JP6078905B2 - LED module and lighting apparatus - Google Patents

Description

  The present invention relates to an LED module and a lighting fixture using the LED module.

  The thing of patent document 1 is illustrated as a prior art example of the lighting fixture using an LED module and an LED module. Patent Document 1 describes a lighting fixture (LED lighting fixture) composed of a rectangular flat plate mounting base and four light source units (LED modules) mounted on the front surface of the mounting base.

  The LED module includes a printed wiring board on which a plurality of LEDs (light emitting diodes) are mounted, a housing in which the printed wiring board is housed, and lead wires drawn from the printed wiring board.

  The housing is formed of a light-transmitting synthetic resin material such as acrylic resin into a flat rectangular box shape having an open back surface. Further, a plurality of lenses are provided on the bottom surface outside the housing in order to expand the light irradiation range of the LED.

  The four LED modules are attached to the front surface of the mounting base so as to provide a space for wiring between adjacent ones. And the lead wire withdraw | derived from the printed wiring board and the connector arrange | positioned in the said space in the front surface of a mounting base are connected.

JP 2007-53027 A

  In the conventional example described in Patent Document 1, a space is required between the LED modules attached to the mounting base in order to store the electric wires (lead wires) for supplying power to the LED modules. Due to the existence of this space, the conventional example described in Patent Document 1 has problems that it is difficult to reduce the size and the uniformity of the light emitting surface is lowered.

  The present invention has been made in view of the above problems, and aims to reduce the size and improve the uniformity of the light emitting surface.

The LED module of the present invention includes a substrate on which a plurality of LEDs are mounted on one surface, an optical block disposed on the one surface side of the substrate, and an electric wire that is drawn from the substrate and supplies power to the LED. The optical block is formed of at least a plurality of lenses provided at positions facing the LEDs, a coupling member that couples the plurality of lenses, and a light- transmitting material, and holds one or more of the electric wires. possess a holding member, further, the optical block is constituted integrally formed of a material the lens and the coupling member and the holding member has a light-transmitting property, the lens and the holding member, the The holding member protrudes forward from the surface of the coupling member, and the holding member has a regulation piece that regulates movement of the electric wire from the holding position to the non-holding position. The projecting dimension is greater than the protruding dimension of the lens, and a portion of the regulating piece, characterized in that configured to be located closer to the coupling member than the lens.

Luminaire of the present invention is characterized by comprising said L ED module, and one or fixture body which supports a plurality of the LED modules.

  In the LED module and the lighting fixture of the present invention, since the optical block has one or more holding members for holding the electric wire, the space for wiring the electric wire can be reduced, and as a result, downsizing and light emission are achieved. There is an effect that the uniformity of the surface can be improved.

The optical block in embodiment of the LED module which concerns on this invention is shown, (a) is a top view, (b) is a side view. It is principal part sectional drawing of the optical block in the same as the above. It is principal part sectional drawing of the light source unit in the same as the above. It is a perspective view of the optical block in the same as the above. It is a principal part perspective view of the optical block in the same as the above. It is principal part sectional drawing of the light source unit in the same as the above. It is an exploded perspective view same as the above. It is a disassembled perspective view which shows embodiment of the lighting fixture which concerns on this invention. It is principal part sectional drawing same as the above. It is principal part sectional drawing same as the above. It is the perspective view which abbreviate | omitted a part of frame in the same as the above. It is the perspective view which abbreviate | omitted partially and same as the above. It is a perspective view of the suspended state same as the above. It is a principal part perspective view of the suspended state same as the above. 2 shows another embodiment of the optical block in the same as above, (a) is a plan view, and (b) is a cross-sectional view taken along line AA of (a).

  Hereinafter, embodiments of an LED module and a lighting fixture according to the present invention will be described in detail with reference to the drawings. In this embodiment, the ceiling-mounted lighting fixture is illustrated, but a ceiling-buried lighting fixture or a hanging lighting fixture may be used.

