JP7033903B2 - Light source unit - Google Patents

Description

The present invention relates to a light source unit provided in a vehicle lamp, and more particularly to a light source unit including a card-type light source in which a light emitting element is mounted on a card-type substrate.

In recent years, a light source device, that is, a light source unit, in which a light emitting element such as an LED (light emitting diode) or LD (laser diode) is unitized as a light source, has been proposed for a lamp for a vehicle such as an automobile. In such a light source unit, one or a plurality of light emitting elements are mounted on a card-type circuit board (hereinafter referred to as a card board) to form a card-type light source, and the card-type light source is incorporated into a lamp. The card-type light source is electrically connected to an in-vehicle power source to supply power to the light emitting element.

Conventionally, in a light source unit using such a card-type light source, a separate power receiving connector is mounted on a part of a card board having a required shape, and a power feeding connector connected to an in-vehicle power supply is fitted to this power receiving connector. It is configured to supply power by doing so. However, in this configuration, it takes a lot of man-hours to mount the power receiving connector on the card board, and it becomes an obstacle when the card type light source is miniaturized by the power receiving connector. Therefore, for example, as in Patent Document 1, by forming an electrode pad on one side of the card substrate as a power receiving connector to form a card edge connector, it is not necessary to mount a separate connector, and the man-hours can be reduced. A card-type light source that enables miniaturization has been proposed.

Japanese Unexamined Patent Publication No. 2017-152371

Patent Document 1 does not describe a specific configuration for supplying power to a card edge connector formed in a card-type light source, but normally, it is fitted to the card edge connector to perform electrical connection. A power supply connector for this is provided. This power supply connector has an electrode terminal arranged in a concave groove provided in the connector body, and when the card edge connector is inserted in the concave groove, the electrode terminal comes into contact with the electrode pad of the card edge connector. It is electrically conductive.

When a card edge connector is provided in the card type light source in this way and the card edge connector is inserted into the concave groove of the power supply connector, the connector body of the power supply connector protrudes on both the front and back surfaces of the card type light source. It becomes. Therefore, when the light source unit is attached to the lamp unit, for example, when the card-type light source is attached to the main surface of the base portion of the heat sink, the power supply connector interferes with the main surface of the base portion, and the card-type light source is used as the main surface. It will not be possible to attach it in close contact. Therefore, when the optical axis position of the light emitting element is positioned with reference to the main surface of the base portion, the positioning accuracy thereof may be lowered, which may unfavorably affect the light distribution characteristics of the lamp.

In order to avoid this, the card edge connector is arranged so as to extend outward from the main surface of the base portion, and then the power supply connector is fitted to prevent interference between the power supply connector and the base portion. However, in this case, the power supply connector is arranged in a protruding state on the outside of the base portion, which makes it difficult to miniaturize the light source unit.

Further, when the card-type light source and the power supply connector are fitted to the base portion and the card-type light source is not sufficiently fitted to a predetermined state (hereinafter referred to as a semi-fitted state). In some cases, it may be difficult or impossible to attach the card-type light source to a predetermined position on the main surface of the base portion. In such a case, it is necessary to correct the fitting state of the two, which causes the assembly process of the lamp unit to be complicated and delayed. In addition, if the lamp is installed in a semi-fitted state, the electrical contact between the two becomes insufficient, the electrical resistance increases, and heat generation during lighting becomes remarkable, and the reliability of the light source device or lamp unit deteriorates. It becomes a factor to do.

An object of the present invention is to provide a compact light source unit that enables a card-type light source to be correctly mounted in a lamp and that eliminates the semi-fitting state between the card-type light source and the power supply connector.

The light source unit of the present invention is a card-type light source in which a light source is mounted on a card board and a card edge connector is formed in a part of the card board, and a card-type light source is fitted to the card-type light source by the card edge connector to supply power. It includes a power supply connector to perform, and has a configuration in which a card-type light source is attached to a base portion of a lamp, and a step portion is formed in the base portion in a region corresponding to the power supply connector.

Further, in the light source unit of the present invention, it is preferable that the card-type light source is provided with an alignment means for confirming the alignment state with the power feeding connector at a portion constituting the card edge connector.

