JP7271247B2 - LIGHT SOURCE UNIT FOR VEHICLE LAMP AND MANUFACTURING METHOD THEREOF - Google Patents

Description

The present invention relates to a light source unit used as a light source for a vehicle lamp and a method of manufacturing the same.

2. Description of the Related Art Conventionally, there is a light source unit disclosed in Patent Document 1, for example, as a light source unit used in a vehicle lamp.

The disclosed light source unit is made of a metal material with high thermal conductivity, and includes a radiator plate having four radiators, namely, a first radiator, a second radiator, a third radiator, and a fourth radiator. and a resin molded portion made of a resin material having excellent thermal conductivity are integrated by insert molding to form a socket housing. A light source module in which light emitting elements and various control elements are mounted is mounted.

As a result, the heat generated when the light-emitting element is turned on is transferred to the heat sink made of a metal material with high thermal conductivity and the molded resin part made of a resin material with excellent thermal conductivity. It is

JP 2016-195098

By the way, the light source unit configured as described above is formed of a resin material containing carbon or the like in order to provide the resin molded portion with excellent thermal conductivity. Since the resin molded portion contains carbon or the like, the resin molded portion has a brittle property, and when the light source unit is locked and attached to the vehicle lamp, the locking claw provided on the resin molded portion is not locked. There is a possibility that foreign matter may be mixed in the vehicle lamp due to scraping due to rubbing over time.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and its object is to provide a light source for a vehicular lamp, which can be attached to the vehicular lamp through the engaging pawls. To provide a light source unit which does not generate dust due to rubbing and a method for manufacturing the same.

In order to solve the above-mentioned problems, the invention recited in claim 1 of the present invention includes a power supply side terminal base in which a metal power supply terminal and a resin base are integrally formed, and a metal heat sink. , a primary molding step of forming a primary molded product by insert molding with a first resin containing a first filler and integrating the primary molded product with a second resin containing a second filler A secondary molding step of forming a secondary molded product by insert molding and integrating with, and an LED mounting board on the heat sink exposed from the portion formed of the second resin of the secondary molded product and mounting the secondary molded product, wherein the flange portion provided on the base of the power supply side terminal base is formed of a molded portion of the first resin and a molded portion of the second resin. It is characterized by being located at a position sandwiched between.

Further, according to the invention recited in claim 2 of the present invention, in claim 1, the first filler makes the first resin harder than the second resin, and the second filler makes the second resin harder. The second resin has a higher thermal conductivity than the first resin.

Further, according to the invention recited in claim 3 of the present invention, in claim 2, the first filler is a ceramic, the first resin is an insulating thermally conductive white resin, and the second The filler of (1) is carbon, and the second resin is an electrically conductive, thermally conductive black resin.

Further, according to the invention recited in claim 4 of the present invention, in any one of claims 1 to 3, the primary molded product has an undercut portion, and the primary molded product is formed in the secondary molding step. It is characterized in that the primary molded product is set in the secondary molding die by inserting the slide core into the undercut portion.

Further, according to the invention recited in claim 5 of the present invention, in any one of claims 1 to 4 , the molded portion made of the first resin is formed with an engaging claw for engaging with a vehicle lamp. It is characterized by

Further, according to the invention recited in claim 6 of the present invention, in any one of claims 1 to 5 , a radiation fin is formed in the molding part made of the second resin. is.

Further, the invention described in claim 7 of the present invention comprises a power supply side terminal base in which a metal power supply terminal and a resin base are integrally formed, and a first resin containing a first filler. A formed body housing portion, a metal heat sink, a socket portion formed of a second resin containing a second filler, and an LED mounted on the heat sink exposed from the body housing portion. a substrate, wherein the first filler is ceramic, the first resin is harder than the second resin, the second filler is carbon, and the second resin is the The thermal conductivity is higher than that of the first resin, the first resin is an insulating thermally conductive white resin, and the second resin is an electrically conductive thermally conductive black resin. It is something to do.

