JP6949673B2 - Lighting equipment and its manufacturing method - Google Patents

Description

The present invention relates to a lighting device suitable for mounting objects having different radii of curvature such as a planar shape and a curved surface shape, and a method for manufacturing the same.

A conventional lighting device includes a main body to be attached, a flexible substrate that is attached to the main body and has an opening and can be bent and deformed, and a light emitting element provided so as to close the opening (see: Patent). Document 1). Therefore, by matching the flexible substrate to the planar shape, curved surface shape, etc. of the main body, it is possible to realize a lighting device suitable for the main body having various shapes.

As another conventional lighting device, a base, a light source provided on the base, a cover for blocking the light source, and a lens assembly provided on the cover are provided, and the light source and the lens assembly are assembled by manually deforming the cover. There is one that changes the distance to Lee to change the diffused light, concentrated light, that is, the light distribution (illumination) area (see: Patent Document 2). However, even if the cover of another conventional irradiation device is adopted, the irradiation range cannot be changed automatically.

Japanese Unexamined Patent Publication No. 2011-82095 (Patent No. 5556116) Republished Patent WO2012 / 099173 (Patent No. 5542218)

However, in the above-mentioned conventional lighting device, the irradiation range emitted by each light emitting element is constant even if the radius of curvature of the shape of the main body, that is, the object to be mounted is different. As a result, when the radius of curvature of the curved surface shape is small, there is a problem that the irradiated area becomes relatively small and the non-irradiated area that is not irradiated becomes large.

FIG. 9 is a diagram illustrating a problem of a conventional lighting device. In FIG. 9, 101 is a flexible substrate and 102 is a light emitting diode (LED) element.

As shown in FIG. 9A, when the mounting target (main body) 100 has a planar shape, the irradiation (light distribution) region R1 of each LED element 102 is in a certain range, for example, spot light distribution in close proximity. Therefore, the non-irradiated region N1 that is not irradiated is small. That is, the larger the radius of curvature of the mounting target 100, the smaller the non-irradiated region N1.

On the other hand, as shown in FIG. 9B, when the mounting target 100'has a ring shape, the spot light distribution is also obtained, and the irradiation range R1 of each LED element 102 is the same as in the case of FIG. 7A. There is a spot light distribution that is not close to each other. Therefore, the non-irradiated region N2 that is not irradiated becomes large. That is, the smaller the radius of curvature of the mounting target 100', the larger the non-irradiated region N2.

In order to solve the above-mentioned problems, the lighting device according to the present invention includes a flexible base material, a light emitting element mounted on the flexible base material, and an elastic transparent resin member provided on the flexible base material and the light emitting element. The elastic transparent resin member connects at least two strut portions located on the flexible base material, a convex lens portion located on the light emitting element in the gap between the strut portions, and the convex lens portion and the strut portion. It is provided with an elastic support portion that supports the convex lens portion.

Further, the method for manufacturing a lighting device according to the present invention includes a step of mounting a light emitting element on a flexible base material and attaching the light emitting element of the flexible base material to an elastic transparent resin member formed by an insert molding method. , The step for embedding the light emitting element in the elastic transparent resin member is provided, and the elastic transparent resin member is located on at least two strut portions located on the flexible base material and the light emitting element in the gap between the strut portions. It is provided with an elastic support portion that connects a convex lens portion, a convex lens portion, and a strut portion to support the convex lens portion.

According to the present invention, the smaller the radius of curvature of the object to be attached, the smaller the distance between the convex lens portion of the elastic transparent material member and the light emitting element. Therefore, even if the radius of curvature of the attachment target becomes small, the increase in the non-irradiated area can be automatically reduced.

