JP2022164277A - light source unit - Google Patents

Abstract

To reduce the costs of a light source unit, having a light emitting element and a substrate mounted with its lighting circuit supported by a heat sink while securing a sufficient heat radiation function of the heat sink.SOLUTION: A heat sink 60 is constituted in the form of a metallic extruded molding. Consequently, heat radiation effect on a light emitting element 40 is enhanced as compared with a case in which the heat sink is constituted in the form of a press molding etc., and the costs of a light source unit 30 are reduced as compared with a case in which the heat sink is constituted in the form a die cast molding etc. Then the heat sink 60 is constituted having a pair of right and left projection parts 66, extending in the lighting fixture front-rear direction, formed on a mount surface 62a for mounting the light emitting element 40 and substrate 50. Then the pair of right and left projection parts 66 engage the substrate 50, which is thereby positioned not only in the right-left direction, but also in the top-bottom direction. Consequently, the substrate 50 is easily positioned and supported by the heat sink 60 without employing screw fastening fixation.SELECTED DRAWING: Figure 5

Description

The present invention relates to a light source unit having a heat sink.

2. Description of the Related Art Conventionally, as a configuration of a light source unit in a vehicle lamp or the like, there has been known a structure in which a light emitting element and a substrate on which a lighting circuit for the light emitting element is mounted are supported by a heat sink for heat radiation.

In "Patent Document 1", as a configuration of such a light source unit, a light emitting element is electrically connected to a lighting circuit via a metal wire, and a plate-shaped heat sink is described as a configuration of the heat sink. It describes that the member is press-molded.

U.S. Patent No. 10208937

In such a light source unit, if a die-cast product or an extrusion-molded product is used as the heat sink instead of a press-molded product, it is possible to sufficiently secure the heat dissipation function. If it is used, it is possible to reduce the cost of the light source unit.

However, even if the heat sink is made of an extruded product, in the case where the substrate is fixed to the extruded product by general screwing, it is necessary to form the screw insertion holes in the substrate and post-process the screw holes in the heat sink. Therefore, it is difficult to reduce the cost of the light source unit.

The present invention has been made in view of such circumstances. It is an object of the present invention to provide a light source unit capable of achieving cost reduction.

The present invention is intended to achieve the above object by devising the configuration of the heat sink.

That is, the light source unit according to the present invention is
A light source unit comprising a light emitting element, a substrate on which a lighting circuit for the light emitting element is mounted, and a heat sink supporting the light emitting element and the substrate,
The light emitting element is electrically connected to the lighting circuit via a metal wire,
The heat sink is configured as a metal extrusion,
The heat sink protrudes in the first direction from the mounting surface at two locations, ie, a mounting surface for mounting the light emitting element and the substrate, and a first direction along the mounting surface. and a pair of protrusions formed to extend in a second direction orthogonal to
The heat sink positions the substrate with respect to the first direction and also positions the substrate with respect to a third direction perpendicular to the first and second directions by engaging the pair of protrusions with the substrate. It is characterized in that it is configured as follows.

The "heat sink" is not particularly limited in its specific material, shape, etc., as long as it is configured as an extruded product made of metal.

As long as the above-mentioned "pair of protrusions" is configured to position the substrate in the first and third directions by engaging with the substrate, the specific configuration for realizing this is particularly limited. not to be

The light source unit according to the present invention has a structure in which the light emitting element and the substrate on which the lighting circuit is mounted are separately supported by a heat sink, and the light emitting element is electrically connected to the lighting circuit via a metal wire. Therefore, the heat generated by the light emitting element can be efficiently dissipated from the heat sink.

At that time, since the heat sink is configured as an extruded product made of metal, it is possible to easily configure the heat sink to include a plurality of heat radiation fins or the like. Therefore, the heat dissipation effect for the light emitting element can be enhanced as compared with the case where the heat sink is configured by a press-molded product or the like. In addition, the cost of the light source unit can be reduced compared to the case where the heat sink is made of a die-cast molded product. a pair of protrusions formed to extend in a second direction perpendicular to the first direction while protruding from the placement surface at two locations in the first direction along the placement surface. , and a configuration in which the pair of protrusions are engaged with the substrate to position the substrate not only in the first direction but also in the third direction (that is, the direction orthogonal to the first and second directions). Therefore, the substrate can be easily positioned and supported by the heat sink without using a screw tightening structure or the like.

As described above, according to the present invention, in the light source unit in which the light emitting element and the substrate on which the lighting circuit is mounted are supported by the heat sink, the heat dissipation function of the heat sink can be sufficiently ensured, and the cost can be reduced.

In the above structure, each of the pair of protrusions is formed so that the tip protrudes in a direction toward each other, and the tip of the pair of side end faces of the substrate is at each corner of the substrate. If configured to abut against the portion, it is readily possible to position the substrate with respect to the first and third directions.

Alternatively, even if the pair of projecting portions are configured so that the tip portions extend in a direction toward each other, and the tip portions are crimped and fixed to the substrate, It is readily possible to position the substrate with respect to the first and third directions.

In the above configuration, a pair of projecting portions projecting in opposite directions to each other in the first direction is formed at one end of the substrate in the second direction. With the configuration in which the substrate is positioned in the second direction by contacting one end surface of the projecting portion in the second direction, the following effects can be obtained.