According to the present invention, it is possible to obtain a light source unit in which the card-type light source is suitably mounted in a lamp and the outer diameter is reduced even in a state where the power supply connector is fitted to the card-type light source. Further, according to the present invention, it is possible to configure a light source unit having improved reliability by preventing a half-fitted state between a card-type light source and a power supply connector.

A front view of the headlamp provided with the light source unit of the present invention, which is a perspective view of the light source unit. Schematic vertical cross-sectional view along line II-II of FIG. Schematic perspective of a card-type light source and power supply connector. Front view of card type light source and power supply connector. Partially disassembled perspective view of the light source unit. Cross-sectional view when the card edge connector of the card type light source and the power supply connector are fitted. The schematic front view explaining the method of confirming the mating state of a card edge connector and a power feeding connector by the alignment groove. Schematic front view illustrating a method of confirming the mating state of the card edge connector and the power feeding connector by the alignment hole. The conceptual block diagram of the confirmation means for confirming the mating state. Sectional drawing of the mounting state of a card type light source. A perspective view of a modified example of the base portion. A perspective view of a modified example of the power supply connector.

Next, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a front view of an automobile headlamp HL provided with the light source unit of the present invention, and a part thereof is shown transparently. FIG. 2 is a schematic cross-sectional view taken along the line II-II. A lamp unit 2 that illuminates light with a required light distribution in a lamp housing 3 composed of a lamp body 31 and a translucent cover 32 attached to the front opening of the lamp body 31, here, a high beam light distribution. The lamp unit is built in.

The lamp unit 2 includes a light source unit 1 and a projection lens 4 that projects light emitted from the light source unit 1 onto a front region of an automobile.

The light source unit 1 includes a heat sink 5 having a base portion 51 having a substantially flat plate shape. The heat sink 5 is attached to the lamp body 31 by a known aiming mechanism 52, for example, an aiming screw, at three peripheral portions of the base portion 51. Although the details of the aiming mechanism 52 are omitted, the base portion 51 of the heat sink 5 can be tilted in the vertical direction and the horizontal direction by performing the aiming adjustment. The main surface of the base portion 51 is directed to the front of the lamp unit, and the card-type light source 6 is attached to the main surface. Further, a heat radiating fan 53 is attached to the rear surface of the heat sink 5 to enhance the heat radiating effect of the heat generated by the card-type light source 6.

A reflector 8 is attached to the main surface of the base portion 51 together with the card-type light source 6, and the light emitted from the card-type light source 6 is reflected in a required direction. At this time, some light is blocked. Further, the projection lens 4 is attached to the base portion 51 by a lens holder 41. The projection lens 4 projects the light emitted from the card-type light source 6 and reflected by the reflector 8 toward the front of the lamp unit 2, and illuminates the front region of the automobile with a required light distribution.

Further, the light source unit 1 includes a power supply connector 7 that is electrically connected to the card-type light source 6. The power supply connector 7 is connected to an in-vehicle power source of an automobile (not shown in the figure) by an electric cord 71, and is electrically connected to a card-type light source 1 fitted via a card edge connector 64 described later to be an in-vehicle power source. Electric power is supplied to the card-type light source 6 to emit light.

FIG. 3 is an external perspective view of the card-type light source 6 and the power supply connector 7, and FIG. 4 is a front view in which a part thereof is cut off. The card-type light source 6 is mainly composed of a card substrate 60 having a required shape. The card substrate 60 has a conductive pattern 61 in which a conductive film is formed in a required pattern on one surface of an insulating substrate, and LEDs 62 as a plurality of light emitting elements are mounted on one surface of the card substrate 60 by surface mounting. .. Here, in the card substrate 60, the side surface on which these LEDs 62 are mounted is referred to as a front surface, and the opposite surface is referred to as a back surface.

The card substrate 60 includes an element mounting portion 60A whose width direction (left-right direction in FIG. 4) is formed to a required width dimension, and a connector portion 60B whose width dimension is shortened by retracting both sides thereof. It is composed of. The plurality of conductive patterns 61 are formed from the element mounting portion 60A to both portions of the connector portion 60B, and in the element mounting portion 60A, a part of the conductive pattern 61 is a mounting land of the plurality of LEDs 62 (FIG. In the connector portion 60B, the other part of the conductive pattern 61 is configured as a connector electrode pad 61P described later.