The first embodiment of the lighting apparatus which concerns on this invention is shown, (A) is a perspective view, (B) is a vertical sectional view of (A). It is a figure for demonstrating the case where the lighting apparatus of FIG. 1 is attached to the attachment object of a curved surface shape. It is a figure for demonstrating the irradiation range of the illuminating apparatus of FIG. It is a top view of the flexible substrate for demonstrating the manufacturing method of the lighting apparatus of FIG. It is a figure for demonstrating the effect of the lighting apparatus of FIG. It is sectional drawing which shows the 1st modification example of the lighting apparatus of FIG. It is sectional drawing which shows the 2nd modification example of the lighting apparatus of FIG. The second embodiment of the lighting apparatus which concerns on this invention is shown, (A) is a perspective view, (B) is a vertical sectional view of (A). It is a figure for demonstrating the problem of the conventional lighting apparatus, (A) shows the case of mounting on a plane shape mounting object, (B) shows the case of mounting on a ring shape mounting object.

FIG. 1 shows a first embodiment of a lighting device according to the present invention, (A) is a perspective view, and (B) is a vertical sectional view of (A).

In FIG. 1, the lighting device 10 includes a flexible base material 1, a light emitting element such as an LED element 2, and an elastic transparent resin member 3. The flexible base material 1 is composed of a base material 11 made of relatively thick, for example, about 2 mm of propylene, and a flexible substrate 12 made of relatively thin, for example, about 1 mm of polyimide. Further, the LED element 2 is mounted on the flexible base material 1. Further, an elastic transparent resin member 3 made of elastic, for example, silicone rubber is provided on the flexible base material 1 and the LED element 2. A gap G is provided between the LED element 2 and the elastic transparent resin member 3.

The height of the elastic transparent resin member 3 is, for example, about 10 mm. The elastic transparent resin member 3 is composed of a strut portion 31 located on the flexible base material 1, a convex lens portion 32 located on the light emitting element 2 by bridging the gap G between the strut portions 31, and an elastic support portion 33. Although both the upper surface and the lower surface of the convex lens portion 32 are convex, only one of the upper surface and the lower surface of the convex lens portion 32 may be flat. In this case, since the support column 31 is fixed to the flexible base material 1, the rigidity is high. On the other hand, since the elastic support portion 33 bridges the void G, the rigidity is small and the mass is also small, so that the elastic support portion 33 sufficiently acts as an elastic body. The rigidity of the convex lens portion 32 is moderate between the rigidity of the strut portion 31 and the rigidity of the elastic support portion 33.

FIG. 2 is a diagram for explaining a case where the lighting device 10 of FIG. 1 is mounted on a curved surface-shaped mounting target.

As shown in FIG. 2, when the lighting device 10 of FIG. 1 is attached to the curved surface-shaped mounting target 100', the lighting device 10 bends along the curved surface shape of the mounting target 100'as shown by the arrow X1. At this time, the elastic transparent resin member 3 is stretched due to the difference between the inner ring and the outer ring, and as shown by the arrow X2, the elastic support portion 33 acts on the elastic support portion 33 around the fulcrum P1 at the upper part of the support column portion 31. Therefore, the convex lens portion 32 descends as shown by the arrow X3. As a result, the distance between the convex lens portion 32 and the LED element 2 becomes small. Therefore, as shown in FIG. 3B, the distance between the convex lens portion 32 and the LED element 2 is reduced with respect to the irradiation region R1 of the planar shape mounting target 100 shown in FIG. The irradiation region R2 of the shape mounting target 100'becomes large.

The manufacturing method of the lighting device 10 of FIG. 1 will be described with reference to FIG.

First, as shown in FIG. 4A, the flexible substrate 12 is preliminarily formed with a silicone rubber penetrating fixing hole 12a for the silicone rubber of the elastic transparent resin member 3. Further, a wiring pattern (not shown) is formed on the flexible substrate 12. Next, the flexible substrate 12 is attached to the base substrate 11 with an adhesive or the like.

Next, as shown in FIG. 4B, the LED element 2 is mounted on the flexible substrate 12 with an adhesive or the like, and at that time, the bump electrode of the LED element 2 and the wiring pattern are connected.

Finally, the flexible base material 1 is attached to the elastic transparent resin member 3 molded by the insert molding method using silicone rubber or the like, and the LED element 2 is pushed in at that time. At this time, the elastic transparent resin member 3 such as silicone rubber also enters the silicone rubber penetrating fixing hole 12a. As a result, the lighting device 10 of FIG. 1 is completed.