Further, according to the eighth aspect of the present invention, a power supply side terminal base in which a metal power supply terminal and a resin base are integrally formed, and a first resin containing a first filler. A formed body housing portion, a metal heat sink, a socket portion formed of a second resin containing a second filler, and an LED mounted on the heat sink exposed from the body housing portion. and a substrate, wherein a flange portion provided on the base of the power supply side terminal base is located at a position sandwiched between the main body housing portion and the socket portion.

Further, the invention recited in claim 9 of the present invention is characterized in that in claim 7 or claim 8 , the body housing portion is formed with a locking claw for locking to the vehicle lamp. It is.

According to a tenth aspect of the present invention, in any one of the seventh to ninth aspects, heat radiation fins are formed in the socket portion.

According to the present invention, a primary molded product is formed by insert-molding the power supply terminal base, the fixed terminal base, and the heat sink with a white resin, and the secondary molded product is formed by insert-molding the primary molded product with a black resin. Then, the LED mounting substrate was mounted on the heat sink exposed from the portion formed of the white resin of the secondary molded product to form a light source unit for a vehicle lamp.

As a result, even if it is used as a light source for a vehicle lamp, it does not give a strange appearance from the outside, and when it is fitted to a vehicle lamp, it does not generate dust due to fitting. A light source unit that can use a molding die with high maintainability has been realized.

1 is an exploded perspective view of a light source unit for a vehicle lamp according to the present invention; FIG. It is the perspective view which looked at the light source unit for vehicle lamps from diagonally upward. It is a top view of the light source unit for vehicle lamps. 4 is a cross-sectional view taken along line AA (XX direction) of FIG. 3; FIG. 4 is a cross-sectional view taken along line BB (YY direction) of FIG. 3; FIG. FIG. 4 is a top view of a terminal base; It is a side view of a terminal base. It is the perspective view which looked at the heat sink from diagonally upper direction. FIG. 2 is a cross-sectional view of the mold for primary molding taken along the XX direction; FIG. 4 is a cross-sectional view in the XX direction of a state in which a primary molding die is filled with molten resin. FIG. 2 is a cross-sectional view of a primary molded product taken along the XX direction; FIG. 2 is a cross-sectional view of the primary molded product in the YY direction; FIG. 2 is a cross-sectional view of a secondary molding die taken along the XX direction; FIG. 4 is a cross-sectional view in the XX direction of a state in which a secondary molding die is filled with molten resin. FIG. 2 is a cross-sectional view of a secondary molded product taken along the XX direction; It is a YY direction cross-sectional view of a secondary molded product. FIG. 10 is a cross-sectional view of a conventional terminal base; FIG. 10 is a YY direction cross-sectional view of a secondary molded product using a conventional terminal base; FIG. 2 is a cross-sectional view in the YY direction of a secondary molded product using the terminal base according to the present invention; 1 is a sectional view of a vehicle lamp using a vehicle lamp light source unit according to the present invention; FIG.

Preferred embodiments of the present invention will now be described in detail with reference to FIGS. 1 to 20 (same parts are denoted by the same reference numerals). Since the embodiments described below are preferred specific examples of the present invention, various technically preferable limitations are applied, but the scope of the present invention is particularly limited in the following description. Unless otherwise stated, the present invention is not limited to these embodiments.

FIG. 1 is an exploded perspective view of a light source unit for a vehicle lamp according to the present invention, FIG. 2 is a perspective view of the light source unit for a vehicle lamp as viewed obliquely from above, FIG. 3 is a top view of the light source unit for a vehicle lamp, and FIG. AA (XX direction) sectional view of FIG. 5 is a BB (YY direction) sectional view of FIG. 3, FIG. 6 is a top view of the terminal base, FIG. 8 is a perspective view of the heat sink viewed obliquely from above.

A vehicle lamp light source unit (hereinafter abbreviated as “light source unit”) 1 includes an LED mounting board 10, a terminal base 20, a main body housing portion 30, a heat sink 40, and a socket portion 50. Among them, the terminal base 20 is composed of a feeding side terminal base 21 and a fixed side terminal base 25, and the terminal base 20, the body housing portion 30, and the heat sink 40 are integrally formed to form the body portion 2. The body portion 2 and the socket portion 50 are integrally formed to form the light source unit housing portion 3 , and the light source unit 1 is formed by mounting the LED mounting board 10 on the light source unit housing portion 3 .

