JP6611063B2 - Lighting apparatus and manufacturing method thereof - Google Patents

Description

  The present invention relates to a lighting fixture including fins and a method for manufacturing the same.

  A conventional lighting device such as a downlight includes a light source such as an LED (Light Emitting Diode) and a heat sink that dissipates heat generated by the light source (see, for example, Patent Document 1). The heat sink described in Patent Document 1 includes a base member and a fin member press-fitted into the opening of the base member.

JP 2013-257971 A

  However, the above-described conventional heat sink has a problem that the thermal conductivity is lowered due to the dimensional tolerance between the fin member and the base member.

  For example, when the outer dimension of the fin member is larger than the inner dimension of the opening of the base member, the fin member may not be press-fitted to the back of the opening. Further, when the outer dimension of the fin member is smaller than the inner dimension of the opening of the base member, the fin member press-fitted into the opening may be detached. In either case, the contact between the fin member and the base member becomes insufficient, and the thermal conductivity decreases.

  Then, an object of this invention is to provide the lighting fixture with improved heat conductivity, and its manufacturing method.

  In order to achieve the above object, a lighting fixture according to an aspect of the present invention includes a light source and a fixture main body to which the light source is attached. The fixture main body includes a first surface to which the light source is attached; A base portion having a second surface opposite to the surface, and a fin fixed to the second surface, the base portion having a protrusion protruding from the second surface, A hole is provided, and the fin is fixed to the base portion in a state where the protrusion is inserted into the hole and the protrusion is plastically deformed.

  According to another aspect of the present invention, there is provided a method for manufacturing a lighting fixture, wherein a first surface to which a light source is attached, a base portion having a second surface opposite to the first surface, and the second surface are fixed. A method of manufacturing a lighting fixture comprising a fin, wherein a step of forming a protrusion on the second surface, a step of forming a hole in the fin, and inserting the protrusion into the hole, A step of bringing the fin into contact with each other, and a step of fixing the fin to the base portion by plastically deforming the protrusion.

  ADVANTAGE OF THE INVENTION According to this invention, the lighting fixture with improved heat conductivity and its manufacturing method can be provided.

FIG. 1 is a schematic perspective view of a lighting apparatus according to an embodiment. FIG. 2 is a cross-sectional view of the lighting fixture according to the embodiment. FIG. 3 is an exploded perspective view showing a part of the lighting apparatus according to the embodiment. FIG. 4 is a schematic perspective view of the instrument body according to the embodiment. FIG. 5 is a plan view showing an outer bottom surface of the instrument body according to the embodiment. 6 is a cross-sectional perspective view of the instrument body according to the embodiment taken along the line VI-VI in FIG. FIG. 7 is a cross-sectional view of the connection portion between the fin and the base portion according to the embodiment taken along line VII-VII in FIG. FIG. 8 is a flowchart showing a method of manufacturing the lighting fixture according to the embodiment. FIG. 9 is a perspective view showing a positioning step between the fin and the base portion in the manufacturing method of the lighting fixture according to the embodiment. FIG. 10: is sectional drawing which shows the plastic deformation process of the protrusion in the manufacturing method of the lighting fixture which concerns on embodiment. FIG. 11 is a plan view of the instrument main body according to the first modification. FIG. 12 is a cross-sectional view of the connection portion between the fin and the base portion according to the first modification. FIG. 13 is an overview perspective view of the base portion according to the first modification. FIG. 14 is a schematic perspective view of the base portion according to the second modification.

  Below, the lighting fixture which concerns on embodiment of this invention is demonstrated in detail using drawing. Note that each of the embodiments described below shows a preferred specific example of the present invention. Therefore, numerical values, shapes, materials, components, arrangement and connection forms of components, steps, order of steps, and the like shown in the following embodiments are merely examples, and are not intended to limit the present invention. Therefore, among the constituent elements in the following embodiments, constituent elements that are not described in the independent claims showing the highest concept of the present invention are described as optional constituent elements.

  Each figure is a mimetic diagram and is not necessarily illustrated strictly. Therefore, for example, the scales and the like do not necessarily match in each drawing. Moreover, in each figure, the same code | symbol is attached | subjected about the substantially same structure, The overlapping description is abbreviate | omitted or simplified.

(Embodiment)
[lighting equipment]
First, the outline | summary of the lighting fixture which concerns on this Embodiment is demonstrated using FIG.1 and FIG.2.

  FIG. 1 is a perspective view of a lighting fixture 1 according to the present embodiment. FIG. 2 is a cross-sectional view of the lighting fixture 1 according to the present embodiment. Specifically, FIG. 2 shows a cross section passing through the optical axis J of the luminaire 1.

  In each figure, the direction parallel to the optical axis J is the z-axis direction, the two directions perpendicular to the optical axis J and perpendicular to each other are the x-axis direction and the y-axis direction. In the present embodiment, the z-axis direction is, for example, the vertical direction.

  The luminaire 1 is an example of an embedded luminaire such as a downlight. The luminaire 1 is embedded in a mounting hole provided in a ceiling of a building, for example, and irradiates light downward (such as a floor). In addition, FIG. 1 has shown the lighting fixture 1 when it looks up from diagonally downward.

  In the present embodiment, as shown in FIG. 1, the lighting fixture 1 includes a fixture body 10, an optical member 60, a frame body 70, and an attachment spring 80. Furthermore, as shown in FIG. 2, the lighting fixture 1 includes a light source 20, a mounting member 30, a connecting member 40, and a reflecting member 50.