5A and 5B are views for explaining the effect of the lighting device of FIG. 1, where FIG. 5A shows a case where a flat shape mounting object is used, and FIG. 5B shows a case where a ring shape mounting target is used.

As shown in FIG. 5A, when the mounting target 100 has a planar shape, the irradiation region R1 of each LED element 2 is in a certain range, for example, spots in close proximity to each other, as in FIG. 9A. The light distribution is provided, and the non-irradiated region N1 is small.

On the other hand, as shown in FIG. 5B, when the mounting target 100'has a ring shape, the distance between the lens portion 32 of the elastic transparent resin member 3 and the LED element 2 becomes small, so that the non-irradiated region is not irradiated. N2 becomes smaller, and for example, in FIG. 5B, a wide light distribution in which the non-irradiated region N2 does not exist is obtained. In this way, even if the radius of curvature of the attachment target is small, the non-irradiated area is small.

FIG. 6 is a cross-sectional view showing a first modification of the lighting device of FIG.

In FIG. 6, an auxiliary elastic support portion 34 provided extending from the connection point between the convex lens portion 32 and the elastic support portion 33 of the elastic transparent resin member 3 of FIG. 1 toward the flexible base material 1 is added. Since the auxiliary elastic support portion 34 is also a part of the elastic transparent resin member 3 and its cross-sectional area is small, it serves as an elastic body for adjusting the distance between the convex lens portion 32 and the LED element 2. Therefore, when the radius of curvature of the object to be mounted is small, the amount of reduction of the convex lens portion 32 is large and the convex lens portion 32 may collide with the LED element 2, and this is prevented by the auxiliary elastic support portion 34. On the contrary, when the radius of curvature of the attachment target is large, the auxiliary elastic support portion 34 acts to push up the convex lens portion 32. Further, by providing a plurality of auxiliary elastic support portions 34 in the cross-sectional direction, the distance between the convex lens portion 32 and the LED element 2 can be maintained at a predetermined value without tilting.

FIG. 7 is a cross-sectional view showing a second modification of the lighting device of FIG.

In FIG. 7, stoppers 35 are provided at both lower ends of the convex lens portion 32 of FIG. The stopper 35 is also a part of the elastic transparent resin member 3. The stopper 35 prevents the convex lens portion 32 from coming into contact with the flexible base material 1 when the radius of curvature of the attachment target becomes small. Further, the elastic support portion 33 is brought into contact with the fulcrum P2 of the flexible base material 1, and the elastic support portion 33'is provided on the support column 31 side to be brought into contact with the fulcrum P2. Therefore, when the illuminating device 10 of FIG. 7 is attached to the curved surface-shaped attachment target, the illuminating device 10 bends as shown by the arrow Y1. At this time, as shown by arrows Y2 and Y2', a moment acts on the elastic support portions 33 and 33' centering on the fulcrum P2. As a result, the convex lens portion 32 descends as shown by the arrow Y3, and the distance between the convex lens portion 32 and the LED element 2 becomes smaller.

FIG. 8 shows a second embodiment of the lighting device according to the present invention, (A) is a perspective view, and (B) is a vertical sectional view of (A).

In the lighting device 10'of FIG. 8, for the component of the lighting device 10 of FIG. 1, an elastic transparent resin member 1'made of silicone rubber or the like and having a thickness of about 2.5 mm is used instead of the flexible base material 1. In addition to being provided, a wiring board 4 and a wiring 5 connected to the wiring board 4 are added for mounting the LED element 2. Further, the elastic transparent resin member 3 is provided with a groove 36 for the wiring 5. As described above, FIG. 8 is different in that the wiring board 4 is provided instead of the flexible board 12 provided with the wiring pattern of FIG.

The manufacturing method of the lighting device 10'in FIG. 8 will be described.

First, elastic transparent resin members 1'3 are formed by an insert molding method using silicone rubber or the like.

Next, the wiring substrate 4 is attached to the elastic transparent resin member 1'with an adhesive or the like, and the LED element 2 is mounted on the wiring substrate 4 with an adhesive or the like. At that time, the bump electrode of the LED element 2 and the wiring on the wiring board 4 are connected.