The LED mounting board 10 includes a circuit board 11 and an LED 12 as a light source and a lighting control component 13 for the LED 12 mounted thereon.

The terminal base 20 includes a power supply side terminal base 21 integrally formed with a pair of power supply terminals 22 extending linearly parallel to each other and a base 23 made of a resin material, and a single power supply terminal base 21 extending linearly. A fixed side terminal base 25 formed by integrally forming a fixed terminal 26 and a base 27 made of a resin material is arranged side by side.

The base 23 of the power supply side terminal base 21 has a pair of power supply terminals 22 penetrating therethrough. It has an extended flange portion 23b. Similarly, the base 27 of the fixed-side terminal base 25 has an upright portion 27a extending in a substantially flat plate shape along the penetration direction through which one fixed terminal 26 penetrates, and vertically extending from the upright portion 27a. It has a flange portion 27b extending in a substantially flat plate shape.

The body housing part 30 is formed of an insulating, thermally conductive white resin containing a ceramic filler, has a substantially cylindrical appearance, and is provided with a partition holding part 31 inside so as to block the inside. At the same time, the outer surface of the side wall is provided with a locking claw 32 and a protrusion 33 protruding from the outer surface. The resin filler forming the body housing portion 30 is not limited to ceramic, but a resin (=hard resin) that is less likely to be scraped off due to rubbing than the resin forming the socket portion 50 described later is selected. do.

The heat sink 40 includes a base portion 43 having a predetermined width and a raised portion 42 having a flat top surface 41 and a projection direction of the raised portion 42 from both ends of the base portion 43 . It has a pair of connecting portions 44 extending in opposite directions and bent outward, and a pair of leg portions 45 extending from both ends of each connecting portion 44 in the direction opposite to the projecting direction of the raised portion 42 . The heat sink 40 has a different thickness at each part and is formed in a block shape as a whole.

The socket portion 50 is formed of an electrically conductive, thermally conductive black resin containing a carbon filler, and has a recess 52 on one side of the base portion 51 and a plurality of sockets extending in the same direction on the other side of the base portion 51 . radiating fins 53 are arranged in parallel. The resin filler forming the socket portion 50 is not limited to carbon, but a resin having higher thermal conductivity than the resin forming the main body housing portion 30 is selected.

Next, a method for manufacturing the light source unit having the above configuration will be described.

In the first step (see FIGS. 6 and 7), a pair of power supply terminals 22 are insert-molded with an insulating resin to form a power supply side terminal base 21 in which the power supply terminals 22 and the base 23 are integrated. Similarly, a single fixed terminal 26 is insert-molded with an insulating resin to form a fixed side terminal base 25 in which the fixed terminal 26 and the base 27 are integrated.

Next, in the second step (see FIG. 9 (sectional view in the XX direction)), the feed side terminal base (not shown), the fixed side terminal base (not shown) and the heat sink 40 are placed in an upper mold 61. , a lower mold 62 and a slide core 63 (hereinafter referred to as a “primary molding mold”) 60 . A cavity 64 forming a main body housing portion is provided in the primary molding die 60 in which the power supply side terminal base, the fixed side terminal base and the heat sink 40 are set.

Next, in the third step (see FIG. 10 (cross-sectional view in the XX direction)), an insulating thermally conductive white resin containing a ceramic filler is placed in the cavity 64 provided in the primary molding die 60. is filled and solidified, and the solidified molded product (primary molded product) is removed from the primary molding die 60 to obtain the main body 2 of the integrally molded product by insert molding.

As shown in FIG. 11 (sectional view in the XX direction) and FIG. 12 (sectional view in the YY direction), the main body 2 has a power supply side terminal base 21 and a fixed side terminal base 25 on both sides of the heat sink 40. The body housing portion 30 is positioned so as to cover the power supply side terminal base 21 , the fixed side terminal base 25 , the raised portion 42 of the heat sink 40 , the base portion 43 , and the connection portion 44 .

