JP5155293B2 - Manufacturing method of heat radiating part of LED bulb and heat radiating part of LED bulb - Google Patents

Description

  The present invention relates to a method of manufacturing a heat sink of an LED bulb that manufactures a heat sink (heat sink) of an LED bulb using a light emitting diode (LED) element as a light source, and a heat sink of an LED bulb manufactured by the manufacturing method. Specifically, the present invention relates to a method for manufacturing a heat sink of an LED bulb that manufactures a heat sink (heat sink) of an LED bulb from a blank material made of aluminum alloy by pressing or the like, and a heat sink of an LED bulb manufactured by the manufacturing method. .

  Lighting that uses a light emitting diode (LED) element as a light source is gradually penetrating the market due to its low power consumption and long life. Among them, a general light bulb type LED light bulb developed to replace existing light bulbs such as incandescent light bulbs and fluorescent lamps has attracted particular attention in recent years.

  However, the LED element of this LED bulb is very vulnerable to heat, and there is a problem that when the temperature exceeds the allowable temperature, the light emission efficiency is lowered and the life is also affected. In order to solve this problem, it is necessary to dissipate heat at the time of light emission of the LED element to the surroundings, and thus the LED bulb is provided with a large heat sink (heat dissipating part). In order to efficiently dissipate heat from this heat radiating part, it is necessary to increase the surface area of the heat radiating part as much as possible, but since the heat radiating part is formed integrally with the LED bulb body, There is a limit. Therefore, at present, the surface area of the heat radiating portion is made as large as possible by forming many heat radiating fins on the outer surface of the heat radiating portion.

  Many of the heat dissipating parts with many fins formed on the outer surface are made of die-cast aluminum alloy, so the manufacturing cost is high, and many heat dissipating fins are formed on the outer surface of the heat dissipating part. There is a problem that a mold having a complicated shape is required.

  Many technologies related to illumination using the LED element as a light source have been proposed in recent years, and a heat dissipating part formed integrally with an LED bulb is also disclosed in, for example, Patent Document 1 and Patent Document 2. The heat dissipating parts disclosed in these patent documents are also formed by forming many heat dissipating fins on the outer surface, and in Patent Document 1, the heat dissipating parts are made of aluminum and are integrally formed. There is also a description.

JP 2009-4130 A JP 2009-170114 A

  The present invention can produce a heat-radiating part of an LED bulb by performing drawing and knurling on a blank made of aluminum alloy, can reduce the production cost, and is die-cast made of an aluminum alloy. It is an object of the present invention to provide a method for manufacturing a heat radiating part of an LED bulb capable of obtaining a heat dissipation comparable to that of a heat radiating part made of LED, and a heat radiating part of an LED bulb manufactured by the manufacturing method. .

  Invention of Claim 1 is a manufacturing method of the heat sink of the LED bulb which manufactures the heat sink of the bulb which uses the LED element as the light source from the blank material made of aluminum alloy, and has a plate thickness of 0.3 to 2.5 mm A preliminary process of forming an aluminum alloy blank by drawing a plurality of times of pressing into a container-shaped heat radiation part having an opening, and a plurality of parallel arrangements on the outer peripheral surface of the heat radiation part formed in the preliminary process A finishing process including a knurling process for forming a groove to be formed. In the knurling process, the depth of the groove formed on the outer peripheral surface of the heat radiating portion is 0.2 to 2.0 mm and the width is 1.0 to 5 0.0 mm, and the number is 30 or more.

  The invention according to claim 2 is the heat radiating part of the LED bulb, which is manufactured by the method for manufacturing the heat radiating part of the LED bulb according to claim 1.

  According to the manufacturing method of the heat dissipation part of the LED bulb of the present invention, the heat dissipation part of the LED bulb can be manufactured by subjecting the aluminum alloy blank material to a drawing process and a knurling process by a plurality of press processes, and a complicated shape. No metal mold is required, and the manufacturing cost can be reduced as compared with conventional mold casting. Moreover, by using an aluminum alloy plate material having a higher thermal conductivity than aluminum alloy die-casting, heat dissipation is enhanced, and heat dissipation comparable to that of die-casting heat-radiating parts made of aluminum alloy is obtained. Can do.