  The lighting fixture of this embodiment is comprised with the light source unit 1, the fixture main body 4, the frame 5, the panel 6, the lighting device 7, etc. as shown in FIG. Note that the vertical and forward / backward / left / right directions used in the following description are the directions defined in FIG. 8 unless otherwise specified.

  The instrument body 4 is formed by integrally forming a rectangular plate-like bottom plate 40 and a side plate 41 bent and raised downward from the periphery of the bottom plate 40 with a metal plate. An electric wire insertion hole 400 for commercial power supply passes through the bottom plate 40. A power supply line (not shown) inserted through the electric wire insertion hole 400 is connected to a power supply terminal block 42 fixed to the rear portion of the bottom surface of the bottom plate 40. The power terminal block 42 is connected to the lighting device 7 via an electric wire (not shown). That is, the lighting device 7 is supplied with commercial power (AC power) via the power terminal block 42. A signal terminal block 43 is fixed to the rear part on the left side of the bottom surface of the bottom plate 40. The signal terminal block 43 is connected to a signal line (not shown) inserted through the electric wire insertion hole 400.

  A plurality of hemispherical dowels 401 project from the upper surface of the bottom plate 40 (see FIGS. 9 and 10). That is, when the bottom plate 40 is screwed to the ceiling material and the instrument body 4 is fixed to the ceiling, a slight gap is formed between the bottom plate 40 and the ceiling surface by the plurality of dowels 401 coming into contact with the ceiling surface. .

  The lighting device 7 is a printed wiring board (not shown) on which a power conversion circuit that converts AC voltage / current into DC voltage / current, an input terminal block 71, two output terminal blocks 72, a signal terminal block 73, and the like are mounted. Are housed in a metal case 70. However, both ends in the longitudinal direction of the printed wiring board on which the input terminal block 71, the output terminal block 72, and the signal terminal block 73 are mounted are exposed from the case 70.

  The frame 5 has a rectangular bottom wall 50 through which the window hole 52 penetrates and a side wall 51 rising upward from the periphery of the bottom wall 50, and is formed in a rectangular box shape having an open upper surface (FIG. 8 to FIG. 8). (See FIG. 11). On the upper surface of the bottom wall 50, an inner wall 53 is formed so as to surround the window hole 52 from the entire circumference at a position separated from the edge of the window hole 52 by a slight distance (several mm to several tens of mm). The inner wall 53 is parallel to the side wall 51, and the height dimension is sufficiently smaller than the height dimension of the side wall 51 (see FIGS. 9 to 11).

  Further, four mounting brackets 55 and one locking bracket 56 are stored in a space (hereinafter referred to as a storage space) surrounded by the bottom wall 50, the side wall 51, and the inner wall 53. The mounting bracket 55 is formed by integrally forming a diamond-shaped locking piece 550 and a fixing piece 551 connected to the lower end of the locking piece 550 from a metal material (see FIG. 11). Two of these mounting brackets 55 are disposed in each of the left and right storage spaces with the window hole 52 in between, and the fixing pieces 551 are caulked and fixed to the inner wall 53.

  On the other hand, on the lower surface of the bottom plate 40 of the instrument body 4, as shown in FIG. 8, holding brackets 44 are provided at positions corresponding to the four mounting brackets 55 (however, in FIG. 8, the two holding brackets on the right side are provided). 44 is omitted). The holding metal fitting 44 is formed into an Ω shape by bending a metal plate having a high elastic modulus. As shown in FIG. 12, the holding metal 44 can hold the locking piece 550 of the mounting metal 55 inserted into the inside through the opening portion on the lower surface by an elastic force. In other words, the frame 5 is detachably attached to the lower surface side of the instrument body 4 by holding the four attachment fittings 55 individually on the four holding fittings 44.

