JP7385444B2 - Light source unit and vehicle lamp equipped with the same - Google Patents

Description

The present disclosure relates to a light source unit and a vehicle lamp equipped with the same.

Lighting devices such as vehicle headlamps and fog lamps are required to be capable of forming a predetermined light distribution pattern. In this regard, for example, Patent Document 1 discloses that a light emitting element functioning as a light emitting part is arranged on a substrate, a frame is provided to surround the light emitting element, and a sealing resin is filled inside the frame to emit light. A light source unit with a sealed element and applied to a combination lamp mainly having the functions of a stop lamp and a tail lamp is described. In Patent Document 1, there is no specific mention of the height between the top surface (light emitting surface) of the light emitting element and the frame, but for example, in FIGS. 7 to 12 of Patent Document 1, the top end of the frame is above the light emitting surface. located higher than.

Japanese Patent Application Publication No. 2016-195099

Generally, the higher the contrast between the light emitting part (for example, a light emitting surface) and the non-light emitting part (for example, a part such as a frame that is not a light emitting part) in a light source unit, the clearer the light distribution pattern can be formed. The light source unit described in Patent Document 1 has room for improvement in terms of increasing the contrast between the light emitting part and the non-light emitting part to form a clearer light distribution pattern.

An object of the present disclosure is to provide a light source unit that can form a clear light distribution pattern by increasing the contrast between a light emitting part and a non-light emitting part, and a vehicular lamp equipped with the same.

As a result of extensive research by the present inventor, we found that when the upper end of the frame is located at a higher position than the light emitting surface as in Patent Document 1, part of the light from the light emitting surface is reflected by the frame, and the reflected light It was found that the contrast between the light-emitting part and the non-light-emitting part deteriorates because the light is irradiated as the light emitted from the lamp. Moreover, the present inventors have found that by setting the upper end of the frame at a position lower than the light emitting surface, the contrast between the light emitting part and the non-light emitting part can be increased and a clearer light distribution pattern can be formed.

That is, the light source unit according to one aspect of the present disclosure is
A substrate and
a light emitting section disposed on the substrate;
a frame provided on the substrate and surrounding the light emitting section;
a sealing resin that seals the inner region of the frame,
In a height direction perpendicular to the substrate, an upper end of at least a portion of the frame portion is located at a lower position than a light emitting surface that is an upper surface of the light emitting portion.

According to this configuration, it is possible to prevent the light emitted from the light emitting surface from being reflected by the frame and the reflected light being irradiated as the light emitted from the vehicle lamp, and as a result, the light emitting part and the non-light emitting part It becomes possible to increase the contrast between the two and form a clear light distribution pattern.

Furthermore, in the light source unit,
The upper end of the at least part of the frame part is adjacent to a part of the inner area that corresponds to an illumination area of a light distribution pattern formed by the light emitted from the light emitting part. It may be configured so that it is at the upper end.

According to this configuration, it becomes possible to form a clearer light distribution pattern.

Furthermore, in the light source unit,
The light emitting part is
LED light source and
a phosphor plate disposed above the LED light source and containing a phosphor that converts the wavelength of light emitted from the LED light source;
The light emitting surface may be configured to be an upper surface of the fluorescent screen.

According to this configuration, for example, the color of the light emitted from the light emitting part can be changed, and the contrast between the light emitting part and the non-light emitting part can be increased to form a clear light distribution pattern.

In addition, the above light source unit is
In the height direction, the upper end of the at least part of the frame portion may be located at a higher position than the upper surface of the LED light source.

According to this configuration, for example, it is possible to increase the contrast between the light-emitting part and the non-light-emitting part, while reducing the possibility that the sealing resin will flow out of the frame when sealing the inner region with the sealing resin. .

In addition, the above light source unit is
The frame portion may be made of white resin.

