JP4345059B2 - Lighting device manufacturing method, lighting device and lighting apparatus - Google Patents

Description

  The present invention relates to a method for manufacturing a lighting device for lighting a discharge lamp such as a fluorescent lamp with improved waterproofness and dustproofness, a lighting device, and a lighting fixture.

In a lighting fixture installed outdoors or in a high humidity environment, a lighting device for lighting a discharge lamp included in the fixture may be exposed to high humidity, and thus the lighting device is required to be waterproof. Conventionally, in order to obtain such waterproof performance, the inverter lighting device is housed in a cylindrical case made of an integrally molded product having a seamless cross section, and both ends of the cylindrical case are closed with side plates, and these cylindrical cases are There is known a technique in which a waterproof case serving as an outer shell is formed by the side plate and the inverter lighting device is waterproofed with this waterproof case (see, for example, Patent Document 1).
Japanese Patent Laying-Open No. 2003-7212 (paragraphs 0004, 0005, 0008-0019, FIGS. 1 to 14, 17, and 19)

  In the technique of Patent Document 1, the inverter lighting device itself is assembled with a case that forms an outer case thereof. Since such a lighting device is accommodated in a waterproof case, the waterproof case that forms the outer case of the entire lighting device is large. It is a shape. Further, in addition to the assembly of the inverter lighting device, the labor for housing the device in the cylindrical case and the labor for assembling the waterproof case are required, which requires many man-hours for assembly. Therefore, as described above, in addition to an increase in cost due to the use of a large waterproof case itself, a large cost is required for assembling, so that the cost is high.

  An object of the present invention is to provide a lighting device having waterproof performance and improved assembly workability, and a lighting fixture including the same.

  In order to solve the problem, the invention of claim 1 includes a circuit board, various electrical components including a ground terminal mounted on the board and forming a lighting circuit, and a circuit board connected to the lighting circuit. Fabricate a circuit module with a cap-capped wire connector; place the circuit module in an insulating tray; expose the circuit module connector cap, and place the tray containing the circuit module in a conductive cover Fixing the cover together with the ground terminal of the circuit module and the tray, and electrically connecting with the cover; waterproofing and electrical insulation, filling the entire circuit module and filling the tray; and filling the filling material The manufacturing method of the lighting device is characterized by being connected to a covering case and a cover;

  The invention of claim 2 includes a circuit board, various electrical components including a ground terminal mounted on the board to form a lighting circuit, and a wire connector mounted on the circuit board connected to the lighting circuit and fitted with a connector cap. A circuit module provided; an insulating tray for accommodating the circuit module; a conductive cover for accommodating the tray in which the connector cap is exposed and the circuit module is accommodated; a ground terminal and a cover for the circuit module; A fixing means for electrical connection; a waterproof material and an electrical insulating material, a filling material filled in a tray by filling a part of the fixing means and the entire circuit module; and a case which is connected to a cover and covers the filling material A lighting device characterized by comprising:

  In the present invention, for the tray, a resin having a low material cost such as a synthetic resin and having a heat resistance that can withstand the temperature of the heat curing treatment of the filler, such as a PET resin, can be suitably used. The tray is preferably formed according to the size of each electric component arranged on the circuit board. As a result of forming the tray according to the size of the electrical component, the surface of the tray is uneven, which is effective for heat dissipation of the circuit module.

  Also, the tray can be provided with a hole of a size that exposes the connector cap. The connector cap is preferably made of rubber such as EPDM, and it is easy to expose from the tray by providing a step in the exposed part of the tray or by providing a taper toward the tip. Since it can be easily adhered, the filler to be filled later is not leaked.

  As the filler, a synthetic resin such as a silicon resin, a urethane resin, an epoxy resin, an unsaturated polyester resin, or the like can be used. Preferably, a urethane resin with a low material cost can be used, and higher heat dissipation can be obtained. For this purpose, silicon resin or unsaturated polyester resin may be used. In the present invention, the outer case composed of the cover and the case is electrically connected to the ground terminal of the circuit module so that it can function as a ground, and has good thermal conductivity in order to obtain the heat radiation performance to the outside. It may be made of metal such as aluminum alloy.