In the element mounting portion 60A, a plurality of mounting lands are arranged in a substantially row in the width direction, and the LED 62 is surface-mounted on each mounting land by soldering or the like. As shown in an enlarged view of the main part in FIG. 2, the light emitting surface portion 62a of each LED 62 is directed to the front of the lamp, and the light reflecting portion 62b is provided so as to surround the light emitting surface portion 62a. The light reflecting portion 62b reflects the light emitted from the light emitting surface portion 62a toward the side of the lamp toward the front of the lamp. Further, each LED 62 is electrically connected to one end of each of the conductive patterns 61 by a bonding wire 62c. The bondig wire 62c is sealed with a resin 63.

Further, in the plurality of LEDs 62, the LED 62H on the right side of FIG. 4 has a small arrangement pitch dimension and is arranged at a high density, and the LED 62L on the left side has a large arrangement pitch dimension and is arranged at a low density. Here, the LED 62H on the right side is referred to as a high-density LED, and the LED 62L on the left side is referred to as a low-density LED.

On the other hand, the other end of the conductive pattern 61 electrically connected to the LED 62 extends to the edge of the connector portion 60B and is arranged in the width direction along the edge to form the connector electrode pad 61P. .. With these connector electrode pads 61P, the edge portion of the connector portion 60B is configured as a card edge connector 64.

A pair of circular holes 65 and 66 are penetrated in the element mounting portion 60A at both ends in the width direction in the plate thickness direction, respectively. Of the holes that form a pair, the lower hole 65 in FIG. 4 has a slightly larger hole diameter than the other hole 66, and this large-diameter hole 65 attaches the card-type light source 6 to the base portion 51. The small-diameter hole 66 is configured as a mounting hole for positioning the card-type light source 6 with respect to the base portion 51.

The connector portion 60B is formed with notches 67 at both ends in the width direction toward the inner width direction, and is configured as a hook groove. Further, a circular hole 68 having a small diameter is penetrated in the vicinity of the hook groove 67 in the plate thickness direction, and is configured as a positioning hole for confirming the fitting state with the power feeding connector 7. The alignment hole 68 is one form of the alignment means in the present invention.

Further, the connector portion 60B is formed with a single linear notch groove 69 perpendicular to the element mounting portion 60A from the edge portion constituting the card edge connector 64. The notch groove 69 is penetrated in the plate thickness direction of the card substrate 60, and is formed between predetermined connector electrode pads 61P among a plurality of connector electrode pads 61P arranged in parallel. Further, the length L of the notch groove 69 is accurately determined so that the tip portion thereof is at a specific position on the surface of the card substrate 60. The notch groove 69 is configured as an alignment groove for confirming the fitting state with the power feeding connector 7, and is another form of the alignment means in the present invention.

The alignment groove 69 is extended along the boundary between the region AH of the conductive pattern 61 (61H) connected to the high-density LED 62H and the region AL of the conductive pattern 61 (61L) connected to the low-density LED 62L. .. As a result, the connector portion 60B is separated into the conductive pattern region AH of the high-density LED 62H and the conductive pattern region AL of the low-density LED 62L by the alignment groove 69. Further, in this embodiment, since the number of high-density LEDs 62H is larger than the number of low-density LEDs 62L, the alignment groove 69 is located at a position biased toward the low-density LED 62L with respect to the center position in the width direction of the connector portion 60B. It is formed.

By separating the connector portion 60B in the width direction by the alignment groove 69 in this way, the heat generated on the high-density LED 62H side, which increases the amount of heat generated per unit area, moves toward the region of the low-density LED 62L. Can be suppressed, and the temperature rise on the low density LED 62L side can be suppressed. Further, since the area of the region of the high-density LED 62H is wider than that of the low-density LED side, the heat generated by the high-density LED 62H can be effectively dissipated from the front surface or the back surface of the region.

Further, the alignment groove 69 may be provided in a part of the region AL. For example, as shown by a virtual line (dashed-dotted line) in FIG. 4, it may be configured as a positioning groove 69A between the conductive patterns 61L connected to the low-density LED 62L. In this way, if the alignment groove 69A is formed in the region AL on the low density side, the area of the region AH on the high density side is not reduced, the heat capacity of the card substrate 60 in the region AH is increased, and the heat dissipation effect is increased. Is enhanced.

