JP5584668B2 - LED unit manufacturing method - Google Patents

Description

Relates to a manufacturing method of the present invention is the LED unit, in particular a plurality of LED elements be comprised disposed in a plane, the manufacturing method of the LED unit can be a display device having a large screen by arranging further plurality of these About.

  Display devices installed on the walls of stadiums and buildings are sized on the screen according to the range in which services are provided. When the service provision range is wide, that is, in order to make it visible from a distance, the screen size is simply increased. However, it is necessary to consider the height of the installation location of the display device and the installation method in order to make it visible from near.

  When the service provision range is narrow, for example, a display device installed for guidance in a large waiting room is tilted when installing the display device so that it can be seen from as close as possible. To be done. This is because the display elements that constitute the display device have a viewing angle that cannot be normally viewed when viewed from the front in the horizontal and vertical directions. When the viewing angle is small, the viewing distance is long, and when the viewing angle is large, the viewing distance is short. For this reason, when a display device using a display element with a small viewing angle is installed at a high place, the display device can be seen from a short distance by tilting the display device downward.

  However, in the case of a display device with a large screen, since the display device itself is heavy, it is difficult to install the display device tilted. Therefore, it is known that the optical axis of the LED unit constituting the display device can be changed in the vertical direction (see, for example, Patent Document 1). According to the structure described in Patent Document 1, the panel has an elongated panel extending in the horizontal direction, and has a shaft at which the panel can be pivoted forward so that a plurality of LED units are arranged in the horizontal direction. Are mounted side by side. In order to change the optical axis of the LED unit in the vertical direction, the panel is inclined and the panel is fixed with bolts at a desired angular position.

Japanese Patent Laid-Open No. 2000-200054

  However, in the above structure, the horizontal LED units fixed to the same panel can all change the optical axis at the same time, but this adjustment is the same and the same for the vertically arranged panels as well. There was a problem that it was necessary to adjust the angle. In addition, each LED unit is arranged on the same plane in the horizontal direction, but is not on the same plane in the vertical direction. Therefore, the image is displayed in a direction other than the direction in which the lower side and the upper side of the adjacent LED units match. There was a problem that sometimes overlapped or separated.

  Further, the current LED unit has a problem that the LED element and the printed circuit board on which the LED element is mounted can be mounted only vertically due to manufacturing problems such as equipment and cost.

The present invention has been made in view of the above points, and can display an image with the optical axis directed downward without having a complicated configuration and a variable mechanism, and can be manufactured with conventional equipment and cost. It aims at providing the manufacturing method of a unit.

In the present invention, in order to solve the above-described problem, in a method of manufacturing an LED unit configured by arranging a plurality of LED elements in a plane, the bullet-shaped portion of the LED elements is separated from the printed circuit board by a predetermined distance. It is, and the LED element mounted on the printed circuit board by soldering the lead wire in a state oriented in a direction perpendicular to the plane of the printed circuit board, perpendicular to the mounting surface of the front Symbol PCB an optical axis of the LED element on the side of the front cover you have the LED element holes drilled in the direction inclined with respect to the direction the LED elements of the printed circuit board is mounted is mounted on the printed circuit board wherein the opening center of the rear surface side opening of the LED element holes formed in the front cover is arranged to coincide, one of the printed circuit board and the front cover and or Closes both sides to fit the hemispherical portion at the tip of the LED element into the LED element hole, and to align the optical axis center of the LED element with the axis center of the LED element hole. One or both of the covers are moved relative to each other to bend the lead wire of the LED element, and one or both of the printed circuit board and the front cover are moved in parallel in the direction of the axial center of the LED element hole. A method for manufacturing an LED unit is provided, in which the bullet-shaped portion is mounted in the LED element hole .

According to such an LED unit manufacturing method , the printed circuit board is moved with respect to the front cover so that the axial centers of the LED elements coincide with each other while the hemispherical portion at the tip of the LED element is fitted in the hole for the LED element. Therefore , it can change so that the optical axis of an LED element may turn to the same direction all at once.

  The LED unit having the above-described configuration has an advantage that the optical axis of the LED element can be changed without tilting the LED unit because the LED element hole for accommodating the LED element is formed obliquely.

  Since the optical axis of the LED unit is changed by the optical axis of the LED element, the display device installed at a high place where the LED units are arranged is a complicated mechanism for changing the optical axis as in the prior art. Since the display screen is always installed vertically, the image can be displayed without being disturbed depending on the viewing direction.

