JPH1041551A - Light emitting diode lamp assembly - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a light emitting diode lamp assembly which can provide a large light emitting area, a high brightness on its axis and a uniform luminous surface. SOLUTION: An assembly includes reflectors 4 each having a spherically- curved recess 4b whose inner surface is used as a reflecting surface 4c, lead frames 5 each mounted to the associated reflector 4 and a tip end of which is extended along the inner surface of the recess 4b up to the center of the recess, LED chips 6 each bonded to a surface of the associated lead frame 5 on the recess 4b side in the center of the recess 4b, and resin mold 7 for sealing the periphery of the associated LED chip 6. Light emitted from the LED chips 6 all over a solid angle of 180 degrees can be reflected forwardly directively by the reflecting surface 4c as the spherical recess surface. Thereby, there can be obtained an assembly which has a lightweight structure and provides a high luminous surface with a high brightness on its axis (front).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a light-emitting diode lamp assembly using a light-emitting diode which can be used as a vehicular lamp such as a high-mount stop lamp or a rear combination lamp of an automobile. The present invention relates to a light-emitting diode lamp assembly having improved on-axis brightness and the like by providing the same.

[0002]

2. Description of the Related Art In recent years, a high-mount stop lamp has been mounted on a rear window or a roof to assist the stop lamp. In general, such a high-mount stop lamp is formed using a light-emitting diode (hereinafter, the light-emitting diode is also simply referred to as “LED”), which is a small light-emitting element. In addition, recently, formation of a combination lamp using an LED has been studied.

Specifically, a bullet-shaped LED lamp is used as a light emitting diode element, and this LED lamp is mounted on a printed circuit board or the like, and its front surface is covered with a cover lens. A vehicle lamp is formed. Note that this bullet-shaped LED lamp has a form in which an LED chip electrically connected to and attached to a lead frame is sealed with a bullet-shaped resin mold whose tip is formed as a round convex lens. The lens effect converges the radiated light from the LED chip and distributes the light forward, thereby increasing the on-axis (front) brightness (luminous intensity).

[0004] However, such a vehicular lamp as a signal lamp needs to have a sufficient light emitting area and a sufficient brightness, particularly a sufficient on-axis brightness. Therefore, although the on-axis brightness is enhanced by the lens of the resin mold, it is still insufficient, and the bullet-shaped LED lamp, which is substantially only a point light source, has a predetermined light emitting area. Many are used to form a light-emitting surface having high brightness and brightness.

Although there is no direct connection with such a technique, Japanese Patent Laid-Open Publication No. 1-204481 discloses a plurality of LEs.
In the technology relating to a linear light source using D as a light source,
A plurality of light-emitting elements (LED chips) are electrically connected to a surface of a lead portion formed on a transparent substrate and linearly attached,
There is disclosed one in which this is opposed to a concave columnar reflecting surface, and the light emitted from the LED chip is once reflected by the reflecting surface and then emitted to the outside (forward).

Further, Japanese Patent Application Laid-Open Nos. 8-37321 and 8-56019 disclose a technology relating to a reflective LED lamp used for an outdoor display (dot display) device or the like, which is arranged in a plane. An LED chip is electrically connected to and attached to the surface of the lead frame, and a light-transmitting resin is molded and sealed in a dome shape (spherical head shape or plano-convex lens shape) around the LED chip, and the dome shape is formed. There is disclosed a resin mold in which a reflective coating is formed on the surface on the convex side of the resin mold to form a reflective surface facing the LED chip. In this reflective LED lamp, the radiated light radiated from the LED chip over the entire range of the solid angle of 180 degrees is reflected by the reflecting surface having the concave curved surface, and is directed forward from the plane including the LED chip. It is emitted directionally as substantially parallel light.

[0007]

As described above, when a vehicular lamp such as a high-mount stop lamp is formed by using a bullet-shaped LED lamp, a luminous light having a sufficient luminous area and sufficient brightness is provided. In order to obtain a surface, it was necessary to use a large number of the bullet-shaped LED lamps. Therefore, such a vehicular lamp tends not only to be relatively expensive to manufacture, but also to have relatively high power consumption.