On the other hand, as shown in FIGS. 3 and 4, the power supply connector 7 as one of the components of the light source unit 1 has a flat rectangular tubular resin connector body 70. The card edge connector 64 of the card-type light source 6 is inserted into a cylindrical groove 72 opened in one end surface 70a (hereinafter referred to as a front surface). In the tubular groove 72 of the connector main body 70, connector electrode terminals 73 made of a conductive member such as metal are arranged at positions corresponding to a plurality of connector electrode pads 61P constituting the card edge connector 64. There is. These connector electrode terminals 73 come into contact with the corresponding connector electrode pads 61P when the card edge connector 64 is inserted and are electrically connected. The electric cord 71 is connected to each connector electrode terminal 73.

In the tubular groove 72 of the connector main body 70, a rib 74 for increasing the strength of the connector main body 70 is formed in an intermediate part of the connector electrode terminals 73 in the arrangement direction. The rib 74 is a position corresponding to the alignment groove 69 provided in the card-type light source 6. That is, when the card edge connector 64 is inserted into the tubular groove 72, the rib 74 enters the alignment groove 69 to enable the insertion. As described above, the alignment groove 69 is located at a position biased with respect to the center in the width direction, and the rib 74 is also provided at a position biased with respect to the width direction. It is prevented that the mold light source 6 is fitted in the opposite directions.

Further, hooking pieces 75 are provided at both side positions in the width direction in which the connector electrode terminals 73 are arranged in the tubular groove 72 of the connector main body 70. These hook pieces 75 are configured as cantilever pieces integrally formed with the connector main body 70. When the card edge connector 64 is inserted into the tubular groove 72, the hooking piece 75 is hooked on the hooking groove 67 of the connector portion 60B, and the card-type light source 6 is easily dropped by the hooking force. To prevent it from being done.

Here, the dimension in the tubular axis direction of the connector body 70, that is, the dimension in the direction in which the card-type light source 6 is fitted is when the card edge connector 64 is inserted into the power feeding connector 7 to a predetermined correct position. In addition, the front surface 70a of the connector main body 70 is formed to have a dimension that coincides with the tip end portion of the alignment groove 69.

Further, in the connector main body 70, small circular holes 76 are opened at positions on both sides close to the front surface 70a of the connector main body 70 in a state of penetrating in the thickness direction of the connector main body 70. These holes 76 are opened at the positions where the tubular grooves 72 are present, and are configured as position reference holes. The position reference hole 76 is formed to have substantially the same diameter as the alignment hole 68 provided in the card type light source 6, and the card edge connector 64 and the power supply connector 7 are fitted in a predetermined state. At that time, it is formed at a position where the centers of the alignment holes 68 and the alignment holes 68 coincide with each other.

The card-type light source 6 and the power supply connector 7 having the above configurations are fitted to each other and attached to the base portion 51 of the heat sink 5 to form the light source unit 1. FIG. 5 is an exploded perspective view of the light source unit 1. A mounting screw hole 54 is opened on the main surface of the base portion 51 of the heat sink 5 at a position corresponding to the mounting hole 65 of the card-type light source 6. Further, a columnar positioning boss 55 is erected at a position corresponding to the positioning hole 66. Further, a shallow step portion 56 is formed in the region from one edge portion of the base portion 51 to reach the positioning boss 55. The step portion 56 is composed of a recess in which a part of the main surface of the base portion 51 is recessed, and the width dimension thereof is substantially equal to the width dimension of the connector main body 70 of the power supply connector 7 and its depth. Is a dimension substantially equal to the thickness dimension in which the connector main body 70 protrudes from the back surface side of the card board 60 of the card type light source 6 when the power supply connector 7 and the power receiving connector 64 are fitted.

To assemble the light source unit 1, first, the card-type light source 6 is fitted to the power supply connector 7 to integrate the two. Specifically, the card edge connector 64 of the card-type light source 6 is inserted into the tubular groove 72 from the front surface 70a side of the connector main body 70 of the power feeding connector 7. FIG. 6 is a cross-sectional view when inserted, and as shown in FIG. 6A, each of the plurality of connector electrode pads 61P on the surface of the card substrate 60 constituting the inserted card edge connector 64. The connector electrode terminals 73 of the power feeding connector 7 are brought into contact with each other and are electrically connected to each other.