Next, in the fourth step (see FIG. 13 (cross-sectional view in the direction of XX)), the main body portion 2 of the primary molded product composed of the terminal base (not shown), the heat sink 40 and the main body housing portion 30 is placed in the upper mold. 71 , a lower mold 72 and a slide core 73 in an insert molding mold (hereinafter referred to as a “secondary molding mold”) 70 . A cavity 74 forming a socket portion is provided in the secondary molding die 70 in which the main body portion 2 is set.

Next, in the fifth step (see FIG. 14 (cross-sectional view in the XX direction)), a conductive, thermally conductive black powder containing a carbon filler is placed in the cavity 74 provided in the secondary molding die 70 . A melt-molded resin 75 made of resin is filled and solidified, and the solidified molded product (secondary molded product) is removed from the secondary molding die 70 to obtain the light source unit housing portion 3 as an integrally molded product by insert molding.

As shown in FIG. 15 (sectional view in the XX direction) and FIG. 16 (sectional view in the YY direction), the light source unit housing portion 3 has a power supply side terminal base 21 and a fixed side terminal base 21 on both sides of the heat sink 40. 25 is positioned, and a main body housing part 30 is positioned so as to cover the power supply side terminal base 21, the fixed side terminal base 25, the raised part 42 of the heat sink 40, the base part 43, and the connecting part 44. , the socket portion 50 is positioned so as to cover the leg portion 45 of the heat sink 40 .

Next, in a sixth step, the LED mounting substrate 10 is mounted on the top surface 41 of the raised portion 42 of the heat sink 40 exposed from the light source unit housing portion 3 of the secondary molded product, and the power supply side terminal base 21 is supplied with power. The terminals 22 and the fixed terminals 26 of the fixed-side terminal base 25 are mechanically and electrically connected (for example, soldered) to the circuit board 11 of the LED mounting board 10 , and the LED mounting board 10 is mounted on the light source unit housing section 3 . A light source unit 1 (see FIGS. 4 and 5) is formed. The LED mounting substrate 10 is mounted on the heat sink 40 via thermally conductive grease.

By the way, the body portion 2 of the primary molded product has an undercut portion 34 formed on the projecting portion 33 by the slide core 63 that constitutes the primary molding die 60 (see FIG. 11). When the body portion 2 of the primary molded product is set in the secondary molding die 70 in secondary molding, the slide core 73 constituting the secondary molding die 70 is inserted into the undercut portion 34 of the body portion 2. As a result, the body portion 2 is held in the secondary molding die 70 by the slide core 73 (see FIG. 13).

Therefore, the body portion 2 set in the secondary molding die 70 has its lower end (specifically, the lower end 45a of the leg portion 45 of the heat sink 40) of the cavity 74 in the secondary molding die 70. The molten molding resin 75 filled into the cavity 74 covers the entire surface of the leg portion 45 without coming into contact with the inner surface 74a (see FIG. 14).

That is, in the molding process (primary molding process and secondary molding process), a moving mold as shown in the above background art is provided, moved during filling of the molten molding resin, and further filled with the molten molding resin. Insert molding can be performed using a molding die that is unnecessary and has high maintainability.

17 (cross-sectional view), a conventional terminal base 80 (power-supply-side terminal base 81 and fixed-side terminal base 85), specifically, a pair of power-supply terminals 82 and the power-supply terminals 82 passing through A power supply side terminal base 81 integrally formed with a base 83 extending in a substantially flat plate shape along the penetrating direction, one fixed terminal 86, and the fixed terminal 86 penetrating and extending in the penetrating direction When primary molding is performed using a fixed-side terminal base 85 integrally formed with a base 87 extending in a substantially flat plate shape along the primary molding as shown in FIG. The body housing portion 30 of the body portion 2 of the molded product has thick portions (thickness α1 and thickness α2).