  In addition, even when the display screen of a display device installed at a high place has the same height, it is possible to see from a short distance compared to a conventional LED unit, and the service is improved. In addition, it is not necessary to provide a complicated mechanism for the design of the display device, so it can be designed easily, the product cost can be reduced, and there is no complicated mechanism at the time of installation or adjustment after installation. It can be carried out. Moreover, since the number of parts constituting the LED unit does not change from the conventional one, the conventional equipment can be used, and the manufacturing cost can be made equivalent to the conventional one.

It is a figure which shows the external appearance of the LED unit which concerns on 1st Embodiment, Comprising: (A) is a front view of an LED unit, (B) is AA arrow sectional drawing of (A). It is explanatory drawing which shows the interconnection relation of the component of an LED unit. It is a figure which shows the example of the printed circuit board which mounted the LED element. It is a figure which shows the assembly procedure of an LED unit, (A) shows the state before the assembly of the main body frame to which the printed circuit board was fixed, and a front cover, (B) shows the state which the LED element contacted the front cover. (C) shows a state in which the LED element is mounted in the LED element hole. It is a partial expanded sectional view of the LED unit which concerns on 2nd Embodiment. It is a partial expanded sectional view which shows the state in the middle of the assembly of the LED unit which concerns on 3rd Embodiment. It is a partial expanded sectional view which shows the state after the assembly of the LED unit which concerns on 3rd Embodiment. It is a partial expanded sectional view which shows the LED unit which concerns on 4th Embodiment. It is a partial expanded sectional view which shows the LED unit which concerns on 5th Embodiment. It is the partial expanded sectional view which shows the LED unit which concerns on 6th Embodiment, (A) is a fragmentary sectional view which shows the mounting state of an LED element, (B) is B arrow directional view of the hole for LED elements. (Partial front view).

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a diagram illustrating an appearance of an LED unit according to the first embodiment, wherein (A) is a front view of the LED unit, and (B) is a cross-sectional view taken along line AA in (A). FIG. 2 is an explanatory diagram showing the interconnection relationship between the components of the LED unit, and FIG. 3 is a diagram showing an example of a printed circuit board on which LED elements are mounted.

  As shown in FIG. 1A, the LED unit according to the first embodiment has a plurality of LED elements 12 arranged in a matrix on the front cover 11 when viewed from the front. In the illustrated example, this LED unit has 32 × 32 = 1024 LED elements 12 mounted thereon, which can be used to display, for example, one character. In the display device, a plurality of such LED units are closely arranged in a matrix to form a display screen.

  The front cover 11 of the LED unit is integrally formed with a hood 13 that is an eaves-like cover protruding forward at the top of each LED element 12. In the illustrated example, the number of the hoods 13 provided in one LED unit is 32 in total, one by one in the horizontal direction of the LED elements 12.

  As shown in the cross-sectional view of FIG. 1B, the LED unit accommodates the front cover 11 disposed on the front side, the printed board 14 on which the LED element 12 is mounted, the LED element 12 and the printed board 14. The main body frame 15 is provided. Here, the LED element 12 has a cannonball shape and is accommodated in an LED element hole 16 formed through the front cover 11. The LED element hole 16 is formed so as to be inclined downward from the back surface of the front cover 11 toward the front surface, and the LED element 12 accommodated therein has an optical axis directed downward from the horizontal. It is held in a state. For this reason, a display device configured by closely arranging LED units in a matrix shape may partially overlap or separate depending on the direction in which the screen is viewed, compared to a display device configured by tiltable LED units. There will be no disturbing image display. In addition, it is not necessary to provide a complicated mechanism for the design of the display device, so it can be designed easily, the product cost can be reduced, and there is no complicated mechanism at the time of installation and adjustment after installation. It can be carried out.

  The front cover 11, the printed circuit board 14, and the main body frame 15 are coupled to each other in the relationship shown in FIG. That is, a front cover fixing portion 17 is projected on the back side of the front cover 11, and a thread that engages with the front cover fixing screw 18 is formed in the front cover fixing portion 17. The printed circuit board 14 has a front cover fixing portion hole 19 formed at a position corresponding to the front cover fixing portion 17, and the main body frame 15 has a front cover fixing screw hole 20 formed at a position corresponding to the front cover fixing portion 17. It has been drilled.

  The main body frame 15 is also provided with a printed circuit board fixing portion 21 projecting from the inner surface thereof, and the printed circuit board fixing portion 21 is formed with a thread that engages with the printed circuit board fixing screw 22. The printed circuit board 14 has a printed circuit board fixing screw hole 23 formed at a position corresponding to the printed circuit board fixing portion 21 of the main body frame 15.

