JP2019046714A - Lamp unit and vehicular lamp - Google Patents

Abstract

To provide a light unit capable of enhancing degree of freedom for component layout, and suppressing influence on a resin-based member due to condensation of sunlight, and a vehicular lamp.SOLUTION: A lamp unit is configured such that on a surface of a mounting board (41), a light-emitting element (43c) and connector parts (44a, 44b) are mounted, a reflector (30) is arranged near the light-emitting element (43c), and the light-emitting element (43c) is arranged near a reward focal point of a projection lens. In the reflector (30), a connector cover part (307) is formed, wherein the connector cover part extends to a position of overlapping with the connector parts (44a, 44b) in a surface view of the mounting board (41), and covers at least a part of the connector parts (44a, 44b).SELECTED DRAWING: Figure 15

Description

  The present invention relates to a lamp unit and a vehicular lamp, and more particularly to a lamp unit and a vehicular lamp in which a plurality of light emitting diodes are provided on the surface of an element mounting substrate.

  In general, a vehicular lamp can be switched between a low beam and a high beam. The low beam illuminates the neighborhood with a predetermined illuminance, and the light distribution regulation is determined so as not to give glare to the oncoming vehicle and the preceding vehicle, and is mainly used when traveling in an urban area. On the other hand, the high beam illuminates a wide area in the front and a distant area with a relatively high illuminance, and is mainly used when traveling at high speed on a road with few oncoming vehicles and preceding vehicles. Therefore, although the high beam is more visible to the driver than the low beam, there is a problem that glare is given to the driver or pedestrian of the vehicle existing in front of the vehicle.

  In recent years, an ADB (Adaptive Driving Beam) technique has been proposed that dynamically and adaptively controls a high-beam light distribution pattern based on the surroundings of a vehicle. ADB technology reduces glare given to a vehicle or a pedestrian by detecting the presence of a preceding vehicle, an oncoming vehicle or a pedestrian in front of the vehicle, and dimming a region corresponding to the vehicle or the pedestrian. is there. In such ADB technology, there has been proposed one in which light emitting elements such as a plurality of LEDs (Light Emitting Diodes) are mounted in a row on a substrate, and the LEDs in a region corresponding to a vehicle or a pedestrian are turned off ( For example, Patent Document 1).

  Further, in recent years, there has been proposed a technique in which a large number of light emitting elements are two-dimensionally arranged on a substrate and a high beam light distribution pattern is controlled in more detail by selectively switching off and on the light emitting elements. In a vehicular lamp that performs such a two-dimensional arrangement of light-emitting elements, it is necessary to increase the mounting density of the light-emitting elements and improve the mounting position accuracy in order to irradiate a two-dimensional light distribution pattern satisfactorily. is there. When an LED is used as a light emitting element, a surface mount type package is used, and a structure in which individual LEDs are positioned and mounted on lands formed on a substrate is mounted with high density.

  FIG. 18 is a schematic plan view showing the light source module 1 using the conventionally proposed ADB technique. As shown in FIG. 18, a conventional light source module 1 has a connector 3 mounted on a substrate 2 for electrical connection to the outside, and a wiring pattern 4 is formed on the surface of the substrate 2 extending from the connector 3. A plurality of LEDs 5 are mounted on the wiring pattern 4. In the light source module 1, the vicinity of the LED 5 mounting portion of the wiring pattern 4 is formed wide and used as a heat radiation pattern for radiating heat generated by the light emission of the LED 5 satisfactorily.

  In the conventional vehicular lamp, the light source module 1 and the projection lens shown in FIG. 18 are combined, and the LED 5 is arranged in the vicinity of the rear focal point of the projection lens to constitute a lamp unit. In such a conventional vehicular lamp, the substrate 2 is arranged in the vertical direction and the optical axis of the projection lens is used in the horizontal direction.

JP2015-16773 A

  As described above, in the light source module 1 of the prior art shown in FIG. 18, the LED 5 is located in the vicinity of the rear focal point of the projection lens, and the light emitted from the LED 5 passes through the projection lens and is projected to the front of the vehicle. Light is irradiated with a desired light distribution. Since the light source module 1 is thus arranged on the optical axis of the projection lens, when external light enters the vehicle lamp from the front of the vehicle, the external light is transmitted through the projection lens and collected near the LED 5. It will be lighted. In particular, in the early morning when the solar altitude is low and the incident angle is almost horizontal or immediately before sunset, there is a possibility that such outside light is condensed inside the lamp unit.

  In particular, when the sun is positioned slightly above the optical axis of the projection lens, there is a high possibility that light is condensed below the optical axis on the substrate 2, and the sun is formed on a member made of a material such as resin. When the light is condensed, there is a problem in that the member deteriorates. By disposing a resin member such as the connector 3 above the optical axis of the projection lens, deterioration due to sunlight collection can be avoided, but the degree of freedom in component layout is reduced and the connection to the inside of the connector 3 is reduced. The problem of water droplet intrusion occurs.

  SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a lamp unit and a vehicle lamp capable of improving the degree of freedom of component layout and suppressing the influence of sunlight concentration on a member made of resin. To do.

  In order to solve the above-described problem, the lamp unit of the present invention includes a light emitting element and a connector portion mounted on the surface of a mounting substrate, a reflector disposed in the vicinity of the light emitting element, and the light emitting element in the vicinity of a rear focus of the projection lens. The reflector is formed with a connector concealing portion that extends to a position overlapping the connector portion in a surface view of the mounting board and covers at least a part of the connector portion. It is characterized by being.

  In such a lamp unit of the present invention, the reflector is formed with a connector concealing portion that extends to a position overlapping with the connector portion and covers at least a part of the connector portion, so that the degree of freedom of component layout is increased. While improving, it becomes possible to suppress the influence of the condensing of the sunlight to the member comprised with resin.

  In one aspect of the present invention, the mounting substrate is arranged in a vertical direction, and the connector portion is arranged below the optical axis of the projection lens.

  In one embodiment of the present invention, the mounting board includes a metal wire that is a part of a power supply path to the light emitting element, and a wire protection resin portion that seals the metal wire. A protective resin concealing portion that extends to a position overlapping the wire protective resin portion in a surface view of the mounting substrate and covers at least a part of the wire protective resin portion is formed.

  Moreover, in order to solve the said subject, the vehicle lamp of this invention is provided with the lamp unit as described in any one of the above.

  In such a vehicular lamp of the present invention, the connector concealing portion that extends to a position overlapping the connector portion and covers at least a part of the connector portion is formed, thereby improving the degree of freedom of component layout. It is possible to suppress the influence of sunlight condensing on the member made of resin.

  According to the present invention, it is possible to provide a lamp unit and a vehicular lamp that can improve the degree of freedom of component layout and can suppress the influence of sunlight concentration on a member made of resin.