That is, if the substrate is too close to the light emitting element on the mounting surface of the heat sink, interference with the light emitting element occurs, and if the substrate is too far away from the light emitting element, the metal wires cannot be properly connected. It is possible to prevent problems such as heat generation from occurring due to the lack of heat.

At this time, by forming a slit extending in the second direction in a portion near the side end surface of the substrate, the portion of the substrate located between the side end surface and the slit is elastically deformed in the first direction. The pair of protruding portions of the substrate are arranged on the other end of the pair of side end surfaces of the substrate in the second direction, and the pair of protruding portions of the heat sink are aligned with each other. With a configuration in which a pair of engaging portions that engage with the other end surfaces of the pair of projecting portions when abutting on the end surfaces is formed, the substrate can be reliably positioned in the second direction.

The "slits" may be formed only in the vicinity of one side end face of the substrate, or may be formed in the vicinity of both side end faces of the substrate. In the latter case, the pair of "slits" may be formed to extend from the end face on the same side with respect to the second direction, or may be formed to extend from the end face on the opposite side.

In the above configuration, further, a groove extending in the second direction is formed in the mounting surface of the heat sink, and a through hole is formed in the substrate at a position facing the groove. If the substrate is fixed to the heat sink by a fixture inserted into the recessed groove through the through hole, the substrate can be perfectly positioned in the third direction.

A specific configuration of the "fixing tool" is not particularly limited, and for example, a screw, a clip, or the like can be used.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional side view showing a vehicle lamp having a light source unit according to one embodiment of the present invention; Detailed view of main parts in Fig. 1 Figure 2 III direction arrow view IV-IV line sectional view of Fig. 3 The perspective view which shows the said light source unit A view similar to FIG. 3 showing how the light source unit is assembled. 4, showing a light source unit according to a first modification of the above embodiment; FIG. FIG. 4 is a view similar to FIG. 3, showing a light source unit according to a second modification of the embodiment; IX-IX line sectional view of FIG. A view similar to FIG. 8 showing how the light source unit according to the second modification is assembled. FIG. 4 is a view similar to FIG. 3, showing a light source unit according to a third modification of the embodiment; FIG. 4 is a view similar to FIG. 3, showing a light source unit according to a fourth modification of the above embodiment; A view substantially similar to FIG. 9, showing a main part of a light source unit according to fifth and sixth modifications of the above embodiment.

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a side cross-sectional view showing a vehicle lamp 10 having a light source unit 30 according to an embodiment of the present invention, and FIG. 2 is a detailed view of the essential part of FIG. 3 is a view taken along line III in FIG. 2, and FIG. 4 is a cross-sectional view taken along line IV--IV in FIG.

In these figures, the direction indicated by X is the "front of the lamp", the direction indicated by Y is the "left direction" ("right direction" when viewed from the front of the lamp) orthogonal to the "front of the lamp", and the direction indicated by Z. is the "upward direction". The same applies to figures other than these.

As shown in FIGS. 1 to 4, a vehicle lamp 10 according to the present embodiment is a headlamp provided at the front end of a vehicle, and includes a lamp body 12 and a transparent lamp attached to the front end opening of the lamp body 12. A lamp unit 20 is incorporated in a lamp chamber formed by a light-transmitting cover 14 having a shape.

The lamp unit 20 has a configuration including a light source unit 30 and a reflector 70 .

The light source unit 30 includes three light emitting elements 40, a substrate 50 on which the lighting circuit 52 is mounted, and a heat sink 60 that supports them.

The reflector 70 has a reflective surface 70a on which a plurality of reflective elements 70s are formed. Each reflective element 70s reflects the emitted light from the three light emitting elements 40 toward the front of the lamp, thereby forming a desired light distribution pattern. is designed to form

The reflector 70 is supported by the heat sink 60 at a pair of left and right horizontal flanges 72 formed at its lower end.

Next, a specific configuration of the light source unit 30 will be described.

FIG. 5 is a perspective view showing the light source unit 30. FIG.

As shown in FIG. 5, the heat sink 60 is a metal (for example, aluminum) extruded product, and maintains a constant cross-sectional shape along a vertical plane orthogonal to the longitudinal direction of the lamp. It is formed so as to extend to

The heat sink 60 has a flat base portion 62 extending along a horizontal plane, and a plurality of radiation fins 64 extending vertically downward from the base portion 62 .

The base portion 62 has a laterally long rectangular outer shape in plan view, and its upper surface is configured as a mounting surface 62a for mounting the three light emitting elements 40 and the substrate 50 thereon.

The three light emitting elements 40 are white light emitting diodes having oblong rectangular light emitting surfaces 40a, and all have the same configuration.

The three light emitting elements 40 are arranged side by side in the left-right direction in the central front region of the mounting surface 62a of the heat sink 60 with the light emitting surfaces 40a facing upward. Each light emitting element 40 is adhered to the heat sink 60 with a thermally conductive adhesive.

The substrate 50 is a flat plate-shaped resin substrate, and includes a substrate body portion 50A formed in a substantially oblong rectangular shape, and a pair of left and right elastic pieces 50B and 50C extending in the longitudinal direction of the lamp. ing.

The substrate body portion 50A is mounted on the mounting surface 62a of the heat sink 60 on the rear side of the lamp of the three light emitting elements 40. As shown in FIG. The front edge of the substrate main body 50A is positioned near the rear of the three light emitting elements 40, and the rear edge is positioned on the rear side of the lamp with respect to the rear end surface of the heat sink 60. As shown in FIG.