  According to the heat radiating part of the LED bulb of the present invention, it is possible to ensure a heat dissipation comparable to that of a conventional die-casting heat radiating part regardless of the heat radiating part manufactured from the aluminum alloy blank.

It is a perspective view which shows the outer peripheral surface of the thermal radiation part of the LED bulb which concerns on one Embodiment of this invention. It is a perspective view which shows the internal peripheral surface of the thermal radiation part of the LED bulb which concerns on one Embodiment of this invention. It is a top view which shows the thermal radiation part of the LED bulb which concerns on one Embodiment of this invention. It is a longitudinal cross-sectional view which shows the state which concerns on one Embodiment of this invention and attached the LED element to the thermal radiation part of the LED bulb via the cover plate. It is a front view which shows the external appearance of the LED light bulb incorporating the heat radiating part which concerns on one Embodiment of this invention. It is explanatory drawing which shows the manufacturing method of the thermal radiation part of the LED bulb which concerns on one Embodiment of this invention later on in order of a manufacturing process, Comprising: In each manufacturing process, an upper stage is a top view and a lower stage is a longitudinal cross-sectional view. It is explanatory drawing which shows an example of the knurling process in the manufacturing method of the thermal radiation part of the LED bulb which concerns on one Embodiment of this invention, Comprising: (a) is the side view which showed only the thermal radiation part in cross section, (b) is die | dye. It is a longitudinal section.

  Hereinafter, the present invention will be described in more detail based on embodiments shown in the accompanying drawings.

  1 to 5 show a heat radiating portion of an LED bulb according to an embodiment of the present invention, FIG. 1 is a perspective view showing an outer peripheral surface of the heat radiating portion of the LED bulb, and FIG. 2 shows an inner peripheral surface of the heat radiating portion of the LED bulb. FIG. 3 is a plan view of the heat radiation part of the LED bulb, FIG. 4 is a longitudinal sectional view in which the LED element is attached to the heat radiation part of the LED bulb via a cover plate, and FIG. 5 is the overall shape of the LED light bulb. FIG.

  The heat radiation part 1 of the LED bulb according to the present invention is, for example, an aluminum alloy blank 1A (shown in FIG. 6) having a plate thickness of 0.3 to 2.5 mm made of a JIS 5000 series 5052 standard aluminum alloy material. It is formed by performing a drawing process by a plurality of press processes, and is formed into a container shape having an opening 1a, that is, a substantially cup shape. A plurality of parallel grooves 1b are formed on the surface (outer peripheral surface) by knurling. In addition, about the manufacturing method including the press work and knurl process from 1A of aluminum alloy blanks, it demonstrates in detail by description of the manufacturing method mentioned later.

  In order to efficiently dissipate the heat generated in the light emitting diode (LED) element 2 that is the light source of the LED bulb, which will be described later, the heat dissipating unit 1 needs to have as large a surface area as possible, The surface area is ensured by forming a plurality of grooves 1b on the outer peripheral surface of the heat dissipating part 1. The plurality of grooves 1b must have a depth of 0.2 to 2.0 mm, a width of 1.0 to 5.0 mm, and a number of 30 or more. In consideration of the fact that the depth and width of the plurality of grooves 1b are formed by knurling, it is desirable that all the grooves 1b have the same depth and width, but they are not necessarily the same.

  The depth of the groove 1b formed on the outer peripheral surface of the heat radiating portion 1 is 0.2 to 2.0 mm. If the depth of the groove 1b is less than 0.2 mm, the surface area required for heat dissipation cannot be ensured even if the number of the grooves 1b is increased as much as possible. On the other hand, it is impossible to make the depth of the groove 1b deeper than 2.0 mm considering the thickness of the aluminum alloy blank 1A. A more preferable depth of the groove 1b is 0.3 to 1.7 mm.