Furthermore, in such a vehicle lamp, the brightness on the axis (front) is important.
As the D lamp, a lamp with a reduced directivity, that is, a lamp in which a lens is appropriately formed so that light emitted from an LED chip is focused on an axis is used. Therefore, the light emitting surface formed by the arrangement of a large number of bullet-shaped LED lamps emits a very bright light at the place where the lamps are arranged, and thus remains mottled even when appropriately dispersed by the cover lens. Tended to be. Therefore, the uniform brightness of the light emitting surface is desirable in design, but if the directivity of the LED lamp is widened, the on-axis brightness decreases accordingly. Was difficult.

[0009] These points also relate to the fact that not all of the radiated light from the LED chip is effectively used as illumination light in the bullet-shaped LED lamp. That is, part of the radiation emitted from the LED chip is directed forward by the lens, but such radiation is part and other radiation is dispersed and diffused to the side. This is because that. In view of this, it is conceivable to apply the above-described technology relating to the LED linear light source (Japanese Patent Application Laid-Open No. Hei 1-204481). It is directed to the front side. Therefore, it is possible to obtain a light-emitting surface that is brighter than when a bullet-shaped LED lamp is used. However, in the case of this technology, the radiation light reflected by the concave cylindrical reflection surface and directed toward the front (on the axis) is only radiation light from a direction perpendicular to the reflection surface, and the other radiation light is reflected light. Even if the light is reflected by the surface, the light is dispersed not to the front but to the side (the length direction of the reflection surface). That is, according to this technology, the on-axis brightness can be improved to some extent,
There is also a limit, and the brightness uniformity of the light emitting surface is not improved at all.

Further, the above-mentioned dome-shaped reflective LED lamps (JP-A-8-37321, JP-A-8-5601)
No. 9) can direct the light emitted from the LED chip as substantially parallel light, and has high on-axis brightness.
Moreover, since a uniform light emitting surface can be formed, it can be considered to apply this to a vehicle lamp such as a high-mount stop lamp. However, in that case, the dome-shaped reflection type L
The ED lamp needs to be formed large enough to have a sufficiently large light emitting surface. However, if the dome-shaped resin mold is formed large, the internal strain increases, and the internal stress causes the destruction of the LED chip. There is fear.
Also, a dome-shaped reflection type LE formed so large.
The vehicle lamp formed by assembling the D lamp has a very heavy weight.

Accordingly, the present invention provides a light-emitting diode lamp having a large light-emitting area, a high on-axis brightness, a uniform light-emitting surface, and a light weight as a whole. It is an object to provide an assembly.

[0012]

According to a first aspect of the present invention, there is provided a light emitting diode lamp assembly comprising a concave portion which is curved and concaved in a spherical shape, and an inner surface of the concave portion formed as a concave surface is formed as a reflective surface. A reflector, a plurality of lead frames attached to the reflector, the tips of which extend along the plane of the opening of the recess to the center of the opening, and are electrically connected to the lead frame; A light emitting diode chip mounted on the surface of the lead frame on the side of the recess at the center of the opening, sealing the light emitting diode chip and its electrical connection, and
A resin mold made of a light-transmitting resin that mechanically couples the plurality of lead frames to each other.

According to a second aspect of the present invention, there is provided a light-emitting diode lamp assembly further comprising a cover lens in addition to the light-emitting diode lamp assembly of the first aspect, further comprising a concave portion which is curved and concaved in a spherical shape. A reflector having a concave curved surface, the inner surface of which is formed as a reflective surface; and a plurality of lead frames attached to the reflector, the leading ends of which extend along the plane of the opening of the recess to the center of the opening. And electrically connected to the lead frame,
A light emitting diode chip mounted on the surface of the lead frame on the side of the recess at the center of the opening of the recess, sealing the light emitting diode chip and its electrical connection, and the plurality of lead frames; And a cover lens that covers the front surface of the reflector.

Further, a light-emitting diode lamp assembly according to a third aspect of the present invention is the light-emitting diode lamp assembly according to the second aspect, wherein the light-emitting portion is particularly constituted by a plurality of light-emitting portions, and is concavely curved in a spherical shape. With multiple recesses,
A reflector having a concave curved surface, the inner surface of which is formed as a reflective surface, attached to the reflector,
A plurality of lead frames whose tips extend along the plane of each opening of the plurality of recesses to the center of the opening; and the lead frame is electrically connected to the lead frame, and the lead frame is located at the center of the opening of the recess. A light-emitting diode chip mounted on the surface of the concave portion side; and a light-transmitting material for sealing the light-emitting diode chip and its electrical connection portion and mechanically coupling the plurality of lead frames to each other. And a cover lens that covers the front side of the reflector.