It is a disassembled perspective view which shows the lamp unit 100 in 1st Embodiment. It is a model perspective view which shows the light source module 40 in 1st Embodiment. It is a schematic plan view which shows the mounting substrate 41 in 1st Embodiment. It is a figure explaining the structure of the mounting substrate 41 in 1st Embodiment in detail, Fig.4 (a) is a disassembled perspective view, FIG.4 (b) is a schematic cross section. 4 is a schematic plan view showing a light source module 40 in a state where each member is mounted on a mounting substrate 41. FIG. It is an expansion perspective view which expands and shows submount 43. FIG. 6 is a partial enlarged cross-sectional view illustrating a state where a submount 43 is mounted on a light emitting unit mounting region 49. FIG. 6 is an enlarged plan view showing an enlarged periphery of a light emitting unit mounting area 49. It is a perspective view which shows typically the lens holder 20 in 2nd Embodiment. It is a disassembled perspective view which shows typically alignment with the heat sink 50 and the lens holder 20 in 2nd Embodiment. It is the front view which looked at the state which mounted the light source module 40 on the heat sink 50, and fixed the lens holder 20 and the lens 10 from the lens 10 side. It is a figure which shows typically the state which mounted the light source module 40 and the reflector 30 on the heat sink 50, and fixed the lens holder 20 and the lens 10, and Fig.12 (a) is the side surface seen from the side extension part 204 side. FIG. 12B is a side view seen from the fixing portion 202c side. FIG. 13A is a perspective view schematically showing a structural example of a reflector 30 in the third embodiment, FIG. 13A is a perspective view seen from the light extraction direction, and FIG. 13B is a side facing the mounting substrate 41. It is the perspective view seen from. It is a figure which shows typically the structural example of the reflector 30, FIG.14 (a) is the front view seen from the light extraction direction, FIG.14 (b) was shown by AA in FIG.14 (a). It is sectional drawing in a dashed-dotted line. It is a figure which shows typically the state which mounted the reflector 30 in the light source module 40, Fig.15 (a) is a front view seen from the light extraction side, FIG.15 (b) is a perspective view. It is a partial expanded sectional view which shows typically the relationship between the light source module 40 and the reflector 30 in 4th Embodiment. FIG. 17A is a partial enlarged cross-sectional view schematically showing a modification of the reflector 30. FIG. 17A is an example in which the concave portion 304a is tapered, and FIG. 17B is a diagram in which the concave portion 304a is formed vertically. FIG. 17C shows an example in which the entire recess 304a is formed with a curved surface. It is a schematic top view which shows the light source module 1 using the ADB technique proposed conventionally.

(First embodiment)
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The same or equivalent components, members, and processes shown in the drawings are denoted by the same reference numerals, and repeated descriptions are omitted as appropriate. FIG. 1 is an exploded perspective view showing a lamp unit 100 in the present embodiment. The lamp unit 100 includes a lens 10, a lens holder 20, a reflector 30, a light source module 40, a heat sink 50, and a cooling fan 60, and each member is positioned relative to each other and fixed by fixing means (not shown). Yes.

  The lens 10 is a member that is made of a translucent material and irradiates light from the light source module 40 forward so as to have a predetermined light distribution, and corresponds to a projection lens in the present invention. The lens holder 20 is a member for holding the lens 10 while maintaining the relative positional relationship between the light source module 40 and the reflector 30. The reflector 30 is a member that is disposed in front of the light source module 40 and reflects light from the light source module 40 forward, and corresponds to an optical member in the present invention.

  The light source module 40 is a member that emits light according to electric power and signals supplied from the outside of the lamp unit 100, and will be described in detail later. The heat sink 50 is a member having good thermal conductivity disposed in contact with the light source module 40 on the back surface of the light source module 40, and the cooling fan 60 in which heat radiation fins are formed on the back surface side is provided on the back surface side of the heat sink 50. It is a member which is arrange | positioned and produces the flow of air by supplying electric power.

  In the lamp unit 100, when electric power and a signal are supplied from the outside, the light source module 40 emits light according to the electric power and the signal, and the light reflected forward by the reflector 30 is forward through the lens holder 20 and the lens 10. Is irradiated. Further, the heat accompanying the light emission of the light source module 40 is radiated into the air via the heat sink 50, and is cooled by the ventilation from the cooling fan 60.

  FIG. 2 is a schematic perspective view showing the light source module 40 in the present embodiment. The light source module 40 includes a mounting substrate 41, a wiring pattern 42, a submount 43, power supply connectors 44 a and 44 b, a metal wire 45 a, a light absorbing resin portion 45, and a resist layer 46. An optical member mounting area 47 is formed in the optical member mounting area 47, and an optical member fixing portion 48 is formed in the optical member mounting area 47.

  The mounting substrate 41 is a substantially flat plate member made of a material having good thermal conductivity. The wiring pattern 42 is formed on one surface, and a plurality of submounts 43 and power supply connectors 44a and 44b are mounted. Has been. A resist layer 46 is formed so as to cover the wiring pattern 42. Although the material which comprises the mounting substrate 41 is not limited, It is preferable to use metals with favorable heat conductivity, such as copper and aluminum.

  Further, as the mounting substrate 41, a composite substrate in which an insulating substrate is bonded to a conductive substrate may be used. For example, a substrate in which a glass epoxy resin layer is bonded to a metal substrate may be used. When the mounting substrate 41 is composed of a metal substrate, it is preferable to form an antioxidant film on the back side of the mounting substrate 41 in order to prevent a decrease in thermal conductivity due to oxidation of the metal material. Examples of the method for forming the antioxidant film include a preflux process and an Au plating process, but an Au plating process is preferable from the viewpoint of improving heat dissipation.

  The wiring pattern 42 is a conductive pattern formed on the surface of the mounting substrate 41, and is used to ensure electrical connection from the terminals of the power feeding connectors 44 a and 44 b to the submount 43.

  The submount 43 is a member that is mounted on the surface of the mounting substrate 41, is electrically connected to the wiring pattern 42 by the metal wire 45a, and emits light according to the power when power is supplied through the metal wire 45a. It is. The detailed structure of the submount 43 will be described later.

  The power feeding connectors 44a and 44b are members for ensuring electrical connection with the outside mounted on the surface of the mounting substrate 41, and a plurality of terminals are electrically connected to the wiring pattern 42, and the connector portion of the present invention. It corresponds to. As the shapes of the power feeding connectors 44a and 44b, FIG. 2 shows a substantially rectangular parallelepiped shape. However, the outer shape, the terminal shape, and the like are not limited as long as they can be connected to a known cable harness.

  The lens holder 20 is fixed to the heat sink 50 by a plurality of fixing portions, and a misassembly prevention portion is formed at a position corresponding to the power supply connectors 44a and 44b as will be described in detail later in the second embodiment. (The illustration is omitted in FIGS. 1 and 2). As a result, the left and right misassembly can be prevented by interference between the power feeding connectors 44a and 44b and the misassembly prevention unit, and the misassembly can be prevented with a simple configuration regardless of the shape of the mounting board 41 on which the LED is mounted. It becomes possible.

  Further, as will be described in detail later in the third embodiment, the reflector 30 extends to a position where it overlaps with the power feeding connectors 44a and 44b in the surface view of the mounting substrate 41, and at least a part of the power feeding connectors 44a and 44b. A connector concealing portion is formed (not shown in FIGS. 1 and 2). Thereby, while improving the freedom degree of component layout, it becomes possible to suppress the influence of the condensing of sunlight to the member comprised with resin.

  The metal wire 45a is a member for connecting the terminal provided on the submount 43 and the wiring pattern 42 formed on the mounting substrate 41, and is a metal conductive member that can be realized by a known wire bonding technique. is there. The material constituting the metal wire 45a is not limited, and gold, copper, aluminum, or the like can be used, but gold is preferably used.

  The light-absorbing resin portion 45 is a resin member in which an inorganic filler and a light-absorbing material are mixed in a base resin, covers and seals the metal wire 45a, and corresponds to the wire protection resin portion in the present invention. The metal wires 45a may be sealed with the light-absorbing resin portion 45 by individually sealing the metal wires 45a one by one, but it is preferable to seal a plurality of metal wires 45a at once. The base resin of the light-absorbing resin portion 45 is preferably a curable resin composition having high heat resistance, light resistance, and translucency and good handling, and includes known sealing materials such as epoxy resins and silicone resins. It is done. In particular, in order to prevent the metal wire 45a from being stressed due to expansion or contraction of the light-absorbing resin portion 45 due to heat, it is possible to use a silicone resin having a low elastic modulus after curing as the base resin. preferable. Examples of the light absorbing material mixed in the base resin include a carbon filler.

