heat generated by the LED itself is small, and a high life of about 40000 hours can be maintained as compared with a discharge lamp such as an HID lamp.

B. The following lamps have been devised as LED lamps to replace conventional outdoor HID lamps.
As with the conventional discharge lamp, an inert gas is sealed in the glass bulb 21, and after sealing, a screw-shaped base 23 is attached to facilitate compatibility with the conventional discharge lamp, and at the same time, a concave mirror is placed behind the LED. By providing it, the light emission angle of the LED is expanded (Patent Document 2: Japanese Patent Laid-Open No. 62-124781).

JP 2009-4130 A Japanese Patent Laid-Open No. 62-124781 JP 2010-55993 A JP 2010-182796 A JP 2009-23915 A Japanese Patent Laid-Open No. 09-102632 JP 2011-108424 A JP 2010-129431 A JP 2005-158746 A JP 2000-21209 A JP 2009-289543 A JP 2009-48994 A

A. HID can be used to illuminate the outdoors widely and far away like conventional HID lamps by simply replacing the lighting device in the widely used street and security light fixtures and using the reflectors and receiving metal. Light distribution and emission intensity that are practically comparable to lamps are required.
B. If the light distribution is non-directional and the light from the light emitting diode 11 is distributed in almost all directions, it can be used not only for street lights that are mainly lit on the lower surface but also for base-down and base-up fixtures. Is possible.
C. With the LED lamp of Patent Document 2, it is difficult to obtain a light distribution and light emission intensity that are inferior to those of an HID lamp, and it is necessary to greatly increase the number of LEDs and to direct the LED light in all directions as with the HID lamp.
D. Due to the accumulation of a large number of LEDs, the temperature inside the lamp becomes high, and the LEDs deteriorate quickly, making it difficult to maintain the life of the LED lamp as in Patent Document 1. In addition, when a metallic heat dissipator as in Patent Document 1 is installed on the lower surface of the LED substrate in order to release heat generated by the LED, the number of LEDs is large, and the LEDs are arranged along a vertically long cylindrical bulb. For this reason, not only the heat dissipating body becomes heavy, but the heat dissipating efficiency becomes worse as the length of the vertically long arrangement becomes longer.
E. In order to use a large number of LEDs and direct the LED light in all directions like HID lamps, the LEDs must be arranged in a distributed manner in the length direction and circumferential direction of the lamp. In order to manufacture, the material cost and the manufacturing cost become high.

The light emitting diode lamp according to the present invention is:
A light emitting diode unit mounted with a light emitting diode;
A glass bulb having the light emitting diode unit disposed therein;
A base attached to the glass bulb,
The glass bulb has an opening through which air is passed inside the base.

  According to this invention, regardless of the internal temperature of the glass bulb, the internal pressure of the glass bulb can be maintained at atmospheric pressure, and the luminous flux of the light emitting diode can be prevented from decreasing.

1 is a front side view of a light emitting diode unit 10 according to Embodiment 1. FIG. FIG. 3 is a plan view of the light emitting diode unit 10 according to the first embodiment. 1 is a front side view of a light emitting diode lamp 20 according to Embodiment 1. FIG. FIG. 3 is a plan view of the light-emitting diode lamp 20 according to the first embodiment. FIG. 3 is a front side view of the light emitting diode lamp 20 without the base 23 in the first embodiment. FIG. 6 shows a change in color temperature of the light-emitting diode lamp 20 in the first embodiment. FIG. 6 is a development view of a support member 13 of the light emitting diode unit 10 according to Embodiment 3. FIG. 6 is a front side view of a support member 13 of a light emitting diode unit 10 according to Embodiment 3. FIG. 6 is a plan view of a support member 13 of a light emitting diode unit 10 according to Embodiment 3. FIG. 6 is a front side view of a light emitting diode unit 10 according to Embodiment 3. FIG. 6 is a plan view of a light emitting diode unit 10 according to Embodiment 3. FIG. 6 is a front side view of a light-emitting diode lamp 20 according to Embodiment 3. FIG. 6 is a plan view of a light-emitting diode lamp 20 according to Embodiment 3. FIG. 7 is a dimensional diagram of the light-emitting diode lamp 20 according to the third embodiment. FIG. 4 shows Table-1, Table-2, and Table-3 in Embodiment 3. FIG. 4 shows Table-4 in the third embodiment. The top view of the light emitting diode lamp 20 of the light emitting diode unit 10 of the hexagonal column in Embodiment 3. FIG. FIG. 5 shows Table-5 in the third embodiment. FIG. 10 shows a table of a comparative example in the third embodiment. FIG. 6 is a front side view of a light emitting diode unit 10 according to a fourth embodiment. FIG. 6 is a plan view of a light emitting diode unit 10 according to a fourth embodiment. FIG. 6 is a front side view of a light emitting diode lamp 20 according to a fourth embodiment. FIG. 6 is a plan view of a light emitting diode lamp 20 according to a fourth embodiment. FIG. 6 shows Table-6 in the fourth embodiment. The figure which shows the graph of h / D of Table-6 in Embodiment 4, and valve | bulb surface temperature. FIG. 8 shows Table-7 in the fourth embodiment. The figure which shows the graph of h / D of Table-7 in Embodiment 4, and valve | bulb surface temperature. FIG. 8 shows Table-8 in the fourth embodiment. The figure which shows the graph of (DELTA) d of Table-8 in Embodiment 4, and valve | bulb surface temperature. The figure of the light emitting diode lamp 20 of the support member 13 of the octagonal prism in Embodiment 5. FIG. The figure of the light emitting diode lamp 20 of the hexagonal column support member 13 in Embodiment 5. FIG. FIG. 6 shows a lighting fixture equipped with a light-emitting diode lamp 20 according to a fifth embodiment. FIG. 6 shows a lighting fixture equipped with a light-emitting diode lamp 20 according to a fifth embodiment. FIG. 6 shows a lighting fixture equipped with a light-emitting diode lamp 20 according to a fifth embodiment. FIG. 16 is a conceptual diagram showing a comparative example 1 of the silicone injection method in the sixth embodiment. FIG. 16 is a conceptual diagram showing a comparative example 2 of the silicone injection method in the sixth embodiment. FIG. 11 is a conceptual diagram showing a silicone injection method in a sixth embodiment. FIG. 10 is a flowchart showing a manufacturing method (silicone injection method) of the light-emitting diode lamp 20 according to the sixth embodiment. FIG. 3 is a development view of the support member 13 of the light emitting diode unit 10. The figure which shows the flare pipe | tube 22. FIG. The figure which shows the state which assembly process S20 was complete | finished. The figure at the time of silicone injection. The figure in which the light emitting diode 11 is covered with silicone 290 between the support member and the glass bulb 21. The figure which adhere | attached the plate glass 240 on the package surface of the light emitting diode 11. FIG. The perspective view of the glass bulb | bulb 21 in Embodiment 7. FIG. The perspective view of the glass bulb | bulb 21 in Embodiment 7. FIG. FIG. 46 is an AA sectional view of the glass bulb 21 of FIG. 45 in the seventh embodiment. FIG. 10 is a front side view of a light emitting diode unit 10 according to a seventh embodiment. FIG. 9 is a plan view of a light emitting diode unit 10 according to a seventh embodiment. FIG. 10 is a front side view of a light emitting diode lamp 20 according to a seventh embodiment. FIG. 9 is a plan view of a light emitting diode lamp 20 according to a seventh embodiment. The front side view of the light emitting diode lamp 20 without the nozzle | cap | die 23 in Embodiment 7. FIG. FIG. 9 is a dimensional diagram of a light-emitting diode lamp 20 according to a seventh embodiment. FIG. 10 shows a method for manufacturing the light-emitting diode lamp of the seventh embodiment. FIG. 20 shows an example of a street lamp in an eighth embodiment. Comparison of specifications of street lamps using HID lamps and street lamps using LED lamps. Comparison result of lamp and power supply combination. Comparison result of lamp and power supply combination. FIG. 10 is an example diagram of a light-emitting diode lamp 20 with improved heat dissipation in a ninth embodiment. FIG. 20 is another example diagram of the light-emitting diode lamp 20 with improved heat dissipation in the ninth embodiment. FIG. 18 is an exploded view of the light emitting diode lamp 20 according to the tenth embodiment. FIG. 18 is a conceptual cross-sectional view of a flare tube 22 in the tenth embodiment. Sectional drawing of the light emitting diode unit 10 in Embodiment 10. FIG. FIG. 18 shows a method for measuring an enclosed gas pressure and a total luminous flux change in the tenth embodiment. FIG. 18 is a graph of the atmospheric pressure of the glass bulb 21 and the brightness of the light-emitting diode lamp in the tenth embodiment. FIG. 25 shows a base hole 226, a filter 227, and a hole 259 in the tenth embodiment. FIG. 18 shows a base hole 226 and a filter 227 in the tenth embodiment. The schematic diagram which the flux 256 in Embodiment 11 moves. FIG. 20 is a graph of the flux amount and brightness in the eleventh embodiment. FIG. 20 is a comparison of mounting of a substrate and an LED in the twelfth embodiment. FIG. 18 is an attachment diagram of a substrate and LEDs in the twelfth embodiment. FIG. 18 is a diagram of a notch in the substrate in Embodiment 12. FIG. 20 shows a recess of a substrate in Embodiment 12.

Embodiment 1 FIG.
(1) 1st form (FIGS. 1-6)
FIG. 1 is a front side view of the light emitting diode unit 10, and FIG. 2 is a plan view.
The light emitting diode unit 10 includes an aluminum octagonal column support member 13. The support member 13 is a holding member that holds the light emitting diode 11. The light emitting diode unit 10 has a trapezoidal cone 18 having eight faces on the top of the support member 13.

  A ribbon-like flexible substrate 12 (light-emitting diode substrate) on which one light-emitting diode 11 is mounted is attached to the eight surfaces of the cone 18 with a heat-resistant adhesive. Further, a ribbon-like flexible substrate 12 (light emitting diode substrate) on which three light emitting diodes 11 are mounted on each of the eight side surfaces of the octagonal prism is attached with a heat resistant adhesive.

A pair of base support columns 14 are attached in the axial direction of the octagonal column to a base portion (a base portion on the base 23 side of a pair of side surfaces facing each other) of one side surface of the octagonal column.
Further, a shaft column 15 is attached to the center of the bottom surface of the octagonal column in the axial direction of the support member 13 of the octagonal column.

  A lead-in wire 17 is led out from the bottom surface of the octagonal column support member 13 to input and output a direct current to the light emitting diode 11.

These three support columns are connected to another connection support column 16 in a direction perpendicular to the axial direction of the octagonal column support member 13.
These struts are made of stainless steel.

For example, the diameter of the circumscribed circle of the bottom surface of the octagonal column support member 13 is 50 mm, and the height of the octagonal column support member 13 not including the pyramid portion is 150 mm.
A substrate on which the light emitting diode 11 is mounted is a flexible substrate 12. The light emitting diode 11 is mounted on the flexible substrate 12, and the flexible substrate 12 is attached to an aluminum substrate. A vertically long substrate is connected to form a prismatic polyhedral structure. By making the apex of the prismatic polyhedral structure into a prismatic shape, it can be adapted to the hemispherical or dome-shaped apex of the glass bulb 21. The light emitting diode 11 can be disposed in the angled portion. The bending angle of the angled portion is determined according to the radius R of the top of the glass bulb 21.

FIG. 3 is a front side view of the light-emitting diode lamp 20, and FIG. 4 is a plan view. FIG. 5 shows a front side view without the base 23.
The light emitting diode lamp 20 includes a housing 24. The housing 24 includes a glass bulb 21 and a flare tube 22. The casing 24 is all transparent. Alternatively, the lower portion of the casing 24 where the light emitting diode 11 is not disposed may be opaque. The glass bulb 21 has a cylindrical shape with a hemispherical upper portion.

  The light emitting diode unit 10 is inserted into the glass bulb 21. The space between the glass bulb 21 and the light emitting diode unit 10 is transparent and thermally conductive silicone resin from the inner surface of the hemispherical top of the glass bulb 21 to the height of the bottom surface of the octagonal column support member 13 of the light emitting diode unit 10. Silicone rubber made of Shin-Etsu silicone (KE109) is filled (not shown).

The flare tube 22 is a glass sealing part fused to the end of the glass bulb 21.
The shaft column 15 led out in the axial direction of the octagonal column support member 13 from the center of the bottom surface of the octagonal column support member 13 is embedded in the end portion of the shaft column 15 when the flare tube 22 is pinched. Embedded in the flare tube 22. When the glass flare tube 22 fused to the end of the glass bulb 21 is pinched, the introduction line 17 led out from the bottom surface of the octagonal column support member 13 is configured such that the end of the introduction line 17 is the flare tube 22. It is embedded in the flare tube 22 so as to be led out from the end of the flare tube.

  When sealing the tip tube at the end of the glass bulb 21, nitrogen gas is sealed and replaced with the air in the bulb.

  The two lead wires 17 are wired to an E39 base 23 installed at the end of the glass bulb 21.

  As shown in FIG. 6, the one filled with the heat conductive silicone resin has a higher color temperature of the lamp, and the color of the lamp is shifted in the blue direction, as shown in FIG. 6. Looks bright. Further, since the color temperature of the lamp becomes high, the light emitting diode 11 having a lower color temperature can be used in advance. This can reduce the amount of yellow YAG phosphor that is the cause of deterioration in the most common pseudo-white light-emitting diode 11 formed by coating the blue light-emitting diode 11 with a yellow YAG phosphor.

  The reason why the color of the lamp shifts in the blue direction due to the filling of the thermally conductive silicone resin is not clear, but is considered to be due to absorption from infrared to red by an organic substance such as silicone resin.

  Although the E39 base 23 is used as the base 23, an E26 base 23 compatible with the HID lamp may be used.

Embodiment 2. FIG.
(2) Second embodiment (not shown)
Instead of the transparent and heat conductive silicone resin in the first embodiment, a perfluorocarbon liquid may be filled as a transparent heat conductive liquid. The perfluorocarbon liquid has a high density and efficiently absorbs heat generated by the light emitting diode 11 and transmits it to the glass bulb 21. The perfluorocarbon liquid is an insulating liquid and does not cause a short circuit even when it comes into contact with the wiring portion such as the introduction line 17.

  As shown in FIG. 6, the lamp filled with the perfluorocarbon liquid has a higher color temperature of the lamp and the lamp color shifts in the blue direction and appears brighter than the lamp not filled (only with nitrogen). Further, since the color temperature of the lamp becomes high, the light emitting diode 11 having a lower color temperature can be used in advance. This can reduce the amount of yellow YAG phosphor that is the cause of deterioration in the most common pseudo-white light-emitting diode 11 formed by coating the blue light-emitting diode 11 with a yellow YAG phosphor.

  The reason why the color of the lamp shifts in the blue direction due to the filling of the perfluorocarbon liquid is not clear, but is considered to be due to absorption of infrared to red by the perfluorocarbon liquid.

For example, density 1.83 (kg / m ³ @ 25 ° C.), specific heat 1.050 (J / kg K @ 25 ° C.), dielectric strength 43 kV (2.54 mm Gap @ 25 ° C.), dielectric constant 1.91 kV (@ 25 ° C. ) [1 kHz] Sumitomo 3M Co. "Fluorinert (" FLUORINERT "is a registered trademark)" FC-3283 is filled.

The perfluorocarbon liquid is transparent and insulative, and if the density is higher than water and the specific heat is similar to water, the light emitting diode substrate can be cooled directly in the energized state, and the heat radiation efficiency is better than water cooling. The density may be 1.5 (kg / m ³ @ 25 ° C.) or more.

For example, density 1.68 (kg / m ³ @ 25 ° C.), specific heat 1.050 (J / kg K @ 25 ° C.), dielectric strength 38 kV (2.54 mm Gap @ 25 ° C.), dielectric constant 1.76 kV (@ 25 ° C. ) [1 kHz] Sumitomo 3M Co. "Fluorinert (" FLUORINERT "is a registered trademark)" FC-72 may be used.

Embodiment 3 FIG.
(3) Third embodiment (FIGS. 7 to 13)
Hereinafter, differences from the first and second embodiments will be described.
FIG. 7 is a development view of the support member 13 of the light emitting diode unit 10.
8 and 9 are a front side view and a plan view of the light emitting diode unit 10, respectively.

  As shown in the figure, the support member 13 is formed by bending a solid aluminum plate to form a plurality of surfaces. If the integrated plate is formed by bending, the thermal conductivity is improved.

  FIG. 10 is a front side view of the light emitting diode unit 10, and FIG. 11 is a plan view.

An aluminum octagonal pyramid is formed on the top of the aluminum octagonal column support member 13.
Four surface light emitting diodes 11 are mounted on each of the eight faces of the octagonal pyramid. In addition, three light emitting diodes 11 are mounted on each of the eight surfaces of the octagonal column support member 13 in one row.
The support member 13 is insulated and doubles as a light emitting diode substrate.

  FIG. 12 is a front side view of the light-emitting diode lamp 20, and FIG. 13 is a plan view.

  The transparent heat conductive medium in which the light emitting diode unit 10 is inserted into a cylindrical glass bulb 21 having a hemispherical upper portion and the space between the glass bulb 21 and the light emitting diode unit 10 is filled is described in the first and second embodiments. (Not shown).