Here, the shape of the inner surface of the concave portion that is curved and concaved in a spherical shape, that is, the shape of the reflecting surface formed of a concave curved surface is more specifically a radiation surface, a spherical head surface, or It can be a concave surface based on a quadratic surface such as an elliptical surface.

In this light-emitting diode lamp assembly, since the inner surface of the concave portion formed as a reflecting surface is a concave curved surface which is curved in a spherical shape, the center of the opening of the concave portion is closer to the concave portion side of the lead frame. The light emitted from the light-emitting diode chip mounted on the surface is radiated radially over the entire range of a solid angle of 180 degrees, and substantially all of the emitted light is formed by a concave reflecting surface. Reflected directionally to the side. Therefore, it is possible to form a light-emitting surface having a wide light-emitting area with a large size of the opening of the concave portion, and a high brightness on the axis (front) and a uniform light-emitting surface. In addition, the lead frame has substantially no weight, and the resin mold can be formed with a minimum size enough to surround the periphery of the light emitting diode chip, so that the whole can be formed lightweight.

According to the second aspect of the present invention, since a cover lens is provided, the light-emitting surface is protected from wind and rain by the cover lens, and the radiated light is appropriately dispersed.
Light distribution is possible. In claim 3, particularly, since the reflector is provided with a plurality of recesses and each of the recesses is similarly provided with an LED chip, the plurality of light-emitting portions are formed as a single unit, and replacement thereof is performed. It will be easier.

[0018]

Embodiments of the present invention will be described below.

FIGS. 1 to 5 show a light emitting diode lamp assembly according to an embodiment of the present invention. FIG. 1 is a plan view showing the light emitting diode lamp assembly with a part cut away, and FIG. 1 is a cross-sectional view taken along the line XX,
FIG. 3 is a sectional view taken along the line YY in FIG. FIG. 4 is an enlarged plan view showing a mounting portion of the light emitting diode chip. FIG. 5 is an explanatory diagram showing an optical path of light emitted from the light emitting diode chip.

As shown in FIGS. 1 to 3, the light-emitting diode lamp assembly according to the present embodiment is mounted on a high-mount stop lamp as a vehicle lamp (indicating lamp), that is, mounted on a rear window or a roof of an automobile. This is embodied as a signal lamp that emits red light during braking and displays the braking on a following vehicle. This lamp assembly is formed in a slightly elongated rectangular shape as a whole, and has a base 1 as a mounting portion to a vehicle body, a cover lens 2, and a lamp as a light source or a light emitting portion, that is, a reflection type light emitting diode lamp. (Note that the light-emitting diode is simply referred to as “LED” in the following.)

More specifically, the base 1 is generally formed in a substantially flat plate shape from a suitable synthetic resin material or the like, and is attached to the vehicle body with screws or the like via a fixing portion (not shown). Further, the base 1 is provided with a mounting groove 1a for mounting the cover lens 2 circumferentially along an edge of the upper surface thereof. On the other hand, the cover lens 2 is formed in a box shape having an inner side wall 2a and an outer side wall 2b, and the tip of the inner side wall 2a is fitted into the mounting groove 1a via an adhesive 1b such as butyl rubber. By fitting them together (FIG. 2), they can be attached to the base 1. Therefore, the cover lens 2 and the base 1 are assembled through the adhesive 1b to form a substantially sealed housing for the LED lamp assembly 3 and can be separated from each other when necessary. It has become.

The cover lens 2 is formed of a transparent, that is, light-transmitting synthetic resin material or another material, and is generally formed of a transparent or appropriately colored acrylic resin. Further, on the inside of the front surface, an uneven surface 2c made of a collection of fine lenses or prisms is provided, and the light emitted from the LED lamp assembly 3 is appropriately dispersed and distributed. The structures in the lamp assembly 3 and the cover lens 2 are not visually recognized.