Three pairs of conductive layers 52A and connectors 52B are arranged as lighting circuits 52 for the three light emitting elements 40 on the upper surface of the substrate main body 50A. Each of the three pairs of conductive layers 52A is formed to extend in a belt shape in the longitudinal direction of the lamp, and its front edge is located near the front end surface of the substrate 50. As shown in FIG. The connector 52B is mounted on the central rear region of the upper surface of the board main body 50A, and is opened toward the rear of the lamp while being electrically connected to the three pairs of conductive layers 52A.

Each light emitting element 40 is electrically connected via a metal wire 42 to each of the pair of conductive layers 52A located on the rear side of the lamp.

Each metal wire 42 is composed of an aluminum ribbon, and is formed so as to curve and extend like an arch. Each metal wire 42 is conductively fixed to each terminal portion 40b of the light-emitting element 40 at its front end by ultrasonic welding, and at its rear end is conductively connected to the front end of each conductive layer 52A by ultrasonic welding. Fixed.

The base portion 62 of the heat sink 60 is formed with a pair of protrusions 66 that protrude upward from two locations in the left-right direction on the mounting surface 62a.

The pair of left and right protrusions 66 are formed in a substantially rail-like shape with a symmetrical positional relationship with respect to the center position of the heat sink 60 in the left-right direction and a symmetrical shape.

Each of the pair of left and right projecting portions 66 has a tip portion 66a that protrudes toward each other in a wedge-shaped vertical cross section, and abuts on the substrate 50 at the tip portion 66a. Specifically, the tip portion 66a of each projecting portion 66 has its lower inclined surface in contact with the corner portion 50a1 on the upper end side of each side end surface 50a. Thereby, the substrate 50 is positioned with respect to the heat sink 60 in the horizontal direction and the vertical direction.

The plurality of radiation fins 64 are formed to extend in the front-rear direction of the lamp at regular intervals in the left-right direction. The thickness of each radiation fin 64 is set to be less than half the thickness of the base portion 62 .

A pair of slits 50b and 50c extending in the longitudinal direction of the lamp are formed in the vicinity of the pair of left and right side end faces 50a of the substrate 50, and the portion positioned between them constitutes a substrate body portion 50A. A portion positioned between the left side end face 50a and the left slit 50b is configured as an elastic piece portion 50B, and a portion positioned between the right side end face 50a and the right slit 50c is an elastic piece portion. It is configured as a section 50C.

The rear end positions of the elastic pieces 50B and 50C are set flush with the rear end position of the board main body 50A, but the front end positions are displaced to the front side of the lamp with respect to the board main body 50A. Specifically, each of the elastic pieces 50B and 50C is formed to extend linearly from a position on the rear side of the lamp from the rear end surface of the heat sink 60 to a position on the front side of the lamp from the front end surface of the heat sink 60. .

The left elastic piece 50B has a folded portion 50Ba that extends from the front end toward the rear side of the lamp in a folded manner, and the rear end of the folded portion 50Ba is connected to the left front end of the board main body 50A. It is On the other hand, the right elastic piece 50C is connected at its rear end to the right rear end of the board main body 50A. That is, the left slit 50b is formed as a slit that opens toward the rear of the lamp, and the right slit 50c is formed as a slit that opens toward the front of the lamp.

A pair of projecting portions 50d projecting in both the left and right directions are formed at the rear end portions of the pair of left and right side end surfaces 50a of the substrate 50. As shown in FIG. Each protruding portion 50d is formed to protrude in a rectangular shape from the rear end portion of each elastic piece portion 50B, 50C. The pair of left and right protruding portions 50d abut on the rear end surfaces of the pair of left and right projecting portions 66 of the heat sink 60, thereby positioning the substrate 50 with respect to the heat sink 60 in the longitudinal direction of the lamp.

A pair of left and right engaging portions 50e and 50f are formed at the front end portions of the pair of left and right side end surfaces 50a of the substrate 50. As shown in FIG. The engaging portions 50e and 50f are formed to protrude in a wedge shape from the distal end portions of the elastic pieces 50B and 50C. The pair of left and right engaging portions 50e and 50f engage with the front end surfaces of the pair of left and right projecting portions 66 when the pair of left and right projecting portions 50d abut on the rear end surfaces of the pair of left and right projecting portions 66. It's like As a result, the substrate 50 is reliably positioned with respect to the heat sink 60 in the longitudinal direction of the lamp.

A mounting surface 62a of the base portion 62 of the heat sink 60 is formed with a pair of left and right recessed grooves 62b extending in the front-rear direction of the lamp at positions further left and right from the pair of left and right protrusions 66. As shown in FIG.

As shown in FIG. 3, the horizontal flange portion 72 of the reflector 70 is formed with screw insertion holes 72a at two front and rear positions located right above the left groove portion 62b. Screw insertion holes 72b are formed in two front and rear positions positioned directly above and substantially right beside the screw insertion holes 72a. The two screw insertion holes 72a on the left side are formed with a circular cross section, and the two screw insertion holes 72b on the right side are formed with an oval cross section elongated in the left-right direction.

The reflector 70 has its horizontal flange portion 72 mounted on the mounting surface 62a of the heat sink 60, and tapping screws 74 are inserted into a pair of left and right recessed groove portions 62b through four screw insertion holes 72a and 72b. It is fixed to the heat sink 60 by being tightened.