According to this configuration, for example, it is possible to prevent the light emitted from the light emitting section from being absorbed by the frame and the temperature of the frame increases, and as a result, it is possible to suppress deterioration of the light source unit. Become. Note that if the frame is made of white resin when the upper end of the frame is located at a higher position than the light emitting surface as in the conventional method (for example, Patent Document 1), a large amount of reflected light is reflected from the frame. However, in the light source unit of the present disclosure, the upper end of at least a portion of the frame is located at a lower position than the light emitting surface, so the above-mentioned problem can be avoided. Such disadvantages are unlikely to occur.

Further, a vehicle lamp according to one aspect of the present disclosure includes:
Equipped with a light source unit described in any of the above,
A light distribution pattern having a cutoff line can be formed.

According to this configuration, it is possible to obtain a vehicle lamp that can form a clear light distribution pattern.

According to the present disclosure, it is possible to provide a light source unit that can increase the contrast between a light emitting part and a non-light emitting part to form a clearer light distribution pattern, and a vehicular lamp equipped with the same.

It is a perspective view showing an example of a light source unit concerning a first embodiment. 1A is a cross-sectional view taken along line AA of the light source unit shown in FIG. 1A. FIG. It is a perspective view showing an example of a light source unit concerning a conventional example. 2A is a cross-sectional view taken along line BB of the light source unit shown in FIG. 2A. FIG. FIG. 2 is a circuit diagram showing an example of a circuit included in the light source unit according to the first embodiment. FIG. 2 is a schematic diagram showing an example of a lamp unit including a light source unit according to the first embodiment. 5 is a schematic cross-sectional view showing an example of a vehicle lamp including the lamp unit shown in FIG. 4. FIG. 7 is an example of a light distribution pattern that can be formed by the vehicle lamp shown in FIG. 6. FIG. 7 is a top view showing a light source unit according to a first modification.

Hereinafter, embodiments of a vehicle lamp according to the present disclosure will be described with reference to the drawings. In the following description, the same or equivalent elements will be denoted by the same reference numerals even in different drawings, and redundant description will be omitted as appropriate. Further, in each of the drawings used in the following explanation, the scale is appropriately changed in order to make each member a recognizable size.

[First embodiment]
(light source unit)
FIG. 1A is a perspective view showing a light source unit 10 according to the first embodiment. FIG. 1B is a cross-sectional view of the light source unit 10 shown in FIG. 1A taken along line AA. As shown in FIGS. 1A and 1B, the light source unit 10 includes a substrate 11, a light emitting section 12 including a light emitting element 13 and a fluorescent screen 14, a frame section 15, a sealing resin 16, and a conductive section (not shown). ).

A light emitting element 13 is mounted on the substrate 11. Furthermore, a conductive portion for supplying current to the light emitting element 13 is formed on the substrate 11 . The conductive portion includes, for example, a wiring formed on the substrate 11, a conductive wire connecting the wiring and the light emitting element 13, and the like. Although the substrate 11 is not particularly limited, for example, a rigid printed circuit board can be used.

The light emitting element 13 is arranged on the substrate 11 and electrically connected to the conductive part. Although the light emitting element 13 is not particularly limited, examples thereof include an LED (Light Emitting Diode) and an LD (Laser Diode). In this embodiment, three light emitting elements 13 are arranged at the center of the substrate 11, but the arrangement location and number of the light emitting elements 13 can be changed as appropriate depending on the performance required of the light source unit 10, etc.

The fluorescent screen 14 is arranged on the light emitting element 13. The fluorescent screen 14 includes a fluorescent substance that converts the wavelength of light emitted from the light emitting element 13, and is made of resin, for example. The light emitted from the light emitting element 13 enters the fluorescent screen 14 and is wavelength-converted by the fluorescent material. As a result, light of a different color from the light emitted by the light emitting element 13 is emitted from the light emitting surface (the upper surface of the fluorescent screen 14) 17.