  In the light source module 40 of the present embodiment, the metal wire 45a is covered with the light-absorbing resin portion 45 and sealed, so that it is possible to prevent a conductive foreign matter from adhering to the metal wire 45a and causing a short circuit. Further, since the light-absorbing resin portion 45 is mixed with a light-absorbing material, the light from the submount 43 reaches the metal wire 45a, is reflected, and is irradiated to the outside of the lamp unit 100 as stray light. Can be prevented. In particular, when the light emitting elements included in the submount 43 are selectively turned on using the ADB technique, stray light reflected by the metal wire 45a can be prevented from reaching the non-irradiation region, and the light emitting elements can be densely formed. It is possible to suppress the occurrence of glare while mounting.

  When forming the light-absorbing resin part 45, the base resin kneaded with the inorganic filler and the light-absorbing material is supplied onto the metal wire 45a with a dispenser or the like and then cured. The viscosity and thixotropy after kneading the light-absorbing material can be adjusted arbitrarily by adjusting the material selection of the base resin and the amount of inorganic filler added, taking into account the moldability after application and stress on the power supply wire. Is possible. The thixotropy is based on the injection property of the dispenser / moldability after application, at a viscosity of 23 ° C., a viscosity of 0.5 rpm and a viscosity of 5 rpm in the E type viscometer (viscosity of 0.5 rpm) / (5 rpm The viscosity is preferably 2.0 or more and 3.5 or less from the viewpoint of handling. If the thixotropy is set in this range, the fluidity of the base resin is maintained moderately, and even if the periphery of the submount 43 is not surrounded by a dam member or the like, the resin flows out and the metal wire 45a is exposed, or the metal wire 45a It is possible to prevent a gap from occurring between the gaps and the lower part.

  As will be described in detail later in the fourth embodiment, a concave portion is formed on the surface of the reflector 30 that faces the mounting substrate 41 at a position that overlaps the light-absorbing resin portion 45 that is a wire protection resin portion in plan view. . Thereby, even if a reflective surface is made to adjoin to a light emitting element, interference with the reflector 30 and the light absorptive resin part 45 can be prevented.

  The resist layer 46 is an insulating film-like member formed on the surface side of the mounting substrate 41 so as to cover the wiring pattern 42. The material constituting the resist layer 46 is not limited, but in order to suppress stray light due to the difference in light reflection between the surface of the mounting substrate 41 and the wiring pattern 42, the light reflectance in the region where the resist layer 46 is formed is uniform. It is preferable to use a light-reflective material or a light-absorbing material so that

  The optical member mounting region 47 is a region on the surface of the mounting substrate 41 for mounting the reflector 30 which is an optical member, and is a region where the surface of the mounting substrate 41 is exposed without the resist layer 46 being formed. The optical member mounting area 47 is located on both sides of the mounting substrate 41 across the area where the submount 43 is mounted, and the optical member mounting area 47 is fixed by contacting the reflector 30 with the optical member mounting area 47. The reflector 30 can be disposed across 43.

  The optical member fixing portion 48 is a through hole provided in the optical member mounting area 47. The reflector 30 is brought into contact with the optical member mounting region 47, and a fixing member such as a screw is inserted into the optical member fixing portion 48 from the surface side of the mounting substrate 41 to fix the mounting substrate 41 and the reflector 30 to the heat sink 50. Although the details of the formation position of the optical member fixing portion 48 will be described later, the submount 43 is arranged between the two optical member fixing portions 48.

  FIG. 3 is a schematic plan view showing the mounting substrate 41 in the present embodiment. As shown in FIG. 2, a wiring pattern 42 is formed on the mounting substrate 41, and a resist layer 46 is formed so as to cover the wiring pattern 42. As shown in FIG. 3, the optical member mounting area 47, the light emitting section mounting area 49 for mounting the submount 43, the portion for bonding the metal wire 45a, and the power supply connector mounting section 44a1, for mounting the power supply connectors 44a and 44b. A resist layer 46 is formed in a region excluding a portion connecting 44b1 and the terminals of the power feeding connectors 44a and 44b.

  As described above, the light emitting unit mounting region 49 is a region on which a plurality of submounts 43 are mounted, and is formed so that the submounts 43 can be arranged in two rows with the left-right direction in the drawing as the longitudinal direction. Further, the line L1 connecting the centers of the optical member fixing portions 48 is in a positional relationship that crosses the substantial center of the light emitting portion mounting area 49 along the longitudinal direction.

  4A and 4B are diagrams for explaining in detail the structure of the mounting substrate 41 in the present embodiment, FIG. 4A is an exploded perspective view, and FIG. 4B is a schematic cross-sectional view. As shown in FIG. 4A, the mounting substrate 41 has a laminated structure of a metal plate 41a, an adhesive sheet 41b, and a glass epoxy resin layer 41c. In the adhesive sheet 41b and the glass epoxy resin layer 41c, openings 49b and 49c having shapes corresponding to the light-emitting portion mounting areas 49 are formed, and the positions of the openings 49b and 49c coincide with each other. The openings 49b and 49c may be formed in advance in predetermined regions of the adhesive sheet 41b and the glass epoxy resin layer 41c, and may be aligned and pasted. The metal plate 41a and the glass epoxy resin layer 41c are pasted with the adhesive sheet 41b. After that, the openings 49b and 49c may be collectively formed by cutting or the like.

  As shown in FIG. 4B, an adhesive sheet 41b and a glass epoxy resin layer 41c are laminated around the light emitting portion mounting region 49, and a wiring pattern 42 and a resist layer 46 are formed on the glass epoxy resin layer 41c. Yes. Inside the light emitting unit mounting region 49, a part of the surface of the metal plate 41a is exposed in a region corresponding to the openings 49b and 49c. Further, since the resist layer 46 is not formed in the optical member mounting area 47 as described above, the glass epoxy resin layer 41 c is exposed in the optical member mounting area 47.

  In the light source module 40 of the present embodiment, the resist layer 46 is not formed in the optical member mounting region 47, and the reflector 30, which is an optical member, is directly mounted and fixed on the glass epoxy resin layer 41c. Thereby, the positional deviation between the reflector 30 and the submount 43 caused by the variation in the film thickness of the resist layer 46 is suppressed, and the relative positional relationship between the optical member and the light emitting element 43c is precisely aligned, thereby providing good light distribution characteristics. Can be irradiated with light. In addition, by attaching the glass epoxy resin layer 41c to the metal plate 41a using the adhesive sheet 41b, there is no need to form an insulating layer containing a high thermal conductive filler on the metal plate 41a. Reduction can be achieved.

  FIG. 5 is a schematic plan view showing the light source module 40 in a state where each member is mounted on the mounting substrate 41. Solder is applied to the power supply connector mounting portions 44a1 and 44b1 and terminal connection portions of the mounting substrate 41 shown in FIG. 4, and the surface mount type power supply connectors 44a and 44b are mounted by solder reflow. In addition, the back surface of the submount 43 and the metal plate 41a exposed in the light emitting unit mounting area 49 are fixed with an adhesive, and a plurality of submounts 43 are arranged in two rows along the longitudinal direction. At 45a, the submount 43 and the wiring pattern 42 are electrically connected. Finally, the light absorbing resin portion 45 is applied to the plurality of metal wires 45a with a dispenser and cured. As described above, the line L1 connecting the centers of the optical member fixing portions 48 is located substantially at the center along the longitudinal direction of the submounts 43 arranged in two rows.