Further, when the card edge connector 64 is inserted, as shown in FIG. 6B, the hook-shaped tips of the hook pieces 75 located at both sides of the connector main body 70 are hooked to the hook groove 67 of the card type light source 6. Will be done. At this time, the fitted state of the card-type light source 6 and the power feeding connector 7 can be visually confirmed by the click feeling generated between the hooking piece 75 and the hooking groove 67. Further, the engaging force can prevent the card-type light source 6 from easily falling off.

Then, as shown in FIG. 5, a card-type light source 6 to which the power supply connector 7 is fitted is attached to the base portion 51. In this attachment, the card-type light source 6 is positioned by inserting the positioning boss 55 of the base portion 51 into the positioning hole 66 of the card-type light source 6. Next, the card-type light source 6 is fixedly attached to the base portion 51 by inserting the mounting screw 57 into the mounting screw hole 54 of the base portion 51 after inserting the mounting hole 65 of the card-type light source 6.

In this embodiment, at the same time as attaching the card-type light source 6, the reflector 8 is integrally attached to the base portion 51 by the mounting screw 57 in a state of being overlapped with the card-type light source 6. As shown in the enlarged cross section of FIG. 2, the reflector 8 is partially opened with an opening 81 having a tapered light reflecting surface 82, and the opening 81 is positioned to face the light emitting surface portion 62a of the LED 62. To. This completes the assembly of the light source unit 1. After that, although detailed description is omitted, as shown in FIG. 2, the lamp unit 2 is configured by attaching the projection lens 4 to the base portion 51 by the lens holder 41.

In the lamp unit 2 assembled in this way, the card-type light source 6 and the power supply connector 7 are fitted so that the power of the vehicle-mounted power source is supplied to the card-type light source 6 and the LED 62 emits light. The light emitted from the light emitting surface portion 62a of each of the emitted LEDs 62 is reflected by the light reflecting surface 82 when passing through the opening 81 of the reflector 8, and then projected forward by the projection lens 4. As a result, the lamp unit 2 or the headlamp HL is turned on, and the front area of the automobile is illuminated.

When assembling the light source unit 1, the power supply connector 7 is fitted to the card type light source 6, but if the fitting is insufficiently half-fitted at this time, the lamp unit 2 is assembled as described above. The card-type light source 6 and the power supply connector 7 may be disengaged during the process, which causes a defect in the assembly process of the lamp unit 2. Further, if the lamp unit 2 is assembled to the headlamp HL in the same state, the electric resistance in the electrical connection between the two increases and the heat generation at the time of lighting becomes remarkable, and the lamp unit 2 or the headlamp HL becomes remarkable. Reliability may decrease.

In order to prevent half-fitting in such an assembly, it is possible to confirm the fitting by using the click feeling when the hooking piece 75 and the hooking groove 67 shown in FIG. 6B are hooked. Although it is possible, this click feeling is due to the tactile sensation of the assembler, so it is difficult to reliably prevent half-fitting due to individual differences in sensation.

In order to reliably prevent this semi-fitting, in the light source unit 1 of the embodiment, the alignment groove 69 as the alignment means provided in the card type light source 6 functions effectively. FIG. 7 is a front view illustrating this alignment. When the card edge connector 64 of the card-type light source 6 is inserted into the power supply connector 7 and the two are fitted to each other, as shown in FIG. 7A, FIG. The front surface 70a of the connector main body 70 is moved along the alignment groove 69, and the connector main body 70 is gradually moved so as to cover the alignment groove 69.

As described above, the dimension of the connector main body 70 in the fitting direction is formed to be a predetermined dimension corresponding to the length L of the alignment groove 69. Therefore, as shown in FIG. 7B, the connector main body 70 is formed. When the front surface 70a is aligned with the tip of the alignment groove 69 and the connector body 70 is moved to a position where it completely covers the alignment groove 69, the power supply connector 7 fits in the correct state with respect to the card-type light source 6. It is confirmed that it was done. That is, the fitting state can be confirmed by observing the transmission of light in the alignment groove 69.