In addition, in this embodiment, the light emitting part 12 is formed by the light emitting element 13 and the fluorescent screen 14, but may be formed only by the light emitting element 13. In that case, the upper surface of the light emitting element 13 becomes the light emitting surface 17. Furthermore, a lens may be placed on the light emitting section 12 in order to increase the efficiency of condensing the light emitted from the light emitting section 12.

The frame portion 15 is provided in a circumferential manner on the substrate 11 so as to surround the light emitting portion 12 . The frame portion 15 is provided to block the sealing resin 16 during manufacturing of the light source unit 10. The frame portion 15 is made of, for example, a resin material. It is preferable that the frame part 15 is formed of a material having light reflectivity, and specifically, it is preferable that it is formed of a white resin material.

The sealing resin 16 is a resin that seals the inner region of the frame portion 15. The light emitting element 13, the conductive part, and the like are sealed with the sealing resin 16. The sealing resin 16 is, for example, a cured liquid curable resin. When manufacturing the light source unit 10, a liquid curable resin is injected into the inner region of the frame portion 15, and is cured to form the sealing resin 16.

The sealing resin 16 is not particularly limited, but is preferably a resin that has a white color in a hardened state, for example. Since the sealing resin 16 is white, for example, light emitted from the light emitting element 13 in a direction not directed toward the light emitting surface 17 can be reflected by the sealing resin 16 and guided to the light emitting surface 17. .

In the light source unit 10 according to the present embodiment, the upper end of the frame portion 15 is located at a higher position than the upper surface of the light emitting element 13 in the height direction perpendicular to the substrate 11. That is, the height h2 of the upper end of the frame portion 15 is higher than the height h1 of the upper surface of the light emitting element 13. With such a configuration, when sealing the inner region of the frame portion 15 with the sealing resin 16, it is possible to prevent the uncured liquid resin from flowing out to the outside of the frame portion 15.

Further, in the light source unit 10 according to the present embodiment, the upper end of the frame portion 15 is located at a position lower than the light emitting surface 17 in the height direction perpendicular to the substrate 11. That is, the height h2 of the upper end of the frame 15 is lower than the height h3 of the light emitting surface 17 over the entire area of the frame 15. Therefore, as shown by the arrow in FIG. 1B, even if the light emitted from the light emitting surface 17 heads in the direction of the frame 15, the light is considered to pass above the frame 15. There is little risk of reflection from the top of the screen. As a result, according to the light source unit 10 according to the present embodiment, it is possible to increase the contrast between the light emitting part 12 and the non-light emitting part and improve the clarity of the light distribution pattern. Therefore, the light source unit 10 can be suitably used, for example, in a vehicle lamp that requires a light distribution pattern having a cutoff line, and specifically, can be suitably used in a fog lamp or a headlamp.

On the other hand, as shown in FIGS. 2A and 2B, in the conventional example, the positional relationship between the upper end of the frame portion 15 and the light emitting surface 17 did not satisfy the above relationship. Hereinafter, a conventional light source unit 10' will be described using FIGS. 2A and 2B. FIG. 2A is a perspective view showing an example of a conventional light source unit 10'. FIG. 2B is a cross-sectional view of the light source unit 10' shown in FIG. 2A taken along line BB.

As shown in FIG. 2B, in the conventional light source unit 10', the upper end of the frame 15 is located higher than the light emitting surface 17 in the height direction perpendicular to the substrate 11. That is, the height h2 of the upper end of the frame portion 15 is higher than the height h3 of the light emitting surface 17. Therefore, as shown by the arrow in FIG. 2B, when the light emitted from the light emitting surface 17 heads in the direction of the frame part 15, the light is reflected at the upper end of the frame part 15, and the reflected light is used for the vehicle. It is irradiated as the light emitted from the lamp. As a result, the contrast between the light emitting part 12 and the non-light emitting part is lower than in the light source unit 10 shown in FIGS. 1A and 1B, and the clarity of the light distribution pattern is inferior.