  The circuit board is provided with a ground terminal, and is preferably arranged upright perpendicular to the circuit board. When the circuit board is inserted into the tray and the cover, the ground terminal is fixed with screws or the like from the side surface of the cover to fix the circuit board, and the cover and the ground terminal are electrically connected.

  Then, the grounding terminal of the circuit module is electrically connected to the conductive cover and fixed by the fixing means, and then the charging material is filled. Even if a fixing screw is used as the fixing means, the screw portion is buried in the filler. By doing so, it is possible to obtain a sufficient waterproof function while providing a grounding function in the outer case.

  The invention of claim 3 comprises: an appliance body; a lamp socket attached to the appliance body; a discharge lamp removably supported by the socket; and attached to the appliance body to light the discharge lamp. And a lighting device according to 2 above. Since the lighting device provided in the lighting fixture of the present invention is the one described in claim 1 or 2, it is possible to provide a lighting fixture having a waterproof and performance and a small and inexpensive lighting device.

  According to the first aspect of the present invention, it is possible to manufacture a lighting device having a predetermined waterproof performance while grounding the circuit module and the outer case. According to the invention of claim 2, it is possible to provide a lighting device having a predetermined waterproof performance while grounding the circuit module and the outer case.

  According to invention of Claim 3, a lighting fixture provided with the lighting device which has the waterproof performance of Claim 1 or 2 and improved assembly workability | operativity can be provided.

  An embodiment of the present invention will be described with reference to FIGS.

  The luminaire denoted by reference numeral 1 in FIG. 1 is used with a favorable waterproof property as an outdoor lamp, a tunnel lamp installed in a tunnel, an eaves lamp of a station building, or the like. The lighting fixture 1 includes a fixture body 2, a lamp socket 3, a discharge lamp, for example, a straight fluorescent lamp 4, and a waterproof lighting device 5 that functions as an electronic ballast.

  The appliance main body 2 illustrated in FIG. 1 is made of metal and has a rectangular parallelepiped shape, and lamp sockets 3 are projected downward at both ends in the longitudinal direction, for example. The fluorescent lamp 4 is detachably supported by the lamp socket 3. A lighting device 5 for lighting the fluorescent lamp 4 is built in the instrument body 2. The lighting device 5 is configured as follows.

  As shown in FIGS. 2 to 4, the lighting device 5 includes an outer case 11 having a housing base 12 and a cover 15 connected thereto, a circuit module 21, a tray 41, and a filler 55. It has.

  The outer case 11 is. The housing base 12 and the cover 15 are preferably made of a metal, for example, an aluminum alloy having excellent heat dissipation, but can also be made of iron with a low material cost.

  As shown in FIG. 4, the circuit module 21 is an inverter circuit that includes a semiconductor such as a power transistor constituting a lighting circuit on a substrate 22, an electrical component 23 such as a resistor, a capacitor, a coil, a transformer, a diode, and other various chip components. Part. Reference numeral 26 denotes a power transistor with heat generation, which is one of the electrical components 23. Reference numeral 27 denotes a heat sink thermally connected to the power transistor 26. The heat sink 27 also serves as a ground for the circuit portion of the substrate 22. Thus, the heat radiating plate 27 is erected on the side edge so as to be perpendicular to the substrate 22.

  Moreover, the electric wire connector 24 is soldered to both ends of the substrate 22 in the longitudinal direction, and a core wire of an insulation coated electric wire (not shown) on the power source side (not shown) is inserted and connected to the electric wire connector 24. A core wire of an insulation coated electric wire (not shown) for wiring in the instrument is inserted and connected to the electric wire connector 25. The substrate 22 is provided with several cutouts 22a and through holes 22b on the side surface. The notches 22a and the through holes 22b are small ones of 3 mm or less, and are useful for pouring the filler 55 when filling the filler 55 described later.