  9 and 11, a pair of locking claws 560 formed in a bowl shape as shown in FIGS. 9 and 11 and a fixing piece 561 formed in a square hook shape and fixed to the inner wall 53 are made of a metal plate. It is integrally formed by processing. As shown in FIG. 9, the fixing piece 561 is stored in the storage space so as to contact the bottom wall 50 and the inner wall 53 and is fixed to the inner wall 53 by caulking. Further, the fixed piece 561 has a portion facing the side wall 51 extended to the vicinity of the upper end of the side wall 51. The pair of locking claws 560 are provided at the upper end of the portion facing the side wall 51 of the fixed piece 561 with a space in the front-rear direction.

  On the other hand, the instrument body 4 is provided with a pair of locking holes 410 into which the pair of locking claws 560 are inserted and locked separately. In other words, the frame 5 can be suspended from the instrument body 4 by inserting the locking claws 560 into the locking holes 410 and locking the locking claws 560 to the lower edge of the locking holes 410. (See FIGS. 13 and 14). When the mounting bracket 55 is held by the holding bracket 44 and the frame 5 is attached to the instrument body 4, the pair of locking claws 560 and the locking holes 410 are unlocked and formed by the dowels 401. The locking claw 560 is retracted in the gap between the instrument body 4 and the ceiling material (see FIGS. 9 and 12).

  The panel 6 is formed in a rectangular flat plate shape with a synthetic resin (for example, an acrylic resin) having translucency and mixed with a diffusing material. However, the vertical and horizontal dimensions of the panel 6 are larger than the vertical and horizontal dimensions of the window holes 52 and smaller than the distance between the inner walls 53. The panel 6 is housed inside the inner wall 53 and placed on a portion of the bottom wall 50 inside the inner wall 53 (hereinafter referred to as a flange 54) to close the window hole 52 (FIG. 8). To FIG. 11). The panel 6 placed on the flange 54 is restricted (moving out) from upward movement by the presser fitting 58.

  As shown in FIGS. 9 and 11, the presser fitting 58 includes a fixed piece 580 fixed to the inner wall 53 and a protruding piece 581 protruding in parallel with the flange 54 from the lower end of the fixed plate 580 to form a rectangular metal plate. It is integrally formed by bending into a letter shape. The presser fitting 58 is attached to the frame 5 by fixing the fixing piece 580 to the inner wall 53 together with the fixing piece 551 of the locking metal piece 56.

  The light source unit 1 includes four LED modules 2 and a reflector 3 as shown in FIG. The reflector 3 has a rectangular flat plate-shaped mounting plate 30 and four reflecting plates 31 bent and raised downward from the periphery of the mounting plate 30 and is formed in a box shape having an open bottom surface. In addition, an outer casing 32 that protrudes outward is formed integrally with the reflecting plate 31 at the lower end of each reflecting plate 31.

  Further, the lighting device 7 is attached to the front surface side of the reflector 3 by the mounting base 74. The mounting base 74 has a long mounting piece 740 to which the lighting device 7 is screwed and attached, and a long fixing piece 741 that protrudes from one end edge along the longitudinal direction of the mounting piece 740. The mounting base 74 is fixed by screwing the fixing piece 741 to the upper surface of the mounting plate 30 of the reflector 3 so as to leave a space between the reflecting plate 31 on the front side of the reflector 3 and the mounting piece 740. (See FIG. 8).

  The LED module 2 includes a rectangular substrate 20, a plurality of LEDs 21 mounted on one surface (lower surface) of the substrate 20, a reflection sheet 22 that covers the entire lower surface of the substrate 20 except for an area where the LEDs 21 are mounted, And a block 23.

  The LED 21 is a commercially available package-type white LED, and is mounted (surface mounted) on the lower surface of the substrate 20 by soldering electrodes to lands (not shown) formed on the lower surface of the substrate 20. .

  The substrate 20 is formed with the lands arranged vertically and horizontally at regular intervals, and a conductor (copper foil) that electrically connects the lands is formed on the lower surface. In addition, a receptacle connector 24 is mounted at the front center in the left-right direction on the lower surface of the substrate 20. The receptacle connector 24 is electrically connected to all the LEDs 21 via a conductor, and is detachably connected to a plug connector (not shown). However, it is not always necessary to mount the LEDs 21 on all lands, and the LEDs 21 may be mounted by thinning out some lands.