(Circuit configuration)
Next, the configuration of a circuit for supplying current to the light emitting element 13 will be described. FIG. 3 is a circuit diagram showing an example of the circuit 20 included in the light source unit 10 according to the first embodiment. As shown in FIG. 3, the circuit 20 includes a diode 22, an ESD (Electro Static Discharge) suppressor 23, a resistor R1, and a light emitting element 13 in a path from the terminal 21a to the terminal 21b. . The circuit 20 is formed on the substrate 11, for example.

The diode 22 is arranged so that the current input from the terminal 21a flows to the terminal 21b. The current input from the terminal 21a is supplied to the light emitting element 13 through the resistor R1, so that the light emitting element 13 emits light.

ESD suppressor 23 is arranged in parallel with light emitting element 13. The ESD suppressor 23 is a protective element to prevent electrostatic discharge, and has a property that its resistance value rapidly decreases when a high voltage is applied.

As a measure against electrostatic discharge, a capacitor may be used in place of the ESD suppressor 23, but when a capacitor is used in the circuit of a light source unit for an LED socket, a large current will flow if a short circuit occurs due to a failure, which is dangerous. . One possible method is to connect multiple capacitors in series to prevent short circuits. However, with such a configuration, the use of a plurality of capacitors increases the area occupied by the components on the board 11 and increases the manufacturing cost. On the other hand, when using the ESD suppressor 23, the number may be one, and its size can also be made smaller than the capacitor. Therefore, the ESD suppressor 23 is suitable from the viewpoint of reducing the area occupied by components on the board 11 and from the viewpoint of lowering manufacturing costs.

Although not shown, the circuit 20 may include a Zener diode. The Zener diode is connected in parallel with the light emitting element 13, for example. Although the location of the Zener diode is not particularly limited, for example, from the viewpoint of reducing the area occupied by components on the substrate 11, it is preferable to arrange it inside the frame portion 15.

(Lighting unit)
Next, a lamp unit including a light source unit will be explained. FIG. 4 is a schematic diagram showing an example of a lamp unit 40 including the light source unit 10 according to the first embodiment. As shown in FIG. 1, the lamp unit 40 includes a light source unit 10 and a socket 30. Note that the socket is not limited to the example described below, and is not particularly limited as long as it can hold the light source unit 10 and supply current to the light source unit 10.

The socket 30 includes a base portion 31 , a protruding portion 32 , a light source unit holding portion 33 , an engaging portion 34 , a connector portion 35 , and a radiation fin 36 . The base portion 31 is a disc-shaped member. The protruding portion 32 is a substantially cylindrical member formed to protrude from near the center of one surface of the base portion 31 .

The light source unit holding portion 33 is formed in a recessed portion provided near the upper end of the protruding portion 32 . The light source unit 10 is placed and fixed on the light source unit holding part 33. Although not shown, a connection terminal is formed near the light source unit holding portion 33. Further, this connection terminal is electrically connected to the connector section 35, and when the connector section 35 is connected to an external power source, a current is supplied to the connection terminal. By connecting the connection terminal on the socket side and the terminal on the substrate 11 with a conductive wire or the like, it becomes possible to supply current to the light emitting element 13.

The engaging portion 34 is provided on the outer peripheral surface of the protruding portion 32 near the upper end thereof. The engaging portion 34 engages with a predetermined portion of the housing of the vehicle lamp, for example, and fixes the lamp unit 40 as a part of the vehicle lamp. The connector section 35 is configured to be electrically connectable to an external power source. The heat radiation fin 36 is a member that facilitates releasing heat generated in the light emitting element 13 to the outside.

(vehicle lighting)
Next, a vehicle lamp equipped with a lamp unit (including a light source unit) will be explained. FIG. 5 is a schematic cross-sectional view showing an example of a vehicle lamp 50 including the lamp unit 40 shown in FIG. 4, and is a horizontal cross-sectional view of the vehicle lamp 50.