  As shown in FIGS. 2 and 3, the storage base 12 has a bowl shape with a U-shaped cross section. The overall length of the housing base 12 is longer than the circuit board 22 described later. Fixing portions 13 each having a hole or a notch are formed at both ends in the longitudinal direction of the base wall 12a. The lighting device 5 is attached to the appliance main body 2 such that the base wall 12 a is brought into contact with the metal portion of the appliance main body 2 by a fixing component such as a screw passing through the fixing portions 13. Therefore, the accommodation base 12 functions as a heat transfer surface to the instrument body 2. Square holes 16 and 17 are individually opened at one end and the other end of the cover 15 in the longitudinal direction. One hole 16 is provided to expose an input-side connector cap 43 described later, and the other hole 17 is provided to expose an output-side connector cap 44 described later.

  The tray 41 functions as a filling container for filling the filling material 55. As shown in FIG. 3, the tray 41 is a film-shaped molded product made of an inexpensive electrical insulating material, for example, a PET resin, which is slightly smaller than the cover 15 and preferably has heat resistance.

  The connector caps 43 and 44 are made of rubber, for example. The connector caps 43 and 44 are formed so as to be tightly fitted to the input / output electric wire connectors 24 and 25 by elastic deformation thereof, provided with a step on the lower side of the outer surface, and provided with a taper toward the tip. Yes. Then, the circuit module 21 is accommodated in the tray 41 in a state where the connector caps 43 and 44 are fitted on the electric wire connectors 24 and 25 of the circuit module 21. In the tray 41, opening holes through which the connector caps 43 and 44 can be exposed are formed in both ends of the tray 41, and the steps provided in the connector caps 43 and 44 come into contact with the opening holes. 41 and the connector caps 43 and 44 can also be adhered elastically. With these fittings, the circuit module 21 is positioned with respect to the tray 41.

  The filler 55 is a synthetic resin having electrical insulation and waterproofing, and in this embodiment, a urethane resin mixed with an aluminum oxide filler (not shown) is used in order to improve heat dissipation. The filling material 55 is filled in the tray 41 by embedding the entire circuit module 21 accommodated in the tray 41.

  A method for manufacturing the lighting device will be described. First, the circuit component 23 is loaded on the circuit board 22 to complete the circuit module 21. Then, the tray 41 into which the circuit module 21 has been inserted is fitted and stored inside the cover 15, and the heat dissipation plate 27, which also serves as the cover 15 and the earth function, is fixed from the outside of the cover 15 by the fixing screw 18. By doing so, the circuit board 22, the tray 41, and the cover 15 are fixed, and the cover 15 and the ground terminal 27 are electrically connected.

  Next, the filling material 55 is filled in the tray 41. Since the filling material 55 is filled in the state where the tray 41 is fitted in the cover 15, the filling is easy because the tray 41 is supported by the cover 15. The filler 55 is filled in the entire area inside the tray 41 through a plurality of notches 22a and through holes 22b on both side edges provided on the substrate 22 of the circuit module 21. The filler 55 is cured by filling the tray 41 with the filler 55 and then passing it through a heat curing furnace. The tray 41 made of PET can exhibit sufficient heat resistance against the heat given by this heat treatment.

  In addition, since the heat sink 27 connected to the circuit board 22 and connected to the power transistor 26a that generates a large amount of heat passes through the side wall of the cover 15 and the fixing screw 18, heat conduction from the heat sink 27 to the cover 15 is achieved. And the ground connection with the cover 15 is reliable. Since the filler 55 is electrically insulating and waterproof, the filler 55 can waterproof the circuit board 22 of the circuit module 21, the electrical component 26, and their soldering surfaces. Furthermore, since the cover 15 and the ground terminal 27 are fixed after being filled, the filling material is also filled around the fixing screw 18, so that the fixing screw 18 exposed from the outer cover 15 is exposed. There is no risk of moisture, moisture, etc. coming into contact with the circuit board.