  Hereinafter, each component (component) of the lighting fixture 1 will be described in detail with reference to FIGS. 1 and 2. In addition, although detailed description is abbreviate | omitted except for one part, the fixing members, such as the latching | locking part or screw for connecting and fixing component members, etc. are suitably provided in the lighting fixture 1. FIG.

[Equipment body]
The fixture body 10 is a main body of the lighting fixture 1 and is a metal member to which the light source 20 is attached. The instrument body 10 also functions as a heat sink that dissipates heat generated by the light source 20. For this reason, the instrument main body 10 is formed from a metal material having a high thermal conductivity such as aluminum.

  As shown in FIGS. 1 and 2, the instrument main body 10 includes a base portion 11 and a plurality of fins 12. The plurality of fins 12 are fixed to the base portion 11 by plastic deformation of a part of the base portion 11. Details of the base portion 11 and the plurality of fins 12 will be described later.

[light source]
The light source 20 is an example of a light source in the lighting fixture 1 and is a light emitting unit that emits light of a predetermined color (wavelength) such as white. The light source 20 is attached to the base portion 11 of the instrument body 10. In the present embodiment, as shown in FIG. 2, the light source 20 is fixed to the attachment surface 110 a of the bottom surface portion 110 of the base portion 11 by the attachment member 30 and the connection member 40.

  As shown in FIG. 2, the light source 20 is an LED module including a substrate 21 and a plurality of LEDs 22. The light source 20 is a so-called COB (Chip On Board) module in which a bare chip (LED 22) is directly mounted on the substrate 21.

  As the substrate 21, for example, a ceramic substrate, a resin substrate, a metal base substrate, or the like can be used. The planar view shape of the substrate 21 is, for example, a rectangle, but may be a polygon such as a hexagon or an octagon, or a circle. Metal wiring (not shown) is formed on the substrate 21, and the plurality of LEDs 22 are electrically connected.

  The LED 22 is an example of a light emitting element, and is a semiconductor light emitting element that emits light with a predetermined power. The LED 22 is, for example, a bare chip that emits monochromatic visible light. Specifically, the LED 22 is a blue light emitting LED chip that emits blue light when energized. The plurality of LEDs 22 are arranged in a plurality of rows or a matrix on the main surface of the substrate 21.

  The plurality of LEDs 22 are collectively sealed by a sealing member (not shown). For example, the plurality of LEDs 22 may be collectively sealed for each element row, or all the LEDs 22 on the substrate 21 may be collectively sealed.

The sealing member includes, for example, a translucent resin material such as silicone resin as a main component, and includes a wavelength conversion material that converts the wavelength of light from the LED 22. The wavelength conversion material is, for example, phosphor particles, and specifically, yellow phosphor particles. In the present embodiment, the light source 20 emits white light by mixing the blue light emitted from the LED 22 and the yellow light emitted when the yellow phosphor particles are excited by the blue light. The sealing member may contain a light diffusing material (light scattering particles) such as silica (SiO ₂ ).

  The light source 20 may be an SMD (Surface Mounted Device) type module. Specifically, a package type LED element (SMD type LED element) may be mounted on the substrate 21. The package type LED element includes, for example, a resin container having a recess (cavity), an LED chip (LED 22) mounted in the recess, and a sealing member (phosphor-containing resin) sealed in the recess. With.

[Mounting member]
The attachment member 30 is a member for attaching the light source 20 to the attachment surface 110 a of the base portion 11. In the present embodiment, the attachment member 30 functions as a frame for the light source 20. Specifically, the attachment member 30 regulates the position of the light source 20 in the lateral direction (directions orthogonal to the optical axis J (x-axis direction and y-axis direction)).

  As shown in FIG. 3, the attachment member 30 includes a restriction portion 31 and a claw portion 32. Here, FIG. 3 is an exploded perspective view showing a part of the lighting fixture 1 according to the present embodiment. Specifically, FIG. 3 shows the instrument body 10, the light source 20, the attachment member 30, and the connection member 40.

  The restricting portion 31 is a rectangular frame portion having an opening 33 at the center. The opening 33 has a shape corresponding to the substrate 21 of the light source 20, and the light source 20 is disposed in the opening 33.

  The claw portion 32 is a claw-shaped portion for supporting the reflecting member 50. In the present embodiment, the two claw portions 32 are erected from the restriction portion 31 in the direction along the optical axis J.

  The attachment member 30 is disposed on the attachment surface 110 a of the bottom surface portion 110 and is fixed to the bottom surface portion 110 by the connection member 40 and the screw 45. Specifically, as shown in FIG. 3, two screw holes 34 and two screw holes 113 are provided in the restriction portion 31 and the bottom surface portion 110, respectively. The attachment member 30 is fixed to the bottom surface portion 110 by inserting the screw 45 into the screw hole 34 of the restriction portion 31 and screwing into the screw hole 113 of the bottom surface portion 110.

  The attachment member 30 is integrally formed using a resin material such as polybutylene terephthalate (PBT) or ABS (acrylonitrile / butadiene / styrene).

[Connecting member]
The connection member 40 is a member to which an electric wire (not shown) that supplies current to the light source 20 is connected. As shown in FIG. 3, in the present embodiment, the luminaire 1 includes two connection members 40. One of the two connecting members 40 is connected to a high potential side electric wire, and the other is connected to a low potential side electric wire.

  In the present embodiment, the connection member 40 includes a main body 41 and an electrode 42 as shown in FIG. The main body 41 is a resin casing for supporting the electric wires. A screw hole 43 is provided in the main body 41 of the connection member 40. In the present embodiment, the screw 45 is inserted into the screw hole 43 and screwed into the screw hole 34 of the restricting portion 31 and the screw hole 113 of the bottom surface portion 110, so that the connecting member 40 sandwiches the mounting member 30 and the bottom surface. It is fixed to the part 110.