  The reflection sheet 22 is formed by forming a reflection layer made of a material having a relatively high reflectance on the surface (lower surface) of a sheet material made of an insulating material such as synthetic rubber or synthetic resin. In the reflection sheet 22, through holes 220 for exposing the LEDs 21 and the lands are formed side by side in the vertical and horizontal directions. That is, the light radiated from the LEDs 21 is reflected downward by the reflection sheet 22 by arranging the reflection sheet 22 on the lower surface side of the substrate 20.

  As shown in FIG. 1, the optical block 23 is a synthetic resin in which a plurality of (in the illustrated example, 72) lenses 230 that diffuse the light of the LED 21 and a coupling member 231 that couples the plurality of lenses 230 are translucent. (For example, acrylic resin) is integrally formed. As shown in FIG. 3, the lens 230 is formed in a paraboloid shape and is incident surface 2300 on which light emitted from the LED 21 is incident, a propagation unit 2301 that propagates light incident from the incident surface 2300, and a propagation unit And an exit surface 2302 from which light propagated through 2301 exits. The emission surface 2302 is formed in a curved surface that is concave in the direction of the LED 21 around the center point (intersection with the optical axis) and convex in the direction away from the LED 21 (upward in FIG. 3). The propagation part 2301 is composed of a region (resin molding) surrounded by the incident surface 2300 and the exit surface 2302.

  The lens 230 has a cylindrical recess 2303 that has a bottom surface connected to the incident surface 2300 and accommodates the LED 21 therein (see FIGS. 3 to 5). The inner diameter X1 of the recess 2303 is larger than the outer diameter X2 of the entrance surface 2300 and smaller than the outer diameter X3 of the exit surface 2302 (X2 <X1 <X3). That is, as compared with the case where the LED 21 is housed in the space surrounded by the incident surface 2300, the space around the LED 21 is enlarged by housing the LED 21 in the recess 2303, so that it is possible to suppress a decrease in heat dissipation. .

  Since the recess 2303 is formed so that the depth dimension is equal to or greater than the height dimension of the LED 21, it does not easily hit the LED 21 even if the optical block 23 is thermally expanded. Further, the recess 2303 is formed to have an inner diameter dimension that does not overlap with a junction (land) that joins the LED 21 to the conductor of the substrate 20 when viewed from the depth direction (vertical direction). Therefore, of the light emitted from the LED 21, the light incident on the bottom surface of the recess 2303 can be controlled by the lens 21.

  However, the intensity of light incident on the bottom surface of the recess 2303 and exiting from the exit surface 2302 is relative to the intensity of light entering near the boundary with the recess 2303 on the entrance surface 2300 and exiting from the exit surface 2302 To be high. Therefore, a light streak may be seen around the lens 21. In order to suppress the generation of such light streaks, the bottom surface of the recess 2303 facing the substrate 20 is preferably formed as an inclined surface whose depth dimension increases as the distance from the LED 21 increases (see FIG. 3). If the bottom surface of the recess 2303 is an inclined surface, the light emitted from the LED 21 is not directly incident on the bottom surface of the recess 2303, so that the generation of light streaks as described above can be suppressed. Furthermore, if the boundary portion between the incident surface 2300 and the recess 2303 is formed into a curved shape protruding toward the LED 21, the generation of light streaks can be further suppressed.

  The optical block 23 is attached to the mounting plate 30 together with the substrate 20 and the reflection sheet 22 by screwing. In the optical block 23, a circular first screw insertion hole 2310 passes through a coupling member 231 at a position corresponding to the center (intersection of diagonal lines). Further, the optical block 23 has second screw insertion holes 2311 passing through both sides of the first screw insertion hole 2310 along a straight line (hereinafter referred to as a center line) passing through the midpoint and center of two opposite sides. Yes. However, each of the pair of second screw insertion holes 2311 is formed in a long hole shape whose major axis direction is parallel to the center line (see FIG. 1).