  FIG. 6 is an enlarged perspective view showing the submount 43 in an enlarged manner. In the submount 43, a plurality of submount wirings 43b are formed on a submount substrate 43a, a plurality of light emitting elements 43c are mounted on the submount wiring 43b, and the side surfaces of the plurality of light emitting elements 43c are collectively reflected. Resin portion 43d is sealed. Further, the light-reflective resin portion 43d is not formed on a part of the submount substrate 43a, and the surface of the submount substrate 43a and the submount wiring 43b are exposed. The light emitting element 43c is flip-chip mounted across the adjacent submount wirings 43b inside the light reflective resin portion 43d.

  The submount substrate 43a is a substantially rectangular flat plate member made of a material having insulating properties and good thermal conductivity, and is made of, for example, Si or AlN. The submount wiring 43b is a conductive pattern formed on one surface of the submount substrate 43a. The submount wiring 43b is electrically connected to the light emitting element 43c and is wire-bonded with the metal wire 45a.

  The light emitting element 43c is a member that is electrically connected to the two metal wires 45a and emits light when a voltage is applied between the metal wires 45a, and is configured by a combination of an LED chip and a phosphor material. . As the LED chip, a known compound semiconductor material such as GaN that emits blue, purple, or ultraviolet light as primary light can be used. As the phosphor material, a known material that is excited by primary light and emits desired secondary light can be used. A material that obtains white color by mixing primary light from an LED chip, or a plurality of phosphor materials can be used. It is possible to use one that obtains white color by mixing a plurality of secondary lights.

  The light-reflective resin portion 43d is a member in which light-reflective fine particles are mixed into the base resin, and includes, for example, a white resin in which fine particles such as titanium oxide are mixed, and reflects light emitted from the light emitting element 43c well. The light-reflective resin portion 43d is filled with the side surface sealed and filled with the light-emitting element 43c, and reflects light emitted from the side surface of the light-emitting element 43c toward the inside of the light-emitting element 43c. As a result, light emitted from the light emitting element 43c does not leak sideways from the side surface of the light emitting element 43c, and is favorably irradiated to the outside from the upper surface of the light emitting element 43c.

  As shown in FIG. 6, in the plurality of light emitting elements 43c arranged along the longitudinal direction of the submount 43, the distance between the side surfaces of the adjacent light emitting elements 43c is d1, and the distance between the centers of the light emitting elements 43c is d2. As shown in FIG. 2, a plurality of submounts 43 are arranged in two upper and lower rows to constitute a light source unit, and a plurality of submount substrates 43a are arranged adjacent to each other by extending in the longitudinal direction. The sub-mount substrate 43a in the second row is arranged adjacent to the first row.

  FIG. 7 is a partially enlarged cross-sectional view showing a state where the submount 43 is mounted on the light emitting unit mounting region 49. The submount substrate 43a is fixed with an adhesive on the metal plate 41a exposed in the light emitting portion mounting area 49, and the side surface of the light emitting element 43c on the submount substrate 43a is sealed with a light reflective resin portion 43d. One end of the metal wire 45a is wire-bonded to a region where the light-reflective resin portion 43d is not formed on the submount substrate 43a.

  In the light source module 40 of the present embodiment, a plurality of light emitting elements 43c are mounted on the submount substrate 43a, and metal wires 45a are wire-bonded to the submount wiring 43b formed on the surface of the submount substrate 43a to generate electric power. Supply. As a result, it is possible to supply a larger current with the metal wire 45a having a higher melting point than to mount the light emitting element 43c directly on the wiring pattern 42 using solder, and to increase the luminous intensity of the light source module 40. . Further, the submount substrate 43a is mounted on the metal plate 41a exposed in the light emitting unit mounting region 49, and is fixed by using an adhesive having a high heat resistant temperature, so that the light emitting element 43c is mounted using solder. The heat-resistant temperature can be set high, and a large current can be supplied and the light intensity can be increased.

  As shown in FIG. 7, the wiring pattern 42 formed on the glass epoxy resin layer 41c is covered with a resist layer 46, but the resist layer 46 is formed at the position where the other end of the metal wire 45a is wire-bonded. Not. The entire metal wire 45a is sealed with a light-absorbing resin portion 45, and the wire bond positions at both ends of the metal wire 45a and the upper and lower portions of the metal wire 45a are filled. The light absorbing resin portion 45 is formed adjacent to the light reflecting resin portion 43d at the wire bond position of the submount substrate 43a. In FIG. 7, the adhesive sheet 41b is not shown.

  As described above, the submount 43 is mounted on the metal plate 41a without the glass epoxy resin layer 41c in the light emitting portion mounting region 49, and the height dimension of the light emitting element in the submount 43 is the glass epoxy resin layer 41c. Greater than thickness dimension. Here, the height dimension of the light emitting element in the submount 43 is a distance from the bottom surface of the submount substrate 43a to the upper surface of the light emitting element 43c, and is about 1.3 mm, for example.

  In the light source module 40 of this embodiment, since the height of the submount 43 is larger than the total thickness of the adhesive sheet 41b, the wiring pattern 42, and the resist 46, the upper surface of the light emitting element 43c that is the light extraction surface of the submount 43 is glass. It is located above the epoxy resin layer 41c. Thereby, it can prevent that the light irradiated from the submount 43 injects into the side surface of the glass epoxy resin layer 41c, and is blocked | interrupted, can extract light well and can irradiate with a desired light distribution characteristic.

  In the light source module 40 of the present embodiment, the optical member fixing portion 48 is formed by punching from the back side of the mounting substrate 41 after the metal plate 41a and the glass epoxy resin layer 41c are bonded together by the adhesive sheet 41b. When the thickness of the glass epoxy resin layer 41c is 0.05 mm to 0.2 mm, preferably 0.075 mm to 0.15 mm, burrs generated on the metal plate 41a during punching are suppressed by the glass epoxy resin layer 41c. The reflector 30, which is a member, can be accurately aligned and fixed.

  FIG. 8 is an enlarged plan view showing the periphery of the light emitting unit mounting area 49 in an enlarged manner. As shown in FIG. 8, the light-absorbing resin portion 45 collectively seals a plurality of metal wires 45a, covers the wiring pattern 42 from the wire bond position of the wiring pattern 42 to the wire bond position of the submount 43, and reflects light. It is formed up to a position adjacent to the resin portion 43d. A plurality of submounts 43 are arranged along the left-right direction, and two rows are arranged adjacent to each other in the up-down direction to constitute the light source unit of the present invention.

  In the light source section in which the submounts 43 are arranged in two upper and lower rows, the light emitting elements 43c are also arranged in two rows, and a line L2 shown in FIG. 8 is a light emission center line indicating an intermediate position between the two rows of light emitting elements 43c. . The light emission center line L2 substantially coincides with the line L1 connecting the centers of the optical member fixing portions 48 shown in FIG. 5, and is an optical member on an extension line of the light emission center lines L2 of the plurality of light emitting elements 43c. The reflector 30 is fixed.

