JP4534074B2 - High brightness LED light emitting part - Google Patents

Description

  The present invention relates to a high-intensity LED light emitting unit capable of emitting almost 100% of the light energy irradiated from a light-emitting body of a high-intensity LED with a directivity in a predetermined range in front.

  LEDs are excellent in conversion efficiency from electricity to light, with incandescent bulbs and halogen lamps, etc., 15% to 18% and fluorescent lamps only about 60%, more than 90%, providing extremely efficient energy-saving lighting It can be done. In addition, there is little heat generation and low power consumption. Furthermore, it has excellent durability and can achieve a life of 100,000 hours or longer. Further, the LED has a drawback in that the luminance is low, but in recent years, a high-intensity LED has been developed and the disadvantage has been solved.

  From the above advantages, a light emitting section using an LED as a light emitter has been developed, and various devices for providing directivity in the emission direction have been made as follows for the purpose of effectively using the light from the LED. Yes.

  The light emitting unit in FIG. 6 has an LED (A) disposed in the center of a parabolic curved reflector B, and reflects light rays radiated from diagonally forward or side of the LED (A) by the reflector B. In addition, directivity is given to the emission direction as parallel light beams forward from the front light transmitting body C. In this case, in order to obtain a large number of effective parallel rays, it is necessary to obtain parallel rays as reflected rays by using rays in the angle region of the radiation angle β1. Accordingly, in order to obtain the reflected light beam, it is necessary to project the reflecting mirror B forward and to form the extending portion S. As a result, the entire depth of the reflecting mirror B is greatly increased.

  7 has a convex lens E on the front side of the LED (D) and a curved reflector F continuous to the convex lens E, and is irradiated from the front side and the diagonally front side of the LED (D). The projected light beam is emitted as a parallel light beam in the optical axis direction by the convex lens E, and the light beam irradiated from the diagonally forward and lateral directions is reflected on the back side of the reflector F so that the parallel light beam in the optical axis direction is obtained. It is comprised so that it may be obtained. The above configuration also had the same disadvantages as described above.

In the light emitting section of FIG. 8, a parabolic curved reflector H is disposed on the front side of the LED (G), and an installation plate I is disposed on the back side. The light beam emitted from the LED (G) is totally reflected by the reflecting mirror H and emitted from the light exit surface J in the optical axis direction.
JP-A-6-32171

  As described above, the light-emitting part corresponding only to the parabolic curved reflector needs to form a deeply reflective mirror in order to make the directivity of the light beam the optical axis direction, and the thickness of the light-emitting part is At the same time, there were many drawbacks, and there were many rays that became diffuse light, and the directivity was poor.

  In addition, the light emitting unit provided with the convex lens on the front surface emits light rays emitted forward and obliquely forward in the optical axis direction, but rays in the region of the radiation angle β2 emitted obliquely from the front to the side. Therefore, it is necessary to make the light emitting part thick as described above.

  Furthermore, the light emitting part having a paraboloidal reflecting mirror disposed on the front surface can obtain light rays parallel to the optical axis direction, but cannot directly emit light from the central part of the light emitting part, and the balance is good. There was a drawback of being bad. Further, the LED installation process and the communication process with the power source are complicated, and there is a great drawback in manufacturing.

  In consideration of the above-described drawbacks, the present invention improves light emission, improves irradiation efficiency, and obtains a light emitting part with sufficient luminance.

  In the light emitting part in which the reflecting means is provided on the back side and the high brightness LED is arranged at the center position, the front side of the high brightness LED and the reflecting means is integrally covered with a covering made of epoxy resin, and the surface of the covering And a reflecting means comprising a first reflector on the center side having a curved surface made of a metal material, and a ring-shaped body having a sawtooth cross section formed continuously around the first reflector. It is characterized by a high-intensity LED light-emitting unit that comprises two reflectors.

  The curved surface of the first reflector is characterized by a high-intensity LED light-emitting unit formed with a reflection curvature that allows a light beam reaching the spot to be emitted from the light output surface as a light beam parallel to the optical axis.