Further, inside the cover lens 2, a flat plate-like mounting piece 2 d extending to the base 1 side facing each other as a pair is integrally provided, and the mounting piece 2 d is provided with an LE.
The D lamp assembly 3 is mounted and supported. That is, the lamp assembly 3 having a slightly elongated rectangular parallelepiped outer shape is slightly elastically clamped between the pair of mounting pieces 2d, and the locking claws 3 on the side surfaces thereof are provided in a state where the rattle is eliminated.
a is retained with respect to the cover lens 2 by engaging with the engagement opening 2e of the mounting piece 2d. Therefore, the LED lamp assembly 3 can be removed from the cover lens 2 and can be replaced, repaired, and the like.
In FIG. 2, reference numeral 3b denotes a lead wire for supplying electricity to the LED lamp assembly 3, which is connected to the lamp assembly 3 through the base 1.

An assembly as a high-mount stop lamp including the base 1, the cover lens 2, and the LED lamp assembly 3 is at least covered with a suitable cover (not shown). It is further covered except for the front part and is mounted rearward on the rear window or roof of the vehicle. The assembly structure including the base 1 is merely an example. For example, the LED lamp assembly 3 can be attached to the base 1 by similar means.
By forming the D lamp 3 as having a mounting portion, the base 1 can be omitted. However, the above structure has an effect that the assembling thereof is particularly easy, and the unitized LED lamp assembly 3 can be easily replaced as described later.

Here, the LED lamp assembly 3 forming the basis of the lamp assembly of the present embodiment is configured as a reflection type, and includes a reflector (reflection member) 4, a lead frame 5,
And an assembly of a light emitting diode chip (LED chip) 6 made of a pn-junction optical semiconductor crystal and a resin mold 7 made of a light transmitting resin. Also,
Here, a plurality of units (specifically, four units) of lamp assemblies are configured as a single unit arranged in a row.

The reflector (reflection member) 4 constituting the lamp body is formed of a synthetic resin material such as ABS resin.
Here, it is formed as a slightly elongated rectangular body. In addition, an outer frame 4a serving as a mounting portion for the mounting piece 2d of the cover lens 2 is provided integrally with the periphery thereof, also serving as reinforcement. Then, on the front surface, four concave portions 4b that are curved and concave in a spherical shape are provided in parallel, and the entire inner surface of each concave portion 4b, that is,
The entire surface formed by the spherical concave curved surface is formed as a mirror surface, that is, a reflection surface 4c. That is, the reflector 4 having the reflecting surface 4c formed of the concave curved surface is formed as a concave mirror.

The reflecting surface 4c is, for example, an ABS
After forming the reflector 4 having the concave portion 4b from resin or the like, aluminum or the like is deposited on the inner surface of the concave portion 4b,
Then, a transparent resin coat can be formed on the deposition surface for protection and insulation of the lead frame 5. Further, it can be similarly formed by plating or sticking a reflective film. When the reflector 4 is formed of a metal material, the inner surface of the recess 4b is formed as a reflection surface as it is. However, the reflector 4 itself may be formed of a synthetic resin material to reduce the weight. It is preferred in that respect.

The lead frame 5 has a role as a lead for sending a current to the LED chip 6 and a role as a support for disposing the LED chip 6 at the center of the opening surface of the recess 4a. Therefore, this lead frame 5
Is composed of at least two lead frames serving as a cathode or an anode with respect to the LED chip 6, that is, a main lead frame 5a for die bonding and a sub lead frame 5b for wire bonding for directly attaching the LED chip 6 to the surface thereof. In addition, each extends through the plane of the opening of the concave portion 4b of the reflector 4 to the center thereof. The lead frame 5 is formed, for example, by stamping and molding a thin metal sheet material, and silver plating for ensuring electrical connection is formed on the electrical connection portion of the LED chip 6 at the tip. Formed.

More specifically, in the present embodiment, the lead frames 5 are apparently composed of four leads, and are arranged in a cross shape within the opening surface of the concave portion 4b of the reflector 4 as shown in FIG. More specifically, as shown in FIG. 4, the four lead frames 5 are connected to each other in a "-" shape at a central portion, and are substantially two main lead frames 5a. And a sub-lead frame 5b. However, these lead frames 5 are structurally integrally connected to each other by the resin mold 7 regardless of the number of lead frames. The cross-shaped (cross-shaped) arrangement of the lead frame 5 corresponds to the L
This ensures that the ED chip 6 is held substantially immovably at a central position in the plane of the opening of the recess 4b. The ends of these lead frames 5a, 5b facilitate wire bonding of the LED chip 6,
Even when the resin mold 7 mainly for sealing the LED chip 6 is formed with the minimum size, the lead frame 5 is mechanically coupled by the resin mold 7 at the center of the opening. They are placed close enough. Here, their tips are arranged close to each other so as to be intricate.