  In the light source module 40 of the present embodiment, the line L1 connecting the centers of the optical member fixing portions 48 and the light emission center line L2 of the submount 43 substantially coincide with each other, so that the mounting substrate 41 is warped. In addition, it is possible to reduce the warpage by fastening the reflector 30 on the light emission center line L2, and to appropriately set the positional relationship between the light source unit and the optical member. Further, when the mounting substrate 41 and the reflector 30 are fastened together including the heat sink 50, the back surface side of the light emitting portion mounting region 49 can be brought into close contact with the heat sink, and the heat dissipation characteristics similar to those of the mounting substrate 41 without warping. Can be obtained.

  The wire bonding position of the wiring pattern 42 is provided along the upper and lower sides of the light emitting portion mounting region 49 in the drawing, and a metal wire 45a is wire-bonded to the upper row of submounts 43 from the upper side in the drawing. The metal wires 45a are wire-bonded to the submounts 43 in the lower row in the figure from below in the figure. Therefore, the light emitting elements 43c in the first row and the second row are located between the metal wire 45a connected to the first row and the metal wire 45a connected to the second row.

  In the vehicle lamp using the lamp unit 100 of the present invention, electric power is selectively supplied from the outside to the light emitting element 43c via the power supply connectors 44a and 44b, the wiring pattern 42, the metal wire 45a, and the submount wiring 43b. Then, the light emitting element 43c is turned on. Of the plurality of submounts 43 constituting the light source unit, the selected light emitting element 43c is turned on to determine the light distribution distribution in the entire light source unit, and the lamp unit 100 is obtained by ADB technology via the reflector 30 and the lens 10. A two-dimensional light distribution pattern is irradiated forward.

(Second Embodiment)
Next, a second embodiment of the present invention will be described with reference to FIGS. The description overlapping with the first embodiment is omitted. FIG. 9 is a perspective view schematically showing the lens holder 20 in the present embodiment. In FIG. 9, the figure seen from the side mounted in the heat sink 50 among the lens holders 20 is shown. As shown in FIG. 9, the lens holder 20 includes a holder side wall portion 201, fixing portions 202a to 202c, positioning pins 203, side extension portions 204, half-fitting prevention portions 205a and 205b, and misassembly. It has prevention parts 206a and 206b.

  FIG. 10 is an exploded perspective view schematically showing alignment between the heat sink 50 and the lens holder 20 in the present embodiment. As shown in FIG. 10, fixing holes 502 a to 502 c and positioning holes 503 are formed on the mounting surface of the heat sink 50, and the light source module 40 and the reflector 30 are positioned and mounted.

  The holder side wall portion 201 is a substantially cylindrical portion that constitutes the main body of the lens holder 20, holds the light incident surface side of the lens 10 at one end portion, and is disposed so that the other end portion faces the heat sink 50. Is done. The holder side wall 201 on the heat sink 50 side is integrally formed with a plurality of fixing portions 202a to 202c, positioning pins 203, side extending portions 204, and erroneous assembly preventing portions 206a and 206b. Further, a structure for positioning and fixing the lens 10 is formed on the lens 10 side of the holder side wall 201 (not shown).

  The fixing portions 202 a to 202 c are screw holes formed so as to protrude from the holder side wall portion 201 toward the outside of the cylindrical shape and toward the heat sink 50, and at positions corresponding to the fixing holes 502 a to 502 c provided in the heat sink 50. Is formed. Since the fixing portions 202a to 202c are provided so as to protrude toward the heat sink 50, the distance between the holder side wall portion 201 and the heat sink 50 is secured, and the distance between the light source module 40 and the holder side wall portion 201 is also secured.

  The positioning pin 203 is a pin-shaped portion that is formed in the vicinity of the fixing portions 202 a to 202 c and protrudes in the direction of the heat sink 50, and is formed at a position corresponding to the positioning hole 503 provided in the heat sink 50.

  The laterally extending portion 204 is a flat plate-like portion formed so as to protrude from the holder side wall portion 201 in the cylindrical outer direction, and is formed at a position substantially corresponding to the power supply connectors 44 a and 44 b of the light source module 40. Yes. On the heat sink 50 side of the lateral extension portion 204, half-fitting prevention portions 205a and 205b and erroneous assembly prevention portions 206a and 206b are formed.

  The semi-fitting prevention portions 205a and 205b are ribs erected on the heat sink side of the laterally extending portion 204, and are located on the outer periphery of the holder side wall portion 201 at a position spaced from the outer periphery of the holder side wall portion 201. It is formed in parallel. The protrusion height of the semi-fitting prevention portions 205a and 205b toward the heat sink is such that when the lens holder 20 is fixed to the heat sink 50, it can interfere with the housing of the harness side connector connected to the power supply connectors 44a and 44b. Of height. Further, the formation positions of the half-fitting prevention part 205a and the half-fitting prevention part 205b are different from each other from the outer periphery of the holder side wall part 201.

  The misassembly prevention portions 206a and 206b are ribs erected on the heat sink side of the lateral extension portion 204, and are formed by extending from the outer periphery of the holder side wall portion 201 toward the half-fitting prevention portions 205a and 205b. Has been. The protruding height of the misassembly prevention portions 206a and 206b toward the heat sink is approximately the same as that of the half-fitting prevention portions 205a and 205b. Further, the erroneous assembly preventing portions 206a and 206b are formed at positions and shapes along the housings of the power feeding connectors 44a and 44b, respectively.

  In the example shown in FIG. 2, the power supply connectors 44 a and 44 b have different numbers of terminals and have different widths, and the arrangement of the power supply connectors 44 a and 44 b on the mounting board 41 is not equal left and right but asymmetrical. Yes. Therefore, the power feeding connectors 44a and 44b are asymmetrical with respect to the arrangement of the plurality of fixing portions 202a to 202c for fixing the lens holder 20 to the heat sink 50, and the erroneous assembly preventing portions 206a and 206b are also fixed portions. It is provided asymmetrically with respect to the arrangement of 202a to 202c. Here, asymmetric with respect to the arrangement of the fixing parts 202a to 202c means that at least two of the fixing parts 202a to 202c are not in a symmetric position with respect to the misassembly preventing parts 206a and 206b.

  As shown in FIGS. 9 and 10, in the lens holder 20 of the present embodiment, the distance between the lens 10 and the heat sink 50 is secured by the height of the holder side wall 201 and the fixing portions 202a to 202c. A distance from the module 40 is ensured. Further, the distance between the holder sidewall 201 and the heat sink 50 is secured by the fixing portions 202a to 202c, and the light source module 40 and the reflector 30 are held in alignment with each other without interfering with the holder sidewall 201.

  Next, the functions of the semi-fitting prevention portions 205a and 205b and the erroneous assembly prevention portions 206a and 206b will be described with reference to FIGS. FIG. 11 is a front view of the state in which the light source module 40 is mounted on the heat sink 50 and the lens holder 20 and the lens 10 are fixed as viewed from the lens 10 side. FIG. 12 is a diagram schematically showing a state in which the light source module 40 and the reflector 30 are mounted on the heat sink 50 and the lens holder 20 and the lens 10 are fixed, and FIG. 12A shows the side extension portion 204 side. FIG. 12B is a side view seen from the fixing portion 202c side.

  As shown in FIGS. 11 and 12, the positioning pins 203 are inserted into the positioning holes 503 of the heat sink 50, the fixing portions 202a to 202c and the fixing holes 502a to 502c are aligned, and screwed with screws. The lens holder 20 is fixed to the heat sink 50. Corresponding harness side connectors 400a and 400b are inserted into the power supply connectors 44a and 44b, respectively. Here, only the housing portions of the harness side connectors 400a and 440b are shown, and the wiring for connecting to the outside from the harness side connectors 400a and 400b is not shown.