  The second reflector forms a suitable number of planes that rise and incline outward from the troughs having a serrated cross section, and the light beams that reach the respective planes are emitted as parallel light beams with respect to the optical axis. It is characterized by a high-intensity LED light emitting part formed at an inclination angle that can be emitted from the surface.

  Further, the covering body is characterized by a high-luminance LED light-emitting portion in which a substantially hemispherical condensing convex lens is formed on the front surface of the high-luminance LED arrangement position and the outer peripheral surface thereof is used as a light exit surface.

  In addition, the condensing convex lens is characterized by a high-intensity LED light emitting unit formed by projecting from a position where an irradiation light beam from the high-intensity LED becomes a critical angle with respect to a flat light exit surface.

  Further, the covering body is characterized by a high-intensity LED light-emitting portion that surrounds the front side and the side surface of the reflecting means and is formed integrally with the reflecting means.

  The high-intensity LED light-emitting part of the present invention uses a thin high-intensity LED as a light emitter, and can reduce the thickness of the entire light-emitting part by forming an efficient reflecting means and a light-emitting surface. It became.

  Of the light rays emitted from the light emitter, the light rays directly emitted from the light exit surface of the cover are converted into parallel light rays in the direction of the optical axis by the condensing convex lens and totally reflected beyond the critical angle on the light exit surface. The reflected light can be re-reflected by the reflecting means and emitted from the light exit surface as a parallel light beam in the optical axis direction.

  Further, the light beam that is irradiated obliquely forward and sideward from the light emitter and directly reaches the reflecting means can be emitted as a parallel light beam in the optical axis direction as reflected light by the first reflector formed on the curved surface. became.

  Therefore, it becomes possible to emit all the light rays emitted from the light emitter as parallel light rays in the optical axis direction, and the directivity of the light rays is remarkably increased.

  In addition, since the epoxy resin is used as the covering, the high-intensity LED is not destroyed in the manufacturing process, and the high-intensity LED is in contact with the reflecting means on the back side, and the reflecting means is made of metal. Since it is formed, the heat generated by the light emission of the high-intensity LED can be thermally dispersed through the metal, and heat is not accumulated inside.

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

1 to 5 show cross-sectional views of the high-intensity LED light-emitting portion of the present invention.
The high-intensity LED light-emitting unit 1 includes a light emitter 2, a first reflector 3, a second reflector 4, a translucent covering 5, and a condensing convex lens 6.

The high-intensity LED serving as the light emitter 2 has an LED element disposed on a lead frame, one side is continuous to a lead portion directly mounted on the lead frame, and the other side is connected to another lead portion via a bonding wire. Each lead portion protrudes outward from the first reflector 3 and is connected to the power supply means.
When the lead wire is connected to a power supply voltage such as a dry battery, a circuit is formed through a current limiting resistor. When the voltage fluctuates like an automobile, a constant current diode or the like is used. The voltage may be about 3 to 24V.

The periphery of the LED element and the base portion of the lead portion are molded with an epoxy resin. The epoxy resin serves to protect the LED element while increasing the total reflection angle on the surface of the LED element and increasing the light extraction rate. Since the LED element has low heat resistance, an epoxy resin having a low melting point is employed.
As the high-brightness LED, those having a size of about 0.6 mm × 0.6 mm in length and width and about 0.1 mm in thickness are employed. A magnitude | size is not specifically limited, The thing of a magnitude | size can be employ | adopted suitably.

  The first reflector 3 is formed over a wide range from the back side and the side of the light emitter 2 in the center to the diagonally front. A curved curved surface 3a is formed that forms a parabolic curved surface that reflects the light beam emitted from the light emitter 2 disposed at the center thereof toward the front optical axis direction. In addition, a plurality of serrated cross-sectional irregularities are formed around the first reflector 3, and a second reflector that re-reflects the totally reflected light beam reflected by the surface of the cover 5 forward. 4 is formed.