The lead frame 5 is attached or fixed to the reflector 4 by a small groove (not shown) formed on the surface of the reflector 4 corresponding to the arrangement path as shown in FIGS. Is fitted and positioned, and then bent along the outer frame 4a of the reflector 4 to simplify the operation. In this case, if necessary, they can be further bonded with an adhesive.
Further, in this case, as shown in FIG. 1, if the lead frames 5 adjacent to each other in the length direction of the reflector 4 are connected to each other by the connecting portion 5c, the lead frames 5 are connected by the resin mold 7. , All lead frames 5
Becomes a single structure, and wiring becomes simpler. However, in this case, between the adjacent concave portions 4b,
Main lead frame 5a or sub lead frame 5
b need to be arranged next to each other.

The LED chip 6, which is a light emitting element, has a back surface of the lead frame 5, that is, a side opposite to the front surface, at the center (center) of the opening surface of the concave portion 4b having the inner surface formed as the reflection surface 4c. Die-bonded to the surface. That is, it is attached to the reflection surface 4c side. In the present embodiment, as shown in FIG. 4, two LED chips 6 that emit red light are attached to the back side surface of the lead frame 5 (therefore, FIG. 4 is a plan view seen from the back side). ). Specifically, the two LED chips 6 are die-bonded to the tip of the main lead frame 5a via a silver paste, so that their respective back electrodes are electrically connected and the front electrode is made of gold. It is electrically connected to the sub-lead frame 5b via the line 5d. In this way, the two LED chips 6 are connected in parallel, and by energizing them in the forward direction, red light with sufficiently high brightness can be obtained.

Then, these two LED chips 6
For its protection, a light-transmitting resin, including a wire bonding portion with a gold wire 5d as an electrical connection portion,
For example, it is sealed by a resin mold 7 made of a transparent epoxy resin. However, the resin mold 7 is formed in a minimum size necessary for sealing, and is formed in a hemispherical shape so that a lens effect does not substantially occur. Accordingly, the structure in which the LED chip 6 electrically connected to and attached to the tip of the lead frame 5 is sealed with the resin mold 7 is the same as that of a normal bullet-shaped LED lamp, but much more. It is formed small. As described above, the plurality of lead frames 5 are mechanically connected to each other by the resin mold 7 and are formed together with the LED chip 6 as a single element. In addition, since this element is formed so small that the resin mold 7 has substantially no weight, inertia force does not substantially work.

FIG. 5 shows an optical path of light radiated from the LED chip 6 of the LED lamp assembly of the present embodiment configured as described above. Then, as shown in FIG. 5, the radiated light from the LED chip 6 which is arranged at the center of the opening surface of the concave portion 4b of the reflector 4 and is attached to the surface of the lead frame 5 on the concave portion 4b side is Over the entire circumference of
That is, the emitted light is emitted over the entire range of the solid angle of 180 degrees, but the emitted light is reflected by the reflecting surface 4c formed of the concave curved surface forming the inner surface of the concave portion 4b, and does not travel to the side or the like. It is directed substantially only in the forward (upward direction in the figure) direction. Therefore, according to this reflection type LED lamp assembly, the reflection surface 4c is formed as a secondary light source, a light emitting surface having a large area corresponding to the size of the opening of the recess 4b is formed, and the uniform brightness is obtained. As a result, a light emitting surface that emits light and has high on-axis (front) brightness is formed. Although the lead frame 5 blocks the reflected light, the ratio of the lead frame 5 occupying the opening surface of the concave portion 4b is usually 2-3.
%.