The tapping screw 74 has a threaded portion 74a whose outer diameter is set to be slightly larger than the horizontal width of the concave groove portion 62b. It is designed to reliably engage with the recessed groove portion 62b.

The reflector 70 is formed with a notch 70b for avoiding interference with the pair of left and right protrusions 66 when the horizontal flange 72 is placed on the substrate 50 .

FIG. 6 is a view similar to FIG. 3 showing how the light source unit 30 is assembled.

First, as shown in FIG. 6A, three light emitting elements 40 are placed and fixed on the mounting surface 62a of the base portion 62 of the heat sink 60 in advance.

Next, with the heat sink 60 arranged horizontally, the substrate 50 is brought closer from the rear side of the lamp. At that time, while the substrate 50 is arranged between the pair of left and right protrusions 66 of the heat sink 60, the front ends of the pair of left and right side end surfaces 50a (that is, the front ends of the pair of left and right elastic pieces 50B and 50C) ) are brought into contact with the rear end surfaces of the pair of left and right protrusions 66 .

At this time, the pair of left and right engaging portions 50e and 50f are engaged with the tip portions 66a of the pair of left and right projecting portions 66. As shown in FIG.

Next, as shown in FIG. 6B, while maintaining the engagement state between the pair of left and right engaging portions 50e and 50f and the tip portions 66a of the pair of left and right projecting portions 66, the substrate 50 is further removed from the lamp. Move forward.

At this time, the substrate 50 moves toward the front of the lamp while the pair of left and right elastic pieces 50B and 50C are flexed and deformed. At this time, the folded portion 50Ba of the left elastic piece portion 50B is flexurally deformed, whereas the right elastic piece portion 50C itself is flexurally deformed. becomes larger. Therefore, the direction of the substrate 50 is slightly inclined to the right with respect to the longitudinal direction of the lamp.

Next, as shown in FIG. 6(c), the substrate 50 is further moved forward of the lamp between the pair of left and right projecting portions 66, and the rear ends of the pair of left and right elastic pieces 50B and 50C are moved. The formed pair of left and right projecting portions 50 d are brought into contact with the rear end surfaces of the pair of left and right projecting portions 66 .

At this time, since the substrate 50 is slightly inclined to the right with respect to the front-rear direction of the lamp, the projecting portion 50d of the left elastic piece portion 50B comes into contact with the rear end surface of the left projecting portion 66 first, and The engaging portion 50e engages with the front end surface of the left projection 66, and then the projecting portion 50d of the right elastic piece 50C contacts the rear end surface of the right projection 66, and the right engaging portion 50f is engaged. engages the front end face of the right protrusion 66 .

At this time, the board 50 is in a state in which the upper end corners 50a (see FIGS. 4 and 5) of the pair of left and right side end surfaces 50a are engaged with the tips 66a of the pair of left and right protrusions 66 of the heat sink 60. Become.

As a result, the substrate 50 is supported by the heat sink 60 while being positioned in the left-right direction, the up-down direction, and the front-rear direction of the lamp.

Next, as shown in FIG. 6D, for each of the three light emitting elements 40, a metal wire 42 is arranged so as to straddle the terminal portion 40b and the conductive layer 52A on the substrate 50 side. The front and rear ends are electrically connected by ultrasonic welding. This completes the assembly of the light source unit 30 .

Next, the effects of this embodiment will be described.

In the light source unit 30 according to the present embodiment, the light emitting element 40 and the substrate 50 on which the lighting circuit 52 is mounted are separately supported by the heat sink 60 , and the light emitting element 40 is connected to the lighting circuit 52 via the metal wire 42 . , the heat generated by the light emitting element 40 can be efficiently dissipated from the heat sink 60 .

At this time, since the heat sink 60 is formed as a metal extruded product and includes a plurality of heat radiation fins 64, the heat sink 60 is less likely to dissipate the light emitting element 40 than when the heat sink 60 is formed of a press molded product or the like. It is possible to enhance the heat dissipation effect for In addition, the cost of the light source unit 30 can be reduced compared to the case where the heat sink 60 is configured by a die-cast molded product or the like. The mounting surface 62a and the lamp front-rear direction (second direction perpendicular to the first direction) projecting from the mounting surface 62a at two locations in the left-right direction (first direction) along the mounting surface 62a. The pair of left and right protrusions 66 are engaged with the substrate 50 to move the substrate 50 not only in the horizontal direction but also in the vertical direction (the third direction). 1 and a third direction perpendicular to the second direction), the substrate 50 can be easily positioned and supported by the heat sink 60 without using screws. can.

As described above, according to the present embodiment, in the light source unit 30 in which the light emitting element 40 and the substrate 50 on which the lighting circuit 52 is mounted are supported by the heat sink 60, the heat dissipation function of the heat sink 60 is sufficiently ensured, and the cost is reduced. reduction can be achieved.

In this case, in the present embodiment, each of the pair of left and right projecting portions 66 is configured such that the tip portions 66a protrude in a direction toward each other, and the tip portions 66a protrude from the left and right sides of the substrate 50 at the tip portions 66a. Since the corners 50a1 of the pair of side end faces 50a are in contact with each other, the substrate 50 can be easily positioned in the left-right direction and the up-down direction.

In this embodiment, a pair of projecting portions 50d projecting in opposite directions to each other in the left-right direction are formed at the rear end portion (one end portion in the second direction) of the substrate 50. The substrate 50 is positioned in the longitudinal direction of the lamp by the pair of projecting portions 50d coming into contact with the rear end surfaces (one end surfaces in the second direction) of the pair of left and right projecting portions 66. effects can be obtained.