  In addition, the substrate 20 and the reflection sheet 22 have first screw insertion holes 200 and 221 and second screw insertion holes 201 and 222 that overlap the first screw insertion holes 2310 and the second screw insertion holes 2311 of the optical block 23 in the thickness direction. Are penetrating each other (see FIG. 6). On the other hand, the attachment plate 30 of the reflector 3 is formed with screw holes (not shown) at positions corresponding to the first screw insertion holes 2310 and the second screw insertion holes 2311, respectively. Accordingly, the substrate 20, the reflection sheet 22, and the optical block 23 are stacked, and the screw 10 inserted through each of the first screw insertion hole 2310 and the second screw insertion hole 2311 is screwed into the screw hole of the mounting plate 30. The reflection sheet 22 and the optical block 23 can be attached to the attachment plate 30.

  Here, when the second screw insertion hole 2311 is a long hole, the stress applied to the optical block 23 can be reduced when the optical block 23 is thermally expanded due to the heat generated by the LED 21.

  Further, the optical block 23 has a plurality of holding members 233 that hold the electric wires 26. The electric wire 26 feeds wiring between the four plug connectors, and both ends thereof are connected to the output terminal block 72 of the lighting device 7.

  A total of six holding members 233 are provided, two in the vicinity of the three sides of the optical block 23. These holding members 233 have a bowl shape and are integrally formed of the same material (translucent synthetic resin) as the lens 230 and the coupling member 231. The electric wires 26 are held so as to be hooked on the holding members 233. Therefore, since the electric wire 26 is held by the holding member 233 provided in the optical block 23, a space for wiring between the LED modules 2 attached to the attachment plate 30 of the reflector 3 is not required. The size can be easily reduced as compared with the conventional example described. Furthermore, the uniformity of the light emitting surface can be improved by narrowing the interval between the adjacent LED modules 2.

  Further, the holding member 233 is provided with a regulating piece 2330 for restricting the movement of the electric wire 26 from the holding position to the non-holding position so as to protrude from the tip toward the coupling member 231 (see FIG. 2). For this reason, it is difficult for the electric wire 26 to come off the holding member 233.

  Further, the holding member 233 is configured such that the projecting dimension from the surface of the coupling member 231 is larger than the projecting dimension of the lens 230, and a part of the regulating piece 2330 is disposed at a position closer to the coupling member 231 than the lens 230. (See FIG. 2). This makes it easier to hold the electric wire 26 between the emission surface 2302 of the lens 230 and the holding member 233, and makes it difficult for light emitted from the emission surface 2302 to be placed on the regulation piece 2330.

  Also, holding grooves 234 for storing and holding the electric wires 26 are provided at the four corners of the optical block 23 (see FIGS. 1 and 4). These holding grooves 234 are provided on the recesses 2303 side of the lens 230 located at the four corners, and the electric wires 26 are inserted through the notches 2314 provided in the coupling member 231 (see FIG. 1).

  Since the holding member 233 for holding the electric wire 26 is provided in the optical block 23 as described above, it is not necessary to provide a space between the LED modules 2 as in the conventional example, and compared with the case where the space is provided. Adjacent LED modules 2 can be brought close to each other. As a result, it is possible to reduce the size of the lighting fixture on which the plurality of LED modules 2 are mounted and to improve the uniformity of the light emitting surface.

  In addition, since the holding member 233 is integrally formed of the same light-transmitting material (for example, acrylic resin) as the lens 230 and the coupling member 231, light emitted from the LED 21 is blocked by the holding member 233 and the degree of uniformity. Can be suppressed.

  Further, the coupling member 231 is integrally formed with a recess 2312 for escaping the receptacle connector 24 and a plug connector (hereinafter referred to as a connector) and a flange 2313 covering the connector disposed in the recess 2312 (FIG. 1 and FIG. 4). Therefore, it is possible to prevent the uniformity from being lowered by the light emitted from the LED 21 being blocked by the connector or reflected by the connector.