  Further, a part of the main body 41 presses the substrate 21 toward the bottom surface portion 110. Thereby, the connection member 40 has a function of regulating the position of the light source 20 in the direction along the optical axis J (z-axis direction).

  The electrode 42 is electrically connected to an electric wire supported by the main body 41 and is electrically connected to an electrode terminal provided on the substrate 21 of the light source 20. For example, the electrode 42 is formed in the shape of a leaf spring, and presses the electrode terminal toward the mounting surface 110a by its urging force. Thereby, the electrode 42 and the electrode terminal of the board | substrate 21 can be electrically connected.

  The connection member 40 is formed by insert molding using, for example, a conductive material that constitutes the electrode 42 and a resin material that constitutes the main body 41. The main body 41 is molded using a resin material such as PBT or ABS, for example. The electrode 42 is formed using a conductive material such as copper.

[Reflection member]
The reflecting member 50 is a member that controls light distribution from the light source 20. In the present embodiment, the reflecting member 50 reflects the light from the light source 20 toward the optical member 60. As shown in FIG. 2, the reflecting member 50 is a substantially cylindrical body provided with an opening through which the optical axis J passes substantially through the center.

  Specifically, the inner diameter of the reflecting member 50 gradually increases from the end on the side where the light from the light source 20 is incident (the positive side in the z-axis direction) toward the end where the light is emitted. It is formed to become. The inner surface of the reflecting member 50 is a reflecting surface that reflects light from the light source 20.

  The reflecting member 50 is formed using a hard white resin material such as PBT, for example. At this time, a metal reflecting film such as aluminum may be provided on the inner surface of the reflecting member 50.

[Optical member]
The optical member 60 is a translucent member into which light from the reflecting member 50 is incident. As shown in FIG. 2, the optical member 60 is arranged so as to cover the opening on the light emitting side (the negative side in the z-axis direction) of the reflecting member 50. The optical member 60 may have a function of controlling and emitting the light distribution of the light that has passed through the reflecting member 50. In the present embodiment, the optical member 60 is a Fresnel lens.

  The optical member 60 is formed from a material having translucency. For example, the optical member 60 is formed from a transparent resin material such as acrylic (PMMA) or polycarbonate (PC). Alternatively, the optical member 60 may be formed from a transparent glass material.

  The optical member 60 may have a light diffusion (scattering) structure. For example, the optical member 60 may be formed using a resin material in which a diffusing material is dispersed, or an unevenness or a dot pattern may be formed on the surface.

[Frame]
The frame body 70 is a cylindrical member that allows the light emitted from the optical member 60 to pass therethrough. In the present embodiment, as shown in FIG. 2, the frame body 70 includes an auxiliary reflection member 71, a frame main body 72, and a collar 73.

  The auxiliary reflecting member 71 is a cylindrical member disposed inside the cylindrical frame main body 72. The auxiliary reflecting member 71 has an auxiliary reflecting surface 71 a on the inner side, and has a function of controlling the light distribution of the lighting fixture 1. In the present embodiment, the auxiliary reflecting member 71 is formed of a thin metal plate such as aluminum.

  The frame main body 72 is a main body of the cylindrical frame 70. The frame main body 72 has substantially the same outer diameter as the base portion 11 of the instrument main body 10. The frame main body 72 and the base part 11 are fixed by screws (not shown). The frame main body 72 is formed using a metal material such as aluminum, for example.

  The flange 73 is a part of the frame main body 72 and is a portion extending from the end of the frame main body 72 on the light emission side (z-axis direction negative side) toward the outside in the radial direction. The collar 73 is provided in an annular shape. For example, when the lighting fixture 1 is attached to the ceiling, the flange 73 contacts the lower surface of the ceiling plate.

[Mounting spring]
The attachment spring 80 is used for attaching the luminaire 1 to an attachment portion such as a ceiling. Specifically, the lighting fixture 1 can be attached by holding the ceiling plate between the attachment spring 80 and the flange 73 of the frame body 72 using the restoring force of the attachment spring 80.

  The attachment spring 80 is formed into a long thin plate shape by press working using a metal material such as iron. In the present embodiment, as illustrated in FIG. 1, the lighting fixture 1 includes two attachment springs 80, but the number and positions of the attachment springs 80 are not limited thereto.

[Detailed configuration of the instrument body]
Below, the detailed structure of the instrument main body 10 is demonstrated using FIGS.

  FIG. 4 is a schematic perspective view of the instrument body 10 according to the present embodiment. FIG. 5 is a plan view showing the outer bottom surface 110b of the instrument body 10 according to the present embodiment. 6 is a cross-sectional perspective view of the instrument body 10 according to the present embodiment taken along the line VI-VI in FIG. FIG. 7 is a cross-sectional view of the connection portion between the fin 12 and the base portion 11 according to the present embodiment taken along the line VII-VII in FIG.

  The instrument main body 10 is not formed integrally (as one component) such as aluminum die casting, but is formed by connecting a plurality of components. Specifically, the protrusion 112 provided on the base part 11 is plastically deformed, so that the base part 11 and the fins 12 which are separate parts are connected and fixed. More specifically, the fin 12 is fixed to the base portion 11 in a state where the protrusion 112 is inserted into the hole 122 provided in the fin 12 and the protrusion 112 is plastically deformed.

  For example, the base portion 11 is integrally formed (as one component) by forging a cylindrical member made of aluminum. Each of the plurality of fins 12 is formed integrally (as one component) by, for example, pressing a sheet metal made of aluminum.