Here, the highest on-axis (front) brightness (luminance) is obtained when all the reflected light from the reflecting surface 4c is directed strictly forward in parallel with the optical axis. Such directivity of the reflected light can be obtained by forming the reflecting surface 4c from a paraboloid (a rotating paraboloid). Specifically, this paraboloid is the LED in FIG.
When xy coordinates with the chip 6 as the origin are formed, y = x ²
−1 / 4 · a (a is the diameter of the opening surface of the recess 4b, y ≦ 0)
Is obtained by rotating a parabola represented by However, in practice, it is not necessary that the light be strictly parallel. Rather, it is preferable that the light be dispersed to some extent as a high-mount stop lamp. Therefore, in the present embodiment, the reflection surface 4c, which is the inner surface of the recess 4b, is a quadratic surface approximating the paraboloid, that is, the distance between the LED chip 6 and the bottom of the recess 4b is doubled. Point p shown in FIG.
Is formed from the spherical head centered at the center. However, even with such a concave surface, it is possible to obtain a light emitting surface as a surface light source that emits light with uniform brightness and has high on-axis brightness, which is substantially the same as that of a parabolic surface. It is. In the case of such a spherical surface, the degree of dispersion (spread) of the reflected light can be set arbitrarily by appropriately determining the position (radius of curvature) of the center point P.

As described above, the LED lamp assembly of the present embodiment basically includes the concave portion 4b which is curved and concaved in a spherical shape (specifically, concaved in a ball head shape). A reflector 4 having a concave curved surface (specifically, a spherical head surface) and an inner surface of a concave portion 4b formed as a reflective surface 4c.
Is attached to the reflector 4, and the tip is a concave portion 4b.
A plurality of lead frames 5 extending to the center of the opening along the plane of the opening, and a surface of the lead frame 5 at the center of the opening of the recess 4b which is electrically connected to the lead frame 5. And a resin mold 7 made of a light-transmitting resin that seals the LED chip 6 and its electrical connection and mechanically couples the plurality of lead frames 5 to each other. Is provided.

Therefore, according to this LED lamp assembly, as described above, a light emitting surface having a high on-axis brightness, uniformity, and a large area can be formed.
It can be formed as a high-security high-mount stop lamp. Further, the light emitted from the LED chip 6 can be controlled to be directed in the front direction by the reflection surface 4c, and can be efficiently used as illumination light without waste.
With a small number of LED chips 6, the lamp can be formed as an inexpensive and low power consumption lamp. Further, since the use of the lead frame 5 does not require a printed circuit board or the like, the lamp assembly can be formed with a simple structure, the lead frame 5 has substantially no weight, and the resin mold 7 has a light emitting diode (LED). Since it can be formed with a minimum size that does not substantially weigh the surroundings of the chip 6, it is possible to form a lamp assembly that is lightweight as a whole.

The LED lamp assembly of the present embodiment is more specifically provided with a cover lens 2 that covers the front side of the reflector 4 as in the case of a normal lamp. This protects the reflecting surface 4c of the reflector 4, the lead frame 5, and the respective parts such as the LED chip 6 sealed with the resin mold 7 from the weather and the like,
Further, it is possible to prevent those parts from being damaged or soiled. In addition, the radiation emitted from the LED chip 6 reflected by the reflection surface 4c and directed toward the front side can be appropriately dispersed, and the light can be distributed to prevent dazzling or to exhibit a design such as a glare.

Further, in the LED lamp assembly of the present embodiment, in particular, a plurality of light emitting unit units (lamp units) are unitized, and the reflector 4 is formed as having a plurality of (four) concave portions 4b. And their respective recesses 4b
, A lead frame 5 and an LED chip 6 are provided. Therefore, when the LED chip 6 stops emitting light due to deterioration or the like, it can be easily replaced as a unit. Further, the unitized LED lamp assembly can be used, for example, in such a manner that a plurality of elongated cover lenses 2 are linearly arranged in parallel, thereby providing a high-mount stop lamp having an elongated overall shape. It can be formed as In this case, the unitized LED lamp assemblies can be individually replaced.

In the LED lamp assembly according to the above embodiment, as shown in FIG.
In other words, two red LED chips 6 are used for each light emitting unit, but this number depends on the size of the light emitting surface (the opening of the recess 4b) or It can be arbitrarily determined according to the desired brightness or the like, and may be one or three or more. Here, the two LED chips 6 are simultaneously turned on, but at least one of the main lead frame 5a and the sub lead frame 5b is formed as an individual lead frame for each LED chip 6. The lighting control of these two LED chips 6 can be performed independently. This will be specifically described with reference to FIG.

FIG. 6 is a plan view showing another embodiment of the mounting portion of the LED chip, similarly to FIG. Therefore, FIG. 6 is a plan view of the mounting portion of the LED chip viewed from the back side.