  The width w in the direction perpendicular to the axis of the octagonal column support member 13 on the side surface of the octagonal column support member 13 of the lamp is 17.15 mm from the center of the cross section of the cylindrical bulb. The distance Δk between the point extending perpendicularly to the side surface of the octagonal column support member 13 and the point intersecting the side surface of the octagonal column support member 13 and the inner surface of the valve of the line elongated vertically (one of the support members 13) The distance Δk) from the center of the side surface to the inner surface of the bulb is 2.4 mm, and the inner diameter of the glass bulb 21 of the E39 base 23 specification is 48 mm.

  The diameter d of the circumscribed circle of the octagon is 44.8 mm, and the height h of the octagonal column support member 13 is 110 mm.

(Determination of polygon n)
The width of the polygonal column side surface perpendicular to the axis of the polygonal column w: 17.15 mm, perpendicular to the polygonal column side surface from the center of the cross section of the cylindrical bulb, perpendicular to the point intersecting the polygonal column side surface A polygon that satisfies the distance Δk of the point of intersection of the extended line with the inner surface of the bulb at 3.0 mm and the inner diameter of 48 mm that is compatible with the E39 cap 23 specification HID lamp is selected.

The meanings of the symbols in the dimensional diagram of FIG. 14 are as follows.
D: Inner diameter of glass bulb 21 d: Diameter of circumscribed circle of light emitting diode unit 10 w: Width of one side of light emitting diode unit 10 b: Distance from center of glass bulb 21 to light emitting diode 11 Δr: Inner diameter of glass bulb 21 Difference between D and circumscribed circle diameter d Δk: radial distance from light emitting diode 11 to inner surface of glass bulb 21 Δg: radial distance from light emitting diode 11 to circumscribed circle Width of one side of light emitting diode unit 10 “w” is equal to or larger than the width direction of the light emitting diode 11 and equal to or larger than a width in which a signal line can be wired. When a flexible substrate is attached, the width w is equal to or greater than the width of the flexible substrate and the width that allows signal lines to be wired.

If the width w is increased, n is reduced, and the following advantages are obtained.
1. The number of times of bending of the support member 13 is reduced.
2. The alignment of the top of the cone 18 is facilitated.

If the width w is decreased, n increases, and the following advantages are obtained.
1. The light emitting diode 11 approaches the inner surface of the glass bulb 21.
2. Increases heat dissipation effect (Embodiment 4 described later)

The diameter d of the circumscribed circle of the n-gonal shape with the width w in the direction perpendicular to the axis of the polygonal column on the side surface of the polygonal column is
Sin (180 ° / n) = w / d
Than,
d = w / Sin (180 ° / n)
It is represented by

The difference Δg between (d / 2) and the distance b between the center of the perpendicular extending from the center of the polygon to the side of the polygon and the intersection of the side and the perpendicular is
Δg = d / 2−b
b = √ ((d / 2) ² − (w / 2) ² )
Than,
Δg = (d / 2) −√ ((d / 2) ² − (w / 2) ² )
It is represented by

When the distance Δr between the inner circumference of the valve arranged concentrically and the circumscribed circumference of the polygon,
Δr = Δk−Δg
It is represented by

The valve inner diameter D that satisfies Δk at the determined w is
D = d + 2Δr
= D + 2 (Δk−Δg)
= D + 2 (Δk− (d / 2) + √ ((d / 2) ² − (w / 2) ² ))
= D + 2Δk−d + 2√ ((d / 2) ² − (w / 2) ² )
= 2Δk + 2√ ((d / 2) ² − (w / 2) ² )
= 2Δk + 2√ ((w / 2Sin (180 ° / n)) ² − (w / 2) ² )
It is represented by

  This expression indicates that the inner diameter D of the glass bulb 21 is a function of Δk, w, and n. Further, when Δk and w are constant, the inner diameter D of the glass bulb 21 is a function of n. Conversely, it is shown that n is determined when Δk, w, and the inner diameter D are set to predetermined values.

  When w = 17.15 mm and Δk = 3.0 mm, D = 47.40 obtained from n = 8 from Table-1 in FIG. 15 is closest to the target D = 48 mm.

  When the target is within D = 48 mm, the maximum n that satisfies D = 48 mm may be selected.

  As described above, the width w of one side surface of the support member 13 is fixed to a predetermined width w = 17.15 mm, and the distance Δk from the center of one side surface of the support member 13 to the inner surface of the valve is a predetermined distance Δk = 3. It can be seen that the regular n-gon shape in which the light-emitting diode unit 10 can be arranged inside a cylindrical bulb fixed at 0.0 mm and having a predetermined bulb diameter D = 48 mm is a regular octagon. In other words, it can be seen that the optimum value of n of a regular n-square shape in which the light emitting diode unit 10 can be disposed inside a cylindrical bulb having a predetermined bulb diameter is 8.

  When w = 17.15 mm and Δk = 4.0 mm, D = 49.40 obtained from n = 8 from Table-2 in FIG. 15 is closest to the target D = 48 mm.

Δk when D = 48 mm is actually adopted is 3.3 mm from Table-4 in FIG.
Further, a polygon satisfying the inner diameter of 38.6 mm of the glass bulb 21 compatible with the E26 base 23 specification HID lamp is selected from the table of FIG.

  From Table-2 and Table-3 in FIG. 15, D = 37.7 and 39.7 obtained from n = 6 are closest to the target D = 38.6 mm (FIG. 17).

  Δk when D = 38.6 mm is actually adopted is 4.5 mm from Table-4 in FIG.

  When w = 17.15 mm, the target D = 48 mm and the target D = 38.6 mm can be achieved when n = 6 or more and 8 or less.

  The light-emitting diode unit 10 is desirably originally cylindrical, but a flat surface is necessary for arranging the light-emitting diodes 11. For that purpose, a polygon is formed, and it is ideal that the polygon is also closer to a cylinder. However, if the width w is reduced, n becomes larger and thus approaches a cylinder, but the manufacturing process is complicated due to an increase in the number of bendings.

  When the width w is increased, n is decreased, and the light emitting diode unit 10 becomes a triangular prism or a quadrangular prism and has a shape far from the cylinder.

  The cases where w = 5 mm, 15 mm, 20 mm, and Δk = 5.0 mm are shown in Table-5 in FIG.

  In the case of w = 5 mm, even if n = 18, D does not exceed 40 mm. Therefore, in order to achieve the target D = 48 mm, w = 5 mm is not suitable.

  In the case of w = 15 mm, n = 6 or more and 8 or less is preferable because the target D = 48 mm and the target D = 38.6 mm can be achieved.

  In the case of w = 20 mm, even if n = 6, D does not become 40 mm or less. Therefore, in order to achieve the target D = 38.6 mm, w = 20 mm is unsuitable.

  FIG. 19 is a table when w = 17.15 mm and Δk = 1.5 mm and Δk = 2.0 mm. When Δr is a negative value, it indicates that the light emitting diode unit 10 cannot be stored in the glass bulb 21. When Δr is less than 1 mm, the light emitting diode unit 10 can theoretically be accommodated in the glass bulb 21, but due to dimensional variation (plus or minus 1 to 2 mm) of the glass bulb 21, the light emitting diode unit 10 is made into glass during assembly. It becomes difficult to insert the valve 21.

15, 16, 18, and 19 show the calculated values of w / d and w / D.
As described above, since Sin (180 ° / n) = w / d, according to this equation, when n is determined, the ratio of w and d is known.

When n = 4, Sin (180 ° / n) = 0.71 = w / d
When n = 5, Sin (180 ° / n) = 0.59 = w / d
When n = 6, Sin (180 ° / n) = 0.50 = w / d
When n = 7, Sin (180 ° / n) = 0.43 = w / d
When n = 8, Sin (180 ° / n) = 0.38 = w / d
When n = 9, Sin (180 ° / n) = 0.34 = w / d
When n = 10, Sin (180 ° / n) = 0.31 = w / d
Therefore, when n is desired to be 4 to 10, w may be 0.71 to 0.31 of d.
When n is to be 6 to 8, w may be 0.5 to 0.38 of d.

Actually, as shown in FIGS. 15, 16, 18, and 19,
D = 2Δk + 2√ ((w / 2Sin (180 ° / n)) ² − (w / 2) ² ))
Thus, if n and Δk are determined, the ratio of w and D can be obtained.

According to Table-1 in FIG. 15, when Δk = 3.0 mm and n is 4 to 10, w may be 0.74 to 0.29 of d. When n is 6-8, w is 0.48-0.3 of d.
6 is sufficient.

  According to Table-2 in FIG. 15, when Δk = 4.0 mm and n is desired to be 4 to 10, w may be set to 0.68 to 0.28 of d. When n is to be 6 to 8, w may be 0.45 to 0.35 of d.

  According to Table-3 in FIG. 15, when Δk = 5.0 mm and n is desired to be 4 to 10, w may be set to 0.63 to 0.27 of d. If n is desired to be 6 to 8, w may be 0.43 to 0.33 of d.

According to Table-4 in FIG.
When D = 48 mm, w = 17.15 mm is 0.36 of D.
When D = 38.6 mm, w = 17.15 mm is 0.44 of D.

  As described above, w is preferably in the range of 0.27 to 0.74 of D. Preferably, w is in the range of 0.33 to 0.38 of D. Furthermore, since it is better that Δk is small, w is preferably in the range of 0.48 to 0.36 of d.

From FIG. 15 to FIG. 19, when the target D = 48 mm, suitable n closest to the target is as follows.
When w = 17.15 mm and Δk = 3.0 mm, n = 8
When w = 17.15 mm and Δk = 4.0 mm, n = 8
When w = 15.00 mm and Δk = 5.0 mm, n = 8
When w = 20.00 mm and Δk = 5.0 mm, n = 6

For a target D = 36.8 mm, the preferred n that is closest to the target is:
When w = 17.15 mm and Δk = 3.0 mm, n = 6
When w = 17.15 mm and Δk = 4.0 mm, n = 6
When w = 15.00 mm and Δk = 5.0 mm, n = 6
When w = 5.00 mm and Δk = 5.0 mm, n = 17

  Note that n may be an odd number, but if it is an even number, the support structure is simplified and manufacturing is easy.

  By using the regular n-square light-emitting diode unit 10 having the preferable n thus obtained, even if the diameter of the glass bulb 21 is changed, there is no need to change the width w of each side surface of the light-emitting diode unit 10. There is an effect that the parts of the light emitting diode unit 10 can be shared.

  Further, by using a regular n-gonal light emitting diode unit 10 with a suitable n, even if the diameter D of the glass bulb 21 is changed, the distance Δk between the light emitting diode 11 and the inner surface of the glass bulb 21 can be kept constant or substantially constant. There is an effect that can. If the distance Δk between the light emitting diode 11 and the inner surface of the glass bulb 21 is set to a distance that allows the heat of the light emitting diode 11 to efficiently escape to the glass bulb 21 (a distance described in a fourth embodiment to be described later), a heat dissipation effect. High lamp can be obtained. Even when lamps having different diameters of the glass bulb 21 are manufactured, lamps having the same or substantially the same heat dissipation effect can be realized.

Embodiment 4 FIG.
(4) Fourth embodiment (FIGS. 20 to 29)
A preferred dimension ratio between the height and the diameter of the light emitting diode unit 10 and the distance between the light emitting diode 11 and the inner diameter portion of the glass bulb 21 will be described.

(Test method)
(FIGS. 20 to 23)
A light emitting diode unit 10 having a circumscribed circle diameter D of the octagonal column support member 13 and a height h of the octagonal column support member 13 is created by an aluminum support that also serves as a light emitting diode substrate as in the third embodiment. (FIGS. 22 and 21).
・ The top octagonal pyramid was omitted. Three light emitting diodes 11 are mounted on each side surface of the octagonal column support member 13 in a vertical row.
-The mounting position of the light emitting diode 11 is
A. The midpoint (b point) in the height direction of each surface,
B. The middle point (point a) of the light emitting diode 11 at the position A and the upper side of the side surface,
C. The middle point (point c) of the light emitting diode 11 at the position B and the lower side of the side surface
A total of 3 each, and 24 light emitting diode units 10 as a whole.
A lamp was created by sealing the end of the glass bulb 21 as in the first and third embodiments and mounting the screw-shaped base 23.
Two types of lamps were prepared: one that was filled and sealed with only nitrogen gas, and the other that was filled with perfluorocarbon and then sealed while blowing nitrogen gas (FIG. 22).

The distance l between the upper surface of the light emitting diode unit 10 and the inner surface of the top of the glass bulb 21 was 20 mm in all conditions.
The light emitting diode units 10 having different D: h ratios have the same volume V composed of the diameter of the circumscribed circle and the height of the prism so that they can be compared. The fixture mounting ability of the lamp is greatly influenced by the shape of the fixture, but the conditions for the lamp mounting fixture of the light emitting diode unit 10 having different D: h ratios are made uniform by making V the same. .
The distance Δd between the light emitting diode 11 and the inner diameter portion of the glass bulb 21 was changed by changing the diameter of the glass bulb 21 (FIG. 23).
-Each lamp was lit with the base, 23 parts down, with the same conditions such as power, voltage, and current. The following three temperatures on the outer surface of the glass bulb 21 were measured.
Points corresponding to the position of the upper light emitting diode 11 (B. above): point a,
Points corresponding to the position of the light emitting diode 11 in the center (A. above): point b,
Point corresponding to the position of the lower light emitting diode 11 (C. above): point c

(result)
(Preferred h / D)
Table 6 in FIG. 24: nitrogen gas sealed, no transparent heat conducting medium.
As shown in FIG. 25, the temperature decreases as h / D increases. h / D: Even at point a where the temperature is highest in a range where h / D is larger than about 1.5, the temperature is below 100 ° C. Further, the degree of temperature decrease h / D becomes smoother from about 1.5 to 2.0. This tendency is closer to the light emitting diode 11 and becomes more prominent at the point a which is the upper part of the lamp. Table 7 in FIG. 26: Nitrogen gas sealed, with transparent heat transfer medium (perfluorocarbon liquid).
As shown in FIG. 27, the temperature generally decreases as compared to Table-6. This is an effect of a transparent heat conductive medium (perfluorocarbon liquid).
As h / D increases, the temperature decreases. Temperature decrease h / D: From about 1.5 to 2.0, the temperature decreases more gently. This tendency is closer to the light emitting diode 11 and the effect of becoming more noticeable at the point a, which is the upper part of the lamp, is not as noticeable as without the transparent heat conducting medium, but the same tendency is observed.

  In addition, although temperature falls, so that h / D is large, the tendency will almost disappear from the time h / D exceeds about 3.0.

  On the other hand, when h / D: 3.5 is exceeded, the lamp must be elongated, and the dimensions are significantly different from those of conventional HID lamps used in street lamps.

  A preferable range of h / D is 1.5 to 3.5, and a more preferable range is 2.0 to 3.0.

(Preferred Δd and preferable Δk)
A preferred distance between the light emitting diode 11 and the inner surface of the glass bulb 21 will be described.
Table 8 in FIG. 28: Nitrogen gas sealed, with transparent heat transfer medium (perfluorocarbon liquid).
The radial distance Δd between the surface of the light emitting diode 11 and the inner surface of the glass bulb 21 was changed by changing the diameter of the glass bulb 21 (FIG. 23).

  As shown in FIG. 29, the temperature increases as the light emitting diode 11 moves away from the bulb inner surface.

  The temperature differs from 20 ° C. to 35 ° C. when the light emitting diode 11 is in contact with the inner surface of the bulb and when it is 20 mm away from the inner surface of the bulb.

  When the light emitting diode 11 is in contact with the inner surface of the bulb or closer to the inner surface of the bulb, the heat radiation effect is improved and the temperature is advantageous.

  When separating the light emitting diode 11 and the inner surface of the bulb, the bulb must be thickened or the light emitting diode unit 10 must be thinned. Increasing the thickness of the bulb is disadvantageous in terms of instrument mounting, and reducing the light emitting diode unit 10 is disadvantageous in terms of light distribution.

  As shown in FIG. 29, since the temperature gradient in the range where Δd is 5 mm or less is steeper than the temperature gradient in the range where 5 mm or more, Δd should be 5 mm or less and preferably 0 mm. .

  Therefore, a preferable range of Δd is 0 mm or more and 5 mm or less. Δd is preferably close to 0 mm.

  The light emitting diode 11 has a thickness X of at least 1 mm. Since Δk = Δd + X, a preferable range of Δk is 1 mm or more and 6 mm or less.

  Actually, design such as dimensional variation between the side surfaces of the prismatic support member 13, variation in the height (thickness X) of the light emitting diode 11, variation in height when the light emitting diode 11 is adhered, and dimensional variation in the glass bulb 21, etc. There are errors and manufacturing errors.

  When the design specification is such that the light emitting diode 11 contacts the inner surface of the bulb or the design specification close to the inner surface of the bulb, the variation in height between the respective light emitting diodes 11 is about 1 mm due to the dimensional variation and the like. It becomes difficult to insert into the valve 21. In order to insert the light emitting diode unit 10 into the glass bulb 21 during assembly, a minimum clearance (Δr) is required in all 360 degrees in the circumferential direction.

  If the height (thickness X) of the light emitting diode 11 is equal to or less than Δg, the clearance (Δr) can be provided in all 360 degrees in the circumferential direction without the surface of the light emitting diode 11 protruding from the circumscribed circle.

  According to FIG. 19 of Embodiment 3, when Δk is 2 mm or less, the clearance (Δr) is less than 1 mm, which is not preferable. Therefore, a more preferable range of Δk is 2 mm or more and 6 mm or less. In terms of the heat dissipation effect, Δk is preferably 2 mm or closer to 2 mm.