  By forming each of the base portion 11 and the fins 12 by forging or pressing, the dimensional accuracy can be increased. Moreover, since the thickness of each member can be made thin, weight reduction is realizable. Further, the base portion 11 is not provided with a draft angle. Thereby, workability can be improved. Each of the base portion 11 and the fins 12 may be made of aluminum die casting.

[Base part]
The shape of the base part 11 is a cup shape as shown in FIGS. Thereby, the thickness of the bottom face part 110 can be reduced while securing the envelope volume of the base part 11. Therefore, the heat from the light source 20 can be efficiently conducted to the plurality of fins 12. Specifically, the base portion 11 has a bottom surface portion 110 and a cylindrical side surface portion 111.

  As shown in FIGS. 2 and 3, the bottom surface portion 110 is a substantially circular plate-like portion to which the light source 20 is attached. The bottom surface portion 110 has an attachment surface (first surface) 110a to which the light source is attached and an outer bottom surface (second surface) 110b opposite to the attachment surface 110a.

  The mounting surface 110a is a bottom surface inside the cup-shaped base portion 11, and has a substantially circular shape in plan view. As shown in FIG. 3, the mounting surface 110 a is provided with irregularities in a predetermined shape so that the mounting member 30 and the connection member 40 are arranged. For example, the attachment surface 110a is provided with a screw hole 113 into which the screw 45 is screwed. The mounting surface 110a has a flat portion on which the substrate 21 of the light source 20 is placed. The flat portion of the mounting surface 110a and the substrate 21 are in surface contact.

  The outer bottom surface 110b is the outer bottom surface of the cup-shaped base portion 11, and has a substantially circular shape in plan view. In the present embodiment, the outer bottom surface 110b is a flat surface. Specifically, the outer bottom surface 110b is not provided with a recess. As shown in FIGS. 4 to 6, a plurality of protrusions 112 are provided on the outer bottom surface 110 b.

  As shown in FIG. 6, the plurality of protrusions 112 protrude from the outer bottom surface 110 b of the bottom surface portion 110. Each of the plurality of protrusions 112 is in a plastically deformed state. Specifically, each of the plurality of protrusions 112 is formed by plastically deforming the tip of a substantially cylindrical portion protruding in the normal direction from the outer bottom surface 110b. Specifically, as shown in FIG. 7, the protrusion 112 has a base part 112a and an enlarged diameter part 112b.

  The base part 112 a is a part inserted into a hole 122 provided in the fin 12. The shape of the base portion 112 a substantially matches the shape of the hole 122. In the present embodiment, the base portion 112a is a substantially cylindrical portion protruding from the outer bottom surface 110b in the normal direction.

  The enlarged diameter portion 112b is a portion provided at the tip of the protrusion 112 and is a portion extending in the radial direction. The shape of the enlarged diameter portion 112b is a substantially circular plate shape. The enlarged diameter portion 112b is a plastically deformed portion and presses the bottom portion 120 of the fin 12 toward the outer bottom surface 110b. That is, the fin 12 is fixed to the base portion 11 by sandwiching the bottom portion 120 of the fin 12 between the enlarged diameter portion 112 b of the protrusion 112 and the outer bottom surface 110 b of the bottom surface portion 110.

  In the present embodiment, the plurality of protrusions 112 are provided radially about the optical axis J in plan view as shown in FIG. Further, all of the plurality of protrusions 112 are in a plastically deformed state and are used for joining to the fins 12, but are not limited thereto. At least one of the plurality of protrusions 112 may be a protrusion that is not plastically deformed (specifically, the protrusion 112x (see FIG. 9)).

  As shown in FIG. 6, a fillet 114 having an arc shape in cross section is provided in an annular shape on the periphery of the bottom surface portion 110. Thereby, when the base part 11 is formed by press working, the mold strength can be increased. Moreover, since the periphery of the bottom face part 110 is not sharp, it is possible to improve the safety of the installer during construction of the lighting fixture 1.

  The side surface portion 111 is a portion erected from the periphery of the bottom surface portion 110. As shown in FIGS. 3 and 4, the side surface portion 111 has a flat and substantially cylindrical shape. In the present embodiment, unevenness is formed on the side surface portion 111. Specifically, as shown in FIGS. 4 and 5, the side surface portion 111 is provided with a convex portion 115 protruding outward in the radial direction (in a direction away from the optical axis J).

  As shown in FIGS. 4 to 6, the convex portion 115 has a cylindrical curved surface having a diameter smaller than that of the side surface portion 111, and is smoothly continuous with the side surface portion 111. A screw hole 116 is provided in the bottom surface portion 110 in the vicinity of the convex portion 115. A screw (not shown) for fixing the frame body 70 and the base portion 11 is inserted into the screw hole 116. In the present embodiment, two protrusions 115 and two screw holes 116 are provided, but the number and position of these are not limited thereto.

  As shown in FIG. 4, the side surface portion 111 is provided with a notch 117. The notch 117 is a hole for drawing an electric wire (not shown) connected to the light source 20 to the outside. The said electric wire is connected to the power supply part (lighting circuit) arrange | positioned on the outer side of the instrument main body 10. FIG.

[fin]
The fin 12 is a heat radiating fin for radiating heat from the light source 20. The fin 12 is fixed to the outer bottom surface 110 b of the base portion 11.

  In the lighting fixture 1 according to the present embodiment, a plurality of fins 12 are arranged radially about the optical axis J as shown in FIG. Specifically, the eight fins 12 are arranged at an equal angle (specifically, 45 degrees) around the optical axis J.