That is, on the mounting surface 62 a of the heat sink 60 , interference with the light-emitting element 40 occurs when the substrate 50 is too close to the light-emitting element 40 , and when the substrate 50 is too far away from the light-emitting element 40 , metal interference occurs. It is possible to prevent problems such as heat generation due to improper connection of the wire 42 .

Further, in this embodiment, a pair of left and right slits 50b and 50c extending in the longitudinal direction of the lamp are formed in the vicinity of the pair of left and right side end surfaces 50a of the substrate 50. A portion positioned between the side end surface 50a and the pair of left and right slits 50b and 50c is configured as a pair of left and right elastic piece portions 50B and 50C that can be elastically deformed in the left and right direction. When the pair of left and right projecting portions 50d abut on the rear end surfaces of the pair of left and right projecting portions 66, the front end surfaces of the pair of left and right projecting portions 66 (second Since a pair of right and left engaging portions 50e and 50f are formed to engage with the other end surface in the direction 2), the substrate 50 can be reliably positioned in the longitudinal direction of the lamp.

Moreover, in the substrate 50 of this embodiment, the slit 50b on the left side opens toward the rear of the lamp, while the slit 50c on the right side opens toward the front of the lamp, so that the substrate 50 is rotated clockwise. The pressing force to be pressed can be applied from the heat sink 60 via the pair of left and right elastic piece portions 50B and 50C. can be reliably maintained.

In the above embodiment, the pair of left and right elastic piece portions 50B and 50C are described as having mutually different shapes. A configuration having the same shape as the portion 50B or the same shape as the elastic piece portion 50C) is also possible.

In the above embodiment, the lighting circuit 52 is described as being composed of three pairs of conductive layers 52A and connectors 52B. IC chips, capacitors, etc.) can also be used, and a configuration including only three pairs of conductive layers 52A is also possible.

In the above-described embodiment, as the configuration of the lamp unit 20, the reflector 70 is fixed to the heat sink 60 via the pair of left and right recessed grooves 62b through the screw insertion holes 72a and 72b formed in the pair of left and right horizontal flanges 72. Although it has been described that the tapping screw 74 is tightened, a fixing structure other than the screw tightening structure (for example, a fixing structure similar to the positioning structure of the substrate 50 with respect to the heat sink 60, etc.) can also be adopted.

The lamp unit 20 according to the above-described embodiment has a configuration in which the reflector 70 is arranged above the light source unit 30 in which the three light emitting elements 40 are arranged with their light emitting surfaces 40a facing upward. Although the explanation has been given assuming that there is one, it is also possible to adopt a configuration in which the optical members such as the light source unit 30 and the reflector 70 are arranged in a manner other than this.

In the above embodiment, the vehicular lamp 10 in which the light source unit 30 is incorporated is described as a headlamp. It is also possible to configure the light source unit 30 to be used for applications other than vehicle lamps.

Next, the 1st modification of the said embodiment is demonstrated.

FIG. 7 is a view similar to FIG. 4 showing a light source unit 130 according to this modification.

As shown in FIG. 7, the basic configuration of this modified example is the same as that of the above embodiment, but differs from the above embodiment in that a pair of left and right fixtures 180 are additionally arranged. Accordingly, the configurations of the substrate 150 and the heat sink 160 are partially different from those of the above embodiment.

That is, the heat sink 160 of this modified example has a configuration in which a pair of left and right concave groove portions 162c extending in the longitudinal direction of the lamp are formed on the mounting surface 162a of the base portion 162 thereof.

The pair of left and right recessed grooves 162c are formed in a symmetrical positional relationship at positions closer to the center in the left-right direction than the pair of left and right protrusions 166 on the mounting surface 162a. Each concave groove portion 162c has a tip portion formed in a horizontally long rectangular vertical cross-sectional shape, and the base end portion thereof is narrower in lateral width than the tip portion.

The substrate 150 of this modified example is configured such that a pair of left and right through holes 150Aa are formed at positions facing the pair of left and right concave groove portions 162c in the substrate body portion 150A. Each through hole 150Aa is formed with an inner diameter dimension slightly larger than the lateral width of the base end portion of each concave groove portion 162c.

The pair of left and right fixtures 180 are resin clips, and are inserted into the pair of left and right recessed grooves 162c via the pair of left and right through holes 150Aa. , and its base end 180b is engaged with the mounting surface 162a. As a result, the substrate 150 is maintained in a state of being elastically pressed toward the heat sink 160 at two locations on the left and right.

By adopting the configuration of this modified example, it is possible to more reliably position the substrate 150 with respect to the heat sink 160 in the vertical direction.

In this modified example, it is assumed that the fixtures 180 are additionally arranged at two positions on the left and right, but it is also possible to adopt a configuration in which the fixtures 180 are additionally arranged at one position or at three or more positions.

Next, the 2nd modification of the said embodiment is demonstrated.

FIG. 8 is a view similar to FIG. 3 showing a light source unit 230 according to this modified example, and FIG. 9 is a cross-sectional view taken along line IX-IX of FIG.

As shown in FIGS. 8 and 9, the basic configuration of this modification is the same as that of the above embodiment, but the positioning structure between the substrate 250 and the heat sink 260 is different from that of the above embodiment. Accordingly, the configurations of the substrate 250 and the heat sink 260 are partly different from those of the above embodiment.