The first reflector 3 and the second reflector 4 are continuously formed of a metal material having a smooth surface, and the curved surface 3a and the saw-tooth reflective surfaces 4a, 4b,. Shall be.
The curvature of the curved surface 3a of the first reflector 3 employs a numerical value capable of re-reflecting light rays directly irradiated on the curved surface 3a in a square direction with respect to the optical axis.

  Further, the second reflector 4 irradiates a light beam 2 which is irradiated from the diagonally forward side to the side and totally reflected beyond the adjacent field angle on the light exit surface 7 of the cover 5. A reflective surface is formed that is re-reflected by the first plane 4a, the second plane 4b, and the third plane 4c that are inclined upward and outward from the portion.

The covering 5 covers the exposed portions of the light emitting body 2 and the surfaces and side surfaces of the first reflector 3 and the second reflector 4. As described above, the high-brightness LED that becomes the light-emitting body 2 is molded with an epoxy resin, but an epoxy resin that is the same as the molding material is poured into the exposed portion to form the cover 5. Since the periphery of the high-brightness LED is formed of an epoxy resin, it is good to use the epoxy resin for the covering 5 and there is a risk that the high-brightness LED may be damaged by heat during manufacture. Absent.
Further, in the production of the cover 5 using the epoxy resin, the first reflector 3 and the second reflector 4 serve as a mold for pouring, and a press mold only for the side portion is formed. Then, the covering 5 can be reliably covered over the entire surface of the first reflector 3 and the second reflector 4 and the entire side surface.

In addition, since the covering body 5 is formed of the metal material for the first reflector 3 and the second reflector 4, the state of adhesion with them is good and is firmly connected.
Further, the peripheral portion of the covering 5 is covered so as to cover the side of the second reflector 4 to form a reinforcing portion 5a. Further, the step 10 provided on the side of the second reflector 4 is provided. The covering body 5 is turned around from the side surface 11 to the bottom surface 12 to form a locking portion 5b, and the connection between the first and second reflectors 3 and 4 and the covering body 5 is made stronger.

  A hemispherical condensing convex lens 6 is integrally formed at the center of the surface side of the covering 5. Of the light rays emitted from the light emitter 2, the light rays from the angle region α1 reaching the light exit surface 8 of the condenser convex lens 6 are refracted at the light exit surface 8, and as shown in FIG. The emitted light is parallel to the Y direction.

FIG. 2 shows the irradiation direction of the light beam irradiated from the light emitter 2 in the angle region α2.
The light beam irradiated from the angle region α2 of the illuminator 2 is a region adjacent to the angle region α1 to the condensing convex lens 6 and deviates from the converging convex lens 6, and the incident angle to the light exit surface 7 exceeds the critical angle. Since it is a region, it is totally reflected at the light exit surface 7, reaches the first inclined plane 4 a of the second reflector 4, re-reflects at that portion, and is reflected from the light exit surface 7 as a parallel beam with respect to the optical axis Y. It will be emitted.

  Furthermore, as shown in FIG. 3, the light beam irradiated from the angle region α3 obliquely forward of the light emitter 2 adjacent to the light beam angle region α2 is a region where the incident angle on the light exit surface 7 exceeds the critical angle. Therefore, the light is totally reflected at the light exit surface 7, reaches the second inclined plane 4 b of the second reflector, re-reflects at the portion, and is emitted from the light exit surface 7 as a parallel beam with respect to the optical axis Y. Become.

  Further, as shown in FIG. 4, the light beam irradiated from the angle region α4 obliquely forward of the light emitter 2 adjacent to the light beam angle region α3 is a region where the incident angle to the light exit surface 7 exceeds the critical angle. Therefore, the light is totally reflected at the light exit surface 7, reaches the third inclined plane 4 c of the second reflector 4, is reflected again at the portion, and is emitted from the light exit surface 7 as a parallel light beam with respect to the optical axis Y. become.