  Thereafter, the cover 15 is connected to the storage base 12. For example, this is performed by hooking a cut and raised piece formed on one side of the receiving base 12 and the cover 15 and raised on the inner side to a receiving part such as a hole or notch formed on the other, though not shown. It has been broken. Thus, the outer case 11 is formed, and the waterproof structure in the outer case 11 does not require a large waterproof case that accommodates the outer case 11, and can provide waterproof performance that can withstand a high humidity environment.

  For this reason, the lighting device 5 can be configured in a small size. Moreover, in addition to assembling the lighting device 5, there is no need for the trouble of housing the device 5 in the waterproof case and the trouble of assembling the waterproof case thereafter, so that the lighting device 5 can be easily assembled. As described above, since it is possible to eliminate the cost increase due to the use of the waterproof case itself, the cost for assembling can be reduced, so that the lighting device 5 and thus the lighting fixture 1 including the device 5 can be reduced in cost.

  Further, since the filling material 55 of the lighting device 5 has not only waterproof performance but also heat radiation performance, the heat of the power transistor 26 a and other electrical components that generate heat can be conducted to the outer case 11 through the filling material 55. In this case, since the capacity of the filler 55 is large and the heat conduction area from the filler 55 to the outer case 11 is large, excellent heat dissipation characteristics can be obtained. In particular, the use of the filler 55 mixed with a metal filler can further improve the heat dissipation characteristics. Moreover, since the filler 55 embeds the entire circuit module 21 as described above, the dust can be reliably prevented by the filler 55. Thereby, it can use suitably also as the lighting fixture 1 provided with the lighting device 5 used by this place with much dust and this device 5 by this.

The perspective view which shows the lighting fixture which concerns on one Embodiment of this invention. The perspective view which shows the lighting device which concerns on one Embodiment of this invention with which the lighting fixture of FIG. 1 is provided. Sectional drawing which follows the F3-F3 line | wire in FIG. The perspective view which shows the assembly of the lighting device which concerns on one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Lighting fixture, 2 ... Appliance main body, 3 ... Lamp socket, 4 ... Fluorescent lamp, 5 ... Lighting device, 11 ... Outer case, 12 ... Housing base, 15 ... Cover, 16, 17 ... Hole, 21 ... Circuit module, DESCRIPTION OF SYMBOLS 22 ... Circuit board, 23 ... Lighting circuit, 24 ... Electric wire connector, 26 ... Electrical component, 27 ... Ground and heat sink, 18 ... Fixing screw, 41 ... Tray, 55 ... Filler

Claims (3)

A circuit board, various electrical components including a ground terminal mounted on the board to form a lighting circuit, and a circuit module having a wire connector with a connector cap mounted on the circuit board connected to the lighting circuit are manufactured. ;
Contain the circuit module in an insulating tray;
Exposing the circuit module connector cap and storing the tray containing the circuit module in the conductive cover;
Fix the cover together with the circuit module ground terminal and tray, and make electrical connection with the cover;
A filling material that is waterproof and electrically insulating and that fills the entire circuit module and fills the tray;
Connected to the case and cover covering the filler;
A manufacturing method of a lighting device characterized by manufacturing. A circuit board, various electrical components including a ground terminal mounted on the board to form a lighting circuit, and a circuit module including a wire connector mounted on the circuit board connected to the lighting circuit and fitted with a connector cap;
An insulating tray for accommodating the circuit module;
A conductive cover that exposes the connector cap and houses the tray containing the circuit module;
Fixing means for electrically connecting the ground terminal of the circuit module and the cover;
A filling material that is waterproof and electrically insulating and that fills the tray by filling part of the fixing means and the entire circuit module;
A case connected to the cover and covering the filler;
A lighting device comprising: An instrument body;
A lamp socket attached to the appliance body;
A discharge lamp removably supported in the socket;
The lighting device according to claim 2, wherein the lighting device is attached to the fixture body and lights the discharge lamp;
The lighting fixture characterized by comprising.

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