Further, according to the alignment hole 68 as the alignment means, as shown in FIG. 8, when the card edge connector 64 of the card type light source 6 is inserted into the power supply connector 7 and the two are fitted to each other, the connector is formed. The position reference hole 76 of the main body 70 and the alignment hole 68 of the card-type light source 6 overlap each other. That is, when the inside of the position reference hole 76 is viewed from the outside of the connector main body 70, the alignment hole 68 is observed inside the position reference hole 76. At this time, as shown in FIG. 8A, when both connectors are half-fitted, the center positions of the holes 68 and 76 do not match and are observed as non-circular holes. As shown in FIG. 8B, when the two holes are properly fitted, the center positions of the holes 68 and 76 are aligned and observed as a perfect circular hole. Therefore, the fitted state can be confirmed by confirming the shape of the observed hole.

When confirming the fitting of both connectors by using the alignment groove 69 or the alignment hole 68, it is preferable to use, for example, the confirmation means shown in FIG. FIG. 9A shows a case of visual confirmation by an operator, in which a light diffusing plate 102 is arranged under the workbench in which the card-type light source 6 and the power supply connector 7 are fitted, and the illumination light source 101 is below the workbench. To place.

In this confirmation means, the illumination light source 101 is turned on, and the light diffusing plate 102 illuminated by the illumination light source 101 becomes a uniform surface light source. Therefore, if the alignment groove 69 and the alignment hole 68 are visually observed as described above while fitting the two on the light diffusion plate 102, the alignment groove 69 is completely covered by the power supply connector 7. Alternatively, it becomes easy to confirm the shape of the bright hole observed inside the position reference hole 76, and it is possible to confirm that the two are securely fitted.

FIG. 9B shows a case where confirmation is performed photoelectrically, and a light source unit 201 that emits parallel light having a required luminous flux diameter is arranged vertically upward on the lower side of the workbench to be fitted. Such a light source unit 201 can be realized by, for example, a light source 202 such as an LED and a collimating lens 203. Further, a light receiving unit 204 such as a light receiving element is arranged at a position directly above the light source unit 201, and the amount of light received is detected by a light quantity meter 205 or the like.

In this confirmation means, the card-type light source 6 and the power supply connector 7 are fitted on the optical path of the light emitted from the light source unit 201. The light from the light source unit 201 passes through the alignment groove 69 or the alignment hole 68 from below to above, and is received by the light receiving unit 204. Therefore, in the case of the alignment groove 69, it can be confirmed that the fitting is correctly fitted when the amount of light received by the light receiving portion 204 becomes almost zero. In the case of the alignment hole 68, it can be confirmed that the fitting is correctly fitted when the amount of light received by the light receiving portion 204 is at the maximum peak.

Here, a cross-sectional view of FIG. 10A shows a state when the card-type light source 6 is attached to the main surface of the base portion 51. The card-type light source 6 is mounted so that the front surface on which the LED 62 is mounted is directed toward the front of the lamp unit 2 and the back surface thereof is in close contact with the main surface of the base portion 51. A part of the power feeding connector 7 fitted to the card-type light source 6 by the card edge connector 64 is projected in the thickness direction on the back surface side of the card-type light source 6. Therefore, when the card-type light source 6 is brought into close contact with the main surface of the base portion 51, the power supply connector 7 must be arranged at a lateral position off the main surface. However, in this way, it becomes difficult to reduce the size of the light source unit 1.

In this embodiment, since the base portion 51 is provided with the step portion 56, the power supply connector 7 is housed in the step portion 56. Therefore, the back surface of the card-type light source 6 can be correctly brought into close contact with the main surface of the base portion 51, and the position of the light source, particularly the position of the LED 62 in the optical axis direction of the lamp unit 2, can be accurately set.

At the same time, the height dimension of the main surface of the base portion 51 including the card-type light source 6 and the power supply connector 7 can be reduced by the amount corresponding to the depth dimension of the step portion 56, and the light source unit 1 is thin. It becomes possible to change. Further, it is not necessary to arrange the power supply connector 7 at a position protruding to the side of the base portion 51, and the light source unit 1 can be miniaturized.