  At this time, since the holder side wall portion 201 of the lens holder 20 is held at a predetermined distance from the heat sink 50 by the fixing portions 202a to 202c, the mounting substrate 41, the power feeding connectors 44a and 44b, and the harness side connectors 400a and 400b The part can be located outside the holder side wall part 201. Moreover, as shown in FIG. 11, the side extension part 204 is a position which covers between the electric power feeding connectors 44a and 44b and the harness side connectors 400a and 400b in planar view. As described above, the number of terminals and the width of the power feeding connectors 44a and 44b are different from each other, and the number of terminals and the width of the harness-side connectors 400a and 400b are also correspondingly different. Moreover, the depth of the housing part of harness side connector 400a, 400b is also different, and the protrusion amount to the outer side from the holder side wall part 201 is also different.

  As shown in FIG. 12B, in the fitted state in which the harness side connectors 400a and 400b are fully inserted into the power feeding connectors 44a and 44b, the half-fitting prevention portions 205a and 205b are connected to the harness side connector 400a, It is located further outside the holder side wall portion 201 than the housing portion 400b, and the half-fitting prevention portions 205a and 205b and the outer end portions of the harness side connectors 400a and 400b are separated by a predetermined distance.

  On the other hand, in the half-fitted state where the harness-side connectors 400a and 400b are not sufficiently inserted into the power supply connectors 44a and 44b, the outer end portions of the harness-side connectors 400a and 400b are more than the half-fitting prevention portions 205a and 205b. Since the lens holder 20 is located outside, when the lens holder 20 is assembled to the heat sink 50, the half-fitting prevention portions 205a and 205b interfere with the housing portions of the harness side connectors 400a and 400b, and the lens holder 20 cannot be assembled. .

  As described above, in the lamp unit 100 according to the present embodiment, in the operation of assembling the lens holder 20 to the heat sink 50, the harness-side connector 400a and the harness-side connector 400a, The half-fitted state of 400b can be checked. When the half-fitting prevention portions 205a and 205b interfere with the housing portions of the harness side connectors 400a and 400b, the interfering harness side connectors 400a and 400b are pushed into the power feeding connectors 44a and 44b and fully inserted. Fit into the fitted state.

  As a result, the lamp unit 100 is assembled with the harness-side connectors 400a and 400b in the half-fitted state, and the harness-side connectors 400a and 400b can be prevented from dropping off from the power supply connectors 44a and 44b due to vibration or the like during use. Further, as shown in FIGS. 12A and 12B, the half-fitting prevention portions 205a and 205b are located outside the harness side connectors 400a and 400b, and their tips are heat sinks 50 than the harness side connectors 400a and 400b. Protrudes to the side. Accordingly, it is possible to prevent the fitting state from being loosened due to vibration or the like during use of the lamp unit 100 and falling off through the half-fitting state.

  As shown in FIGS. 11 and 12 (a) and 12 (b), the misassembly prevention portions 206a and 206b are located between the power supply connectors 44a and 44b, respectively, and their tips are heat sinks than the harness side connectors 400a and 400b. It is provided so as to protrude to the 50 side. Accordingly, when the left and right light source modules 40 are correctly mounted on the heat sink 50, the erroneous assembly prevention portions 206a and 206b do not interfere with the power supply connectors 44a and 44b and are inserted between the two. At this time, the side surfaces of the erroneous assembly preventing portions 206a and 206b may be in contact with the power supply connectors 44a and 44b, and a predetermined interval may be secured.

  On the other hand, when the right and left light source modules 40 are mistakenly mounted on the heat sink 50, the positions of the power supply connectors 44a and 44b are different from the correct attachment positions, so that the erroneous assembly preventing portions 206a and 206b are provided with the power supply connectors 44a and 44b. The lens holder 20 cannot be assembled. This is because the power feeding connectors 44a and 44b are provided at asymmetric positions with respect to the mounting substrate 41 and the fixing portions 202a to 202c, and the misassembly prevention portions 206a and 206b are also provided corresponding to the asymmetric positions. Because.

  As described above, in the lamp unit 100 of the present embodiment, in the operation of assembling the lens holder 20 to the heat sink 50, the right and left of the light source module 40 are determined depending on the presence / absence of interference between the misassembly prevention portions 206a and 206b and the power feeding connectors 44a and 44b. It is possible to check whether is mounted on the heat sink 50 correctly. When the incorrect assembly preventing portions 206a and 206b interfere with the power supply connectors 44a and 44b, the left and right sides of the light source module 40 are incorrect, so the light source module 40 is removed and replaced with a correct one. Thereby, it becomes possible to prevent erroneous assembly of the light source module 40 with a simple configuration regardless of the shape of the mounting substrate 41.

  Although FIGS. 1-12 showed the example which provided two electric power feeding connectors 44a and 44b as a connector part, the shape of a connector part is not limited and may be single or three or more. When a plurality of power supply connectors 44a and 44b are provided as connector parts, the number of terminals per connector part can be reduced and the housing size of the connector part can be reduced as compared with the case where a single power supply connector 44a is provided. Thereby, since the force required for inserting and fitting the harness side connector can be small, the work in the assembly process of the lamp unit 100 can be facilitated.

  Further, when a single power supply connector 44a is provided on the mounting substrate 41 as a connector portion, it is important that the power supply connector 44a is provided asymmetrically with respect to the mounting substrate 41 and the fixing portions 202a to 202c. Even when the single power supply connector 44a is provided in this way, the power supply connector 44a is asymmetric with respect to the fixed portions 202a to 202c by providing the misassembly prevention portion 206a at the corresponding position of the lens holder 20. Left and right misassembly can be prevented by interference between the connector 44a and the misassembly prevention portion 206a.

  Further, as the semi-fitting preventing portions 205a and 205b corresponding to the power feeding connectors 44a and 44b, the harness side connectors fitted to the power feeding connectors 44a and 44b by making the distances from the side surfaces of the holder side wall portion 201 different. The half-fitted state can be checked according to the sizes of 400a and 400b. Further, when the light source module 40 is attached to the left and right by mistake, the half-fitting prevention portions 205a and 205b interfere with the harness side connectors 400a and 400b, and the light source module is also affected by the half-fitting prevention portions 205a and 205b. Forty misassembly can be checked.

  As described above, in the lamp unit 100 of the present embodiment and the vehicular lamp using the lamp unit 100, the lens holder 20 includes the erroneous assembly preventing unit 206a, at a position corresponding to the power supply connectors 44a and 44b mounted on the mounting board 41. Since 206b is formed, it is possible to prevent left and right erroneous assembly due to interference between the power feeding connectors 44a and 44b and the erroneous assembly preventing portions 206a and 206b, and an error with a simple configuration regardless of the shape of the board on which the LED is mounted. Assembling can be prevented.

(Third embodiment)
Next, a third embodiment of the present invention will be described with reference to FIGS. The description overlapping with the first embodiment is omitted. FIG. 13 is a perspective view schematically showing a structural example of the reflector 30 in the present embodiment, FIG. 13A is a perspective view seen from the light extraction direction, and FIG. It is the perspective view seen from the opposite side. FIG. 14 is a diagram schematically showing an example of the structure of the reflector 30 in the present embodiment. FIG. 14 (a) is a front view seen from the light extraction direction, and FIG. 14 (b) is FIG. 14 (a). It is sectional drawing in the dashed-dotted line shown by AA in the inside.