That is, the heat sink 260 of this modified example also has a base portion 262 having a laterally long rectangular outer shape in plan view, and a plurality of heat radiation fins 264 extending vertically downward from the base portion 262 . there is

The base portion 262 of the heat sink 260 is formed with a pair of substantially rail-shaped protrusions 266 that protrude upward from two locations in the left-right direction on the mounting surface 262a.

The pair of left and right projections 266 are formed in a symmetrical shape with respect to the central position of the heat sink 260 in the left-right direction. At this time, the pair of right and left protruding portions 266 are formed so that the distal end portions 266a of the protruding portions 266 extend in the vicinity of the upper portion of the substrate 250 in a substantially L-shape in a direction toward each other.

The substrate 250 of this modified example is also configured as a flat plate-shaped resin substrate, but has a lateral width larger than that of the substrate body portion 50A of the substrate 50 of the above-described embodiment (specifically, a pair of left and right protruding portions 266). It is formed in a substantially oblong rectangular shape with a lateral width slightly smaller than the interval. The substrate 250 is mounted on the mounting surface 262 a of the base portion 262 between the pair of left and right projecting portions 266 . At this time, the front edge of the substrate 250 is positioned in the vicinity of the rear of the three light emitting elements 40 , and the rear edge is positioned on the rear side of the lamp with respect to the rear end surface of the heat sink 260 .

A pair of rectangular projecting portions 250d projecting in both the left and right directions are formed at the rear end portions of the pair of left and right side end surfaces 250a of the substrate 250. As shown in FIG. The substrate 250 is positioned in the longitudinal direction of the lamp by the pair of left and right projecting portions 250d abutting the rear end surfaces of the pair of left and right projecting portions 266. As shown in FIG.

The substrate 250 is caulked and fixed to the heat sink 260 while being positioned in the longitudinal direction of the lamp. As shown in FIG. 9, this caulking is carried out by partially crushing the distal end portions 266a of the pair of left and right projecting portions 266 and crimping them onto the substrate 250. As shown in FIG. 9(a) shows the heat sink 60 before being fixed by caulking, and FIG. 9(b) shows the heat sink 60 after being fixed by caulking.

As shown in FIG. 8, a crimped fixing portion 266a1 formed at the tip portion 266a of each projecting portion 266 by crimping is positioned near the front end portion of the substrate 250. As shown in FIG.

A pair of left and right side end surfaces 250 a of the substrate 250 has a front end portion formed with a corner R for facilitating insertion of the substrate 250 from the rear side of the lamp between the pair of left and right projecting portions 266 of the heat sink 260 .

Also in this modified example, on the mounting surface 262a of the base portion 262 of the heat sink 260, a pair of left and right recessed grooves 262b extending in the longitudinal direction of the lamp are formed at positions further left and right from the pair of left and right protrusions 266. formed.

FIG. 10 is a view similar to FIG. 8 showing how the light source unit 230 is assembled.

First, as shown in FIG. 10A, three light emitting elements 40 are placed and fixed in advance on the mounting surface 262a of the base portion 262 of the heat sink 260. As shown in FIG.

Then, with the heat sink 260 horizontally arranged, the substrate 250 is approached from the rear side of the lamp, its front end portion is placed on the mounting surface 262 a of the base portion 262 , and between the pair of left and right projecting portions 66 . insert.

Next, as shown in FIG. 10(b), the substrate 250 is further moved toward the front of the lamp between the pair of left and right projecting portions 266, and the pair of left and right overhanging portions 250d is moved to the pair of left and right projecting portions 266. is brought into contact with the rear end surface of the

Next, as shown in FIG. 10C, the pair of left and right projections 66 are crimped and fixed to the substrate 50 using a crimping jig (not shown). Thereby, the substrate 50 is positioned with respect to the heat sink 60 in the left-right direction, the up-down direction, and the front-rear direction of the lamp.

Next, as shown in FIG. 10D, for each of the three light emitting elements 40, a metal wire 42 is arranged so as to straddle the terminal portion 40b and the conductive layer 52A on the substrate 250 side. The front and rear ends are electrically connected by ultrasonic welding. This completes the assembly of the light source unit 230 .

Even when the configuration of this modified example is employed, substantially the same effects as in the case of the above-described embodiment can be obtained.

That is, the heat sink 260 as an extruded product can be used, and the substrate 250 can be easily positioned and supported by the heat sink 260 without using a screw fastening structure. Accordingly, the cost of the light source unit 230 can be reduced while the heat dissipation function of the heat sink 260 is sufficiently ensured.

In this modified example, it is assumed that the crimping is performed at a position near the front end of the substrate 250 in each projecting portion 266. However, it is assumed that the crimping is performed at a plurality of locations or over the entire length of each projecting portion 266. is also possible.

Also in this modified example, it is possible to adopt a configuration in which the fixture 180 of the first modified example is additionally arranged.

Next, the 3rd modification of the said embodiment is demonstrated.

FIG. 11 is a view similar to FIG. 3 showing a light source unit 330 according to this modification.

As shown in FIG. 11, the basic configuration of this modified example is the same as that of the second modified example, but the configuration of the substrate 350 is partially different from that of the second modified example.