  The width | variety of the groove | channel 1b formed in the outer peripheral surface of the thermal radiation part 1 shall be 1.0-5.0 mm. In the groove 1b having a width of less than 1.0 mm, heat radiation from the outer peripheral surface of the heat radiating portion 1 cannot be sufficiently performed. On the other hand, when the width of the groove 1b is increased beyond 5.0 mm, the surface area required for heat dissipation cannot be ensured. A more preferable width of the groove 1b is 1.5 to 3.0 mm.

  The number of grooves 1b formed on the outer peripheral surface of the heat radiating portion 1 is 30 or more. If the number of the grooves 1b is less than 30, the surface area required for heat dissipation cannot be secured. On the other hand, the larger the number of grooves 1b formed on the outer peripheral surface of the heat radiating portion 1, the better, and the upper limit is not limited. However, although it depends on the size of the heat radiating portion 1, the upper limit of the actual number of the grooves 1b is considered to be about 80 in consideration of the size of a normal LED bulb. Further, the lower limit of the number of the more preferable grooves 1b is 70.

  An attachment base piece 1c for attaching the cover plate 3 is provided at the edge on the opening 1a side of the heat dissipating part 1 so as to protrude inward at equal intervals, and the cover plate 3 opens the opening 1a of the heat dissipating part 1. It attaches to this attachment base piece 1c so that it may coat | cover. Moreover, it is preferable that this cover plate 3 is formed with the material similar to the thermal radiation part 1, and in this embodiment, the cover plate 3 is formed with the shaping | molding material of the rolled plate of the Al-Mg type aluminum alloy of JIS5052. Has been. An LED element 2 serving as a light source of the LED bulb is attached to the surface of the cover plate 3. Since the cover plate 3 is configured as described above, the cover plate 3 is integrated with the heat radiating portion 1 and functions as a heat radiating plate.

  As described above, since the LED element 2 is attached to the heat radiating part 1 via the cover plate 3, the heat generated when the LED element 2 emits light is conducted to the heat radiating part 1 via the cover plate 3, and knurled. Heat is efficiently radiated into the outside air from the surface of the heat radiating portion 1 having a plurality of grooves 1b formed on the surface by processing.

  In addition, a hemispherical globe 4 is attached to the cover plate 3 so as to cover and diffuse the light emitted from the LED element 2 so as to cover the LED element 2. The globe 4 is made of, for example, milky white polycarbonate resin. Although not particularly illustrated, a drive part for causing the LED element 2 to emit light is accommodated in a cavity formed inside the heat radiation unit 1. Moreover, 5 shown in FIG. 5 is a cap part of the LED bulb.

  Next, based on FIG. 6, an example of the manufacturing method of the thermal radiation part of the LED bulb of this invention is demonstrated in order of a manufacturing process.

  (A) is a blank material 1A that is cold-rolled and heat-treated (tempered) with a plate thickness of 0.3 to 2.5 mm made of an Al—Mg-based aluminum alloy of JIS 5052. Since this aluminum alloy blank 1A is formed into a container shape having an opening 1a, that is, a substantially cup shape, by subsequent press working, it is preferably circular as shown in FIG. Since it is excised at the time of processing, it does not necessarily need to be circular.

  The aluminum alloy blank 1A is preferably a 5000 series aluminum alloy material in that it is formed into a container shape or a groove is formed on the outer peripheral surface, but a 3000 series aluminum alloy material, or 6000 series. An aluminum alloy material with good formability, such as an aluminum alloy material, may be used. Moreover, although the plate | board thickness of aluminum alloy blank 1A was 0.3-2.5 mm, when the plate | board thickness of aluminum alloy blank 1A exceeded 2.5 mm, the mass became too heavy and LED. It is not suitable for use as the heat radiating part 1 of a light bulb. On the other hand, when the plate thickness is thinner than 0.3 mm, it is difficult to form the groove 1b having a desired depth and width by knurling, which is not preferable from the viewpoint of manufacturing efficiency. A more preferable thickness of the aluminum alloy blank 1A is 0.5 to 2.0 mm.