Therefore, when forming the main body portion 2 having a thick portion by primary molding using the primary molding die 60, if the thickness of the thick portion is too large, the volume of the cavity 64 forming the thick portion becomes large. As a result, the shrinkage rate of the molten molding resin 65 increases when it cools and solidifies, and there is a possibility that voids (holes) may occur in the thick-walled portion.

On the other hand, when primary molding is performed using the terminal bases 20 (feeding side terminal bases 21 and fixed side terminal bases 25) having the shapes shown in FIGS. 6 and 7, as shown in FIG. In addition, the flange portion 23b of the base 23 of the power supply side terminal base 21 and the flange portion 27b of the base 27 of the fixed side terminal base 25 prevent formation of a thick portion in the body housing portion 30 of the body portion 2 of the primary molded product. The thickness β1 and the thickness β2 are suppressed to β1<α1 and β2<α2.

As a result, when the main body 2 is formed by primary molding using the primary molding die 60, the cavity 64 having a large volume (thickness) is not required, and voids are not generated due to shrinkage of the molten molding resin 65 during cooling and solidification. prevented.

Further, when the light source unit housing portion 3 of the secondary molded product is obtained by integrating the main body portion 2 of the primary molded product by insert molding with the molten molding resin 75, if the primary molded product has a portion that is too thin, the secondary molded product may There is a risk that the thin portion may be broken through by the injection pressure when the molten molding resin 75 is filled during molding.

In this case, if the primary molded product has a thickness of about 5 mm or more, the above problems can be prevented. However, it is necessary to set the thickness to be equal to or less than the thickness at which voids are generated, and to appropriately uniform the thickness.

As can be seen from the arrow C in FIG. 19, by forming the interface between the main body 2 of the primary molded product and the socket 50 formed by the insert molding of the secondary molding in an uneven shape, the area of the interface can be increased. Bonding strength can be increased.

Furthermore, the base 23 of the power supply side terminal base 21 and the base 27 of the fixed side terminal base 25 are each made of the same molten molding resin 65 made of an insulating thermally conductive white resin containing a ceramic filler at the time of primary molding. Mutual adhesive strength can be improved by forming with a resin material.

Also, the cylinder temperature of the molding machine during secondary molding is set higher than the cylinder temperature of the molding machine during primary molding. Specifically, for example, the melting temperature of the primary molding resin is set at 230°C, and the melting temperature of the secondary molding resin is set at 280°C. As a result, the molten molding resin at the time of secondary molding melts the interface on the side of the primary molding, so that the mutual adhesion can be enhanced.

Furthermore, as shown in FIG. 20 (cross-sectional view), the light source unit 1 configured as described above is attached to, for example, a vehicle lamp 90 having a lamp body 91 and an outer cover 92 via the lamp body 91. Looking at the light source unit 1 inside the lamp, the body housing portion 30 made of white resin is visible, but the socket portion 50 made of black resin is shielded by the lamp body 91 and is not visible.

Therefore, it is possible to realize a highly marketable vehicular lamp that does not give a sense of incompatibility when viewed from the outside.

Further, when the light source unit 1 is attached to the outer cover 92, the engaging claws 32 for attachment are formed of an insulating thermally conductive white resin containing hard ceramic filler, and are engaged with the vehicle lamp. A highly reliable vehicle lamp 90 is realized without generating dust due to rubbing of the locking claws when attaching via the claws.

The melt-molded resin used for primary molding and the melt-molded resin used for secondary molding are the same base material such as PET, PBT, nylon, etc., and the melt-molded resin used for primary molding is used for the base material. contains a ceramic filler, and the molten molding resin used for secondary molding contains a carbon filler.

In the above-described embodiment, the fixed terminals 26 are used to fix the LED mounting board 10, but the present invention is not limited to this, and for example, a thermally conductive adhesive may be used for fixing. In this case, the fixed terminal 26 is omitted.