  As shown in FIGS. 13 and 14, the reflector 30 of this embodiment includes two substrate contact portions 301 on both sides, and positioning holes 302 a and 302 b and a fixing hole 303 are opened in the substrate contact portion 301. ing. In addition, the first reflecting portion 304, the second reflecting portion 305, and the third reflecting portion 306 are integrally formed between the two substrate contact portions 301, and the upper end of the third reflecting portion 306 is extended. Thus, a connector concealing portion 307 is formed.

  A light extraction opening 308 is formed between the first reflection unit 304 and the second reflection unit 305, and a light extraction opening is formed between the second reflection unit 305 and the third reflection unit 306. A portion 309 is formed. Further, a concave portion 304 a is formed on the side of the first reflecting portion 304 facing the mounting substrate 41, and a concave portion 306 a is formed on the side of the third reflecting portion 306 facing the mounting substrate 41.

  The substrate contact portions 301 are thin plate portions located at both ends of the reflector 30 in the width direction, and are formed corresponding to the position and shape of the optical member mounting region 47 on the mounting substrate 41. In addition, a first reflecting portion 304, a second reflecting portion 305, and a third reflecting portion 306 are bridged and formed integrally between the left and right substrate contact portions 301. The surface of the substrate contact portion 301 that faces the mounting substrate 41 is flat, and is in surface contact with the optical member mounting region 47 in substantially the entire region.

  The positioning holes 302 a and 302 b are through holes formed in the substrate contact portion 301, and are formed corresponding to the positions and shapes of optical member positioning pins provided in the heat sink 50. The light source module 40 and the reflector 30 are positioned by inserting the positioning pin for the optical member into the through hole provided in the light source module 40 and the positioning holes 302a and 302b. The shape of the positioning hole 302a is substantially oval and has some play when the positioning pin is inserted. The shape of the positioning hole 302b is substantially circular, and the pin is precisely fitted when the positioning pin is inserted.

  The fixing hole 303 is a through hole formed in the substrate contact portion 301 and is formed corresponding to the position and shape of the screw hole provided in the heat sink 50 and the optical member fixing portion 48 of the light source module 40. . The reflector 30 and the mounting substrate 41 are fixed to the heat sink 50 by bringing the reflector 30 into contact with the optical member mounting region 47 and inserting a fixing member such as a screw into the fixing hole 303 from the surface side of the mounting substrate 41.

  The first reflecting portion 304 is formed substantially parallel to the second reflecting portion 305 and the third reflecting portion 306 so as to bridge between the two left and right substrate contact portions 301, and the light extraction opening 308 side is tapered. It is the member made into the shape reflective surface. In addition, a recess 304 a is formed on the surface of the first reflecting portion 304 that faces the mounting substrate 41. The position of the first reflecting portion 304 corresponds to the position of the light absorbing resin portion 45 on the mounting substrate 41 and has a length and a width that cover the entire light absorbing resin portion 45.

  The second reflecting portion 305 is formed substantially in parallel with the first reflecting portion 304 and the third reflecting portion 306 so as to bridge between the two left and right substrate abutting portions 301, and is provided on the side of the light extraction opening 308 and The light extraction opening 309 side is a member having a tapered reflecting surface.

  The third reflecting portion 306 is formed substantially in parallel with the first reflecting portion 304 and the second reflecting portion 305 so as to bridge between the two left and right substrate contact portions 301, and the light extraction opening 309 side is tapered. It is the member made into the shape reflective surface. The reflecting surface of the third reflecting portion extends in the direction of the lens 10, and a connector concealing portion 307 is extended and formed integrally with the tip portion. A recess 306 a is formed on the surface of the third reflecting portion 306 facing the mounting substrate 41. The position of the third reflecting portion 306 corresponds to at least the position of the light absorbing resin portion 45 on the mounting substrate 41, and has a length and a width that cover the entire light absorbing resin portion 45.

  The connector concealing portion 307 is a portion formed by extending the front end portion of the reflecting surface of the third reflecting portion 306 in a direction substantially parallel to the mounting substrate 41, and is located in the lens 10 direction with respect to the substrate abutting portion 301. Yes. The distance of the connector concealing portion 307 from the surface of the mounting substrate 41 is at least larger than the housing height of the power feeding connectors 44a and 44b. Further, the width of the connector concealing portion 307 is set to cover at least a part of the power feeding connectors 44a and 44b.

  The light extraction opening 308 is an opening formed between the first reflecting portion 304 and the second reflecting portion 305, and corresponds to the position and shape of the plurality of light emitting elements 43c mounted on the light source module 40. ing. The light extraction opening 309 is an opening formed between the second reflecting portion 305 and the third reflecting portion 306, and corresponds to the position and shape of the plurality of light emitting elements 43c mounted on the light source module 40. ing.

  The recess 304 a is a recess provided on the surface of the first reflecting portion 304 facing the mounting substrate 41 over substantially the entire length of the first reflecting portion 304, and is spaced a predetermined distance from the light extraction opening 308. From the first position to the opposite side to the light extraction opening 308. The concave portion 306a is a concave portion provided on the surface of the third reflecting portion 306 facing the mounting substrate 41 over substantially the entire length of the third reflecting portion 306, and is spaced a predetermined distance from the light extraction opening 309. From the first position to the opposite side to the light extraction opening 308.

  FIG. 15 is a diagram schematically showing a state in which the reflector 30 is mounted on the light source module 40, FIG. 15A is a front view seen from the light extraction side, and FIG. 15B is a perspective view. is there. The light source module 40 and the reflector 30 are arranged on the heat sink 50, the positioning pins of the heat sink 50 are inserted into the positioning holes 302a and 302b, and screws are screwed into the fixing holes 303 to fix the light source module 40 and the reflector 30.

  As shown in FIGS. 15A and 15B, when the mounting substrate 41 is viewed in plan, the first reflecting portion 304 and the third reflecting portion 306 each cover the light absorbing resin portion 45 on the mounting substrate 41, A plurality of light emitting elements 43 c are exposed from the light extraction openings 308 and 309. The connector concealing portion 307 extends to a position overlapping with a part of the power supply connectors 44a and 44b, and covers at least a part of the resin constituting the power supply connectors 44a and 44b. Here, an example in which the connector concealing unit 307 covers a part of the power supply connectors 44a and 44b and a part of the power supply connectors 44a and 44b is exposed is shown.

  The lamp unit 100 of the present embodiment includes a lens 10 as a projection lens, as shown in FIG. 1, and a plurality of light emitting elements 43 c are arranged near the rear focal point of the lens 10. When power is supplied via the power supply connectors 44a and 44b, the light source module 40 is turned on according to the supplied power, and the emitted light is extracted through the light extraction openings 308 and 309. The light from the light emitting element 43c is reflected by the reflecting surfaces of the first reflecting portion 304, the second reflecting portion 305, and the third reflecting portion 306 disposed in the vicinity of the light emitting element 43c, and passes through the lens holder 20 and the lens 10. Then, it is irradiated forward with a desired light distribution.

  Also in the present embodiment, the mounting board 41 is arranged in the vertical direction as in FIG. 1, and the power feeding connectors 44 a and 44 b are arranged below the optical axis of the lens 10. As described above, since the harness connection side of the power supply connectors 44a and 44b faces downward, even if water droplets are generated in the lamp unit 100, the water droplets are not accumulated in the power supply connectors 44a and 44b. Further, since the connector concealing portion 307 covers at least a part of the power feeding connectors 44a and 44b, the sunlight incident from the lens 10 is blocked by the connector concealing portion 307, and the sunlight condenses on the power feeding connectors 44a and 44b. To prevent melting.