Embodiment 5 FIG.
(5) Fifth embodiment (FIGS. 30 to 34)
FIG. 30 is a diagram of the light-emitting diode lamp 20 of the octagonal column support member 13.
FIG. 31 is a diagram of the light-emitting diode lamp 20 of the hexagonal column support member 13.
32 to 34 show a lighting fixture on which the light emitting diode lamp 20 is mounted. Since the light distribution is not directional and the light from the light emitting diode 11 is distributed almost in all directions, not only the street light (FIG. 32) that is mainly illuminated on the lower surface but also the base down and base up. It can respond also to a lighting fixture (FIG. 33, FIG. 34).

  The features of the light-emitting diode lamps 20 of the first to fifth embodiments are roughly divided into two groups, and the features and effects are described below.

*** First feature group ***
Features 1.
A light emitting diode unit 10 in which a light emitting diode 11 is mounted on a prismatic or cylindrical support member 13 is disposed in a housing 24, and an introduction wire 17 led out from the light emitting diode unit 10 is fitted to an end of the housing 24. In the light-emitting diode lamp 20 wired to the cap 23, the light-emitting surface of the light-emitting diode unit 10 is covered with a glass cover that is a part of the casing 24, and the glass cover inner surface and the light-emitting diode unit 10 The light emitting diodes 11 mounted on the side surfaces of the prismatic or cylindrical support member 13 are close to or in contact with each other, and the height in the axial direction of the prismatic or cylindrical support member 13 of the light emitting diode unit 10 is the angle. It is longer than the circumscribed circle of the bottom surface of the columnar support member 13 or the diameter of the bottom surface of the columnar support member 13. And features.

Feature 2.
The axial height of the prismatic or cylindrical support member 13 of the light emitting diode unit 10 is 1.5 as the circumscribed circle of the bottom surface of the prismatic support member 13 or the diameter of the bottom surface of the columnar support member 13. The length is double to 3.5 times.

Feature 3.
The light emitting diode 11 mounted on the inner surface of the glass cover and the side surface of the prismatic or cylindrical support member 13 of the light emitting diode unit 10 is close to within 5 mm.

Feature 4.
The space between the light emitting surface of the light emitting diode unit 10 and the inner surface of the glass cover is filled with a transparent and insulating heat conducting medium.

Feature 5.
The transparent and insulating heat conductive medium is a silicone resin.

Feature 6
The transparent heat-conductive medium having an insulating property is a fluid having a density of 1.5 or more.

Feature 7.
The transparent, thermally conductive fluid having a density of 1.5 or more is a perfluorocarbon liquid.

Feature 8
The casing 24 including the glass cover is all made of a glass bulb. An inert gas is sealed in the glass bulb 21, and the lead-in wire 17 led out from the light emitting diode unit 10 is connected to the outside of the glass bulb 21. The end portion of the glass bulb 21 led to the above is sealed and sealed.

Feature 9
The light emitting diode unit 10 is held by a support column embedded on the sealing portion side of the glass bulb 21.

Feature 10
The light emitting diode 11 is mounted on a substrate, and the substrate is disposed on a side surface and an upper surface of the support member 13.

Feature 11.
The light emitting diode 11 is directly mounted on a side surface and an upper surface of the support member 13.

Feature 12.
A screw-type metal base 23 is attached to the sealing end of the glass bulb 21.

Feature 13.
Further, the light-emitting diode lamp 20 and a lighting device are arranged as a lighting fixture.

  The effects of the features of the light emitting diode lamp 20 are as follows.

Effect of Feature 1 The light emitting diode 11 on the light emitting surface on the side surface of the light emitting diode unit 10 is covered with or in contact with a glass cover having a larger heat capacity than that of the resin cover, and has a prismatic or cylindrical support member 13. The light emitting diode unit 10 whose axial height is longer than the circumscribed circle of the bottom surface of the prismatic support member 13 or the diameter of the bottom surface of the columnar support member 13 depends on the length direction of the lamp as in the HID lamp. A wide light distribution and light emission intensity can be obtained, and since heat can be efficiently radiated from the side surface of the light emitting diode unit 10, a light emitting diode lamp having a longer life can be provided.

Effect of Feature 2 The height in the axial direction of the prismatic or cylindrical portion of the prismatic or cylindrical support member 13 of the light emitting diode unit 10 is set to the circumscribed circle or columnar support member of the bottom surface of the prismatic support member 13. By making the length of the bottom surface 13 to be 1.5 to 3.5 times as large as the diameter of the bottom surface, a wider light distribution and emission intensity can be obtained in the length direction of the lamp as in the case of the HID lamp, and By enabling more efficient heat dissipation, a light-emitting diode lamp having a longer life can be provided.

Effect of Feature 3 When the light emitting diode 11 mounted on the inner surface of the glass cover and the side surface of the prismatic or cylindrical support member 13 of the light emitting diode unit 10 is close to each other within 10 mm, the side surface of the light emitting diode unit 10 is obtained. Heat dissipation can be performed more efficiently, and the light-emitting diode lamp 20 having a longer life can be provided.

Effect of Feature 4 By filling the space between the light emitting surface of the light emitting diode unit 10 and the inner surface of the glass cover with a transparent heat insulating medium, heat can be efficiently radiated from the side surface of the light emitting diode unit 10. The light emitting diode lamp 20 having a longer life can be provided.

Effect of Feature 5 By using a silicone resin as the transparent and insulating thermally conductive medium, it is possible to secure higher electrical insulation and ensure electrical safety to the LED and wiring. In addition, the lamp appears brighter as the color of the lamp shifts to a higher color temperature.

Effect of Feature 6 By using a heat conductive medium having a transparent insulating property as a fluid having a density of 1.5 or more, heat is applied to a low temperature portion of the glass bulb 21 or the base 23 by convection of a fluid having a high heat capacity. The light-emitting diode lamp 20 that transmits and emits and has better heat dissipation efficiency can be provided.

Effect of Feature 7 Transparent, heat-conductive fluid with a density of 1.5 or more is a perfluorocarbon liquid that ensures electrical safety to LEDs and wiring, and emits light with better heat dissipation efficiency. A diode lamp 20 can be provided. In addition, the lamp appears brighter as the color of the lamp shifts to a higher color temperature.

Effect of Feature 8 The casing 24 including the glass cover is composed of a glass bulb, and an inert gas is sealed in the glass bulb 21,

  In order to seal and seal the end of the glass bulb 21 where the lead-in wire 17 led out from the light emitting diode unit 10 is led out of the glass bulb 21, the housing 24 is bonded to the resin housing at the base of the glass bulb 21. It is not necessary to form the housing 24, the material cost can be reduced, and the housing 24 can be produced with existing HID lamp equipment. In addition, since the inert gas is sealed and hermetically sealed, the metal portion such as the lead-in wire 17 in the housing 24 can be prevented from being corroded, and has a waterproof structure and can be used outdoors. Furthermore, the heat conductive liquid medium can be filled without a special sealing structure such as packing.

Effect of Feature 9 Since the light emitting diode unit 10 is held by a support column embedded in the sealing portion side of the glass bulb 21, the light emitting diode lamp 20 having a shape close to that of a conventional HID lamp can be provided.

Effect of Feature 10 The light-emitting diode 11 is mounted on a substrate, and the substrate is disposed on the side surface and the upper surface of the support member 13, so that the light-emitting diode unit 10 having a cylindrical bulb shape can be obtained. The light-emitting diode lamp 20 having a light distribution and shape close to those can be provided.

Effect of Feature 11 Since the light emitting diode 11 is directly mounted on the side surface and the upper surface of the support member 13, the light emitting diode substrate can be omitted, and the light emitting diode lamp 20 can be produced at a lower cost.

Effect of Feature 12 A screw-type metal base 23 is attached to the sealing end of the glass bulb 21, so that the light-emitting diode lamp 20 having substantially the same shape as a conventional HID lamp can be provided.

Effect of Feature 13 The light-emitting diode lamp 20 can be easily replaced with a lighting device such as a street light and a crime prevention light using a conventional HID lamp in combination with a lighting device. It is possible to provide lighting devices such as street lamps and crime prevention lamps that have long life and are highly energy-saving.

*** Second feature group ***
Features 1.
A light emitting diode unit 10 configured by arranging the light emitting diodes 11 on a plurality of surfaces of the three-dimensional support member 13 is formed by a transparent cylindrical bulb and a base 23 for energizing the light emitting diode unit 10. In the light-emitting diode lamp 20 that is installed in the housing 24 and leads out the wiring led from the light-emitting diode unit 10 to the outside of the housing 24 through the base 23, the support member 13 has a regular polygonal bottom surface. A prismatic shape, a circumscribed circle of the bottom surface of the regular polygon is arranged concentrically with the cylindrical valve, a width w perpendicular to the axis of the polygonal column on the side surface of the polygonal column, and the cylindrical valve The distance between the point extending perpendicularly to the side surface of the polygonal column from the center of the cross section and the point intersecting the side surface of the polygonal column, and the point intersecting the inner surface of the valve of the line extending vertically The k was fixed, when the regular polygon of bottom face of the polygonal prism has a positive n-gon, with polygonal light-emitting diode unit 10 consisting of a regular polygon to adjust the number of n in order to obtain the desired valve size.

Feature 2.
A light emitting diode unit 10 configured by arranging the light emitting diodes 11 on a plurality of surfaces of the three-dimensional support member 13 is formed by a transparent cylindrical bulb and a base 23 for energizing the light emitting diode unit 10. In the light-emitting diode lamp 20 that is installed in the housing 24 and leads out the wiring led from the light-emitting diode unit 10 to the outside of the housing 24 through the base 23, the support member 13 has a regular polygonal bottom surface. It has a prismatic shape, the circumscribed circle of the bottom surface of the regular polygon is arranged concentrically with the cylindrical bulb, and the light emitting diodes 11 are arranged in a line in the polygonal axial direction on the side surface of the polygonal column. It is characterized by that.

Feature 3.
The support member 13 is three-dimensional by bending a single plate to form a plurality of surfaces.

Feature 4.
A width w in a direction perpendicular to the axis of the polygonal column on the side surface of the polygonal column is 5 mm to 20 mm.

Feature 5.
A distance Δk between a point of a line extending perpendicularly to the polygonal column side surface from the center of the cross section of the cylindrical bulb and a point intersecting the polygonal column side surface and a point intersecting the valve inner surface of the vertically extended line is: It is characterized by being 1 mm to 6 mm.

Feature 6
The plurality of surfaces of the three-dimensional support member 13 also serve as a light emitting diode element substrate, and the light emitting diodes 11 are directly mounted on the outer surface of the support member 13.

Feature 7.
The light emitting diode unit 10 is a light emitting diode unit 10 configured by attaching a light emitting diode element substrate to a plurality of surfaces of the support member 13.

Feature 8
The light emitting diode element substrate has a substrate width of about 10 mm.

Feature 9
The light emitting diode element substrate is a ribbon-like flexible substrate 12.

Feature 10
The bottom surface of the polygonal column is a polygon in which some apexes of the regular n-prism are missing.

Feature 11.
The support member 13 is made of metal.

Feature 12.
The height of the polygonal column is higher than the diameter of the circumscribed circle.

Feature 13.
The top surface of the radiator is a polygonal pyramid shape or a trapezoidal polygonal pyramid shape, and a light emitting diode 11 is disposed on each surface of the polygonal pyramid shape.

Feature 14.
In the lighting fixture, the light emitting diode lamp 20 and the lighting device are arranged.

  The effects of the features of the light emitting diode lamp 20 are as follows.

Effect of Feature 1 A light-emitting diode unit 10 configured by arranging light-emitting diodes 11 on a plurality of surfaces of a three-dimensional support member 13 includes a transparent cylindrical bulb, a base 23 for energizing the light-emitting diode unit 10, and In the light-emitting diode lamp 20 that is installed in the housing 24 and is led out of the housing 24 through the base 23, the support member 13 has a regular polygonal bottom surface. It is a polygonal column shape, the circumscribed circle of the bottom surface of the regular polygon is arranged concentrically with the cylindrical valve, the width w in the direction perpendicular to the axis of the polygonal column side surface, and the cross section of the cylindrical valve The distance Δk between the point that intersects the polygonal column side of the line that extends perpendicularly from the center to the side of the polygonal column and the point that intersects the valve inner surface of the line that extends vertically is fixed. When the shape is a regular n-gon, the light-emitting diode lamp 20 has a polygonal light-emitting diode unit 10 having a regular polygon in which the number of n is adjusted in order to obtain a desired bulb diameter. Even if the diameter of the glass bulb 21 and the brightness of the light-emitting diode lamp 20 are changed while the distance between the light-emitting diode 11 disposed on the width and the side surface and the inner surface of the glass bulb 21 is kept constant, The light-emitting diode 11 can be shared, and the heat of the light-emitting diode 11 can be efficiently released to the glass bulb 21, so that the light-emitting diode lamp 20 can be obtained at a low cost and with a high compatibility with a luminaire.

Effect of Feature 2 A light-emitting diode unit 10 configured by arranging light-emitting diodes 11 on a plurality of surfaces of a three-dimensional support member 13 includes a transparent cylindrical bulb and a base 23 for energizing the light-emitting diode unit 10. In the light emitting diode lamp 20 that is installed in the housing 24 formed by the above and leads out the wiring led from the light emitting diode unit 10 to the outside of the housing 24 through the base 23, the support member 13 has a regular polygonal bottom surface. The circumscribed circle of the bottom of the regular polygon is arranged concentrically with the cylindrical bulb, and the light emitting diodes 11 are arranged in a line in the polygonal axial direction on the side of the polygonal cylinder. Thus, the number of side surfaces of the polygonal column can be easily adjusted, and by obtaining the light-emitting diode lamp 20 having a desired bulb diameter, Even if the diameter of the glass bulb 21 and the brightness of the light-emitting diode lamp 20 are changed while keeping the distance between the light-emitting diode 11 and the inner surface of the glass bulb 21 constant, the parts can be shared and the manufacturing process can be made common. In addition, the heat of the light emitting diode 11 can be efficiently released to the glass bulb 21, and the light emitting diode lamp 20 having a low cost, high compatibility with a lighting fixture, and a long life can be obtained.

Effect of Feature 3 By forming a plurality of surfaces by bending the support member 13 as an integrated plate, a light-emitting diode lamp 20 that can achieve more common parts, a smaller number of parts, and a common manufacturing process can be obtained. I can do it.

Effect of Feature 4 By setting the width w in the direction perpendicular to the axis of the polygonal column on the side of the polygonal column to 5 mm to 20 mm, the light emitting diodes 11 are arranged in a line in the axial direction of the polygon on the side of the polygonal column. The number of side surfaces of the polygonal column can be easily adjusted, and by obtaining the light emitting diode lamp 20 having a desired bulb diameter, the width of the side surface of the polygonal column and the inner surface of the light emitting diode 11 and the glass bulb 21 disposed on the side surface are obtained. Even if the diameter of the glass bulb 21 and the brightness of the light emitting diode lamp 20 are changed while keeping the distance constant, the parts can be shared and the manufacturing process can be made common, and the heat of the light emitting diode 11 can be transferred to the glass bulb 21. The light-emitting diode lamp 20 that can be efficiently escaped, has a low cost, is highly compatible with a luminaire, and has a long life can be obtained.

Effect of Feature 5: A point extending perpendicularly to the polygonal column side surface from the center of the cross section of the cylindrical bulb intersects the polygonal column side surface, and a point intersecting the valve inner surface of the vertically extended line By making the distance Δk of 1 mm to 6 mm, the light emitting diode unit 10 can be easily inserted into the glass bulb 21 with good yield, and the heat of the light emitting diode 11 can be efficiently released to the glass bulb 21. Thus, it is possible to obtain the light-emitting diode lamp 20 that is low in cost, highly compatible with a luminaire, and has a long life.

Effect of Feature 6 A plurality of three-dimensional surfaces of the support member 13 also serve as a light-emitting diode element substrate, and the light-emitting diode substrate can be omitted by directly mounting the light-emitting diode 11 on the outer surface of the support member 13. The light emitting diode lamp 20 can be produced at low cost.

Effect of Feature 7 The light emitting diode unit 10 can use an existing general light emitting diode element substrate by attaching the light emitting diode element substrate to a plurality of surfaces of the support member 13.

Effect of Feature 8 By setting the substrate width of the light emitting diode element substrate to about 10 mm, it is possible to use a more general light emitting diode element substrate that is currently available.

Effect of Feature 9 Since the light-emitting diode element substrate is the ribbon-shaped flexible substrate 12, a more general light-emitting diode element substrate currently available can be used.

Effect of Feature 10 Since the bottom surface of the polygonal column is a polygon from which some apexes of the regular n-prism are missing, the light emitting diode unit 10 can be obtained in accordance with a special instrument shape and special light distribution. .

Effect of Feature 11 Since the support member 13 is made of metal, it can efficiently absorb and dissipate heat generated by the light emitting diode 11.

Effect of Feature 12 Since the height of the polygonal column is higher than the diameter of the circumscribed circle, the heat generated by the light emitting diode 11 can be efficiently radiated.

Effect of Feature 13 The top surface of the radiator has a polygonal pyramid shape or a trapezoidal polygonal pyramid shape, and the light emitting diodes 11 are arranged on each surface of the polygonal pyramid shape. I can do it.

Effect of Feature 14 The light-emitting diode lamp 20 can be easily replaced with a lighting device such as a street light and a crime prevention light using a conventional HID lamp in combination with a lighting device. It is possible to provide street lamps and crime prevention lights that have long life and are highly energy efficient.

  In addition, since the light distribution has no directionality and the light from the light emitting diode 11 is distributed in almost all directions, it can be used not only for a substantially horizontally-lit street lamp that is mainly irradiated on the lower surface, but also for base-down and base-up fixtures. Is also available.