FIG. 11 is a diagram showing a modified example of the base portion 51 of the heat sink 5, and the same reference numerals are given to the portions equivalent to the configuration shown in FIG. In this modification, conical or columnar position fixing bosses 58 are erected at two positions of the stepped portion 56 provided on the base portion 51, respectively. These position fixing bosses 58 are provided at a position where the alignment hole 68 is located when the card type light source 6 to which the power supply connector 7 is correctly fitted is attached to the base portion 51. The position fixing boss 58 is formed to have substantially the same diameter as the corresponding alignment hole 68 and the position reference hole 76.

By providing this position fixing boss 58, as shown in the cross-sectional view of FIG. 10B, if the card-type light source 6 and the power supply connector 7 are correctly fitted, the card-type light source 6 is attached to the base portion 51. At this time, the position fixing boss 58 is smoothly inserted into the alignment hole 68 and the position reference hole 76, and the card type light source 6 can be easily attached. Further, when the fitting of the card-type light source 6 and the power supply connector 7 is close to semi-fitting, the position fixing boss 58 is not inserted through the alignment hole 68 and the position reference hole 76, and the card-type light source 6 is used as a base. It cannot be attached to the portion 51. However, if the insertion is forced at this time, the card-type light source 6 is forcibly moved to the power supply connector 7 by the contact between the peripheral surface of the position fixing boss 58 and the inner surfaces of both holes 68 and 76. , It becomes possible to correct the fitting state.

Further, since the position fixing boss 58 is inserted through the position reference hole 68 and the alignment hole 76, the power supply connector 7 is position-constrained with respect to the base portion 51 when the card-type light source 6 is attached to the base portion 51. become. Therefore, it is possible to prevent the power supply connector 7 from coming off from the base portion 51 due to the disengagement of the power supply connector 7. Instead of the position fixing boss 58, the position reference hole 68 and the alignment hole 76 may be fixed to the base portion 51 with a screw.

As a modification of the power supply connector 7, as shown in FIG. 12, a relief portion 77 may be provided in which both side portions of the front surface 70a of the connector main body 70 are cut out toward the rear. The dimension in the thickness direction of the relief portion 77, that is, the dimension in the thickness direction of the connector main body 70 along the vertical direction in the figure is at least a dimension larger than the plate thickness of the card substrate 60 of the card type light source 6. Further, the depth of the relief portion 77, that is, the dimension along the front-rear direction of the connector main body 70 is as large as possible.

By providing the relief portion 77, when the card-type light source 6 is fitted to the power supply connector 7, the front surface 70a of the connector main body 70 is aligned with the depth dimension of the relief portion 77 from the edge portion of the connector portion 60B of the card board 60. It can be fitted in the entered state. Therefore, even if a tolerance or a manufacturing error occurs in the connector body 70 or the card board 60, both connectors can be fitted to a sufficiently deep position, and half-fitting due to these tolerances or manufacturing errors can be prevented. be able to.

As described above, in the light source unit of the embodiment, when the card-type light source is attached to the base portion in a state where the power supply connector is fitted to the card-type light source, the power supply connector is accommodated in the step portion provided in the base portion. Therefore, the card-type light source can be mounted in close contact with the base, the height dimension of the light source unit can be reduced by the dimension of the step portion, and the power supply connector does not need to be arranged outside the base portion. , The light source unit can be miniaturized.

Further, in the light source unit of the embodiment, when the card type light source and the power feeding connector are fitted, the fitting state of both can be visually confirmed by using the alignment groove or the alignment hole. Therefore, even if there is a difference in the operator's feeling for the click feeling between the hook piece and the hook groove, it is possible to reliably confirm the fitting state and prevent half-fitting, and the reliability of the light source unit is improved. Can be improved.

In the above embodiment, the light source unit has been described as having both the alignment groove and the alignment hole (position reference hole) as the alignment reference, but the light source unit may be configured to include only one of them. Further, although the alignment groove is cut out from the edge portion of the card substrate, it may be a long groove formed over a required region including a portion where the front surface of the connector body is located when fitted. Further, the alignment hole is not limited to a circular shape, and may be a hole having another shape such as a triangular hole, a rectangular hole, or an elliptical hole as long as the position relative to the position reference hole can be determined.