  First, as shown in (b), this aluminum alloy blank 1A is subjected to a first press work to form an aluminum alloy blank 1A in a cup shape except for the periphery thereof. This press work is a press forming using a known punch, die, and blank holder, and the punch, die, and blank holder are not particularly shown, including the second and subsequent press work described later.

  In the first press work, as shown in (c), the second press work is performed on the aluminum alloy blank 1A formed in a cup shape except for the periphery. By the second press work, the aluminum alloy blank 1A becomes a deeper container, and a raised burring base is formed at the center.

  The preliminary step is the step of forming the aluminum alloy blank 1A into the container-shaped heat radiation portion 1 having the opening 1a by the drawing process including the above two press processes (b) and (c). In the above description, the preliminary process has been described with respect to the case where the aluminum alloy blank 1A is molded into the container-shaped heat radiation portion 1 having the opening 1a by performing a total of twice pressing. However, the number of press workings is not limited as long as the heat radiating part 1 can be formed into a desired shape.

  Next, in order to cut off the surrounding unnecessary portion from the heat radiating portion 1 formed in a desired shape after finishing the preliminary process, as shown in FIG. 4D, trim processing is performed by a trim die (not shown). However, at the time of the trim processing, a plurality of parts (three places at equal intervals in FIG. 6) are left around the heat dissipating part 1 to become the mounting base piece 1c. Simultaneously with the trim processing, hole processing is performed on the portions (three locations in FIG. 6) to be the mounting base piece 1c, and hole processing is performed on the base portion of the raised burring in the central portion of the heat radiation portion 1.

  Next, as shown in (e), knurling is performed to form 30 or more grooves having a depth of 0.2 to 2.0 mm and a width of 1.0 to 5.0 mm. This knurling process is a process of forming a notch (groove) in the surface of the work material (outer peripheral surface of the heat dissipating part 1). The die 6 is pressed strongly against the outer peripheral surface of the work material and is plastically deformed. Although it can implement by rolling, cutting, etc., an example of the knurling is shown in FIG. In this processing, a core metal 7 is fitted inside the heat radiating part 1 processed into a container shape in the above process, the heat radiating part 1 is rotated together with the core metal 7, and the die 6 whose surface has a jagged cross-sectional uneven shape. The knurling process is performed by pressing strongly against the outer peripheral surface of the heat radiating portion 1 to cause plastic deformation.

  Further, as shown in (f), after the mounting base piece 1c is edged (bent), the mounting base piece 1c shown in (g) is bent (bent), and the central portion of the heat radiating part 1 is formed. Burring processing is sequentially performed on the holes formed in the raised portions to complete the manufacture of the heat radiating portion of the LED bulb. The above is the finishing process.

DESCRIPTION OF SYMBOLS 1 ... Radiation part 1A ... Aluminum alloy blank 1a ... Opening 1b ... Groove 1c ... Mounting base piece 2 ... LED element 3 ... Cover plate 4 ... Globe 5 ... Base part 6 ... Die 7 ... Core metal

Claims (2)

It is a manufacturing method of a heat dissipation part of an LED bulb that manufactures a heat dissipation part of a light bulb using an LED element as a light source from an aluminum alloy blank,
A preliminary process for forming a container-shaped heat radiation part having an opening by performing drawing processing by pressing a plurality of times on a blank material made of aluminum alloy having a plate thickness of 0.3 to 2.5 mm, and the above-described preliminary process It consists of a finishing process including knurling that forms a plurality of parallel grooves on the outer peripheral surface of the heat dissipation part,
In the knurling process, the depth of the groove formed on the outer peripheral surface of the heat radiating portion is 0.2 to 2.0 mm, the width is 1.0 to 5.0 mm, and the number is 30 or more. The manufacturing method of the thermal radiation part of a LED bulb.   A heat radiating part for an LED bulb, which is manufactured by the method for manufacturing a heat radiating part for an LED bulb according to claim 1.

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