Next, the wiring 5 is provided on the elastic transparent resin member 1'and connected to the wiring pattern on the wiring board 4.

Finally, the elastic transparent resin member 1'is attached to the elastic transparent resin member 3 with an adhesive or the like. At that time, the LED element 2 and the wiring substrate 4 are pushed into the gap G of the elastic transparent resin member 3, and the wiring 5 is fitted in the groove 36 of the elastic transparent resin member 3. As a result, the lighting device 10'in FIG. 8 is completed.

In the lighting device 10'of FIG. 8, the modified examples shown in FIGS. 6 and 7 can also be applied.

Further, in the above-described embodiment, the number of the LED elements 2 is 2, but it may be 1 or 3 or more. Further, the LED element 2 may be another light emitting element such as a laser diode (LD) element.

Moreover, the present invention may be applied to any modification of the obvious scope of the embodiments described above.

The present invention can be used as a line-shaped lighting device wrapped around a person's head.

10, 10': Lighting device 1: Flexible base material 1': Elastic transparent resin member 11: Base material 12: Flexible substrate 2: LED element 3: Elastic transparent resin member 31: Strut portion 32: Convex lens portion 33, 33': Elastic support 34: Auxiliary elastic support 35: Stopper 36: Groove 4: Wiring substrate 5: Wiring R1, R2: Irradiation (light distribution) region N1, N2: Non-irradiation region G: Void P1, P2: Support point

Claims (9)

Flexible base material and
The light emitting element mounted on the flexible base material and
The flexible base material and the elastic transparent resin member provided on the light emitting element are provided.
The elastic transparent resin member is
With at least two struts located on the flexible substrate,
A convex lens portion located on the light emitting element in the gap between the support columns and a convex lens portion
An illuminating device including an elastic support portion that connects the convex lens portion and the strut portion to support the convex lens portion. The lighting device according to claim 1, wherein the elastic support portion is connected to the opposite side of the strut portion from the flexible base material. The lighting device according to claim 1, wherein the elastic transparent resin member further includes an auxiliary elastic support portion provided so as to extend from a connection point between the convex lens portion and the elastic support portion toward the flexible base material. .. The lighting device according to claim 1, wherein the elastic transparent resin member further includes a stopper provided so as to extend from a connection point between the convex lens portion and the elastic support portion toward the flexible base material. The lighting device according to claim 1, wherein the elastic support portion is connected to the flexible base material side of the strut portion. The flexible base material is
With the base base material
The lighting device according to claim 1, further comprising a flexible substrate attached to the base base material and on which the light emitting element is mounted. The flexible base material comprises another elastic transparent resin member, and the flexible base material comprises another elastic transparent resin member.
Further, a wiring board provided on the other elastic transparent resin member and for mounting the light emitting element is provided.
The lighting device according to claim 1, wherein the elastic transparent resin member is provided with a groove for wiring to the wiring board. The process for mounting the light emitting element on the flexible base material and
A step of attaching the light emitting element of the flexible base material to an elastic transparent resin member molded by an insert molding method and embedding the light emitting element in the elastic transparent resin member is provided.
The elastic transparent resin member is
With at least two struts located on the flexible substrate,
A convex lens portion located on the light emitting element in the gap between the support columns and a convex lens portion
A method for manufacturing a lighting device including an elastic support portion that connects the convex lens portion and the strut portion to support the convex lens portion. A step for forming a first elastic transparent resin member having voids and grooves by an insert molding method, and
The process for forming the second elastic transparent resin member by the insert molding method and
A process for attaching a wiring board on which a light emitting element is mounted to the first elastic transparent resin member, and
The process for wiring the wiring board and
A step of attaching the first elastic transparent resin member to the second elastic transparent resin member and fitting the wiring into the groove is provided.
The first elastic transparent resin member is
With at least two struts located on the flexible substrate,
A convex lens portion located on the light emitting element in the gap between the support columns and a convex lens portion
A method for manufacturing a lighting device including an elastic support portion that connects the convex lens portion and the strut portion to support the convex lens portion.

Images