That is, the substrate 350 of this modified example is also formed in a substantially oblong rectangular shape with a lateral width slightly smaller than the interval between the pair of left and right protrusions 266 of the heat sink 260 , and the front edge of the board 350 is formed by the three light emitting elements 40 . Although positioned near the rear, the rear end edge is formed so as to be substantially flush with the rear end surface of the heat sink 260 . Further, in the substrate 350 of this modified example, the rear end portions of the pair of left and right side end surfaces 350a are not provided with what corresponds to the pair of left and right projecting portions 250d of the second modified example.

In this modification, the substrate 350 is mounted on the mounting surface 262a so as to be positioned between the pair of left and right projecting portions 266 of the base portion 262 of the heat sink 260, and a positioning jig (not shown) is mounted on the mounting surface 262a. ), the lamp is caulked and fixed to the heat sink 260 in the same manner as in the second modification.

Even when the configuration of this modified example is employed, substantially the same effects as in the case of the second modified example can be obtained.

Further, by adopting the configuration of this modified example, it is possible to reduce the size and simplify the configuration of the light source unit 330 .

Next, the 4th modification of the said embodiment is demonstrated.

FIG. 12 is a view similar to FIG. 3 showing a light source unit 430 according to this modification.

As shown in FIG. 12, the basic configuration of this modified example is the same as that of the second modified example, but the configurations of the board 450 and the lighting circuit 452 are partially different from those of the second modified example. there is

That is, the substrate 450 of this modified example is also formed in a substantially oblong rectangular shape with a lateral width slightly smaller than the interval between the pair of left and right protrusions 266 of the heat sink 260 . Further, the front edge of the substrate 450 is positioned in the vicinity of the rear of the three light emitting elements 40 , and the rear edge thereof is positioned on the rear side of the lamp with respect to the rear end surface of the heat sink 260 . Further, a pair of projections 450d projecting in the left and right directions in a rectangular shape are formed at the rear end portions of the pair of left and right side end surfaces 450a of the substrate 450. As shown in FIG.

However, in the substrate 450 of this modified example, the amount of rearward displacement of the rear edge of the substrate 450 from the rear end surface of the heat sink 260 is set to a larger value than in the case of the second modified example. A pair of left and right notch portions 450 e are formed at the rear edge of the substrate 450 . Each notch 450e is formed in a substantially rectangular shape on both left and right sides of the three pairs of conductive layers 452A.

Further, the lighting circuit 452 of this modified example is composed only of three pairs of conductive layers 452A. The three pairs of conductive layers 452A are formed to extend to the rear edge of the substrate 450. As shown in FIG.

A light source unit 430 according to this modified example is configured such that a power supply side connector 422 is attached to a substrate 450 thereof from the rear side of the lamp. The power-side connector 422 is a card edge connector, and is electrically connected to the lighting circuit 452 while being attached to the rear end of the substrate 450 so as to engage with the pair of left and right cutouts 450e. It's like

Even when the configuration of this modified example is employed, substantially the same effects as in the case of the second modified example can be obtained.

Further, by adopting the configuration of this modified example, it is possible to reduce the number of parts of the light source unit 430 and simplify the configuration.

Next, the 5th modification of the said embodiment is demonstrated.

FIG. 13(a) is a view substantially similar to FIG. 9, showing the essential parts of the light source unit according to this modification.

As shown in FIG. 13A, the basic configuration of this modified example is the same as that of the second modified example, except that a pair of left and right projecting portions 566 formed on the base portion 562 of the heat sink 560 are The shape is partially different from that of the second modification.

That is, also in this modified example, the pair of left and right projecting portions 566 are formed in a substantially rail shape so as to project upward from two locations in the left and right direction on the mounting surface 562a of the base portion 562 . Further, the pair of left and right projections 566 are formed so that their tip portions 566a extend in the vicinity of the upper part of the substrate 250 in the direction of approaching each other.

However, in this modified example, the tip portion 566a of each projecting portion 566 extends obliquely upward and then obliquely downward, and the portion located at the extreme end has a wedge-shaped cross section and faces vertically downward. It is configured as a formed claw portion 566a1.

Also in this modified example, the tip portions 566a of the pair of left and right projecting portions 566 are partially crushed and pressed against the substrate 250 as indicated by the two-dot chain line in FIG. 250 and the heat sink 560 are crimped and fixed.

At this time, the claw portions 566a1 of the tip portions 566a of the projecting portions 566 bite into the upper surface of the substrate 250, so that the substrate 250 is reliably positioned.

Even when the configuration of this modified example is employed, the same effects as in the case of the second modified example can be obtained.

Moreover, by adopting the configuration of this modified example, it is possible to ensure the positioning of the substrate 250 with respect to the heat sink 560 .

Next, the 6th modification of the said embodiment is demonstrated.

FIG. 13(b) is a view substantially similar to FIG. 9, showing a main part of the light source unit according to this modified example.

As shown in FIG. 13(b), the basic configuration of this modification is the same as that of the second modification, except that a pair of left and right projections 666 formed on the base portion 662 of the heat sink 660 The shape is partially different from that of the second modification.

That is, also in this modified example, the pair of left and right protrusions 666 are formed in a substantially rail shape so as to protrude upward from two locations in the left-right direction of the mounting surface 662a of the base portion 662 . The pair of left and right projecting portions 666 are formed so that the distal end portions 666a of the projecting portions 666 extend toward each other in the vicinity of the upper portion of the substrate 250 .