Embodiment 6 FIG.
In the sixth embodiment, a light-emitting diode unit 10 in which an LED is mounted on a prismatic or cylindrical support member by using a liquid or paste-like heat conductive medium (for example, silicone) having a substantially uniform high transmittance in the visible region. A method of filling between the inner surfaces of the glass bulb 21 will be described.

FIG. 35 is a conceptual diagram showing Comparative Example 1 of the silicone injection method.
When silicone 290 is injected into a conventional HID lamp, the inner tube valve is inserted into the outer tube valve, and the outer tube valve is sealed. Therefore, similarly, the light emitting diode unit 10 was inserted into the glass bulb 21, the heat conduction medium was filled in the gap with the inner surface of the glass bulb 21, and then the glass bulb 21 was sealed. However, the heat-conducting medium was burned out by the heat at the time of sealing, resulting in a failure to adopt. For example, the silicone 290 may be lost when the temperature is 200 degrees Celsius or higher, and the silicone 290 is deteriorated because the sealing temperature is 1000 degrees Celsius or higher.

FIG. 36 is a conceptual diagram showing Comparative Example 2 of the silicone injection method.
After sealing the glass bulb 21 by the same manufacturing method as the manufacturing of the HID lamp, an opening hole is made in the glass bulb 21, a heat conduction medium is injected therefrom, and after the injection, the opening hole is heated and sealed. Thought. As a result, the purpose of filling the heat conducting medium could be achieved, but the operation is complicated, costly and not industrial.

FIG. 37 is a conceptual diagram showing a silicone injection method according to the sixth embodiment.
Originally, I came up with the idea of using a vacuum exhaust pipe for silicone injection. An injection needle was inserted into the exhaust pipe, and a heat conduction medium was injected into the glass bulb 21 through this injection needle. This makes it possible to inject the heat conduction medium efficiently and is an industrial means.

  FIG. 38 is a flowchart showing a method for manufacturing the light-emitting diode lamp 20 of the sixth embodiment, in particular, a silicone injection method. The manufacturing process of the light emitting diode lamp 20 includes an assembly process S20 and a sealing process S30.

1. Assembly process: S20
The manufacturing method of the light emitting diode lamp 20 includes an assembly step S20 in which the light emitting diode unit 10 is formed, the light emitting diode unit 10 and the flare tube 22 are mounted, and the light emitting diode unit 10 is inserted into the glass bulb 21 and sealed. Yes.

FIG. 39 is a development view of the support member 13 of the light emitting diode unit 10.
39 differs from FIG. 7 in that a U-shaped cut 218 and a semicircular cut 219 exist. The notches 218 and 219 have an effect of facilitating folding when the support member is folded and an effect of facilitating the positioning at the time of folding. The cuts 218 and 219 are U-shaped and semi-circular, but may be triangular, quadrangular, circular, or trapezoidal.

  FIG. 40 is a diagram showing the flare tube 22. The flare tube 22 is glass. The flare tube 22 penetrates the two lead wires 17. A shaft support 15 is embedded in the center of one end of the flare tube 22. An exhaust pipe 221 extends from the center of the other end of the flare pipe 22 toward the shaft column 15. The exhaust pipe 221 passes through the center of the flare pipe 22, but is bent obliquely before the shaft support 15 to form an exhaust port 222.

  First, the shaft column 15 and the coupling column 16 are connected by soldering or welding to fix the light emitting diode unit 10 and the flare tube 22. Further, the two lead wires 17 are soldered and connected to the circuit terminals of the light emitting diode unit 10 so that electrical connection is possible.

Next, the light emitting diode unit 10 is inserted into the test tube glass bulb 21, and the outer periphery of the flare tube 22 and the inner periphery of the glass bulb 21 are welded to seal the glass bulb 21.
This completes the assembly process S20.
As the shaft column 15, a thin metal column of about 0.3 to 1.5 mm is used in order to provide flexibility in a direction perpendicular to the axis of the shaft column so that the light emitting diode unit 10 can be easily inserted into the glass bulb. Since the injected silicone finally supports the light emitting diode unit 10, the shaft support may be thin.

  FIG. 41 is a diagram illustrating a state in which the assembly process S20 has been completed. The flare tube 22 and the glass bulb 21 are sealed by a sealing portion 216, and the inside of the glass bulb 21 is connected to the outside air only through the exhaust port 222 and the exhaust tube 221.

  In FIG. 41, the ventilation hole 19 exists as a through hole inside and outside the light emitting diode unit 10. Eight ventilation holes 19 are provided at the end corners of the octagonal column. The ventilation hole 19 is a hole formed by the notch 219 and the bottom sheet metal 299.

  FIG. 41 shows a stainless steel injection needle 230 of the silicone dispenser. The injection needle 230 is a substantially straight needle, but is bent so that the tip can protrude from the exhaust port 222. The tip of the injection needle 230 is bent to the extent that it can pass through the inside of the exhaust port 222. Therefore, the injection needle 230 can be inserted into the exhaust port 222.

2. Sealing step: S30
Next, the method for manufacturing the light-emitting diode lamp 20 includes a sealing step of filling the heat conducting medium from the exhaust pipe 221 and exhausting and sealing. Sealing process S30 performs the following three processes in order.

(1) Filling step: S31
An injection needle of a silicone dispenser is inserted into the exhaust pipe 221, and the silicone 290 pushed out from the silicone dispenser is injected into the glass bulb 21. At this time, the injection needle of the dispenser is inserted with the opening of the exhaust pipe 221 facing upward. That is, as the LED lamp, the base side to which the base is attached is arranged upward, and the silicone 290 is dropped from the tip of the injection needle by gravity and injected.
Simultaneously with the injection of the silicone 290, the air in the glass bulb 21 flows out from the gap between the injection needle 230 and the inner surface of the exhaust port 222 by the volume of the injected silicone 290.

  FIG. 42 is a diagram when silicone is injected. Since the silicone 290 is for heat dissipation of the light emitting diode, the silicone 290 may be filled up to a height at which the portion where the light emitting diode is disposed. Further, when the silicone 290 is injected into the light emitting diode unit 10, the silicone 290 is used in a large amount and becomes heavy, so that the silicone 290 does not enter the light emitting diode unit 10. Thus, it is preferable to seal the top (the lower part in FIGS. 41 and 42) of the light emitting diode unit 10. At a height where the silicone 290 is injected, it is preferable to eliminate a gap between the light emitting diode units 10 in the light emitting diode unit 10 so that the silicone 290 does not enter. Specifically, at the time of forming from the state of FIG. 7 to the state of FIG. 8, adhesive silicone is applied and sealed from the inside of the light emitting diode unit 10. If the color of the adhesive silicone is the same as that of the support member 13, even if the adhesive silicone appears on the surface, it does not stand out from the surface. Note that the holes formed by the cuts 218 are clogged, but the holes formed by the cuts 219 are not covered with the silicone 290 and are not used because they are used as the ventilation holes 19.

(2) Exhaust process: S32
The injection needle is pulled out and evacuated from the exhaust pipe (evacuation step). This is for defoaming (vacuum defoaming). At this time, vacuuming is not performed at once, but is performed in several steps. When the atmospheric pressure decreases, the gas in the silicone expands and floats on the top of the silicone 290, so that bubbles can be removed from the silicone 290. When returning from the vacuum state to atmospheric pressure, an inert gas such as nitrogen gas is injected (substitution step). By repeating this evacuation step and the replacement step several times, defoaming and internal inert gas replacement can be performed simultaneously. The air in the glass bulb 21 is gradually replaced with nitrogen by evacuation several times.

  In order to replace the air inside the light emitting diode unit 10 with nitrogen gas, the light emitting diode unit 10 has a ventilation hole 19 formed by a bottom sheet metal 299 and a cut 219 of the light emitting diode unit 10. By evacuation, the air inside the light emitting diode unit 10 flows out from the ventilation hole 19 and is exhausted from the exhaust port 222. Instead, when returning from the vacuum state to the atmospheric pressure, an inert gas such as nitrogen gas flows from the exhaust port 222 and nitrogen gas enters the light emitting diode unit 10 from the ventilation hole 19.

(3) Chip-off process: S33
The tip of the exhaust pipe 221 is turned off.
Thereafter, the base is attached.

A. Specification of Silicone 290 The viscosity (hardness) of the silicone 290 is desirably 100 Pa · s or less. Exceeding this makes it difficult for the dispenser to discharge, and the injected silicone 290 does not uniformly enter the gap between the housing and the glass bulb. In particular, 50 Pa · s or less is desirable, but in order to fill a narrower gap, 1 to several Pa · s is good, and 1.0 Pa · s is desirable.

B. Specifications of the exhaust pipe 221 The thickness of the exhaust pipe 221 preferably satisfies the minimum outer diameter φ4.0 mm (minimum inner diameter φ0.7 mm) and the maximum outer diameter φ8.0 mm (maximum inner diameter φ5.0 mm). If the maximum outer diameter exceeds φ8.0 mm, the flare tube 22 (stem) cannot be manufactured. If the minimum outer diameter is less than 4.0 mm, the functions of injecting silicone and discharging air cannot be performed as shown below.
The length of the exhaust pipe 221 is preferably 30 mm at the shortest and 200 mm at the longest. The shortening of the length of the exhaust pipe 221 is advantageous for silicone injection, but if it is less than 30 mm, the tip-off operation after silicone injection cannot be performed. On the other hand, if the length exceeds 200 mm, it is greatly disadvantageous for silicone injection.

C. Specification of the dispenser injection needle There are two reasons for using the dispenser injection needle.
The first is to perform silicone injection and air discharge simultaneously.
The second reason is that silicone 290 does not adhere inside the exhaust pipe 221.
If the silicone 290 adheres to the inside of the exhaust pipe 221, there is a risk that the silicone 290 may be mixed into the melted glass bulb at the time of chip-off, resulting in problems such as discoloration and cracks.

  The diameter of the dispenser injection needle depends on the diameter of the exhaust pipe 221 to be used. A thicker dispenser injection needle is more effective for silicone injection, but air cannot be discharged because the gap between the chips becomes narrow. The range of the outer diameter of the dispenser injection needle is a minimum outer diameter φ0.5 mm (minimum inner diameter φ0.2 mm) mm to a maximum outer diameter φ4.5 mm (maximum inner diameter φ4.0 mm) in relation to the exhaust pipe 221.

D. Vacuuming specifications The vacuuming conditions for degassing and replacement of inert gas such as nitrogen are such that the degree of vacuum is 21.33 kilopascals or more and less than 101.3 kilopascals. Below 21.0 kilopascals, the physical properties of silicone 290 may be impaired. The degree of vacuum is preferably 25 kilopascals or more and 50 kilopascals or less, specifically 30 kilopascals or more and 40 kilopascals or less, more preferably 33.3 kilopascals.
Moreover, it is necessary to return to atmospheric pressure at least once for the inert gas replacement. It is preferable to carry out about 10 cycles in about 20 minutes and the degree of completion of defoaming and inert gas replacement.

E. Determination method Since the trace of the heat conduction medium that has been dropped from the exhaust port 222 remains on the flare tube 22, the base column 14, the shaft column 15, the connection column 16, and the lead-in line 17, It can be visually discriminated that the product has been manufactured by adopting the silicone injection method from the exhaust pipe 221.

The manufacturing method of the light-emitting lamp of Embodiment 6 is as follows:
An assembly process for mounting the exhaust pipe 221 and sealing the glass bulb;
And a sealing step of filling and exhausting the heat conduction medium from the exhaust pipe 221 and sealing.

The sealing process
After the assembly process, a filling process for filling the heat conduction medium into the glass bulb from the exhaust pipe 221;
After the filling step, an exhaust step of evacuating the gas inside the glass bulb from the exhaust pipe 221;
And a chip-off process for sealing the exhaust pipe 221 after the exhaust process.

In the filling step, an injection needle having a needle outer diameter smaller than the inner diameter of the exhaust pipe 221 is inserted into the exhaust pipe 221 and a heat conduction medium is injected into the glass bulb through the injection needle. And the exhaust through the exhaust pipe 221 are performed simultaneously.
In the filling step, an injection needle having a needle length longer than the length of the exhaust pipe 221 is inserted into the exhaust pipe 221, and the heat conduction medium is injected into the glass bulb through the injection needle.
In the filling step, a heat conduction medium having a viscosity of 100 Pascal seconds or less is injected.

  In the sealing step, an exhaust pipe 221 having a pipe outer diameter of 4 mm to 8 mm, a pipe inner diameter smaller than the pipe outer diameter of 0.7 mm to 5.0 mm, and a pipe length of 30 mm to 200 mm is mounted. To do.

  In the filling step, an injection needle whose needle outer diameter is smaller than the inner diameter of the exhaust pipe 221 and is 0.5 mm or more and 4.5 mm or less, and whose needle inner diameter is smaller than the needle outer diameter and is 0.2 mm or more and 4.0 mm or less. Use to inject a heat transfer medium inside the glass bulb.

The evacuation step includes a evacuation step of evacuating at a vacuum degree of 21.0 kilopascals or more and 101.3 kilopascals or less.
The evacuation step includes a replacement step of repeating the evacuation step a plurality of times and replacing the gas inside the glass bulb with an inert gas during the evacuation step.

  By the manufacturing method as described above, a light emitting diode unit on which a light emitting diode is mounted, a glass cover that covers a light emitting surface of the light emitting diode unit, and a housing in which the light emitting diode unit is disposed, and the light emitting diode unit A light emitting diode lamp provided with a heat conducting medium filled in a gap between the light emitting surface and the inner surface of the glass cover can be manufactured.

The heat conducting medium is a heat conducting medium made of a transparent and insulating silicone resin, or a heat conducting medium containing the silicone resin.
Filling silicone 290 has the following effects.
(1) The heat of the light emitting diode is easily transmitted to the glass bulb 21. (2) The portion covered with silicone 290 is not oxidized.
(3) Even if an external force is applied to the glass bulb 21, it is difficult to break.
(4) Even if the glass bulb 21 is broken, the glass piece has an anti-flight effect, and the portion covered with the silicone 290 has an insulating effect.

  The silicone 290 to be injected is preferably colorless and transparent, but may be a colored silicone or a hybrid silicone of silicone 290 with another substance such as epoxy. In order to increase heat dissipation, it is preferable to use heat dissipation silicone mixed with metal particles and rich in heat dissipation.

  41 and 42 show the case where the exhaust pipe 221 is bent in the flare pipe 22, the exhaust pipe 221 may extend straight through the center of the flare pipe 22. In that case, the injection needle may be straight, the possibility that the silicone 290 adheres to the inner surface of the exhaust pipe 221 is reduced, and the injection of the silicone 290 is facilitated.

  41 and 42 show the case where the silicone 290 is injected and exhausted only through the exhaust pipe 221, an injection pipe (not shown) for injecting the silicone 290 in parallel with the exhaust pipe 221 is shown. It may be provided. When the injection pipe is provided, the exhaust pipe 221 does not adhere to the silicone 290 and the exhaust can be efficiently and reliably performed. In the case of providing an injection tube, in the case of evacuation, the exhaust tube can be evacuated and nitrogen gas can be introduced from the injection tube. A vacuum may be drawn from both the exhaust pipe 221 and the injection pipe, and nitrogen gas may be introduced from both. Finally, both the exhaust pipe 221 and the injection pipe may be chipped off.

Next, measures for lighting the light emitting diode 11 will be described with reference to FIGS. 43 and 44.
FIG. 43 shows a case where the light emitting diode 11 is covered with silicone 290 between the support member and the glass bulb 21. There is an element in the center of the outer shell of the light emitting diode 11, and the element and the bonding wire are covered with a resin 250. When the temperature rises, the silicone 290 may thermally expand and apply an expansion pressure to the surface of the resin 250, which may cause the resin 250 to be crushed and deformed. Since the glass bulb 21 and the support member have a smaller thermal expansion coefficient than that of the silicone 290, the glass bulb 21 and the support member do not expand as much as the silicone 290, and the silicone 290 has no place to go, and it is considered that pressure is applied to the relatively flexible resin 250. For this reason, there is a possibility that the bonding wire 251 inside the resin 250 is disconnected or a contact failure occurs, resulting in a lighting failure of the element.

  Therefore, as shown in FIG. 44, it is preferable to attach a thin plate-like transparent plate glass 240 to the surface of the package of the light emitting diode 11. The plate glass 240 can mitigate the expansion pressure applied to the resin 250. For example, the thickness of the resin 250 is 0.12 to 0.17 mm, but the higher the light transmittance, the better 0.12 mm. The shape of the plate glass 240 may be the same as the shape of the package surface of the light emitting diode 11. The shape of the plate glass 240 is preferably a circle or rectangle that is caught 360 degrees around the outer shell of the package of the light emitting diode 11.

Embodiment 7 FIG.
In the seventh embodiment, differences from the first to sixth embodiments will be particularly described. The feature of the seventh embodiment is the shapes of the glass bulb 21 and the light emitting diode unit 10.

  In a glass-enclosed LED lamp, it is very important to improve heat dissipation. In this Embodiment 7, the case where heat dissipation performance is improved will be described. In particular, a case will be described in which the heat dissipation performance is improved by devising the shape of the glass bulb 21 and the shape of the light emitting diode unit 10.

FIG. 45 is a perspective view of glass bulb 21 in the seventh embodiment.
FIG. 46 is a perspective view of the glass bulb 21 from the opposite direction to FIG.
FIG. 47 is an AA cross-sectional view of glass bulb 21 of FIG. 45 in the seventh embodiment.