  Further, as shown in FIG. 5, the light beam irradiated from the angle region α5 extending obliquely from the front side to the side of the light emitter 2 adjacent to the light beam angle region α4 directly reflects the curved surface of the first reflector 3. 3a, the light is totally reflected by the portion, and is emitted from the light exit surface 7 as a parallel light beam with respect to the optical axis Y.

  As described above, all irradiation light beams from the front side to the side of the light emitter 2 are effectively emitted as parallel light beams forward with respect to the optical axis Y.

  As described above, the entire light emitting body 2 is surrounded by the covering body 5, so that it is necessary to effectively dissipate heat generated from the light emitting body 2. In the present embodiment, since the first reflector 3 and the second reflector 4 are made of metal materials, the light emitter 2 that is in contact with the metal material is generated due to the high thermal conductivity of the metal material. The generated heat can be efficiently dissipated through the metal material without staying in the light emitting body 2 or in the molded epoxy resin, thereby preventing the internal temperature from rising.

Sectional drawing which shows the state of the light ray irradiated to the condensing convex lens from the light-emitting body of the high-intensity LED light emission part of this invention, and radiate | emitted. Sectional drawing which shows the state in which the light ray irradiated from the light-emitting body of the high-intensity LED light emission part of this invention is totally reflected, and is re-reflected from the 2nd reflector. Sectional drawing which shows the state in which the light ray irradiated from the light-emitting body of the high-intensity LED light emission part of this invention is totally reflected, and is re-reflected from the 2nd reflector. Sectional drawing which shows the state in which the light ray irradiated from the light-emitting body of the high-intensity LED light emission part of this invention is totally reflected, and is re-reflected from the 2nd reflector. Sectional drawing which shows the state in which the light ray irradiated from the light-emitting body of the high-intensity LED light emission part of this invention is reflected by the 1st reflector. Sectional drawing of the prior art example of LED light emission part. Sectional drawing of the other conventional example of a LED light emission part. Sectional drawing of the other conventional example of a LED light emission part.

Explanation of symbols

1. High brightness LED light emitting part
2. Light emitter
3. First reflector
3a. Curved surface
4. Second reflector
4a. First inclined plane
4b. Second inclined plane
4c. Third inclined plane
5. Cover
6. Condensing convex lens
7.8. Light emitting surface

Claims (2)

In the light emitting part in which the reflecting means is provided on the back side and the high brightness LED is arranged at the center position, the front side of the high brightness LED and the reflecting means is integrally covered with a covering made of epoxy resin, and the surface of the covering And a reflecting means comprising a first reflector on the center side having a curved surface made of a metal material, and an annular body having a sawtooth cross section formed continuously around the first reflector. It is composed of a second reflecting member,
The curved surface of the first reflector is formed on a reflective curvature surface that can emit light from the light exit surface as light parallel to the optical axis.
The second reflector forms a suitable number of planes that rise upward from the troughs having a sawtooth cross section, and re-reflects the total reflected light reflected by the surface of the covering that has reached each of the planes. And formed at an inclination angle that can be emitted from the light exit surface as a parallel light beam with respect to the optical axis,
A substantially convex hemispherical condensing convex lens is formed on the front surface of the high luminance LED arrangement position on the cover, and light emitted directly from the light emitting surface is emitted by the converging convex lens with its outer peripheral surface as the light emitting surface. A parallel outgoing beam in the axial direction,
The peripheral part of the cover is covered to cover the side of the second reflector to be a reinforcing part, and the cover is wound from the side surface to the bottom of the step provided on the side of the second reflector. A high-luminance LED light-emitting unit characterized in that the locking part is used to make the connection between the first reflector and the second reflector and the cover stronger.   2. The high-intensity LED light emitting unit according to claim 1, wherein the condensing convex lens is formed so as to protrude from a position where a light beam emitted from the high-intensity LED becomes a critical angle with respect to a flat light exit surface.

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