  Here, the printed circuit board 14 is fixed to the main body frame 15 by screwing the printed circuit board fixing screws 22 into the printed circuit board fixing portion 21 of the main body frame 15. The front cover 11 is fixed to the main body frame 15 by screwing the front cover fixing screw 18 to the front cover fixing portion 17 of the front cover 11.

  The front cover fixing portion 17 of the front cover 11 and the printed board fixing portion 21 of the main body frame 15 are not formed on the same plane as shown in FIG. The frames 15 are distributed. For example, as is apparent from FIG. 3 showing the printed circuit board 14 on which the LED elements 12 are mounted, the front cover fixing portion 17 is located at positions corresponding to the nine front cover fixing portion holes 19 formed in the printed circuit board 14. Is formed. The printed circuit board fixing portion 21 is formed at a position corresponding to the four printed circuit board fixing screw holes 23 formed in the printed circuit board 14. In addition, this content is an example of implementation and the method of fixing each component is not limited to this.

  Next, the direction in which the LED element 12 mounted in the direction perpendicular to the mounting surface of the LED element 12 on the printed board 14 (the surface in the front view of FIG. 3) is tilted from the direction perpendicular to the surface of the front cover 11. A procedure for assembling the LED unit by attaching it to the LED element hole 16 drilled in FIG.

  4A and 4B are diagrams showing the assembly procedure of the LED unit, in which FIG. 4A shows a state before the assembly of the main body frame to which the printed circuit board is fixed and the front cover, and FIG. 4B shows that the LED element contacts the front cover. (C) has shown the state by which the LED element was mounted | worn with the hole for LED elements.

  For assembling the LED unit, the LED element 12 is first mounted on the printed circuit board 14 and the printed circuit board 14 and the main body frame 15 are assembled. When the LED element 12 is mounted on the printed circuit board 14, the bullet-shaped portion of the LED element 12 is separated from the printed circuit board 14 by a predetermined distance and is directed in a direction perpendicular to the surface of the printed circuit board 14. In this state, the lead wire 12a is soldered.

  Next, as shown in FIG. 4A, the center of the optical axis of the LED element 12 mounted on the printed circuit board 14 and the opening center of the back surface side opening of the LED element hole 16 formed in the front cover 11 The main body frame 15 and the front cover 11 are positioned so as to match.

  Next, one or both of the main body frame 15 and the front cover 11 are brought close to each other so that the hemispherical portion at the tip of the LED element 12 fits into the LED element hole 16 as shown in FIG. .

  Next, one or both of the main body frame 15 and the front cover 11 are moved in the vertical direction. Thus, the LED element 12 is tilted so that the center of the optical axis coincides with the axis center of the inclined LED element hole 16 while the hemispherical portion at the tip thereof is fitted in the LED element hole 16, and accordingly. The lead wire 12a is bent. Thereafter, one or both of the main body frame 15 and the front cover 11 are moved in parallel in the direction of the optical axis of the LED element 12 to approach the bullet of the LED element 12 as shown in FIG. The shape portion is attached to the LED element hole 16. Thereafter, the front cover 11 is fixed to the main body frame 15 by screwing the front cover fixing screw 18 into the front cover fixing portion 17 of the front cover 11. In addition, this content is an example and is not limited to this. If there is no problem in facilities and cost, after mounting the LED element 12 on the printed circuit board 14 and before mounting the front cover, the LED element 12 can be fitted in the LED element hole 16 in advance so that the LED element 12 can be fitted. The lead wire 12a can be bent and the front cover can be fixed, and the LED element 12 with the lead wire 12a bent in advance can be mounted on the printed circuit board.

FIG. 5 is a partially enlarged cross-sectional view of the LED unit according to the second embodiment.
The LED unit according to the second embodiment is applied to a display device installed outdoors, whereas the LED unit according to the first embodiment is applied to an indoor display device. Is.

  According to the LED unit according to the second embodiment, the entire surface of the printed circuit board 14 on the side of the main body frame 15 to which the front cover 11 is attached is filled with the waterproof seal member 24. The waterproof seal member 24 is thick enough to completely hide the lead wire 12a of the LED element 12, and prevents rainwater from contacting the lead wire 12a of the LED element 12. In addition, since the printed circuit board 14 is mounted with a control circuit, a drive circuit, and other electronic components for controlling the lighting of the LED elements 12 on the back side, rainwater can be prevented from entering the back side.

  The waterproof seal member 24 bends the lead wire 12a of the LED element 12 as shown in FIG. 4C, and then pulls out the LED element 12 from the LED element hole 16 so that the main body frame 15 is in a horizontal state. The surface of the printed circuit board 14 is filled. Thereafter, before the waterproof seal member 24 is solidified, the front cover 11 is attached and fixed to the main body frame 15 to complete the LED unit.