Further, the alignment means provided in the card-type light source is not limited to the alignment groove and the alignment hole of the embodiment, and for example, the alignment mark is made by using a part of the resist or the conductive film formed on the card substrate. May be formed and the fitting position of the power feeding connector may be confirmed by using this alignment mark.

Further, the alignment means in the present invention may be configured so that the alignment hole and the alignment groove of the embodiment are formed in the power feeding connector and the fitting position is confirmed between the alignment means and the card type light source.

Although not shown, when forming a card substrate for a card-type light source, a plurality of card substrates are usually separated and formed separately from one base plate. At this time, if a V-groove is formed on the surface of the base plate and a plurality of card boards are divided and formed using the V-groove, burrs are generated at the divided edges of the portion where the card edge connector is formed, and the power supply connector due to the burrs. It may cause scratches or electrical short circuit.

In the present invention, when a plurality of card substrates are formed from a base plate, at least the edges constituting the card edge connector are formed by shearing by press working or the like. This can prevent the generation of burrs at the edge of the card edge connector, prevent scratches on the power supply connector and electrical short circuit, and improve the reliability of the light source unit.

The present invention is not limited to the light source unit applied to the high beam light distribution lamp unit described in the embodiment, but as a light source unit applied to a low beam light distribution lamp unit or other light distribution lamp units. Needless to say, it can be configured.

1 Light source unit 2 Lamp unit 3 Lamp housing 4 Projection lens 5 Heat sink 6 Card type light source 7 Power supply connector 8 Reflector 51 Base part 56 Step part 58 Position fixing boss 60 Card board 61 Conductive pattern 61P Connector electrode pad 62 Light source (light source: LED) )
64 Card edge connector 65 Mounting hole 66 Positioning hole 68 Alignment hole (alignment means)
69 Alignment groove (alignment means)
70 Connector body 72 Concave groove 73 Connector electrode terminal 71 Electric cord 76 Position reference hole

Claims (10)

Includes a card-type light source in which a light source is mounted on a card board and a card edge connector is formed in a part of the card board, and a power supply connector that is fitted to the card-type light source by the card edge connector to supply power. A light source unit having a configuration in which the card-type light source is attached to a base portion of a lamp, wherein a step portion is formed in the base portion in a region corresponding to the power feeding connector. The card-type light source is attached with the back surface of the card substrate on the side opposite to the side on which the light source is mounted in close contact with the main surface of the base portion, and the step portion is provided on a part of the main surface. The light source unit according to claim 1, which is formed as a recess for accommodating the connector main body of the power supply connector. The light source unit according to claim 2, wherein the connector main body of the power supply connector is not projected to the outside of the base portion. The light source unit according to any one of claims 1 to 3, wherein one of the card-type light source and the power supply connector is provided with an alignment means for confirming an alignment state with the other. The alignment means is an alignment groove formed in the card-type light source and extending in a direction of fitting with the power supply connector, and the alignment groove is when the power supply connector is correctly fitted to the card-type light source . The light source unit according to claim 4, which is covered by the power supply connector. The card-type light source includes a plurality of light emitting elements arranged at different array densities and a plurality of conductive patterns connected to each of the light emitting elements, and the alignment groove emits light arranged at a relatively high density. The boundary position between the region where the conductive pattern connected to the element is arranged and the region where the conductive pattern connected to the light emitting element arranged at a relatively low density is arranged, or arranged at the relatively low density. The light source unit according to claim 5, which is provided in a region where a conductive pattern connected to a light emitting element is arranged. The alignment means is an alignment hole opened in the card-type light source, and is arranged at a position concentric with the position reference hole opened in the power supply connector when the power supply connector is correctly fitted. The light source unit according to claim 4, which is configured to be observed in the position reference hole. The light source unit according to claim 7, wherein the alignment hole and the position reference hole are circular holes. The light source unit according to claim 7, wherein the base portion is provided with a position fixing boss inserted into the alignment hole and the position reference hole in the step portion. The power supply connector includes a connector body having a flat tubular groove into which the card edge connector is inserted, and the connector body has an escape to prevent interference with the card type light source at a portion facing the card type light source. The light source unit according to any one of claims 1 to 9, wherein the unit is formed.

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