  Moreover, the 1st reflection part 304 and the 3rd reflection part 306 are provided with the light absorptive resin part 45 which is a wire protection resin part, and it extends to the position which overlaps with the light absorptive resin part 45, and covers a part. It also has a function as a protective resin concealing part in the present invention. Therefore, the sunlight incident from the lens 10 is blocked by the first reflecting portion 304 and the third reflecting portion 306, and the sunlight can be prevented from being condensed and melted on the light absorbing resin portion 45.

  Thus, in the lamp unit 100 of this embodiment and the vehicular lamp using the lamp unit, the reflector 30 is formed with the connector concealing portion 307 that extends to the position overlapping the power feeding connectors 44a and 44b and covers at least a part thereof. Therefore, it is possible to improve the degree of freedom of component layout and to suppress the influence of sunlight condensing on a member made of resin.

(Fourth embodiment)
Next, a fourth embodiment of the present invention will be described with reference to FIGS. 16 and 17. The description overlapping with the third embodiment will be omitted. FIG. 16 is a partially enlarged cross-sectional view schematically showing the relationship between the light source module 40 and the reflector 30 in the present embodiment.

  As shown in FIG. 16, a plurality of submounts 43 are mounted on the mounting substrate 41, and a light absorbing resin portion 45 is formed adjacent to the submount 43. Here, the configuration of the submount 43 is the same as that shown in FIG. 6 in the first embodiment, and the light absorbing resin portion 45 is the same as that shown in FIG. 8 in the first embodiment. The metal wire 45a is sealed. Further, the light-absorbing resin portion 45 is formed to be higher than the light emitting surface of the submount 43, for example, about 0.3 mm in order to seal the entire metal wire 45a.

  In the present embodiment, similarly to the third embodiment, the first reflecting portion 304 and the third reflecting portion 306 of the reflector 30 are disposed so as to cover the light absorbing resin portion 45. Further, on the surfaces of the first reflecting portion 304 and the third reflecting portion 306 facing the mounting substrate 41, recesses 304a and 306a are formed at positions overlapping the light absorbing resin portion 45 in plan view. The depth of the recesses 304a and 306a is, for example, about 0.2 to 0.5 mm.

  In the present embodiment, the recesses 304a and 306a are formed at positions overlapping the light-absorbing resin portion 45 of the reflector 30, so that a margin between the upper end surfaces of the recesses 304a and 306a and the light-absorbing resin portion 45 is provided. Can be secured. Therefore, even when a variation of about 0.2 mm, for example, occurs in the height due to a manufacturing error when forming the light-absorbing resin portion 45, interference between the reflector 30 and the light-absorbing resin portion 45 can be prevented, and the reflector 30. It is possible to bring the reflecting surface of the light emitting device 43c closer to the light emitting surface of the light emitting element 43c.

  Further, as shown in FIG. 16, reflection surface lower portions 304b and 306b are formed at lower ends of the reflection surfaces of the first reflection portion 304 and the third reflection portion 306 to positions lower than the recess portions 304a and 306a, respectively. The upper end surfaces of the recesses 304a and 306a are located above the lower end of the reflection surface 30. As a result, the lower reflecting surface 304b, 306b can be brought closer to the light emitting surface of the submount 43 than the concave portions 304a, 306a, for example, to about 0.3 to 0.4 mm, and the reflecting surface of the reflector 30 can be made to the light emitting element 43c. It is possible to prevent interference between the reflector 30 and the light-absorbing resin portion 45 while further reducing the light loss by bringing them closer.

  Further, as shown in FIG. 16, the end of the submount 43 and the ends of the recesses 304a and 306a substantially coincide with each other in plan view, thereby preventing the recesses 304a and 306a from being formed wider than necessary. Thereby, the width | variety of the reflective surface lower parts 304b and 306b which protruded below from the recessed parts 304a and 306a can be ensured, and the intensity | strength of the reflective surface lower parts 304b and 306b can be ensured.

  FIG. 17 is a partial enlarged cross-sectional view schematically showing a modification of the reflector 30 of the present embodiment. FIG. 17A is an example in which a taper is formed in the recess 304a, and FIG. In this example, 304a is formed vertically, and FIG. 17C is an example in which the entire recess 304a is formed with a curved surface. The shape of the recessed part 304a shown to Fig.17 (a)-(c) is an example, and a shape is not limited. The same applies to the concave portion 306a formed on the surface of the third reflecting portion 306 facing the mounting substrate 41. Regardless of the shape of the recesses 304a and 306a, the upper end surfaces of the recesses 304a and 306a are farther from the mounting substrate 41 than the lower portions 304b and 306b of the reflection surface, and thus interference with the light-absorbing resin portion 45 can be prevented. .

  As described above, in the lamp unit 100 of the present embodiment and the vehicular lamp using the lamp unit, the reflecting surfaces are formed as light emitting elements by forming the recesses 304a and 306a at positions overlapping the light absorbing resin portion 45 of the reflector 30. Interference between the reflector 30 and the light-absorbing resin portion 45 can be prevented even if it is brought close to the surface.

  The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope shown in the claims, and embodiments obtained by appropriately combining technical means disclosed in different embodiments. Is also included in the technical scope of the present invention.

DESCRIPTION OF SYMBOLS 100 ... Lamp unit 10 ... Lens 20 ... Lens holder 30 ... Reflector 40 ... Light source module 50 ... Heat sink 60 ... Cooling fan 201 ... Holder side wall part 202a-202c ... Fixing part 203 ... Positioning pin 204 ... Side extension part 205a, 205b ... half-fitting prevention parts 206a and 206b ... erroneous assembly prevention part 301 ... substrate contact part 302a ... positioning hole 303 ... fixing hole 304 ... first reflection part 305 ... second reflection part 306 ... third reflection part 304a, 306a: Recesses 304b, 306b ... Reflection surface lower part 307 ... Connector concealing part 308, 309 ... Light extraction opening 400a ... Harness side connector 41 ... Mounting board 41a ... Metal plate 41b ... Adhesive sheet 41c ... Glass epoxy resin layer 42 ... Wiring Pattern 43 ... submount 43a ... submount substrate 43b ... submount arrangement 43c ... Light emitting element 43d ... Light reflecting resin portions 44a, 44b ... Power feeding connectors 44a1, 44b1 ... Power feeding connector mounting portion 45 ... Light absorbing resin portion 45a ... Metal wire 46 ... Resist layer 47 ... Optical member mounting region 48 ... Optical member Fixing part 49 ... Light emitting part mounting areas 49b, 49c ... Openings 502a to 502c ... Fixing hole 503 ... Positioning hole

Claims (4)

A lamp unit in which a light emitting element and a connector portion are mounted on a surface of a mounting substrate, a reflector is disposed in the vicinity of the light emitting element, and the light emitting element is disposed in the vicinity of a rear focal point of a projection lens,
The lamp unit, wherein the reflector is formed with a connector concealing portion that extends to a position overlapping the connector portion in a surface view of the mounting substrate and covers at least a part of the connector portion. The lamp unit according to claim 1,
The lamp unit, wherein the mounting substrate is arranged in a vertical direction, and the connector portion is arranged below the optical axis of the projection lens. The lamp unit according to claim 1 or 2,
On the mounting substrate, a metal wire that is a part of a power supply path to the light emitting element, and a wire protection resin portion that seals the metal wire,
The reflector is formed with a protective resin concealing portion that extends to a position overlapping the wire protective resin portion in a surface view of the mounting substrate and covers at least a part of the wire protective resin portion. Lamp unit to be used.   A vehicular lamp comprising the lamp unit according to any one of claims 1 to 3.