  At this time, if necessary, before filling the waterproof seal member 24, the front cover fixing portion hole 19 opened in the printed circuit board 14 is filled with a cylindrical plug substantially equal to the outer diameter of the front cover fixing portion 17. Keep sealed. This plug is removed immediately before the front cover 11 is attached to the main body frame 15 after the fluidity of the sealed waterproof seal member 24 is reduced.

  Alternatively, the waterproof seal member 24 may be filled first at the stage shown in FIG. 4A before the lead wire 12a of the LED element 12 is bent. In this case, a waterproof seal member 24 having an appropriate viscosity is used so that the waterproof seal member 24 does not easily enter from the front cover fixing hole 19 formed in the printed circuit board 14. That is, while the front cover fixing portion hole 19 and its entire surface except the vicinity thereof are filled with the waterproof seal member 24, the lead wire 12a of the LED element 12 is bent, and the front cover 11 is attached to the main body frame 15, The periphery of the front cover fixing part hole 19 is filled and hardened. In addition, this content is an example and is not limited to this.

  FIG. 6 is a partially enlarged sectional view showing a state in the middle of the assembly of the LED unit according to the third embodiment, and FIG. 7 is a partially enlarged sectional view showing a state after the assembly of the LED unit according to the third embodiment. is there.

  According to the LED unit according to the third embodiment, the positioning guide portion 25 which is a positioning member on the main body frame 15 side protrudes from the main body frame 15 toward the front cover 11, Positioning pins 26, which are positioning members on the front cover 11 side, protrude from positions corresponding to the positioning guide portions 25. The positioning pin 26 has an elongated conical shape and is formed integrally with the front cover 11. The positioning guide portion 25 has a funnel-shaped introduction portion that guides the distal end portion of the positioning pin 26 at its distal end portion, and has a fitting portion that fixes the distal end portion of the positioning pin 26 at the proximal end portion. It is formed integrally with the frame 15.

  When attaching the front cover 11 to the main body frame 15, as shown in FIG. 6, while aligning the optical axis center of the LED element 12 and the opening center of the back surface side opening of the LED element hole 16 of the front cover 11, One or both of the frame 15 and the front cover 11 are brought close to each other. At this time, the positioning pin 26 and the positioning guide portion 25 are not on the same axis, and the LED element 12 has the positioning pin 26 of the positioning guide portion 25 when the hemispherical portion at the tip thereof is fitted into the LED element hole 16. The positional relationship is in contact with the introduction part.

  Next, one or both of the main body frame 15 and the front cover 11 are moved in the vertical direction to bend the lead wires 12a of the LED elements 12 all at once. Thereafter, by moving one or both of the main body frame 15 and the front cover 11 in parallel in the direction of the optical axis of the LED element 12, as shown in FIG. Attached to the LED element hole 16. At this time, the positioning pin 26 is introduced into the positioning guide portion 25, and finally, the distal end portion of the positioning pin 26 is fitted into the fitting portion of the positioning guide portion 25. Thereby, the front cover 11 and the main body frame 15 can be easily attached.

FIG. 8 is a partially enlarged sectional view showing an LED unit according to the fourth embodiment.
The LED unit according to the fourth embodiment includes a collar 27 at the position of the main body frame 15 corresponding to the front cover fixing portion 17 of the front cover 11. The collar 27 has a length penetrating the printed circuit board 14 and is formed integrally with the main body frame 15. For this reason, the front cover fixing portion 17 is formed to have a length that contacts the end face of the collar 27 and is screwed together by a front cover fixing screw 18 that extends through the collar 27.

  The collar 27 is preferably formed to have a length that penetrates the layer of the waterproof seal member 24 as shown. As a result, the front cover fixing portion hole 19 of the printed circuit board 14 is closed by the collar 27. For this reason, when the waterproof seal member 24 is filled on the printed circuit board 14 fixed to the main body frame 15 with the printed circuit board fixing screws 22, the waterproof seal member 24 does not flow to the back surface of the printed circuit board 14. . Thereby, before the front cover 11 is assembled, the work of filling the waterproof seal member 24 can be performed, and the assembly work of the LED unit becomes easier than in the second embodiment. Infiltration of rainwater is prevented.