  In the present embodiment, the plurality of fins 12 have the same shape and the same size. Specifically, the cross-sectional shape of each of the plurality of fins 12 is substantially U-shaped (or substantially U-shaped). As shown in FIGS. 4 and 5, each of the plurality of fins 12 includes a bottom portion 120 and two side wall portions 121. As shown in FIGS. 6 and 7, the bottom 120 is provided with a hole 122.

  The bottom portion 120 is a portion that contacts the outer bottom surface 110 b of the base portion 11. Specifically, the bottom portion 120 is a long flat plate portion, and is in surface contact with the outer bottom surface 110b. Since the bottom part 120 and the bottom part 110 of the base part 11 are thermally coupled, the heat from the light source 20 is conducted from the bottom part 110 to the bottom part 120 of the fin 12.

  The plan view shape of the bottom 120 is substantially rectangular as shown in FIG. The length of the bottom portion 120 in the longitudinal direction is, for example, a length that is at least half of the radius of the bottom surface portion 110 of the base portion 11 in plan view. In the present embodiment, the fin 12 is not provided in the central portion (portion passing through the optical axis J) of the bottom surface portion 110, but the present invention is not limited to this.

  The two side wall parts 121 are erected from both ends of the bottom part 120 in the short direction. In other words, the bottom portion 120 is a portion connecting the end portions of the two side wall portions 121.

  The two side wall parts 121 have the same shape and the same size. Specifically, the side wall part 121 is a substantially rectangular plate part, for example. The size of the side wall 121 may be appropriately changed according to required heat dissipation performance.

  The hole 122 is a through hole that penetrates the bottom 120. The hole 122 is, for example, a cylindrical straight hole. The hole 122 has such a size that the protrusion 112x (see FIG. 9) before plastic deformation can be inserted. In consideration of the dimensional tolerances of the base portion 11 and the fins 12, the hole 122 is formed, for example, approximately 0.5 mm larger than the diameter of the protrusion 112x before plastic deformation.

  In the present embodiment, two holes 122 are provided at both ends of the bottom 120 in the longitudinal direction. The number and position of the holes 122 are not limited to this, and for example, only one hole 122 may be provided.

  As shown in FIGS. 4 and 6, a chamfered portion 123 is provided at the end (upper end) of the side wall 121 opposite to the bottom 120. The chamfered portion 123 has a shape in which the corners of the side wall portion 121 are cut off obliquely. For example, the chamfered portion 123 has a shape chamfered at 45 degrees. The chamfered portion 123 may be formed with a round surface. Thereby, the safety | security of the installer at the time of construction of the lighting fixture 1 can be improved.

  Further, as shown in FIGS. 4 and 6, the side wall 121 is provided with an insertion hole 124. The insertion hole 124 is a hole through which an insulation lock (binding band) that holds the wires drawn out of the instrument body 10 together is passed. By holding the electric wire with the insulation lock, the force can be relaxed when the electric wire is pulled during construction or transportation of the lighting fixture 1. Thereby, it can suppress that tensile force is directly added to the connection part with the light source 20, and a connection with an electric wire and the light source 20 remove | deviates.

[Method of manufacturing lighting apparatus]
Then, the manufacturing method of the lighting fixture 1 is demonstrated using FIGS. 8-10.

  FIG. 8 is a flowchart showing a method for manufacturing the lighting fixture 1 according to the present embodiment. Here, in particular, a method for manufacturing the instrument body 10 will be described in detail.

  First, a plurality of protrusions 112x are formed on the outer bottom surface 110b of the base portion 11 (S10). Specifically, the base 11 having a plurality of protrusions 112x provided on the outer bottom surface 110b is integrally formed by forging an aluminum cylindrical member. The protrusion 112x is a protrusion before plastic deformation (see FIG. 9).

  Next, the hole 122 is formed in the fin 12 (S20). Specifically, by pressing a sheet metal made of aluminum, the fin 12 having a hole 122 provided in the bottom 120 and having a substantially U-shaped cross section is formed. In addition, after forming the fin 12 having a substantially U-shaped cross section, the hole 122 may be formed by additional machining.

  Next, the protrusion 112x is inserted into the hole 122 (S30). Thereby, the fin 12 is made to contact the outer bottom face 110b. That is, the positioning of the fin 12 with respect to the base portion 11 is performed.

  FIG. 9 is a perspective view showing a positioning step (S30 in FIG. 8) between the fin 12 and the base portion 11 in the method for manufacturing the lighting fixture 1 according to the present embodiment. FIG. 9 shows a state immediately before the five fins 12 are arranged at positions to be fixed and the protrusion 112x is inserted into the hole 122 of the sixth fin 12. In addition, although the example which arrange | positions the fin 12 one by one is shown here, you may arrange | position eight fins 12 collectively.

  The protrusion 112 x is a substantially columnar portion that is erected from the outer bottom surface 110 b of the base portion 11. The protrusion 112x has, for example, a diameter and a height of 3 mm to 4 mm, and a radius having a radius of 1 mm to 2 mm is provided at the root. In addition, the dimension of the protrusion 112x is only an example, and is not limited to these.

  9, the fin 12 is moved downward at a position where the two protrusions 112x aligned in the radial direction of the base portion 11 and the two holes 122 of the fin 12 overlap in a top view. . Thus, the two protrusions 112x are inserted into the two holes 122. Since the size of the hole 122 and the size of the projection 112x are substantially the same, the movement of the fin 12 in the lateral direction is restricted.

  After all the fins 12 are arranged, the protrusion 112x is plastically deformed (S40). Thereby, the fin 12 and the base part 11 are fixed.