DESCRIPTION OF SYMBOLS 1... Light source unit for vehicle lamps 2... Main-body part 3... Light source unit housing part 10... LED mounting board 11... Circuit board 12... LED
DESCRIPTION OF SYMBOLS 13... Lighting control part 20... Terminal base 21... Power supply side terminal base 22... Power supply terminal 23... Base 23a... Standing part 23b... Flange part 25... Fixed side terminal base 26... Fixed terminal 27... Base 27a... Standing part 27b ... flange part 30... body housing part 31... partition clamping part 32... locking claw 33... projection part 34... undercut part 40... heat sink 41... top surface 42... raised part 43... base part 44... connecting part 45... leg Part 45a... Lower end 50... Socket part 51... Base part 52... Recess 53... Radiation fin 60... Insert molding mold (primary molding mold)
61 Upper mold 62 Lower mold 63 Slide core 64 Cavity 65 Molding resin 70 Insert molding mold (secondary molding mold)
71... Upper mold 72... Lower mold 73... Slide core 74... Cavity 74a... Inner surface 75... Molded resin 80... Terminal base 81... Power supply side terminal base 82... Power supply terminal 83... Base 85... Fixed side terminal base 86... Fixation TERMINAL 87 BASE 90 VEHICLE LAMP 91 LAMP BODY 92 OUTER COVER

Claims (10)

A power supply side terminal base formed by integrally forming a metal power supply terminal and a resin base, and a metal heat sink are integrated by insert molding with a first resin containing a first filler. A primary molding step of forming a primary molded product by
A secondary molding step of forming a secondary molded product by insert-molding and integrating the primary molded product with a second resin containing a second filler;
placing an LED mounting substrate on the heat sink exposed from the second resin portion of the secondary molded product;
has
In the secondary molded product, the flange portion provided on the base of the power supply side terminal base is located at a position sandwiched between the molded portion made of the first resin and the molded portion made of the second resin.
A method for manufacturing a light source unit for a vehicle lamp, characterized by: The first filler makes the first resin harder than the second resin,
the second filler makes the second resin more thermally conductive than the first resin;
2. The method of manufacturing a light source unit for a vehicle lamp according to claim 1, wherein: The first filler is a ceramic, the first resin is an insulating thermally conductive white resin,
3. The method of manufacturing a light source unit for a vehicle lamp according to claim 2, wherein the second filler is carbon, and the second resin is an electrically conductive, thermally conductive black resin. The primary molded product has an undercut portion, and the primary molded product is set in a secondary molding mold by inserting a slide core into the undercut portion of the primary molded product in the secondary molding step. A method for manufacturing a light source unit for a vehicle lamp according to any one of claims 1 to 3. 5. The manufacture of a light source unit for a vehicle lamp according to claim 1 , wherein the molded portion made of the first resin is formed with an engaging claw for engaging with the vehicle lamp. Method. 6. The method of manufacturing a light source unit for a vehicle lamp according to any one of claims 1 to 5 , wherein the molded portion made of the second resin is formed with heat radiation fins. a power supply side terminal base formed by integrally forming a metal power supply terminal and a resin base;
a body housing portion formed of a first resin containing a first filler;
metal heatsink and
a socket portion formed of a second resin containing a second filler;
an LED mounting substrate mounted on the heat sink exposed from the body housing;
has
The first filler is ceramic, the first resin is harder than the second resin,
The second filler is carbon, the second resin has higher thermal conductivity than the first resin,
The first resin is an insulating thermally conductive white resin, and the second resin is an electrically conductive thermally conductive black resin.
A light source unit for a vehicle lamp, characterized by: a power supply side terminal base formed by integrally forming a metal power supply terminal and a resin base;
a body housing portion formed of a first resin containing a first filler;
metal heatsink and
a socket portion formed of a second resin containing a second filler;
an LED mounting substrate mounted on the heat sink exposed from the body housing,
A light source unit for a vehicle lamp, wherein a flange portion provided on a base of the power supply side terminal base is located at a position sandwiched between the body housing portion and the socket portion. 9. The light source unit for a vehicle lamp according to claim 7 , wherein the body housing portion is formed with an engaging claw for engaging with the vehicle lamp. 10. The light source unit for a vehicle lamp according to claim 7 , wherein the socket portion is formed with heat radiation fins.

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