However, in this modified example, the tip portion 666a of each projecting portion 666 extends obliquely upward and then obliquely downward, and the portion located at the extreme end has a wedge-shaped cross-sectional shape, and each projecting portion extends downward vertically. It is configured as a claw portion 666a1 formed so as to face the direction toward the base end portion of the portion 666. As shown in FIG.

Also in this modified example, the tip portions 666a of the pair of left and right projecting portions 666 are partially crushed and pressed against the substrate 250 as indicated by the two-dot chain line in FIG. 250 and the heat sink 660 are caulked and fixed.

At this time, the claw portions 666a1 of the tip portions 666a of the projecting portions 666 bite into the upper surface of the substrate 250, so that the substrate 250 is reliably positioned. Moreover, since the claw portion 666a1 of each projecting portion 666 bites into the substrate 250 in a direction inclined toward the proximal end portion of each projecting portion 666, the substrate 250 is formed as indicated by the two-dot chain line arrow in FIG. 13(b). As shown, a tensile force acts in the left-right direction, whereby the substrate 250 is reliably maintained in surface contact with the mounting surface 662a of the base portion 662. As shown in FIG.

Even when the configuration of this modified example is employed, the same effects as in the case of the second modified example can be obtained.

Further, by adopting the configuration of this modified example, the positioning of the substrate 250 with respect to the heat sink 660 can be more reliably performed, and the substrate 250 can be reliably positioned with respect to the mounting surface 662 a of the base portion 662 . can be maintained in surface contact with the

As a result, when the front and rear end portions of the metal wire 42 (see FIG. 8) are ultrasonically welded to the terminal portion 40b of the light emitting element 40 and the front end portion of the conductive layer 52A, the substrate 250 is inadvertently vibrated and joined. It is possible to eliminate the possibility that a defect will occur or that the metal wire 42 will be damaged due to the resonance of the metal wire 42 due to the vibration of the substrate 250 .

It should be noted that the numerical values shown as specifications in the above-described embodiment and its modification are merely examples, and it goes without saying that these values may be set to different values as appropriate.

Moreover, the present invention is not limited to the configurations described in the above embodiments and modifications thereof, and configurations with various other modifications can be employed.

10 vehicle lamp 12 lamp body 14 translucent cover 20 lamp unit 30, 130, 230, 330, 430 light source unit 40 light emitting element 40a light emitting surface 40b each terminal portion 42 metal wire 50, 150, 250, 350, 450 substrate 50A, 150A Board main body 50B, 50C Elastic piece 50Ba Folding part 50a, 250a, 350a, 450a Side end face 50a1 Corner 50b, 50c Slit 50d, 250d, 450d Projecting part 50e, 50f Engaging part 52, 452 Lighting circuit 52A, 452A Conductive layer 52B Connectors 60, 160, 260, 560, 660 Heat sinks 62, 162, 262, 562, 662 Base portions 62a, 162a, 262a, 562a, 662a Mounting surfaces 62b, 262b Groove portions 64, 264 Radiation fins 66, 166 , 266, 566, 666 Projection 66a, 266a, 566a, 666a Tip 70 Reflector 70a Reflecting surface 70b Notch 70s Reflecting element 72 Horizontal flange 72a, 72b Screw insertion hole 74 Tapping screw 150Aa Through hole 162c Groove 180 Fixed Tool 180a Tip 180b Base end 266a1 Crimping fixing part 422 Power supply side connector 450e Notch 566a1, 666a1 Claw part

Claims (6)

A light source unit comprising a light emitting element, a substrate on which a lighting circuit for the light emitting element is mounted, and a heat sink supporting the light emitting element and the substrate,
The light emitting element is electrically connected to the lighting circuit via a metal wire,
The heat sink is configured as a metal extrusion,
The heat sink protrudes in the first direction from the mounting surface at two locations, ie, a mounting surface for mounting the light emitting element and the substrate, and a first direction along the mounting surface. and a pair of protrusions formed to extend in a second direction orthogonal to
The heat sink positions the substrate with respect to the first direction and also positions the substrate with respect to a third direction perpendicular to the first and second directions by engaging the pair of protrusions with the substrate. A light source unit characterized by: Each of the pair of projecting portions is formed such that the distal end portions protrude toward each other, and the distal end portions are in contact with the respective corners of the pair of side end surfaces of the substrate. 2. The light source unit of claim 1, wherein the light source unit comprises: 2. The light source unit according to claim 1, wherein the pair of projecting portions are formed so that tip portions extend in a direction toward each other, and are fixed to the substrate by caulking at the tip portions. . a pair of overhanging portions projecting in opposite directions toward the first direction are formed at one end portion of the substrate in the second direction;
The pair of protruding portions is configured to position the substrate in the second direction by contacting one end surface of the pair of projecting portions in the second direction. The light source unit according to any one of claims 1 to 3. A slit extending in the second direction is formed in a portion near the side end surface of the substrate,
a portion of the substrate positioned between the side end surface and the slit is configured as an elastic piece portion that can be elastically deformed in the first direction;
When the pair of protruding portions abut against the one end surfaces of the pair of protrusions at the other end portions in the second direction of the pair of side end surfaces, the other end surfaces of the pair of protrusions 5. The light source unit according to claim 4, wherein a pair of engaging portions that engage with are formed. a concave groove portion extending in the second direction is formed in the mounting surface,
A through hole is formed in the substrate at a position facing the concave groove,
6. The light source unit according to claim 1, wherein the substrate is fixed to the heat sink by a fixture inserted into the recessed groove through the through hole.

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