  It is also possible to cut the positioning pin 26 and make a hole in the positioning guide portion 25 and fix it with the front cover fixing screw 18 from the back side of the main body frame 15 to serve both as a positioning guide and a front cover fixing. . In this case, the waterproofness in the positioning guide portion 25 can be maintained by putting an O-ring rubber in the guide portion 25 and applying pressure thereto with the positioning pin 26. This content is an example of implementation and is not limited to this.

FIG. 9 is a partially enlarged sectional view showing an LED unit according to the fifth embodiment.
The LED unit according to the fifth embodiment makes it easy for the LED element 12 to enter the LED element hole 16 of the front cover 11. That is, a taper 28 is formed on the peripheral edge portion on the back side of the LED element hole 16. As a result, even if the optical axes of the 1024 LED elements 12 are not exactly parallel, the taper 28 guides the head of the LED element 12 when the LED element 12 is inserted into the LED element hole 16. All the LED elements 12 can be inserted smoothly.

  FIG. 10 is a partial enlarged cross-sectional view showing an LED unit according to the sixth embodiment, wherein (A) is a partial cross-sectional view showing a mounted state of the LED element, and (B) is B of the LED element hole. It is an arrow view (partial front view).

  In the LED unit according to the sixth embodiment, a plurality of ribs 29 extending along the insertion direction of the LED element 12 are provided in the inner wall of the LED element hole 16. The rib 29 has a circular arc cross section so as to be in line contact with the LED element 12, thereby reducing contact resistance when the LED element 12 is inserted into the LED element hole 16 and light of all the LED elements 12. It supports in the LED element hole 16 so that an axis | shaft may become parallel.

  In the illustrated embodiment, the LED element 12 is supported from four sides by four ribs 29, but a plurality of ribs 29 are equally arranged in the circumferential direction on the inner peripheral wall of the LED element hole 16. It may be configured. Further, by combining with the fifth embodiment, a configuration in which one rib is provided at the top or bottom is also possible. In addition, this content is an example of implementation, it is not limited to this, Other methods may be used.

DESCRIPTION OF SYMBOLS 11 Front cover 12 LED element 12a Lead wire 13 Hood 14 Printed circuit board 15 Body frame 16 LED element hole 17 Front cover fixing part 18 Front cover fixing screw 19 Front cover fixing part hole 20 Front cover fixing screw hole 21 Printed board fixing Part 22 Printed circuit board fixing screw 23 Printed circuit board fixing screw hole 24 Waterproof seal member 25 Positioning guide part 26 Positioning pin 27 Color 28 Taper 29 Rib

Claims (5)

In the manufacturing method of the LED unit configured by arranging a plurality of LED elements in a plane,
The LED element is soldered by soldering a lead wire in a state in which the bullet-shaped portion of the LED element is separated from the printed circuit board by a predetermined distance and oriented in a direction perpendicular to the surface of the printed circuit board. Mounted on the printed circuit board ,
The pre-Symbol PCB front cover you have a tilted direction is drilled the LED element holes with respect to the direction perpendicular to the mounting surface of the print on the side of the LED element of the printed circuit board is mounted Arranged so that the optical axis of the LED element mounted on the substrate and the opening center of the back side opening of the hole for the LED element formed in the front cover match .
Fit one or both of the printed circuit board and the front cover to fit the hemispherical portion at the tip of the LED element into the LED element hole,
One or both of the printed circuit board and the front cover are moved relative to each other so that the optical axis center of the LED element coincides with the axis center of the LED element hole, and the lead wire of the LED element is bent,
One or both of the printed circuit board and the front cover are translated in the direction of the axial center of the LED element hole, and a bullet-shaped portion of the LED element is attached to the LED element hole.
Manufacturing method of the LED unit, wherein the this. 2. The method of manufacturing an LED unit according to claim 1, wherein after the LED element is mounted on the printed board, the printed board is accommodated and fixed in a main body frame.   3. The method of manufacturing an LED unit according to claim 2, wherein the main body frame and the front cover are fixed after mounting the bullet-shaped portion of the LED element in the LED element hole. After bending the lead wire of the LED element, the printed circuit board is separated from the front cover, and at least the lead wire of the LED element is completely buried in the surface of the printed circuit board on the side where the LED element is mounted. A waterproof sealing member having a thickness of only that is provided, and the printed circuit board and the front cover are disposed so that the hemispherical portion at the tip of the LED element fits into the LED element hole again. Item 2. A method for producing an LED unit according to Item 1. After the LED element is mounted on the printed circuit board, a waterproof sealing member having a thickness that allows at least the lead wire of the LED element to be completely buried in the surface of the printed circuit board on the side where the LED element is mounted The method for manufacturing an LED unit according to claim 1, wherein the LED unit is provided.

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