That is, in the embodiment shown in FIG. 6, the main lead frame 5a and the sub lead frame 5b are
Each of the independent lead frames is composed of two independent lead frames. The two LED chips 6 are die-bonded to the two main lead frames 5a, respectively, and wire-bonded to the two sub-lead frames 5b. Note that one lead frame 5a or 5b is
It may be formed as a substantially single electrically connected common lead frame. Therefore, current can be independently supplied between each main lead frame 5a and sub lead frame 5b, and each LED chip 6 can be turned on independently.

Thus, for example, only one LED chip 6 is turned on or two LED chips 6 are turned on in accordance with the amount of depression of the brake pedal or in accordance with the use of an auxiliary brake such as an exhaust brake. It is possible to change the brightness of the light emitting surface in two stages by performing lighting control as to whether or not to light up. When three LED chips 6 are used, the brightness of the light emitting surface can be changed in three stages. In this case, the lead frame 5
Are, for example, three main lead frames 5a and one sub lead frame 5b serving as a common lead frame.
And can be formed from

By the way, in the LED lamp assembly of the above-described embodiment, the reflector 4 may have various other forms, particularly in the specific shape and arrangement of the concave portions 4b.

FIGS. 7 to 9 show a reflector according to a first alternative embodiment. FIG. 7 is a plan view of the reflector, and FIG. 8 is a cross-sectional view of the reflector taken along the length direction at the center. FIG. 9 is a cross-sectional view of the reflector cut at the center of the recess at right angles to the length direction.

As shown in FIGS. 7 to 9, the reflector according to the first alternative embodiment, which is indicated by reference numeral 10, corresponds to FIGS. 1 to 3.
As in the case of the reflector 4 described above, the reflector 4 is formed as a rectangular body having an outer frame 4a, and four concave portions 4b which are curved and concave in a spherical shape are provided in a line on the front side thereof. Also, the inner surface of each concave portion 4b of the concave curved surface shape is
Similarly, it is formed as a reflection surface 4c. In addition, as shown by a dotted line in FIG. 7, the lead frame 5 in which the LED chip 6 is attached to the center of the back side and electrically connected to each of the concave portions 4 b of the reflector 10,
The reflection type LEs are respectively disposed along the opening surfaces.
It is configured as a D lamp assembly. In FIG. 7, a small groove 4d not shown in FIGS.
A small groove 4d for guiding the lead frame 5 and positioning it with respect to the reflector is shown. However, the attachment claws 3a are not shown.

In the reflector 10 according to the first alternative embodiment, the inner surface of the concave portion 4b, that is, the reflecting surface 4c is basically a concave curved surface composed of an elliptical surface (a rotating elliptical surface). It is formed by notching both ends on the long axis side and the short axis side. Therefore, in plan view, the opening of the concave portion 4b has a slightly elongated substantially hexagonal shape.
The notched portion is formed as a vertical flat surface. In addition, the four recesses 4b having such a shape are continuously arranged with the notches on the long axis side being in contact with each other.

For this reason, the L provided with the reflector 10
In the ED lamp assembly, the elongated rectangular (strip-like) light emitting surface can be obtained as a whole by the concave portions 4b being continuously arranged. In addition, the concave portion 4b
In the light emitting surface according to the shape of the opening surface, the reflecting surface 4c is an elliptical surface, and the radiated light from the LED chip 6 is reflected directionally forward, so that the light emitting surface is the same as that of the reflector 4 of the above embodiment. In addition, the brightness distribution is substantially homogeneous, and
It emits light with high on-axis (front) brightness. However, in this case, a part of the radiated light radiated from the LED chip 6 in the horizontal direction (the direction parallel to the opening surface of the concave portion 4b) is not directed forward because the cutout portion is a vertical plane. The amount is small.

As described above, the inner surface shape of the concave portion 4b (the shape of the reflecting surface 4c) basically has a spherical concave curved surface, that is, it is concavely curved in any cross section.
The next concave curved surface, as long as it is a concave curved surface that is gradually depressed from the annular opening edge to the center thereof, it can be a shape in which a part of the peripheral edge is notched, and such an inner surface shape is The recessed portions 4b can be arranged adjacent to each other with their opening edges in contact with each other. As a result, it is possible to form a uniform continuous light-emitting surface with high on-axis (front) brightness.