  By the way, in this embodiment, the holding member 233 is provided in the vicinity of the three sides of the optical block 23, but the holding member 233 may be provided in the vicinity of the center line of the optical block 23 as shown in FIG. . In the configuration shown in FIG. 15, the direction of the holding member 233 adjacent along the middle dotted line is reversed by 180 degrees to make it difficult for the electric wire 26 to be detached from the holding member 233. However, in the optical block 23 shown in FIG. 15, the holding member 2330 having a shape different from that of the central holding member 233 is provided on each of the four sides.

  The light source unit 1 is arranged inside the inner wall 53 of the frame 5 so that the outer casing 32 of the reflector 3 is inserted into the gap between the protruding piece 581 of the presser fitting 58 and the panel 6 (see FIG. 9). ). Then, the light source unit 1 is fixed to the frame 5 by a fixing bracket 57 provided on the inner wall 53 on the opposite side of the pressing bracket 58 with the panel 6 interposed therebetween (see FIG. 10).

  The fixing bracket 57 is formed by integrally forming a hook-shaped locking piece 570 and a hook-shaped fixing piece 571 extending from the end of the locking piece 57 by processing a metal plate. The fixing bracket 57 is fixed to the inner wall 53 with a locking piece 570 inserted and locked in a locking hole 530 that penetrates the inner wall 53. However, since the diameter of the locking hole 530 is sufficiently larger than the thickness of the locking piece 570, the fixing bracket 57 is rotatable with respect to the inner wall 53 with the locking piece 570 as a fulcrum.

  In addition, a screw insertion hole 572 passes through the tip of the fixed piece 571. A female screw 33 is provided on the mounting plate 30 of the reflector 3. Therefore, the upward movement of the reflector 3 is restricted by screwing the screw 573 inserted into the screw insertion hole 572 of the fixed piece 561 into the female screw 33 of the mounting plate 30. As a result, the light source unit 1 can be securely attached to the frame 5.

  Next, the construction procedure of the lighting fixture of this embodiment will be briefly described. First, the fixture body 4 is attached to the ceiling, the power line inserted through the wire insertion hole 400 is connected to the power terminal block 42, and the signal line is connected to the signal terminal block 43.

  Subsequently, the locking claw 560 of the locking metal fitting 56 is inserted and locked into the locking hole 410 of the instrument body 4, and the frame 5 is suspended from the instrument body 4 (see FIG. 13). In this suspended state, the input terminal block 71 of the lighting device 7 and the power supply terminal block 42 of the fixture body 4 are connected by electric wires, and the signal terminal block 73 of the lighting device 7 and the signal terminal block 43 of the fixture body 4 are connected to the signal line. Connect with.

  When the wiring work is completed, the frame 5 is pivoted to lift up and the frame 5 is attached to the lower surface side of the instrument body 4 by holding the locking piece 550 of the mounting bracket 55 on the holding bracket 44. Also, if the locking piece 550 is detached from the holding metal fitting 44 by pulling the frame 5 downward, and the above-described suspended state is established, maintenance work such as cleaning of the panel 6 can be easily performed.

2 LED module
20 substrates
21 LED
23 Optical block
26 Electric wire
230 lenses
231 Joining member
233 Holding member

Claims (2)

A board on which a plurality of LEDs are mounted on one side, an optical block disposed on the one side of the board, and an electric wire that is drawn from the board and supplies power to the LED, and the optical block includes at least a plurality of lenses provided in a position opposed to the LED, possess a coupling member coupling the plurality of lenses together, one or a plurality of holding members are formed by a light-transmitting material for holding the electric wire Furthermore, the optical block is formed by integrally forming the lens, the coupling member, and the holding member with a light-transmitting material, and the lens and the holding member are forward from the surface of the coupling member. The holding member has a restricting piece that restricts movement of the electric wire from the holding position to the non-holding position, and the protruding dimension from the surface of the coupling member Greater than output size, and the LED module, characterized in that configured such that a portion of the regulating piece is located closer to the coupling member than the lens. A lighting fixture comprising: the LED module according to claim 1; and a fixture main body that supports one or more of the LED modules .

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