  The glass bulb 21 has an external bulb 211 and an internal bulb 212. One end of the external valve 211 has an opening 289.

The internal diameter of the external valve 211 is larger than the external diameter of the internal valve 212, and the gap width F exists between the external valve 211 and the internal valve 212 evenly at 360 degrees.
Inner diameter of outer valve 211> Outer diameter of inner valve 212 Gap width F = ((inner diameter of outer valve 211−outer diameter of inner valve 212) / 2)
Gap width F> 0

The length L1 of the external valve 211 is larger than the length L2 of the internal valve 212.
Length L1 of external valve 211> Length L2 of internal valve 212

  A hollow portion 214 exists inside the internal valve 212. The outer periphery of one end of the internal valve 212 is continuous with the external valve 211. The central portion of one end of the internal valve 212 is open, and the atmosphere can flow into and out of the hollow portion 214. The other end of the internal valve 212 has a bottom 215, and the bottom of the internal valve 212 is a bag path. The internal valve 212 has a shape like a test tube as a whole.

  A portion where the internal bulb 212 exists has a double glass bulb structure, and a portion where the internal bulb 212 does not exist has a single glass bulb structure.

FIG. 48 is a front side view of the light emitting diode unit 10 according to the seventh embodiment.
FIG. 49 is a plan view of the light emitting diode unit 10 according to the seventh embodiment.

  The feature of the light emitting diode unit 10 in the seventh embodiment is that the top cone 18 of the support member 13 of the light emitting diode unit 10 does not exist. Further, the bottom metal plate 299 of the support member 13 of the light emitting diode unit 10 does not exist. Since neither the pyramid 18 nor the bottom metal plate 299 exists, the light emitting diode unit 10 has a cylindrical tube portion 220 having a length L3 with both ends open. All the light emitting diodes are disposed on the surface of the cylindrical portion 220. The shaft support 15 is connected only to the connection support 16.

When the length of the light emitting diode unit 10 is L4, the following relationship is established.
L1>L4>L3> L2

In FIG. 49, when the difference in radius between the inner and outer circles of the light emitting diode unit 10 is the thickness I of the light emitting diode unit 10,
Gap width F> Thickness I
It is.

When the gap width F is the narrowest,
Gap width F = thickness I
It is. In order to improve heat dissipation, it is desirable that the gap width F = thickness I.

FIG. 50 is a front side view of the light-emitting diode lamp 20 according to the seventh embodiment.
FIG. 51 is a plan view of the light-emitting diode lamp 20 according to the seventh embodiment.
FIG. 52 is a front side view of the light-emitting diode lamp 20 without the base 23 in the seventh embodiment.
FIG. 53 is a dimension diagram of the light-emitting diode lamp 20 according to the seventh embodiment.

The light-emitting diode lamp 20 in the seventh embodiment includes a light-emitting diode unit 10 and a glass bulb 21.
The light emitting diode unit 10 has a cylindrical tube portion 220 in which the light emitting diodes 11 are arranged.
The glass bulb 21 has an internal bulb 212 provided inside the cylindrical portion 220 of the light emitting diode unit 10 and an external bulb 211 provided outside the cylindrical portion 220 of the light emitting diode unit 10.

The glass bulb 21 has a cylindrical portion 220 disposed in a space between the external bulb 211 and the internal bulb 212.
The glass bulb 21 encloses the light emitting diode unit 10.
The inner bulb 212 is a bottomed cylindrical glass bulb having one end opened and the other end closed and having a hollow portion in the center. The external bulb 211 is a cylindrical glass bulb longer than the internal bulb 212.
The glass bulb 21 has an annular end 213 that seals one end of the internal bulb 212 and one end of the external bulb 211, and a sealing portion 216 that seals the other end of the external bulb 211.

FIG. 53 is a dimension diagram of the light-emitting diode lamp 20 according to the seventh embodiment. The difference from FIG. 14 is that the following dimensions related to the external valve 211 and the internal valve 212 are added.
E: outer diameter of the external valve 211,
F: gap width,
H: Radius of the inner surface of the external bulb 211 I: Thickness of the light emitting diode unit 10

  45 to 53 show the light emitting diode unit 10 having an octagonal cross section, but it may be a hexagon or another polygon. Alternatively, the light emitting diode unit 10 having a circular cross section may be used.

  Although not shown, the glass bulb 21 may be filled with silicone 290. The silicone 290 is preferably filled between the outer valve 211 and the inner valve 212. Silicone 290 is filled on both sides of the front surface and the back surface of the light emitting diode unit 10, and both heat conduction from the front surface of the light emitting diode unit 10 to the external bulb 211 and heat conduction from the back surface of the light emitting diode unit 10 to the internal bulb 212 are performed. It is because it can promote.

Further, since the silicone 290 is for heat dissipation of the light emitting diode 11, it is sufficient to fill only the double tube portion where the cylindrical portion 220 in which the light emitting diode 11 is disposed exists.
Although not shown, the hollow portion 214 of the internal bulb 212 of the light emitting diode lamp 20 may be provided with a metal heat radiating member such as an aluminum fin.

  Moreover, although not shown in figure, you may apply | coat the thermal radiation coating used as a thermal radiation member to at least one or both of the inner surface and outer surface of the said external valve 211.

Similarly, a heat dissipating paint serving as a heat dissipating member may be applied to at least one of or both the inner surface and the outer surface of the internal valve.
In order to maintain the brightness, it is desirable that the heat dissipating paint be transparent, but in order to increase heat dissipating properties, gray or light color heat dissipating paint or heat dissipating silicone mixed with metal particles may be used.

  The light-emitting diode lamp of the seventh embodiment has an effect that heat dissipation can be promoted also from the hollow portion 214 of the internal bulb 212. By improving the heat dissipation, the deterioration of the luminous flux is reduced and the life can be extended. Moreover, the recessed part is formed from the center front-end | tip, and can provide the light emitting diode lamp which was rich in the design nature and design which were not until now.

FIG. 54 is a diagram showing a method for manufacturing the light-emitting diode lamp of the seventh embodiment.
The manufacturing method of the light-emitting diode lamp of Embodiment 7 is as follows:
Step S11 for producing a glass bulb 21 having a double tube portion;
Step S12 for manufacturing the light emitting diode unit 10 including a cylindrical tube portion in which the light emitting elements are arranged;
An assembly step S2 in which the light emitting diode unit 10 is disposed in a space between the double tube portions of the glass bulb 21;
And a sealing step S3 for sealing the glass bulb 21.

  In the step S11 for manufacturing the glass bulb 21, a bottomed cylindrical internal valve 212 having one end opened and the other end closed and having a hollow portion in the center, a cylindrical external valve having both ends opened and longer than the internal valve 212 is used. 211 and sealing one end of the internal valve 212 and one end of the external valve 211.

In this step, the glass bulb 21 shown in FIGS. 45, 46, and 47 is created.
In step S12 for manufacturing the light emitting diode unit 10, the light emitting diode unit 10 is manufactured through the steps described in the first to fifth embodiments. However, the cone 18 is not created. The bottom sheet metal 299 is also not used.

In this step, the light emitting diode unit 10 shown in FIG. 48 is created.
The order of the step S11 for manufacturing the glass bulb 21 and the step S12 for manufacturing the light emitting diode unit 10 does not matter.
In the assembling step S2, the flare tube 22 is attached to the light emitting diode unit 10 having a cylindrical tube portion in which the light emitting elements are arranged. Then, the light emitting diode unit 10 is inserted from the opening 289 of the external bulb 211, and the cylindrical portion 220 is disposed in the space between the external bulb 211 and the internal bulb 212.

The sealing step S3 includes a step of injecting silicone 290 and exhausting the exhaust pipe 221 to seal the exhaust pipe 221.
For the assembly step S2 and the sealing step S3, the method of filling the glass bulb 21 with the silicone 290 described in the sixth embodiment can be applied.

Embodiment 8 FIG.
In the eighth embodiment, the case where the light-emitting diode lamp 20 described in the first to seventh embodiments is used for a street lamp will be described. Conventionally, there is a street lamp using a high-intensity discharge lamp (HID lamp) such as a mercury lamp. On the other hand, LED lamps are starting to be used as street lamps.

FIG. 55 is a diagram illustrating an example of a street lamp.
The column 310 is erected on the ground with the lower end buried in the ground. The support post 310 has a power supply arrangement part 311 for arranging a power supply in the lower part, a socket arrangement part 312 for arranging an E-shaped socket in the upper part, and accommodates two electric wires 313 in the support pillar that connect the power supply and the socket. ing. Each electric wire of the two in-post electric wires 313 is an electric wire having a cross-sectional area of 2.0 square mm or more. The two electric wires 313 in the column are electric wires that do not break down even when an alternating current of 1000 V or higher or 1500 V or higher is energized.

  The E-shaped socket 314 has two functions of attaching the E-shaped base of the light-emitting diode lamp 20 to fix the light-emitting diode lamp 20 and supplying power to the E-shaped base of the light-emitting diode lamp 20.

Either the DC power supply 315 or the AC stabilizer 316 is arranged in the power supply arrangement unit 311.
The DC power supply 315 and the AC stabilizer 316 have two input terminals that are connected to the 100V or 200V AC commercial power supply wire 317 that is drawn through the ground and drawn from the lower end of the column.
The DC power source 315 has a constant current DC circuit, and has two output terminals for outputting a DC constant current of about 20 V 700 mA, 40 V, 350 mA, 80 V, 200 mA to two electric wires from a 100 V or 200 V AC commercial power source. Have.

The AC ballast 316 has an AC booster circuit, and has two output terminals for outputting 1000 V or 1500 V AC to two electric wires from a 100 V or 200 V AC commercial power source.
The light emitting diode lamp 20 is covered with a lamp cover 318.

FIG. 56 is a comparison of specifications between a street lamp using an HID lamp and a street lamp using an LED lamp.
A street lamp is composed of a column, a lamp, a socket, a power source, an electric wire, and the like. Therefore, in order to repair the street light, it is necessary to bring a replacement lamp or a replacement power source for replacement.

  In order to change the HID lamp to the LED lamp when the street lamp using the conventional HID lamp is broken or has reached the end of its life, the LED lamp 20 described in the first to seventh embodiments is replaced with the HID lamp. An E-shaped base that is compatible with the E-shaped base may be used. Further, at the same time as replacing the HID lamp with the LED lamp, the AC ballast for the HID lamp may be replaced with a DC power source for the LED lamp.

  In the future, street lights using conventional HID lamps and street lights using LED lamps will be mixed in the streets. The specifications of the street lamp using the HID lamp and the street lamp using the LED lamp are different as shown in FIG. 56. Therefore, in the repair / replacement, the street lamp using the HID lamp and the street lamp using the LED lamp are used. It is necessary to clearly distinguish it from street lights.

  In particular, if an E-shaped base that is compatible with the E-shaped base of the HID lamp is used for the light-emitting diode lamp 20 described in the first to seventh embodiments, the light-emitting diode lamp 20 described in the first to seventh embodiments can be obtained. It can be physically replaced with the HID lamp, and the AC ballast and the DC power supply have two input terminals and two output terminals, so that they can be arranged in the power supply arrangement portion of the support column. If the size, the AC power supply and the DC power supply can be physically exchanged, which may be confused.

(1) Correct combination of lamp and power source FIG. 57 shows a case where a failure occurs due to the thickness of the electric wire even if the lamp and power source are correct. HID lamps operate with an alternating current of 1000 V or more (several thousand volts), so electric wires with a cross-sectional area of 2 square mm or more are used. However, since LED lamps operate with a direct current of 80 V or less, the cross-sectional area is 0.75. A square mm wire is used. Therefore, when an alternating current of 1000 V or more flows through an electric wire having a cross-sectional area of 0.75 square mm, there is a possibility of short circuit, disconnection, or destruction between the electric wires, which may cause an electric shock. In particular, since the pillars are often made of metal, electric shock and leakage are very dangerous. For this reason, a thick electric wire having a cross-sectional area of 2 square mm or more is used for the street lamp of the eighth embodiment. If it is a street light using a thick electric wire, it can be safely turned on with either an HID lamp or an LED lamp. That is, if the street light uses thick wires, the HID lamp and AC ballast may be replaced with an LED lamp and a DC power source, or the LED lamp and DC power source may be replaced with an HID lamp and an AC power source. It is safe and secure that you don't mind.

(2) Incorrect combination of lamp and power source FIG. 58 shows a case where a malfunction occurs due to the thickness of the electric wire due to an incorrect combination of the lamp and the power source. When the HID lamp and the DC power supply are combined, the HID lamp is not turned on and there is no danger.

  If a thick wire is used when an LED lamp and an AC ballast are combined, the LED lamp does not light up and there is no danger. In the combination of the LED lamp and the AC power source, a voltage of 1000 V or more may be applied to the LED lamp, and the electric circuit in the LED lamp may be destroyed. However, the electric power of the light-emitting diode lamp 20 described in the first to seventh embodiments is not limited. Since the circuit is insulated and sealed inside the glass bulb 21, there is no risk of electric shock, and at the worst, only the LED lamp circuit is damaged.

  On the other hand, if a thin wire is used when an LED lamp and an AC ballast are combined, when the electrical circuit in the LED lamp is short-circuited, an AC of 1000 V or more is applied to an electric wire having a cross-sectional area of 0.75 square mm. There is a risk of electric shock as it may cause a short circuit, breakage or breakage between the wires. For this purpose, a thick electric wire having a cross-sectional area of 2 square mm or more is used for the street lamp according to the eighth embodiment. A street light that uses a thick electric wire has the effect that there is no danger of an electric shock even if the lamp and power supply are combined incorrectly.

  The street lamp of the eighth embodiment is characterized by using a light emitting diode lamp 20 having an E-shaped base. Furthermore, a thick electric wire having a cross-sectional area of 2 square mm or more is used.

  The light emitting diode lamp 20 is an insulating / waterproof lamp in which a light emitting diode and an electric circuit are completely sealed and completely sealed by a glass bulb 21. Further, if the silicone 290 is filled, the lamp is a solid lamp that can prevent the glass from being broken, and the lamp covered with the silicone 290 can be insulated even if the glass is broken.

Next, the case where the existing street lamp HID lamp is replaced with an LED lamp will be described.
In order to replace all street lamps including poles with LED lamp street lights, it is not only expensive to remove existing street lamps, but also to purchase and install new LED lamp street lamps. There is also a problem of environmental burden such as the abolition of a new pole.

  In other words, while using a highly efficient light-emitting diode lamp as a light source for street lamp illumination using HID lamps such as mercury lamps that are relatively inefficient, divert equipment such as poles for existing street lamps to reduce initial capital investment. However, it is a problem to measure the renewal with the minimum processing.

  In the case of replacing the HID lamp of the existing street light in this Embodiment 8 with an LED lamp, (1) equipment to be diverted, (2) equipment to be replaced, and (3) the replacement method are as follows: is there.

(1) Equipment to be used Prop 310,
Power supply arrangement section 311,
Socket placement section 312,
Electric wire 313 in the column,
Lamp socket (E type socket) 314,
AC commercial power cable 317,
Lamp cover 318,

(2) Equipment to be replaced HID (mercury, metal halide, sodium) lamp → light emitting diode lamp 20,
AC ballast 316 → DC power supply 315,

(3) Lamp replacement method The LED lamp used in the eighth embodiment is the light-emitting diode lamp 20 described in the first to seventh embodiments. The LED lamp is fed from the E-shaped base and includes the integrated base in the light source unit. Does not include power supply for LED.

Then, the E-shaped socket of the existing street lamp is used as it is, and the E-shaped socket is provided with both functions of fixing the light emitting diode lamp and supplying power.
In addition, diverting the equipment including the existing pole, the light-emitting diode lamp power supply is installed in the space where the existing AC ballast is removed.
A direct current for LED driving is supplied to the E-type socket.

The direct current power source 315 for the light emitting diode lamp is equal to or less than the length, width, and height of the existing HID ballast (AC ballast 316).
The direct current power supply for the light emitting diode lamp has fixing screw holes, fixing holes, fixing hooks, and the like in the same or similar position as the mounting means of the existing HID ballast. After the ballast is removed, the power source for the light-emitting diode lamp can be installed in the power supply arrangement portion as it is.

  The E-shaped base and E-shaped socket of the light-emitting diode lamp 20 are connected so that the central power supply terminal side is positive and the circumferential side is ground potential.

  In this way, the existing HID lamp street lamp can be used as a light-emitting diode lamp street lamp, and the existing equipment can be diverted with minimal processing.

  As described above, the lamp replacement method according to the eighth embodiment is a method for replacing a street lamp using a high-intensity discharge lamp having an E-shaped base.

The lamp replacement method of the eighth embodiment is as follows:
A lamp replacement step of replacing a high-intensity discharge lamp having an E-shaped base with a light-emitting diode lamp having an E-shaped base;
A power supply replacement step of replacing the AC ballast that supplies power to the high-intensity discharge lamp with a DC power source that supplies power to the light-emitting diode lamp.

In the lamp replacement step, the E-shaped socket is not replaced, and a light-emitting diode lamp having an E-shaped base is attached to the E-shaped socket that is not replaced.
In the power supply exchange step, the electric wire is not exchanged, and a DC power supply is connected to the electric wire not to be exchanged.

  Replacing all street lamps, including poles, with LED lamps requires expensive costs such as removing existing street lamps and purchasing / installing new LED lamp street lamps. Environmental burdens such as the abolition of waste will occur.