  FIG. 10 is a cross-sectional view showing a plastic deformation step of the protrusion 112x in the method for manufacturing the lighting fixture 1 according to the present embodiment. As shown to (a) of FIG. 10, the metal mold | die 90 is pressed from the front-end | tip direction of the processus | protrusion 112x. By pushing the mold 90 as it is, as shown in FIG. 10B, the projection 112x is plastically deformed to form the enlarged diameter portion 112b. Note that not only the protrusion 112x but also the periphery of the hole 122 of the bottom 120 of the fin 12 may be plastically deformed.

  Thus, the fin 12 is joined and fixed to the base part 11 by caulking. Specifically, the enlarged diameter portion 112 b formed by plastic deformation presses the bottom portion 120 of the fin 12 toward the outer bottom surface 110 b of the base portion 11. Thereby, detachment | desorption of the fin 12 can be suppressed.

  As can be seen by comparing FIGS. 10A and 10B, a gap is formed between the projection 112x before plastic deformation and the hole 122 of the fin 12, whereas after plastic deformation. No gap is formed between the projection 112 and the hole 122. This is because when the protrusion 112x is pressed by the mold 90, the protrusion 112x expands in the lateral direction.

  Therefore, in the present embodiment, not only the lower surface of the bottom portion 120 of the fin 12 contacts the outer bottom surface 110 b of the base portion 11, but also the side surface of the base portion 112 a contacts the wall surface of the hole 122 of the bottom portion 120. Further, the lower surface of the enlarged diameter portion 112 b is in contact with the upper surface of the bottom portion 120. Thus, since the contact area of the fin 12 and the base part 11 is large, the heat conduction from the base part 11 to the fin 12 can be performed efficiently.

  For example, since the contact area is larger than when the fin 12 is screwed to the base portion 11, the thermal conductivity can be increased. Moreover, compared with the case of screwing, joining of the fin 12 and the base part 11 is easy, and it is excellent in mass production.

  Here, in the present embodiment, the enlarged diameter portion 112 b is close to the side wall portion 121. Specifically, the gap between the enlarged diameter portion 112b and the side wall portion 121 is, for example, 0.5 mm or less. The enlarged diameter portion 112b may be in contact with the side wall portion 121. When the enlarged diameter portion 112b and the side wall portion 121 are in contact with each other, the contact area between the fin 12 and the base portion 11 is increased, so that the thermal conductivity is further increased.

  Thus, the enlarged diameter portion 112 b is not formed so as to be recessed with respect to the side wall portion 121. That is, the enlarged diameter portion 112b formed by plastic deformation is formed so as not to deform the side wall portion 121. Thereby, it can suppress that the heat dissipation performance of the fin 12 is impaired.

  In the present embodiment, the example in which the plurality of fins 12 are fixed to the base portion 11 at the same time has been described. However, the present invention is not limited to this. The protrusion 112x may be plastically deformed and fixed for each fin 12.

[Effects, etc.]
As described above, the lighting fixture 1 according to the present embodiment includes the light source 20 and the fixture main body 10 to which the light source 20 is attached. The fixture main body 10 has the attachment surface 110a to which the light source 20 is attached and the attachment surface 110a. And a fin 12 fixed to the outer bottom surface 110b. The base portion 11 is provided with a protrusion 112 protruding from the outer bottom surface 110b. The fins 12 are fixed to the base portion 11 with the projections 112 inserted into the holes 122 and the projections 112 being plastically deformed.

  Thereby, the heat of the light source 20 emitted at the time of lighting is conducted to the fins 12 through the base portion 11 and dissipated to the outside. That is, the instrument body 10 not only holds the light source 20 but also functions as a heat sink.

  Here, as for the instrument main body 10, the base part 11 and the fin 12 are not integrally formed as one component like aluminum die casting. That is, the base part 11 and the fin 12 are formed as separate parts. For this reason, the shape, size, and number of the fins 12 can be appropriately changed so as to correspond to the heat dissipation performance required according to the output of the light source 20 and the like. Therefore, since the base part 11 can be shared between a plurality of different lighting fixtures, the manufacturing cost can be greatly reduced, and the fixture main body 10 as a heat sink excellent in customization can be provided. .

  Moreover, in the lighting fixture 1 which concerns on this Embodiment, since the processus | protrusion 112 of the base part 11 is inserted in the hole 122 of the fin 12, and is fixed in the state which deformed plastically, the dimension of the base part 11 and the fin 12 is carried out. Tolerance effects are suppressed. Therefore, since the base part 11 and the fin 12 can be more securely and firmly fixed, the base part 11 and the fin 12 can be sufficiently brought into contact with each other, and the fin from the base part 11 can be obtained. 12 desorption can be suppressed. Therefore, heat conduction from the base portion 11 to the fins 12 can be performed efficiently.

  Thus, according to this Embodiment, the lighting fixture 1 with improved heat conductivity can be provided.

  For example, the outer bottom surface 110b is a flat surface.

  Thereby, when using the lighting fixture 1 in the condition where water can splash, such as the outdoors, it can suppress that water accumulates in the outer bottom face 110b of the base part 11. FIG.

  In addition, for example, in the method of manufacturing the lighting fixture 1 according to the present embodiment, the mounting surface 110a to which the light source 20 is attached, the base 11 having the outer bottom surface 110b opposite to the mounting surface 110a, and the outer bottom surface 110b. A method of manufacturing a lighting fixture 1 including a fixed fin 12, a step of forming a protrusion 112 x on the outer bottom surface 110 b, a step of forming a hole 122 in the fin 12, and inserting the protrusion 112 x into the hole 122. The method includes a step of bringing the fin 12 into contact with the outer bottom surface 110b and a step of fixing the fin 12 to the base portion 11 by plastic deformation of the protrusion 112x.