In addition, in FIG. 5 and FIG. 7 described later, "F", "B", "L", "R", "U", and "D" are relative values set for the vehicle lamp 50 shown in FIG. It shows the direction. In this specification, "F" is forward, "B" is backward, "L" is left, "R" is right, "U" is upward, and "D" is downward. . In addition, the direction including "front direction" and "rear direction" is referred to as "front-back direction," the direction including "left direction" and "right direction" is referred to as "left-right direction," and the direction including "upward direction" and "downward direction." ” is referred to as the “vertical direction”. Note that the "vertical direction" is a direction perpendicular to the "front-back direction" and the "horizontal direction."

The vehicle lamp 50 is a fog lamp mounted at the front of the vehicle. Therefore, when the vehicle lamp 50 is mounted on a vehicle, the front direction F is the front side of the vehicle, the rear direction B is the rear side of the vehicle, the left direction L is the left side of the vehicle, and the right direction R is the front side of the vehicle. is on the right side of the vehicle, upward direction U is on the upper side of the vehicle, and downward direction D is on the lower side of the vehicle.

As shown in FIG. 5, the vehicle lamp 50 includes a lamp unit 40, a lamp housing 51, a transparent cover 52, a lens holder 53, an opening 54, and a projection lens 55. The vehicle lamp 50 is a fog lamp, and can form a light distribution pattern having a cutoff line.

The lamp housing 51 has an opening on the front side, and the opening is covered with a light-transmitting cover 52. The lamp housing 51 also has an opening on the rear side, and the lamp unit 40 is fitted and fixed in the opening.

Lens holder 53 is supported by lamp housing 51. The lens holder 53 holds a projection lens 55 having an optical axis Ax. The lens holder 53 is made of, for example, a colorless and transparent resin member. Further, an opening 54 centered on the optical axis Ax is formed in the lens holder 53. A reflective element having a surface shape such as a triangular pyramid surface is provided near the opening 54 in the lens holder 53, and external light reaching the reflective element from outside the vehicle lamp 50 is reflected by the reflective element. It can be totally reflected by the element.

The projection lens 55 is formed of, for example, a colorless and transparent resin member. The optical axis Ax of the projection lens 55 extends in the front-rear direction, and passes near the center of the light-emitting section 12 in the left-right direction, and near the bottom of the light-emitting section 12 in the vertical direction (see FIG. 7). Further, the projection lens 55 has a horizontally elongated elliptical shape when the vehicle lamp 50 is viewed from the front side. Further, the projection lens 55 is arranged so as to be inclined toward the rear of the vehicle lamp 50 from its left end to its right end. With these configurations, the projection lens 55, for example, emits direct light from the light emitting unit 12 forward as light that is directed slightly downward and spreads in the vehicle width direction, thereby forming a light distribution pattern for fog lamps. There is.

Note that it is also possible to form different light distribution patterns by changing the surface shape of the projection lens 55, etc. Alternatively, a light distribution pattern having a cutoff line may be formed by providing a shade that blocks part of the light emitted from the light emitting section 12.

FIG. 6 is an example of a light distribution pattern that can be formed by the vehicle lamp 50 shown in FIG. In the example of FIG. 6, a horizontal cut-off line CL is formed slightly below a line HH passing horizontally through HV, which is a vanishing point in the front direction of the vehicle lamp 50. Further, an illuminated region Rb is formed below the cut-off line CL, and a non-illuminated region Rd is formed above the cut-off line CL. The cutoff line CL corresponds to, for example, the lower edge of the light emitting section 12. Further, the illumination area Rb corresponds to, for example, an area located above the straight line when the inner area of the frame portion 15 is divided by a straight line that is parallel to the left-right direction and passes through the optical axis Ax. There is. Similarly, the non-illuminated region Rd corresponds to the region located below the straight line when the inner region of the frame portion 15 is divided by the straight line.

Although the present embodiment has been described using a fog lamp as an example of the vehicle lamp 50, the vehicle lamp of the present disclosure is not particularly limited as long as it is mounted on a vehicle. The vehicle lamp of the present disclosure is preferably capable of forming a light distribution pattern having a cutoff line, and may be a headlamp, for example.