According to the lamp replacement method of the eighth embodiment, it is possible to divert existing street light parts as much as possible and convert them to LED lamps with high energy consumption efficiency.
Compared to the HID lamp lighting in indoor gymnasiums, the ballast for outdoor street lamps is usually in a position where it is easy to replace the lower part of the column. LED power supply can be easily expanded or replaced. From the viewpoint of recycling, replacement is good instead of expansion.

  There are two wires to the socket connected to the lamp. Conventionally, AC current for HID lighting has flown here, but it is possible to flow DC current for LED lamp lighting using two existing wires. If there is no problem from the viewpoint of deterioration, two existing wires are used, and only the lamp is replaced with the LED lamp from a mercury lamp with relatively low efficiency.

  If the HID lamp to be replaced here is a lamp having a relatively low efficiency such as a mercury lamp, the effect of the improved replacement is improved. Replacing with relatively efficient sodium lamps and metal halide lamps can also be improved.

  As shown in FIGS. 32 to 34, the street light on which the light emitting diode lamp 20 is mounted may be substantially horizontal lighting (FIG. 32), base down (FIG. 33), or base up (FIG. 34).

  The E-type socket / E-type base may be either E26 type or E39 type. Moreover, it does not have to be the E type, it has two functions of lamp fixing and power feeding, and it is sufficient if there is physical mounting compatibility and electrical contact compatibility between the HID lamp and the LED lamp.

Embodiment 9 FIG.
FIG. 59 shows an example of the light emitting diode lamp 20 with improved heat dissipation.
The glass bulb 21 covers a part of the support member 31 of the light emitting diode unit 10 and exposes the other part of the support member 13 to the atmosphere. There is an opening in the head of the glass bulb 21, and the other part of the support member 13 of the light emitting diode unit 10 is exposed and protrudes from the opening. A portion where the light emitting diode 11 exists is covered with a glass bulb 21. Only the support member 13 is exposed and protrudes. The support member 13 is a metal such as aluminum, and heat dissipation is enhanced when the end of the support member directly contacts the atmosphere.

  The opening portion has a sealing portion 320, and the sealing portion 320 is coated (sealed) with a glass epoxy adhesive or silicone rubber in order to ensure waterproofness.

The base portion may also be coated (sealed) with a glass epoxy adhesive or silicone rubber. The coating can simplify the manufacturing process and reduce the cost.
If a heat radiation paint is applied to the inner and outer surfaces of the glass bulb 21, the heat radiation effect is further improved.
In the glass-enclosed LED lamp, the 18w class is the limit, but according to the ninth embodiment, since the heat dissipation is improved, the capacity can be increased.

FIG. 60 shows another example of the light emitting diode lamp 20 with improved heat dissipation.
A metal fin 241 is attached to the base of the glass bulb 21 near the base. The metal fin 241 has an annular shape and an inner diameter that is the same as the outer shape of the glass bulb 21, and slides into the glass bulb 21. The metal fins 241 are metal blades such as aluminum, and the heat dissipation from the glass bulb 21 is enhanced when the metal fins 241 come into direct contact with the atmosphere.

The metal fin 241 is fitted to the protrusion 242 of the glass bulb 21 in order to determine the position.
The metal fins 241 are stopped so as not to be peeled off by a glass epoxy adhesive or a silicone adhesive.
The shape and size of the metal fin 241 are set so as not to obstruct the lamp cover 318 and the like. The shape and size of the metal fins 241 may be arbitrarily selected according to the installation space. In that case, the metal fins 241 are detachable from the glass bulb 21.

  If the entire inside of the glass bulb 21 is filled with the silicone 290, or if the silicone 290 is filled up to the portion where the metal fins 241 of the glass bulb 21 are present, the heat dissipation is further enhanced.

Moreover, if a thermal radiation coating is apply | coated to the inner surface and outer surface of the glass bulb 21, the thermal radiation effect will improve.
In the glass-enclosed LED lamp, the 18w class is the limit, but according to the ninth embodiment, since the heat dissipation is improved, the capacity can be increased.

Embodiment 10 FIG.
Hereinafter, differences from the above-described embodiment will be described.

Assuming that a glass-enclosed light emitting diode lamp chipped off with nitrogen gas sealed at atmospheric pressure is turned on and the temperature rises from 25 degrees Celsius to 100 degrees Celsius, the volume of nitrogen gas due to the temperature rise of 75 degrees is About 27.5% (75 degrees × 1/273). For this reason, the internal pressure of the glass bulb 21 is about 1.3 times. As a result, the light-emitting diode 11 (hereinafter also referred to as an LED package) is pressed, which may lead to a decrease in luminous flux.
On the other hand, when a glass-enclosed light-emitting diode lamp that has been chipped off by evacuating the interior is turned on, the brightness may similarly decrease.

As a result, the following can be considered.
(1) When the internal pressure of the glass bulb is higher than the atmospheric pressure, the inside of the LED package is pressed and the brightness is lowered.
(2) When the internal pressure of the glass bulb is lower than the atmospheric pressure, the inside of the LED package is depressurized and the brightness is lowered.

  Therefore, it is desirable that the internal pressure of the glass bulb is atmospheric pressure regardless of the internal temperature of the glass bulb.

In order to maintain the internal pressure of the glass bulb at atmospheric pressure, the following examples can be considered.
Example 1. Do not seal the glass bulb.
Example 2 Set the internal pressure of the glass bulb to atmospheric pressure when lit.
Example 3 Exclude gas from inside the glass bulb.
Each example will be described below.

Example 1. <<< Example in which glass bulb is not sealed >>>
FIG. 61 is an exploded view of the light emitting diode unit 10 in which the exhaust pipe 221 is chip-cut instead of chip-off.
FIG. 62 is a conceptual cross-sectional view of the flare tube 22.
FIG. 63 is a cross-sectional view of the light emitting diode unit 10 in which the base 23 is attached to the chip-cut exhaust pipe 221.

  In the glass-sealed light-emitting diode lamp 20 described in the sixth embodiment, the glass bulb 21 is sealed and then chipped off in the same manner as in a normal lamp manufacturing process. In order to maintain, the feature is that the chip is cut.

Chip-off means heating and melting a thin glass tube (exhaust tube 221) such as a glass chip tube with a gas burner or the like to cut and seal.
Chip cutting means cutting without sealing a thin glass tube (exhaust tube 221) such as a glass chip tube.
If the chip is turned off, the glass bulb 21 is completely sealed and sealed, and has a 100% waterproof effect.
If the tip is cut, the glass bulb 21 does not have a 100% waterproof effect, but has the effect that the atmospheric pressure inside the glass bulb 21 becomes the same as the atmospheric pressure.

As shown in FIG. 61, the left end (one end) of the glass bulb 21 has a closed structure. On the other hand, a flare tube 22 is welded to the right end (the other end) of the glass bulb 21, and a screw portion 224 is formed around the right end of the glass bulb 21.
The exhaust pipe 221 passes through the flare pipe 22 from side to side. An exhaust port 222 is provided at the lower end of the exhaust pipe 221, and an opening 231 is provided at the right end of the exhaust pipe 221, so that the inside and outside of the glass bulb 21 can be ventilated only by this opening 231. Yes.

  As shown in FIG. 62, the flare tube 22 is made of a test tube or cup-shaped glass body 228 having a recessed portion 223 recessed therein. An exhaust pipe 221 is provided at the center of the recess 223, and an exhaust port 222 is provided in the middle of the lower side surface of the body portion of the flare pipe 22. There are two lead wires 17 on the left and right sides of the exhaust pipe 221, and penetrate the flare pipe 22 up and down.

  As shown in FIG. 63, the inner periphery of the base 23 has a thread groove and a thread formed by an outer thread and a thread groove. The base 23 is screwed into a spiral screw portion 224 around the upper end of the glass bulb 21. The base 23 is fixed to the upper end of the glass bulb 21 so that it cannot be reversed by soldering or caulking a part of the outer periphery of the base 23.

  The screw thread and the screw groove on the inner periphery of the base 23 coincide with the screw groove and the screw thread of the screw screw portion 224, but the base 23 and the glass bulb 21 are located between the screw thread and the screw groove. A gap 229 is formed. Air leaks through the gap 229. The gap 229 adjusts the atmospheric pressure so that the internal pressure of the glass bulb 21 is the same as the external atmospheric pressure, and is an example of the atmospheric pressure adjusting unit 233.

*** Air ventilation path ***
As shown by the arrows in FIG. 63, air leaks through the following path.

  The inner space of the glass bulb 21 ← → the exhaust port 222 of the exhaust pipe 221 ← → the exhaust pipe 221 ← → the opening 231 of the exhaust pipe 221 ← → the inner space of the base 23 ← → the gap 229 (atmospheric pressure between the base 23 and the glass bulb 21 Adjustment unit 233) ← → Outside air.

  Here, the meaning that air leaks does not mean that air is actively circulated to dissipate heat. The meaning that the air leaks here means that the air expanded by the temperature rise in the internal space of the glass bulb 21 is pressurized inside the glass bulb 21 and escapes into the outside air through the above path. Therefore, the pressure inside the glass bulb 21 is almost the same as the atmospheric pressure.

  As described above, this embodiment is characterized in that the exhaust pipe 221 is cut and the opening 231 is used as a decompression hole.

  When the temperature of the internal space of the glass bulb 21 drops, the air is decompressed inside the glass bulb 21 due to the temperature drop of the internal space of the glass bulb 21, so that outside air is sucked in the above path, and the glass bulb 21. The pressure inside is almost the same as atmospheric pressure.

*** Waterproof measures ***
In this embodiment, since the exhaust pipe 221 is not sealed, water may enter through the exhaust pipe 221, so it is desirable to take the following waterproof measures.

Waterproofing measures
As shown in FIG. 63, the opening 231 of the exhaust pipe 221 is in the internal space of the base 23. Since the opening 231 is disposed inside the base 23, rain and wind are less likely to enter, and moisture from the outside can be prevented from directly entering the opening 231.
The opening 231 of the exhaust pipe 221 is preferably in the center (substantially the center) of the internal space of the base 23. This is because the opening 231 can be kept away from the water transmitted through the inner wall of the base 23 by separating it as far as possible from the inner wall of the base 23.
Further, the opening 231 of the exhaust pipe 221 is preferably kept away from the introduction line 17. Or it is good to provide in the center of the two introduction lines 17. This is because the opening 231 can be kept away from the water transmitted through the introduction line 17.

1. Waterproof measures
As shown in FIGS. 62 and 63, the exhaust pipe 221 is chip-cut above the upper end of the glass body 228. Accordingly, the opening 231 is above the upper end of the glass body 228. The reason is to prevent water from entering the inside of the glass bulb 21 from the opening 231 at the tip of the exhaust pipe 221 when water accumulates in the recess 223. As shown in FIG. 62, even if water overflows from the recess 223 and flows out, water does not enter because the cut line is above the upper end of the glass body 228.
When the light emitting diode unit 10 is used in an upside down state with respect to FIGS. 62 and 63, the opening 231 at the tip of the exhaust pipe 221 faces downward (towards the direction of gravity). Water does not enter upward from the hole of the opening 231 at the tip.

2. Waterproof measures
When the pressure difference from the outside air is equal to or greater than a predetermined pressure difference, the air is allowed to pass through the gap 229 (atmospheric pressure adjusting unit 233). For example, the gap 229 (atmospheric pressure adjusting unit 233) is closely attached or narrowed so that the atmosphere passes when the pressure difference from the outside air is 0.1 atm or more.
When such a predetermined pressure is not applied, water does not enter from the gap 229 (atmospheric pressure adjusting unit 233), and ventilation is performed only when the internal pressure greatly changes due to a temperature difference in the glass bulb 21 caused by turning on or off. Will be.
The pressure difference from the outside air will be described in “Atmospheric pressure and brightness” below.

*** Air pressure and brightness ***
FIG. 64 shows data on the atmospheric pressure of the glass bulb 21 and the brightness of the light-emitting diode lamp after 24 hours of continuous lighting.
FIG. 65 is a graph of the data of FIG.
The horizontal axis of FIG. 65 is atmospheric pressure (unit: atmospheric pressure).
The vertical axis in FIG. 65 is the brightness (unit: lumen).

  The brightness of the light-emitting diode lamp is the highest brightness of 1850 lumens at 1 atm. Whether the atmospheric pressure increases or decreases, the brightness decreases.

  With respect to the maximum brightness at 1 atm, the decrease is less than 3%, but the decrease is abrupt when the decrease is less than 3%. If a reduction of less than 3% is allowed, the adaptive range of atmospheric pressure is 0.82 to 1.15 atmospheric pressure.

  Moreover, if the reduction of less than 1% is made an allowable range with respect to the maximum brightness at 1 atmosphere, the adaptive range of the atmosphere is 0.88 to 1.1 atmosphere.

The atmospheric pressure adjusting unit 233 is for bringing the internal pressure of the glass bulb 21 into an allowable range. If the permissible range is 0.9 or more and 1.1 or less, the atmospheric pressure adjustment unit 233 may be anything that allows the atmosphere to pass when the pressure difference from the outside air is 0.1 atmosphere or more.
Although it is desirable for the atmospheric pressure adjusting unit 233 to always make the internal pressure of the glass bulb 21 the same as the atmospheric pressure, in order to add a waterproof function, the atmospheric pressure can be passed only when pressurized. It is good.

***Production method***
The manufacturing method of the light emitting diode lamp of Example 1 is the same as the manufacturing method of Embodiment 6 except for the following points.

  That is, the light emitting diode lamp of Example 1 can be manufactured by performing chip cutting instead of chip-off in the chip-off process S33 without performing the exhaust process S32 of FIG.

  Note that it is sufficient if air can be leaked. Therefore, when the chip is cut, the circular opening 231 is heated and flattened by applying pressure from the left and right, and deformed into a linear opening 231, thereby reducing the opening area of the opening 231. It is desirable to do. That is, it is desirable to make the opening area as zero as possible in order to make it difficult for water to pass through.

*** Other example 1 of Example 1 ***
FIG. 66 and FIG. 67 are other examples of chip cutting.
66 and 67, a cap hole 226 may be provided in the cap top surface 232, and a filter 227 may be attached so as to close the cap hole 226 outside the cap top surface 232. The filter 227 is made of a breathable material having a waterproof function. Therefore, air can leak from the base hole 226, but moisture cannot pass through. The filter 227 may be attached to the inside of the base top surface 232. The base hole 226 may be provided on the side surface of the base 23 instead of the base top 232.

The cap hole 226 and the filter 227 adjust the atmospheric pressure so that the internal pressure of the glass bulb 21 becomes the same as the external atmospheric pressure, and are an example of the atmospheric pressure adjusting unit 233.
As a specific example of the filter 227, for example, a material that includes hundreds of millions of fine holes per square centimeter and has both waterproofness and air permeability can be used.

66 and 67, the gap 229 may be omitted or may be present.
In the case of the atmospheric pressure adjusting unit 233 having the filter 227, it is desirable that the internal pressure of the glass bulb 21 is always the same as the atmospheric pressure, but the filter 227 passes through the atmosphere only when the filter 227 is pressurized. You may make it make it.
Only the base hole 226 may be used as the atmospheric pressure adjusting unit 233 without the filter 227, but in this case, the base hole 226 is formed as a minute hole so that water droplets do not pass therethrough.

  Although not shown, a filter 227 may be attached to the opening 231 or the exhaust port 222 so that air can leak from the opening 231 or the exhaust port 222 but moisture cannot pass therethrough.

*** Other example 2 of Example 1 ***
As shown in FIG. 67, without using the exhaust pipe 221, the glass body 228 of the flare pipe 22 may be provided with a hole 259 connected to the outside air. The hole 259 is an example of an opening.
The hole 259 of the flare tube 22 is opened even when the flare tube 22 is welded to the glass bulb 21, and functions as a decompression hole.
The hole of the flare tube 22 is covered with the base 23 and can prevent water from entering from the outside.
A filter 227 may be attached to the hole 259 so that air can leak but moisture cannot pass therethrough.

*** Summary of Example 1 ***
As described above, the light-emitting diode lamp of Example 1 is
A light emitting diode unit 10 on which the light emitting diode 11 is mounted;
A glass bulb 21 having the light emitting diode unit 10 disposed therein;
A base 23 attached to the glass bulb 21;
The glass bulb 21 has an opening 231 through which air passes inside the base 23.

  The light-emitting diode lamp includes a thin tube such as an exhaust pipe 221 that communicates the inside of the glass bulb 21 and the inside of the base 23 and protrudes from the glass bulb 21 to the inside of the base, and the opening 231 is a narrow tube. It is formed at the tip.

  The narrow pipe is an exhaust pipe 221 and the opening 231 is formed by cutting the exhaust pipe 221 into chips.

  The base 23 has an atmospheric pressure adjusting unit 233 through which air can pass.

The glass bulb 21 has a screw portion 224 having a spiral structure,
The base 23 is screwed into a screw part 224 and has a gap 229 that becomes the atmospheric pressure adjustment part 233 between the screw part 224 and the screw part 224.

  The atmospheric pressure adjusting unit 233 allows the atmosphere to pass through when the pressure difference with the outside air is 0.1 atm or more.

  The light-emitting diode lamp is in a lighting state, and the pressure inside the glass bulb 21 is 0.9 atm or more and 1.1 atm or less.

As described above, in the light emitting diode lamp of Example 1, the light emitting diode 11 (LED package) is mounted on the substrate (LED substrate) on which the support member 13 is insulated and the light emitting diode is mounted, and the LED substrate is transparent. The light-transmitting container (glass bulb 21) is housed, one end of the light-transmitting container is closed, and the other end is an electrical input line (introduction line) for lighting the LED. 17) and a base 23 for connecting to the socket.
A pressure reducing hole (opening 231) for reducing the internal pressure of the light emitting diode lamp that has risen due to heat when the light emitting diode lamp is turned on is provided inside the base 23.