  Thereby, the lighting fixture 1 with which heat conductivity was improved can be manufactured easily.

(Modification 1)
Below, the modification 1 of the lighting fixture 1 which concerns on embodiment is demonstrated. In addition, in the lighting fixture which concerns on this modification, only the fixture main body is different compared with embodiment. Specifically, in the instrument body according to this modification, the shapes of the protrusions of the base portion and the holes of the fins are different. Therefore, below, an instrument main body is demonstrated and description of another structural member is abbreviate | omitted or simplified.

  FIG. 11 is a plan view of the instrument body 200 according to the present modification. FIG. 12 is a cross-sectional view of a connection portion between the fin 220 and the base portion 210 according to this modification. Specifically, FIG. 12A shows a cross section taken along line XIIA-XIIA in FIG. 11 and orthogonal to the outer bottom surface 110b. FIG. 12B is a cross section taken along line XIIB-XIIB of FIG. 12A, and shows a cross section passing through the bottom 120 of the fin 220 and parallel to the outer bottom surface 110b.

  As shown in FIG. 11, the base portion 210 according to this modification is different from the base portion 11 according to the embodiment in that a protrusion 212 is provided instead of the protrusion 112. Specifically, the shape of the protrusion 212 is different from that of the protrusion 112.

  In this modification, as shown in FIG. 12B, the cross-sectional shape of the protrusion 212 in a cross section parallel to the outer bottom surface 110b is a substantially rectangular shape. Specifically, the cross-sectional shape of the base portion 212a of the protrusion 212 is substantially rectangular. The same applies to the enlarged diameter portion 212b. Moreover, as shown in FIG. 11, the top view shape of the protrusion 212 is a long shape, specifically, a rectangle with rounded corners.

  In this modification, as shown in FIGS. 11 and 12, the short direction of the bottom portion 120 and the short direction in the cross-sectional shape of the protrusion 212 substantially coincide with each other. As shown in FIG. 11, the plurality of protrusions 212 are arranged such that each longitudinal direction is radial from the optical axis J.

  FIG. 13 is a schematic perspective view of the base portion 210 including the protrusion 212x before plastic deformation according to this modification. As shown in FIG. 13, the protrusion 212x before plastic deformation is a columnar protrusion having a long bottom surface and top surface. The cross-sectional shape of the protrusion 212x in a cross section parallel to the outer bottom surface 110b is a substantially elliptical shape or a substantially rectangular shape.

  As shown in FIG. 12, a hole 222 is provided in the bottom 120 of each of the plurality of fins 220. The hole 222 is substantially oval or substantially rectangular according to the shape of the protrusion 212x. The protrusion 212x is inserted into the hole 222, and the protrusion 212x is plastically deformed, whereby the protrusion 212 shown in FIGS. 11 and 12 is formed. The plastic deformation process of the protrusion 212x is the same as that of the embodiment.

  As described above, in the lighting fixture according to the present modification, for example, the cross-sectional shape of the protrusion 212 in the cross section parallel to the outer bottom surface 110b is a substantially elliptical shape or a substantially rectangular shape.

  Thereby, since the contact area of the wall surface of the hole 222 and the side surface of the protrusion 212 can be increased, the thermal conductivity from the base part 210 to the fin 220 can be enhanced.

  In addition, when the short side direction of the fin 220 and the longitudinal direction of the protrusion 212x coincide, the side wall part 121 of the fin 220 may be deformed by the pressure of plastic deformation. On the other hand, in the lighting fixture according to the present modification, the fin 220 is provided with a hole 222 and stands from each of the long bottom portion 120 that contacts the outer bottom surface 110b and both ends of the bottom portion 120 in the short direction. The lateral direction of the bottom part 120 and the lateral direction in the cross-sectional shape of the protrusion 212 substantially coincide with each other.

  Thereby, when the protrusion 212x is plastically deformed, the side wall portion 121 of the fin 220 can be prevented from being unnecessarily deformed by the pressure. Therefore, it can suppress that the heat dissipation performance of the fin 220 is impaired.

  Further, for example, a diameter-enlarged portion 212 b extending in the radial direction is provided at the tip of the protrusion 212, and the diameter-enlarged portion 212 b is in contact with or close to the side wall portion 121.

  Thereby, it can suppress that the protrusion 212 deform | transformed plastically presses the side wall part 121, and deform | transforms unnecessarily. Therefore, it can suppress that the heat dissipation performance of the fin 220 is impaired.

(Modification 2)
Then, the modification 2 of the lighting fixture 1 which concerns on embodiment is demonstrated. In addition, in the lighting fixture which concerns on this modification, only a base part differs compared with embodiment. Therefore, below, a base part is demonstrated and description of another structural member is abbreviate | omitted or simplified.

  FIG. 14 is a schematic perspective view of the base portion 310 including the protrusion 112x before plastic deformation according to the present modification. As for the base part 310 which concerns on this modification, the unevenness | corrugation is provided in the cylindrical side part 111. FIG. Specifically, a plurality of convex portions 315 are provided. The plurality of convex portions 315 have substantially the same shape as the convex portion 115, have a cylindrical curved surface having a smaller diameter than the side surface portion 111, and are smoothly continuous with the side surface portion 111.