[First variation]
Next, a first modification of the light source unit according to the first embodiment will be described. FIG. 7 is a top view showing a light source unit 110 according to a first modification. Below, only changes from the first embodiment will be explained. Unless otherwise specified, the content described in the first embodiment may also be used in the first modification.

In the light source unit 10 according to the first embodiment, the height h2 of the upper end of the frame part 15 is lower than the height h3 of the light emitting surface 17 over the entire area of the frame part 15, but in the first modification In the light source unit 110 according to the example, only the frame portion 15a that is a part of the frame portion 15 is configured such that the height h2 of the upper end is lower than the height h3 of the light emitting surface 17.

The frame part 15a is a part of the inner area of the frame part 15, and is adjacent to the area corresponding to the illumination area Rb of the light distribution pattern formed by the light emitted from the light emitting part 12. It is. In the example of FIG. 7, when the inner area of the frame portion 15 is divided by a straight line CL' that is parallel to the left-right direction and passes through the position where the optical axis Ax passes when mounted on the vehicle lamp 50, , a region adjacent to a region located on the upper side of straight line CL'. The region above the straight line CL' is a region corresponding to the illumination region Rb. By setting the height h2 of the upper end of the frame portion 15a adjacent to such a region to be lower than the height h3 of the light emitting surface 17, for example, clarity in the outline portion of the illumination region is improved.

On the other hand, the area located above the straight line CL' in the inner area of the frame portion 15 is an area corresponding to a non-illumination area. In the frame portion 15b adjacent to such a region, even if the height h2 of the upper end is not lower than the height h3 of the light emitting surface 17, the effect on the clarity of the light distribution pattern is small.

Note that the straight line CL' is a straight line corresponding to the cut-off line CL in the light distribution pattern. The position of the straight line CL' may vary depending on the position of the optical axis Ax and the method of forming the cut-off line CL. That is, the position of the frame portion 15a may also vary depending on the position of the optical axis Ax and the method of forming the cut-off line CL.

Although the present disclosure has been described in detail and with reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. The number, positions, shapes, etc. of the constituent members described above are not limited to those in the above embodiments, and can be changed to suitable numbers, positions, shapes, etc. for carrying out the present disclosure. Further, elements included in the embodiments and modified examples according to the present disclosure can be combined with each other to the extent that no contradiction occurs.

10, 10', 110: Light source unit 11: Substrate 12: Light emitting section 13: Light emitting element 14: Fluorescent screen 15: Frame section 16: Sealing resin 17: Light emitting surface 21a, 21b: Terminal 22: Diode 23: ESD suppressor 30 : Socket 40: Light unit 50: Vehicle light Ax: Optical axis

Claims (5)

A substrate and
a light emitting section disposed on the substrate;
a frame provided on the substrate and surrounding the light emitting section;
a sealing resin that seals the inner region of the frame,
In a height direction perpendicular to the substrate, an upper end of at least a portion of the frame portion is located at a lower position than a light emitting surface that is an upper surface of the light emitting portion;
The upper end of the at least part of the frame part is adjacent to a part of the inner area that corresponds to an illumination area of a light distribution pattern formed by the light emitted from the light emitting part. is the upper end,
light source unit. The light emitting part is
LED light source and
a phosphor plate disposed above the LED light source and containing a phosphor that converts the wavelength of light emitted from the LED light source;
the light emitting surface is the top surface of the fluorescent screen;
The light source unit according to claim 1 . In the height direction, the upper end of the at least part of the frame is located at a higher position than the upper surface of the LED light source.
The light source unit according to claim 2 . the frame portion is formed of white resin;
The light source unit according to any one of claims 1 to 3 . comprising the light source unit according to any one of claims 1 to 4 ,
It is possible to form a light distribution pattern with a cut-off line.
Vehicle lighting.

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