The decompression hole (opening 231) is a narrow tube protruding from the translucent container (glass bulb 21) such as an exhaust pipe 221, for example. The decompression hole (opening) may be a hole 259 provided in the flare pipe 22 separately instead of the exhaust pipe 221.
The translucent container is made of glass.
The thin tube protruding from the translucent container is made of glass.

As described above, the base 23 having the pressure reducing hole for reducing the internal pressure in the light emitting diode lamp is formed in a manner that does not seal the other end of the light transmitting container. Fixed to the container.
The base 23 is fixed to the translucent container with a screw structure in a manner that does not seal the other end of the translucent container.

  As a result, the LED package of Example 1 in which the LED package is mounted on the LED substrate by soldering and the LED substrate is accommodated in the translucent container is the same as that in the translucent container that accommodates the LED substrate. The internal pressure is at or near atmospheric pressure.

*** Comparison with conventional ventilation holes and ventilation holes ***
In an LED lamp, providing a vent hole or a vent hole in a cover or a base for heat dissipation is generally performed. If there are ventilation holes and ventilation holes for heat dissipation, the internal pressure will be the same as the atmospheric pressure.
In the first embodiment, an opening is provided in a portion of the glass bulb covered with a base attached to the glass bulb so that the glass bulb is not completely sealed, so that the inside of the glass bulb at the time of the temperature rise is increased. Air leaks from the gap between the base and the glass bulb through the opening, and the air inside is released to the outside (the reverse process is followed when the pressure is reduced due to the temperature drop).

On the other hand, water from the outside has a structure in which the opening is covered with the base 23 and the gap between the base and the glass bulb is also a minute gap, so that it does not easily enter.
As in the sixth embodiment, when the chip tube (narrow tube) is sealed and the glass bulb (translucent container) has a sealed structure, a waterproof structure can be used. If the brightness of the LED decreases due to the pressure increase or decrease in the glass bulb (translucent container) due to the rise, when the temperature rises by opening the glass bulb and opening the glass bulb to the atmosphere Is also characterized by keeping the same as the atmospheric pressure. Along with the provision of the opening in the glass bulb, it is also characterized in that it is not completely waterproof.

Example 2 << Example in which the internal pressure of the glass bulb is set to atmospheric pressure when the lamp is turned on >>>>
In the second embodiment, an example in which the internal pressure of the glass bulb 21 is reduced, the exhaust pipe 221 is chipped off to seal and seal the glass bulb 21, and the internal pressure of the glass bulb 21 is set to 1 atm when lit is on. To do.
FIG. 64 is a diagram showing a method of measuring the sealed gas pressure and the total luminous flux change.
FIG. 65 is a graph of the atmospheric pressure of the glass bulb 21 and the brightness of the light-emitting diode lamp.

First, the relationship between the enclosed pressure in the lamp and the total luminous flux of the lamp will be described.
As shown in FIG. 64, the base 23 is removed using the lamp that has been turned on for 24 hours, and the lamp is set on the exhaust stand in the base-up direction. The exhaust port 222 that was cut here was set at the exhaust position of the exhaust stand, the inside of the lamp was replaced with nitrogen, and this nitrogen pressure was varied to examine the change in the total luminous flux.
Since the total luminous flux could not be measured in the integrating sphere, it was measured as a substitute characteristic with an illuminometer fixed at a distance of 1000 mm from the central portion of the lamp. The lamp was turned on by removing the base 23 and stopping the DC power supply on the exposed lead wire (introduction wire 17) with a crocodile clip to achieve rated lighting. First, nitrogen was filled to about 0.7 atm, the lamp was turned on, and the experiment was started after about 1 hour when the characteristics were stabilized after the lamp was turned on. After stabilization, the illuminance was measured with nitrogen gas at 0.7 atm. Subsequently, the nitrogen gas was raised, the illuminance measurement was repeated after waiting for stabilization again, and the measurement was performed up to 1.3 atm.
The result is shown in FIG.
The horizontal axis in FIG. 65 is the enclosed nitrogen pressure (unit: atmospheric pressure).
The vertical axis in FIG. 66 represents the relative total luminous flux (unit:%) with the illuminance at 1.0 atm being 100%.
As is clear from FIG. 65, the total luminous flux reached a maximum at 1.0 atm, and the total luminous flux decreased both above and below. Accordingly, the total luminous flux has a peak at 1.0 atm, and FIG. 65 shows the relative value with the illuminance at this time being 100. All experiments were performed in an atmosphere of 25 degrees Celsius. Therefore, a substantially stable state was maintained except that only the nitrogen gas pressure in the lamp was changed.
The larger the total luminous flux, the better. Therefore, if the reduction of the total luminous flux is recognized to 1%, the pressure inside the lamp is in the range of 0.88 atm to 1.10 atm.
If the reduction of the total luminous flux is recognized up to 3%, the pressure inside the lamp is in the range of 0.82 atm to 1.15 atm.

In Example 2, the lamp is manufactured in an atmosphere of 25 degrees Celsius, the internal pressure of the glass bulb 21 is reduced, the exhaust pipe 221 is chipped off, and the glass bulb 21 is sealed and sealed.
When the light emitting diode lamp is turned on when the lamp is used, the temperature rises to 100 degrees Celsius. Therefore, the internal pressure may be reduced in advance at the time of manufacture so that the internal pressure at 100 degrees Celsius is 1 atmosphere. The volume of the gas due to the temperature rise of 75 degrees expands by about 27.5% (75 degrees x 1/273). For this reason, when the gas of the glass bulb 21 increases by about 27.5%, the pressure may be reduced in advance so that the pressure becomes 1 atm.

  However, in practice, it is difficult to accurately set the pressure to 1 atm due to the temperature at the time of manufacture, the temperature at the time of lighting, the accuracy of pressure reduction, and the like. Therefore, in a steady lighting state, the internal pressure of the glass bulb 21 is 0.82 to 1.15 atm, or preferably 0.88 to 1.1 atm (about 0.9 to 1.1 atm). The pressure may be reduced to

***Production method***
The manufacturing method of the light emitting diode lamp of Example 2 is the same as the manufacturing method of Embodiment 6 except for the following points.
That is, in the evacuation step S32 of FIG. 38, the evacuation step is executed after the inert gas replacement step, the tip-off step S33 is performed while evacuating, and the exhaust pipe 221 is tip-off. Two light emitting diode lamps can be manufactured. At this time, the value of the reduced pressure can be adjusted according to the time and intensity of evacuation.

*** Summary of Example 2 ***

The light emitting diode lamp of Example 2 is
A light emitting diode unit 10 on which the light emitting diode 11 is mounted;
The light emitting diode unit 10 is disposed inside and sealed with a glass bulb 21;
The atmospheric pressure inside the glass bulb 21 in the unlit state is reduced so that the atmospheric pressure inside the glass bulb 21 becomes 0.9 atmospheric pressure or higher and 1.1 atmospheric pressure or lower in the lighting state.

  That is, the internal state of the glass bulb 21 at about 25 degrees Celsius has a state in which the internal pressure of the glass bulb 21 is about 0.9 to 1.1 atmospheres at about 100 degrees Celsius. To do.

  Thus, in the light emitting diode lamp of Example 2, the internal pressure in the container at the time of extinguishing was lowered in advance, and 0.82 to 1.15 atm or 0.88 to 1.1 atm ( About 0.9 to 1.1 atm).

  As a result, the reduction in brightness can be suppressed to less than 3% or less than 1%.

Example 3 <<< Example of eliminating gas inside glass bulb 21 >>>
In the second embodiment, an embodiment in which the inside of the glass bulb 21 is filled and the gas inside the glass bulb 21 is excluded will be described.
Compared with the expansion coefficient of gas, the expansion coefficient of liquid and solid is small. Therefore, in order to exclude the gas inside the glass bulb 21, it is preferable to fill the inside of the glass bulb 21 with a liquid or a solid. A liquid and a solid may be mixed and filled.

The following can be considered as the filler for excluding gas.
1. 1. Transparent heat conductive silicone resin Transparent thermal conductive perfluorocarbon liquid

Specific examples are as follows.
1. "Fluorinert"("FLUORINERT" is a registered trademark) manufactured by Sumitomo 3M Co., Ltd. "FC-3283
2. “Fluorinert” (“FLUORINERT” is a registered trademark) FC-72 manufactured by Sumitomo 3M Limited

The characteristics of the packing are as follows.
1. It must be colorless and transparent. Or it must be translucent.
2. It must be an insulator.
3. Higher thermal conductivity is desirable than gas.
4). Lighter is desirable.

***Production method***
The manufacturing method of the light-emitting diode lamp of Example 3 is the same as the manufacturing method of Embodiment 6 except for the following points.
That is, in the filling step S31 of FIG. 38, a filling material such as silicone is filled up to just below the exhaust port 222 of the exhaust pipe 221. The evacuation step S32 may be performed. However, if the gas inside the glass bulb 21 is almost exhausted at the end of filling, the evacuation step S32 may not be performed. When the exhaust process S32 is performed, the pressure may be reduced as in the second embodiment.

  After the filling step S31 or the exhausting step S32, the chip-off step S33 is performed to chip-off the exhaust pipe 221, whereby the light-emitting diode lamp of Example 3 can be manufactured.

  Also in the light emitting diode lamp of Example 3, since the filling itself and the remaining gas thermally expand, the internal pressure in the translucent container changes. Even in that case, the internal pressure in the translucent container due to the thermal expansion of the filling itself and the remaining gas from 25 degrees Celsius to 100 degrees Celsius is 0.82 to 1.15 atmospheres during steady lighting, Or it is good to set it as 0.88-1.1 atmospheres (about 0.9-1.1 atmospheres).

*** Summary of Example 3 ***
The light-emitting diode lamp of Example 3 is
A light emitting diode unit 10 on which the light emitting diode 11 is mounted;
The light emitting diode unit 10 is disposed inside and sealed with a glass bulb 21;
In the lighting state, the glass bulb is filled with a filler having a thermal expansion coefficient smaller than that of the gas so that the pressure inside the glass bulb is 0.9 to 1.1 atm.

  That is, the internal state of the glass bulb at about 25 degrees Celsius is characterized in that the internal pressure of the glass bulb is about 0.9 to 1.1 atmospheres at about 100 degrees Celsius.

  As a result, the reduction in brightness can be suppressed to less than 3% or less than 1%.

  The atmospheric pressure inside the glass bulb can be measured by analyzing and examining the atmospheric pressure inside the glass bulb when the lamp is sold in the market.

Embodiment 11 FIG.
Hereinafter, differences from the above-described embodiment will be described.

  In this embodiment, an example in which brightness is improved by reducing solder flux will be described.

FIG. 68 is a schematic diagram in which the flux 256 moves between the silicone 290 and the light emitting diode 11.
The LED substrate 257 includes a support member 13, an insulating layer 252, a copper foil 253, a resist layer 254, solder 255, and the light emitting diode 11.
The LED substrate 257 is covered with silicone 290 and sealed inside the glass bulb 21.
Cream solder contains 10% or more of flux as a metal surface cleaning agent. If approximately 20% of the flux disappears and approximately 80% remains during soldering, the remaining flux 256 remains around the solder 255 of the LED substrate 257. This residual flux reaches a resin 250 of the light-emitting diode 11 by evaporating at a high temperature, moving the surface of the gap between the silicone 290 and the light-emitting diode 11, or penetrating into the silicone 290, Further, the resin 25 may enter and reach the surface of the light emitting portion 258.

  That is, the glass-enclosed light-emitting diode lamp 20 has a hermetically sealed structure for sealing the glass bulb 21, and the solder flux (organic matter) inside the light-emitting diode lamp 20 is used in the package of the light-emitting diode 11 (LED package). It may get inside and cause a decrease in brightness.

This phenomenon is not observed in a normal unsealed light emitting diode unit. This phenomenon is likely to occur when the following conditions overlap.
1. Sealed state (sealed state with glass bulb sealed)
2. High temperature (high temperature load)
3. Covered state (LED package covered with silicone)

  The reason for the decrease in brightness is not because the solder flux penetrates into the inside of the LED package and carbonizes on the surface of the light emitting portion 258 of the LED chip, and the surface of the light emitting portion 258 of the LED chip is blackened, leading to a decrease in luminous flux. It is thought.

  Therefore, after creating the LED substrate on which the LED package is mounted on the substrate formed using the support member 13 as a base, the LED substrate is cleaned and sealed in the glass bulb 21 without any flux residue. This phenomenon can be eliminated.

FIG. 69 is a graph showing the relationship between the flux amount and the brightness of the light-emitting diode lamp.
The horizontal axis of FIG. 69 is a flux amount (unit: milligram).
The vertical axis in FIG. 69 is the brightness (unit: lumen).
The square line graph of FIG. 69 is a case where there is no silicone filler (when it is not in a coated state).
The triangular line graph in FIG. 69 is the case where there is a silicone filler (in the coated state).

For example, the specific specifications are as follows.
1. Solder amount used for LED substrate to which 32 LEDs (64 terminals) are soldered: 0.45 g
2. Cream solder flux content: 13%
3. LED board surface area of LED board: 169 square cm

Assuming that 20% flux disappears and 80% remains during soldering, the flux amount per square centimeter (unit area) can be calculated as follows.
Flux amount per unit area = 0.45g * 13% * 80% / 169 square cm
= 0.0002769 g
= 0.2769 mg
Therefore, about 0.28 mg of flux per 1 cm 2 may remain.

  From the above, when a flux residue of up to about 0.28 mg per square centimeter remains, the degree of adverse effect on brightness was measured. In the experiment, the degree of cleaning of the LED substrate 257 was changed, and a plurality of lamps were actually created using samples each of which adjusted the amount of flux residue, and an accelerated deterioration test was performed at an ambient temperature of 60 degrees Celsius. After lighting for 1,000 hours, their total luminous flux values were measured and compared. FIG. 69 shows the result.

The brightness of the light-emitting diode lamp can maintain the highest brightness of 1850 lumens as the flux decreases. As the flux increases, the brightness decreases.
The brightness is reduced when the silicone filler is present compared to when the silicone filler is absent.
In the absence of silicone filler, 1850 lumens can be maintained if the flux per unit area is 0.16 mg or less.
When there is a silicone filler, 1850 lumens can be maintained if the amount of flux per unit area is 0.11 mg or less.

  When the LED is covered with the filler, the residual flux of the LED substrate 257 acts on the light emitting diode 11 through the gap between the light emitting diode 11 and the filler or in the filler. The residual amount needs to be smaller.

***Production method***
The light-emitting diode lamp of this embodiment is a light-emitting diode lamp in which an LED package is mounted on an LED substrate 257 by soldering, and the LED substrate 257 is housed in a translucent container. The metal surface cleaning agent attached to 257 can be manufactured by cleaning the LED package after soldering and then storing the LED substrate 257 in the translucent container.

  The light-emitting diode lamp of this embodiment is a light-emitting diode lamp in which an LED package is mounted on an LED substrate 257 by soldering, and the LED substrate 257 is housed in a translucent container (glass bulb 21). The adhesion amount of the metal surface cleaning agent to be used is 0.16 mg or less per square centimeter of the LED substrate by cleaning the substrate.

That is, the light-emitting diode lamp of this embodiment is
A light emitting diode unit 10 having an LED substrate 257 soldered with a light emitting diode (LED) using a metal surface cleaner (flux 256);
The light emitting diode unit 10 is disposed inside and sealed with a glass bulb 21;
The adhesion amount of the metal surface cleaner (flux 256) on the LED substrate 257 is set to 0.16 mg or less per square centimeter of the LED substrate.

  In addition, when the space between the LED substrate and the container containing the LED substrate is filled with a filler such as silicone, the amount of the metal surface cleaning agent used during soldering is reduced to 1 square of the LED substrate by cleaning the substrate. It is characterized by being 0.11 mg or less per cm.

The metal surface cleaner is a flux, and the translucent container is made of glass.
The glass container has a sealed structure.

*** Difference from conventional substrate cleaning ***
Conventionally, cleaning of an electronic board on which electronic components are soldered has been performed. However, even when the conventional cleaning is performed, the brightness is reduced. Then, when the cause of the decrease in brightness was investigated, it was found that the cause was flux, and this embodiment starts from the point that the decrease in brightness cannot be solved by normal cleaning.
As mentioned above, 1. 1. Sealed state by sealing; 2. High temperature state of about 100 degrees Celsius; We have determined that the environment where the three states of the silicone coating state overlap, that is, as the three states overlap, causes the flux to decrease in brightness and occurs in an environment different from the environment where the normal electronic substrate is used. It was.
In addition, this embodiment is specified so that the allowable range of the flux is very small as compared with the allowable range of the conventional flux, and is completely different from the allowable range of the conventional flux.

  The amount of the metal surface cleaning agent (flux) remaining on the substrate can be measured by analyzing and inspecting the LED substrate at the time of lamp sales in the market.

Embodiment 12 FIG.
Hereinafter, differences from the above-described embodiment will be described.

  In this embodiment, the bending of the substrate and the arrangement of the LEDs will be described.

  When a metal substrate is bent, the surface created by bending (for example, the cross section of the side surface when the substrate is bent to create an octagon) is warped with the opposite direction to the bending direction as the apex, thereby mounting the LED Since the substrate surface is not flat, the LEDs are easily peeled off from the substrate.

  In particular, when the LED is mounted so that the line connecting the terminals of the LED and the bent line are perpendicular to each other, the floating due to the warpage of the substrate becomes large, so that the LED is easily peeled off.