  In the example shown in FIG. 14, the convex portion 315 is provided on the opening side of the side surface portion 111 (on the side opposite to the bottom surface portion 110), and is provided with a length that is approximately half the height of the side surface portion 111. Yes. Specifically, the convex portion 315 is provided from the opening of the side surface portion 111 to the vicinity of the center in the height direction of the side surface portion 111. In addition, the convex part 315 may be provided from the opening part of the side part 111 to the bottom face part 110 similarly to the convex part 115.

  Further, for example, the base portion 310 includes a bottom surface portion 110 having a mounting surface 110a and an outer bottom surface 110b, and a cylindrical side surface portion 111 standing from the periphery of the bottom surface portion 110. A portion 315 is formed.

  Thereby, since the surface area of the base part 310 can be increased, the heat dissipation of the base part 310 can be improved.

  In this modification, the convex portion 315 is provided as an example of the concave and convex portions, but may be a concave portion. The surface of the side part 111 may be formed in a wave shape.

(Other)
As mentioned above, although the lighting fixture which concerns on this invention was demonstrated based on the said embodiment and its modification, this invention is not limited to said embodiment.

  For example, in the above embodiment, the protrusion 112x is plastically deformed by caulking, but the present invention is not limited to this. For example, the protrusion 112x may be plastically deformed by inserting the protrusion 112x into the hole 122 and then bending the protrusion 112x toward the bottom 120 of the fin 12. In this case, in order to facilitate the bending of the protrusion 112x, the protrusion 112x may have a thin plate shape.

  Further, for example, in the above-described embodiment, the example in which the outer bottom surface 110b is a plane is shown, but the present invention is not limited to this. The outer bottom surface 110b may be a curved surface such as a spherical surface, as long as it has a structure in which water does not easily accumulate. Alternatively, an inclined groove or the like for flowing the water accumulated on the outer bottom surface 110b may be provided.

  Further, for example, in the above-described embodiment, the fin 12 has been illustrated with an example in which the cross-sectional shape is substantially U-shaped, but the present invention is not limited thereto. For example, the cross-sectional shape of the fin 12 may be substantially L-shaped. Specifically, the fin 12 may include a bottom portion 120 and only one side wall portion 121. Moreover, the bottom part 120 of the fin 12 may not be long, for example, a square-shaped board part etc. may be sufficient.

  Further, for example, the plurality of fins 12 are provided radially on the outer bottom surface 110 b of the base portion 11, but the present invention is not limited to this. For example, the plurality of fins 12 may be arranged in a stripe pattern. For example, the number of fins 12 is not limited to a plurality, and may be only one, for example.

  In addition, for example, the hole 122 provided in the fin 12 may have a shape that is not a through-hole but is cut out from the end surface of the bottom 120 along the longitudinal direction. In this case, the protrusion 112x can be inserted into the hole 122 by sliding the fin 12.

  Further, for example, in the above-described embodiment, the example in which the lighting fixture 1 is an embedded lighting fixture such as a downlight has been described, but the invention is not limited thereto. The lighting fixture 1 may be a spotlight or the like.

  In addition, the embodiment can be realized by arbitrarily combining the components and functions in each embodiment without departing from the scope of the present invention, or a form obtained by subjecting each embodiment to various modifications conceived by those skilled in the art. Forms are also included in the present invention.

DESCRIPTION OF SYMBOLS 1 Lighting fixture 10,200 Appliance main body 11,210,310 Base part 12,220 Fin 20 Light source 110 Bottom face part 110a Mounting surface (1st surface)
110b Outer bottom surface (second surface)
111 Side surface portions 112, 112x, 212, 212x Protrusions 112b, 212b Expanded diameter portions 115, 315 Protruding portion 120 Bottom portion 121 Side wall portions 122, 222 Hole

Claims (7)

A light source;
An instrument body to which the light source is attached,
The instrument body is
A base portion having a first surface to which the light source is attached, and a second surface opposite to the first surface;
A fin fixed to the second surface;
The base portion is provided with a columnar protrusion protruding from the second surface,
The fin is provided with a hole,
The fin is fixed to the base portion in a state where the projection is inserted into the hole and the projection is plastically deformed,
The protrusion fills the entire inside of the hole,
The tip of the projection is provided with an enlarged diameter portion extending in the radial direction,
A shape of the enlarged diameter portion is a circular plate. The lighting fixture according to claim 1, wherein the second surface is a flat surface. The lighting fixture according to claim 1, wherein a cross-sectional shape of the protrusion in a cross section parallel to the second surface is a substantially elliptical shape or a substantially rectangular shape. The fin is
An elongate bottom provided with the hole and contacting the second surface;
Two side walls provided upright from both ends in the short direction of the bottom,
The lighting fixture according to claim 3, wherein a short direction of the bottom portion and a short direction in a cross-sectional shape of the protrusion substantially coincide with each other. The lighting apparatus according to claim 4, wherein the enlarged diameter portion is in contact with or close to the side wall portion. The base portion is
A bottom surface portion having the first surface and the second surface;
A cylindrical side surface provided upright from the periphery of the bottom surface,
The lighting apparatus according to any one of claims 1 to 5, wherein the side surface portion is provided with irregularities. A manufacturing method of a lighting fixture comprising: a first surface to which a light source is attached; a base portion having a second surface opposite to the first surface; and a fin fixed to the second surface,
Forming columnar protrusions on the second surface;
Forming a hole in the fin;
Inserting the protrusion into the hole and bringing the fin into contact with the second surface;
Said radially enlarged portion is formed on the tip of the projection, and the projection in so that fill the entire interior of the hole by causing plastic deformation, and a step of fixing the fins to the base portion,
The shape of the said enlarged diameter part is a circular plate shape. The manufacturing method of the lighting fixture.

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