As shown in FIG. 70, when the LED is mounted such that the fold line of the support member 13 and the line connecting the two electrode terminals of the LED are orthogonal, the direction in which the support member 13 extends (the direction orthogonal to the fold line). The two electrode terminals are soldered to each other, and stress is easily applied to the LED package or the soldered portion. For this reason, possibility that a crack will arise in LED package and solder becomes high.
Therefore, as shown in FIG. 71, the LED is mounted so that the line connecting the terminals of the LED and the fold line are horizontal.

  In the glass-enclosed light-emitting diode lamp described in the above-described embodiment, the aluminum support member 13 is used. However, a wire connecting the bent line of the support member 13 and the two electrode terminals of the LED (anode and The line connecting the cathode) should be parallel.

  As shown in FIG. 71, the influence of the stress applied to the LED package can be reduced by making the bend line of the support member 13 parallel to the line connecting the two electrode terminals of the LED.

  Further, in order to reduce the warpage of the substrate at the time of folding, as shown in FIG. 72, a linear notch is provided on the back side of the folding line along the folding line. Alternatively, as shown in FIG. 73, a plurality of continuous recesses are provided on the back side of the folding line.

***Production method***
The light emitting diode unit according to this embodiment is manufactured by arranging an LED having two electrode terminals on a metal substrate provided with an insulating layer, and then bending the metal substrate. The LED is mounted in advance so that the line connecting the terminals and the bent line of the bent substrate are parallel to each other.
The bent portion of the bent substrate is previously provided with a notch or a recess in the bent portion on the back side of the portion protruding by bending.

*** Summary ***
As described above, the light-emitting diode unit according to this embodiment includes the insulating layer 252 and the light-emitting diode in which the light-emitting diode 11 having two electrode terminals is disposed on a three-dimensionally bent metal substrate. In the unit 10, the LED is mounted on the light emitting diode 11 so that the line connecting the terminals and the bent line of the bent substrate are parallel to each other.

The bend line of the bent substrate is characterized in that a linear notch is provided on the bend line on the back side of the portion protruding by the bend.
The bent line of the bent substrate is characterized in that a continuous recess is provided on the bent line on the back side of the portion protruding by bending.

Note that the above embodiments may be combined.
In each of the above embodiments, the glass bulb 21 has been described as the translucent container. However, a resin or plastic such as polycarbonate may be used.

  Hereinafter, the characteristic points of the respective embodiments described above will be described.

The light emitting diode lamp according to the above-described embodiment includes a light emitting diode unit in which a light emitting diode is mounted on a side surface of a prismatic support member, and
The light emitting diode unit is disposed inside, and includes a cylindrical bulb having a predetermined bulb diameter,
A width w of one side surface of the support member is fixed to a predetermined width;
A distance Δk between the center of one side surface of the support member and the inner surface of the valve is fixed to a predetermined distance;
When the prismatic support member has a regular n-square cross section, n is a value that allows the light emitting diode unit to be disposed inside a cylindrical bulb having the predetermined bulb diameter. It is a value obtained from a diameter, a predetermined width, and a predetermined distance.

Light emitting diodes are arranged in one row in the axial direction of the support member on each side surface of the support member,
The circumscribed circle of the regular polygon is arranged concentrically with the cylindrical valve,
The n is a maximum value that allows the light emitting diode unit to be disposed inside a cylindrical bulb having the predetermined bulb diameter.

  The support member is three-dimensionally formed into a prismatic shape by bending a single plate to form a plurality of side surfaces.

  The width w of one side surface of the support member is 5 mm to 20 mm.

  The distance Δk is 1 mm to 6 mm.

  The side surface of the support member also serves as a light emitting diode element substrate, and the light emitting diode is directly mounted on the outer surface of the support member.

  The light emitting diode unit is a light emitting diode unit configured by attaching a light emitting diode element substrate to a plurality of surfaces of the support member.

  The light emitting diode element substrate has a substrate width of about 10 mm.

  The light emitting diode element substrate is a ribbon-like flexible substrate.

  The bottom surface of the polygonal column is a polygon in which some apexes of the regular n-sided prism are missing.

  The support member 13 is made of metal.

  The height of the support member is larger than a diameter of a circumscribed circle of the support member.

  The shape of the top of the support member is a polygonal pyramid shape or a trapezoidal polygonal pyramid shape, and a light emitting diode is arranged on each surface of the polygonal pyramid shape.

  The lighting fixture according to the embodiment described above includes the light emitting diode lamp and a lighting device.

The light-emitting diode lamp according to the above-described embodiment includes a light-emitting diode unit on which the light-emitting diode is mounted,
A housing made of glass that covers the light emitting surface of the light emitting diode unit, and a housing in which the light emitting diode unit is disposed,
And a heat conductive medium filled in a gap between the light emitting surface of the light emitting diode unit and the inner surface of the glass cover.

  The heat conduction medium is a heat conduction medium made of a transparent and insulating silicone resin, or a heat conduction medium containing the silicone resin.

The light emitting lamp manufacturing method according to the above-described embodiment is a light emitting lamp manufacturing method in which a heat conducting medium is sealed inside a glass bulb.
An assembly process for welding a flare pipe with an exhaust pipe to a glass bulb;
After the assembly process, a filling process for filling the heat conduction medium from the exhaust pipe into the glass bulb;
After the filling process, an exhaust process of evacuating the gas inside the glass bulb from the exhaust pipe,
And a chip-off process for sealing the exhaust pipe after the exhaust process.

The filling step is
Insert an injection needle having a needle outer diameter smaller than the inner diameter of the exhaust pipe into the exhaust pipe, inject the heat conduction medium into the glass bulb through the injection needle, inject the heat conduction medium with the injection needle, and Exhaust is performed at the same time.

The filling step is
An injection needle having a needle length longer than the length of the exhaust pipe is inserted into the exhaust pipe, and the heat conduction medium is injected into the glass bulb through the injection needle.

The filling step is
A heat conducting medium having a viscosity of 100 Pascal seconds or less is injected.

The sealing step is
An exhaust pipe having a pipe outer diameter of 4 mm to 8 mm, a pipe inner diameter smaller than the pipe outer diameter of 0.7 mm to 5.0 mm, and a pipe length of 30 mm to 200 mm is mounted.

The filling step is
Inside the glass bulb using an injection needle whose needle outer diameter is smaller than the inner diameter of the exhaust pipe and is 0.5 mm or more and 4.5 mm or less, and whose needle inner diameter is smaller than the needle outer diameter and is 0.2 mm or more and 4.0 mm or less. A heat conducting medium is injected into the liquid crystal.

The exhaust process includes
It is characterized by having a evacuation step of evacuating at a vacuum degree of 30.3 kilopascals or more and 101.3 kilopascals or less.

The exhaust process further includes a replacement process of replacing the gas inside the glass bulb with an inert gas,
The evacuation process and the replacement process are repeated a plurality of times.

The light-emitting diode lamp according to the above-described embodiment includes a light-emitting diode unit including a cylindrical tube portion in which a light-emitting diode is disposed,
A glass bulb having an internal bulb provided inside the cylindrical portion of the light emitting diode unit and an external bulb provided outside the cylindrical portion of the light emitting diode unit is provided.

The glass bulb is arranged in a space between the external bulb and the internal bulb, the cylindrical portion,
The glass bulb encloses the light emitting diode unit.

The internal bulb is a bottomed cylindrical glass bulb having one end open and the other end closed and having a hollow portion in the center,
The external bulb is a cylindrical glass bulb longer than the internal bulb,
The glass bulb includes an annular end portion that seals one end of the internal bulb and one end of the external bulb, and a sealing portion that seals the other end of the external bulb.

The light emitting diode lamp further includes:
The hollow portion of the internal valve is provided with a heat radiating member.

The light emitting diode lamp further includes:
A heat radiating member is provided on at least one of the inner surface and the outer surface of the external valve.

The method of manufacturing the light emitting diode lamp according to the above-described embodiment includes a step of manufacturing a glass bulb having a double tube portion,
A step of manufacturing a light emitting diode unit including a cylindrical tube portion in which a light emitting element is disposed;
Arranging a light emitting element in a space between the double tube portions of the glass bulb;
And a step of sealing the glass bulb.

The step of manufacturing the glass bulb includes inserting a bottomed cylindrical internal valve having one end open and the other end closed and having a hollow portion in the center into a cylindrical external valve open at both ends and longer than the internal valve. A step of sealing one end of the internal valve and one end of the external valve;
The step of arranging the light emitting element includes inserting a light emitting diode unit having a cylindrical tube portion in which the light emitting element is arranged from the other end of the external bulb, and inserting the cylindrical portion between the external bulb and the internal bulb. Having a step of arranging in
The step of sealing the glass bulb includes a step of sealing the other end of the external bulb.

The street lamp according to the embodiment described above includes a light-emitting diode lamp having an E-shaped base,
An E-shaped socket for attaching an E-shaped base of a light-emitting diode lamp to fix the light-emitting diode lamp, and supplying power to the E-shaped base of the light-emitting diode lamp;
Two electric wires in the column connected to the E-shaped socket;
A direct current power source for supplying direct current to the electric wires in the two columns;
The power supply arrangement part which arrange | positions DC power supply is provided in the lower part, The socket arrangement | positioning part which arrange | positions an E-shaped socket is provided in the upper part, The support | pillar which accommodated the electric wire in a support | pillar inside was provided.

  Each of the electric wires in the columns of the two electric wires in the column is an electric wire having a cross-sectional area of 2.0 square mm or more.

  The two in-post electric wires are electric wires that do not break down even when an alternating current of 1000 V or more is applied.

  The light emitting diode lamp is an insulating lamp having an electric circuit sealed by a glass bulb.

The lamp replacement method according to the above-described embodiment is a lamp replacement method for a street lamp that uses a high-intensity discharge lamp having an E-shaped base.
A lamp replacement step of replacing a high-intensity discharge lamp having an E-shaped base with a light-emitting diode lamp having an E-shaped base;
And a power supply replacing step of replacing the AC ballast for supplying power to the high-intensity discharge lamp with a DC power source for supplying power to the light emitting diode lamp.

In the lamp replacement step, the E-shaped socket is not replaced, and a light-emitting diode lamp having an E-shaped base is attached to the E-shaped socket that is not replaced.
The power supply replacement step is characterized in that a direct current power source is connected to the electric wires in the pillars not to be exchanged without changing the electric wires in the pillars.

The light-emitting diode lamp according to the embodiment described above includes a light-emitting diode unit having a light-emitting diode and a support member on which the light-emitting diode is mounted,
A glass bulb that covers a part of the support member of the light emitting diode unit and exposes the other part of the support member to the atmosphere from the opening;
The opening of the glass bulb and the supporting member are provided with a sealing part under sealing.

The light emitting diode lamp according to the embodiment described above includes a light emitting diode unit having a light emitting diode,
A glass bulb covering the light emitting diode unit;
And a metal fin attached around the glass bulb.

The light-emitting diode lamp according to the above-described embodiment includes a light-emitting diode unit on which the light-emitting diode is mounted,
A glass bulb having the light emitting diode unit disposed therein;
A base attached to the glass bulb,
The glass bulb has an opening through which air is passed inside the base.

  The light emitting diode lamp includes a thin tube that communicates the inside of the glass bulb and the inside of the base and protrudes from the glass bulb to the inside of the base, and the opening is formed at the tip of the thin tube. .

  The narrow tube is an exhaust tube, and the opening is formed by cutting the exhaust tube.

  The base has an atmospheric pressure adjustment section through which air can pass.

The glass bulb has a screw portion with a helical structure,
The base is screwed into a screw part, and has a gap serving as the atmospheric pressure adjustment part between the screw part.

  The atmospheric pressure adjusting unit allows the atmosphere to pass through when the pressure difference from the outside air is 0.1 atm or more.

  The light emitting diode lamp is in a lighting state, and an atmospheric pressure inside the glass bulb is 0.9 atm or more and 1.1 atm or less.

The light-emitting diode lamp according to the above-described embodiment includes a light-emitting diode unit on which the light-emitting diode is mounted,
A glass bulb sealed with the light emitting diode unit disposed therein;
The pressure inside the glass bulb in the unlit state is reduced so that the pressure inside the glass bulb becomes 0.9 atm or more and 1.1 atm or less in the on state.

The light-emitting diode lamp according to the above-described embodiment includes a light-emitting diode unit on which the light-emitting diode is mounted,
A glass bulb sealed with the light emitting diode unit disposed therein;
In the lighting state, the glass bulb is filled with a filler having a thermal expansion coefficient smaller than that of the gas so that the pressure inside the glass bulb is 0.9 to 1.1 atm.

  The state inside the glass bulb at about 25 degrees Celsius is characterized in that the pressure inside the glass bulb is about 0.9 to 1.1 atmospheres at about 100 degrees Celsius.

The light emitting diode lamp according to the above-described embodiment includes a light emitting diode unit having an LED substrate to which a light emitting diode (LED) is soldered using a metal surface cleaner,
A glass bulb sealed with the light emitting diode unit disposed therein;
The adhesion amount of the metal surface cleaning agent on the LED substrate is set to 0.16 mg or less per square centimeter of the LED substrate.

The light-emitting diode lamp
Comprising a filler filled in the gap between the light emitting surface of the light emitting diode unit and the inner surface of the glass bulb;
The adhesion amount of the metal surface cleaning agent on the LED substrate is set to 0.11 mg or less per square centimeter of the LED substrate.

  DESCRIPTION OF SYMBOLS 10 Light emitting diode unit, 11 Light emitting diode, 12 Flexible board, 13 Support member, 14 Base support | pillar, 15 Axis support | pillar, 16 Connection support | pillar, 17 Lead wire, 18 Cone, 20 Light emitting diode lamp, 21 Glass bulb, 22 Flare tube, 23 base, 24 housing, 211 external valve, 212 internal valve, 213 annular end, 214 hollow part, 216, 320 sealing part, 218, 219 cut, 220 cylindrical part, 221 exhaust pipe, 222 exhaust port, 223 concave part, 224 Screw part, 225 gap, 226 mouth hole, 227 filter, 228 glass body, 229 gap, 230 injection needle, 231 opening, 232 top face, 233 pressure adjusting part, 240 plate glass, 241 metal fin, 242 protrusion, 250 Resin, 251 Bonde Wire, 252 insulating layer, 253 copper foil, 254 resist layer, 255 solder, 256 flux, 257 LED substrate, 258 light emitting part, 259 hole, 289 opening, 290 silicone, 299 bottom sheet metal, 310 support, 311 power supply arrangement part, 312 Socket arrangement part, 313 Electric wire in post, 314 E-type socket, 315 DC power supply, 316 AC ballast, 317 AC commercial power supply cable, 318 Lamp cover.

Claims (12)

A light emitting diode unit mounted with a light emitting diode;
A glass bulb having the light emitting diode unit disposed therein;
A base attached to the glass bulb,
The glass bulb has an opening through which air is passed inside a base.   The light emitting diode lamp includes a thin tube that communicates the inside of the glass bulb and the inside of the base and protrudes from the glass bulb to the inside of the base, and the opening is formed at the tip of the thin tube. The light emitting diode lamp according to claim 1.   3. The light emitting diode lamp according to claim 2, wherein the narrow tube is an exhaust tube, and the opening is formed by chip-cutting the exhaust tube.   The light emitting diode lamp according to any one of claims 1 to 3, wherein the base includes an atmospheric pressure adjusting unit through which air can pass. The glass bulb has a screw portion with a helical structure,
The light emitting diode lamp according to claim 4, wherein the base is screwed into a screw part and has a gap serving as the atmospheric pressure adjusting part between the screw part and the screw part.   6. The light-emitting diode lamp according to claim 4, wherein the atmospheric pressure adjusting unit allows the atmosphere to pass through when the pressure difference with the outside air is 0.1 atm or more.   The light emitting diode lamp according to any one of claims 1 to 5, wherein the light emitting diode lamp is in a lighting state, and the pressure inside the glass bulb is 0.9 atm or more and 1.1 atm or less. A light emitting diode unit mounted with a light emitting diode;
A glass bulb sealed with the light emitting diode unit disposed therein;
A light-emitting diode lamp, wherein the pressure inside the glass bulb in the unlit state is reduced so that the pressure inside the glass bulb becomes 0.9 atm or more and 1.1 atm or less in the on state. A light emitting diode unit mounted with a light emitting diode;
A glass bulb sealed with the light emitting diode unit disposed therein;
A light emitting diode characterized by filling a glass bulb with a filler having a coefficient of thermal expansion smaller than that of a gas so that the pressure inside the glass bulb is 0.9 to 1.1 atm in a lighting state. lamp.   The state inside the glass bulb at about 25 degrees Celsius is such that the atmospheric pressure inside the glass bulb is about 0.9 to 1.1 atmospheres at about 100 degrees Celsius. 9. The light emitting diode lamp according to 9. A light emitting diode unit having an LED substrate to which a light emitting diode (LED) is soldered using a metal surface cleaner;
A glass bulb sealed with the light emitting diode unit disposed therein;
A light emitting diode lamp characterized in that an adhesion amount of the metal surface cleaning agent on the LED substrate is set to 0.16 mg or less per square centimeter of the LED substrate. The light-emitting diode lamp
Comprising a filler filled in the gap between the light emitting surface of the light emitting diode unit and the inner surface of the glass bulb;
12. The light emitting diode lamp according to claim 11, wherein the amount of the metal surface cleaning agent attached to the LED substrate is 0.11 mg or less per square centimeter of the LED substrate.

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