Further, the inner surface shape (shape of the reflecting surface 4c) of the concave portion 4b is formed of a plurality of discontinuous concave curved surfaces as long as the concave portion 4b has a substantially spherical concave curved surface as a whole. And can also include planes. Thereby, a light emitting surface having various designs can be formed.

FIGS. 10 and 11 schematically show a reflector according to a second embodiment of the present invention. FIG. 10 is a perspective view of the reflector, and FIG. 11 is a cross-sectional view of the reflector taken at the center in the longitudinal direction. FIG.

As shown in FIGS. 10 and 11, the reflector of the second embodiment shown by the reference numeral 20 has a recess 4b.
The inner surface shape (shape of the reflection surface 4c) is a plurality of (here, three) annular concave curved surfaces, which are concavely formed concentrically and discontinuously via a step. Things. In addition, in the center of the opening surface of each of the concave portions 4b,
Similarly to the above, the LED chip is arranged toward the reflection surface 4c. Therefore, according to this reflector 20,
The radiated light from the LED chip is annularly reflected by the respective annular concave curved surfaces forming the reflecting surface 4c, and the overall brightness is uniform, but a multiple ring-shaped light emitting surface is formed.

FIGS. 12 and 13 schematically show a reflector according to a third embodiment of the present invention.
FIG. 13 is a perspective view of the reflector, and FIG. 13 is a partial cross-sectional view showing the reflector cut at the center in the length direction.

As shown in FIGS. 12 and 13, the reflector of the third embodiment shown by the reference numeral 30 has a recess 4b.
Is formed in a diamond-cut shape (the shape of the reflection surface 4c). That is, the concave surface is a polygonal surface in which many small triangular planes are collectively formed into a concave surface. Therefore, according to the reflector 30, since the radiated light from the LED chip is dispersedly reflected by each of the reflecting surfaces formed of small flat surfaces, the light emitting surface has a uniform brightness, but has a glittering feeling as a whole. Is formed.

The decorative light-emitting surface obtained by the reflectors 20 and 30 can be similarly obtained by appropriately forming the uneven surface 2c of the cover lens 2. However, by combining these, that is, by forming the reflecting surface 4c of the concave portion 4b into a concave curved surface from which a light emitting surface with a design can be obtained, and simultaneously appropriately forming the concave and convex surface 2c of the cover lens 2 at the same time Thus, it is possible to obtain various light emitting surfaces having a more design.

Incidentally, although the LED lamp assembly of the above-described embodiment is embodied as a high-mount stop lamp, it can be embodied similarly as a rear combination lamp. In such a case, the reflector can be formed in a shape that is entirely curved as shown in FIG.

FIG. 14 is a sectional view showing a reflector according to a fourth embodiment of the present invention, cut at the center in the longitudinal direction.

As shown in FIG. 14, the reflector indicated generally by 40 is the reflector 4 (10,
As in the case of 20, 30), it is formed as a slightly long rectangular body having an outer frame 4a from a synthetic resin material, and has four concave portions 4b which are curved and concave in a spherical shape on the front side thereof in the longitudinal direction. It is provided along. Similarly, the inner surface of each concave curved portion 4b is formed as a reflective surface 4c by, for example, aluminum evaporation. However, the reflector 40 is formed so as to be entirely curved in a lengthwise direction so as to be disposed along a curved corner at the rear of the vehicle.

For this reason, this reflector 40 is
The lead frame 5 to which the chip 6 has been bonded and sealed with the resin mold 7 is similarly assembled (since the assembly of the lead frame 5 is only to bend along the outer frame 4a, the reflector 40 Can be easily performed irrespective of the shape of the LED), and can be provided as a rear combination lamp together with the curved cover lens 2 at the curved corner portion at the rear of the vehicle. Since the opening surfaces of the recesses 4b forming the light emitting surface are respectively oriented in the directions corresponding to the curvature, the radiated light from the LED chip 6 is emitted not only to the rear of the automobile but also to the side rear. Radiate,
Signal display in these directions can be performed. Therefore, in this case, since the radiated light from the LED chip 6 needs to be dispersed in a predetermined angle range, the concave portion 4b
7, that is, the shape of the reflection surface 4 c
It is preferable that the elliptical surface as in the case of the reflector 4 is used, and that the recessed portions 4b are continuous as shown in FIG. Note that, when embodied as a rear combination lamp as described above, two different brightnesses (types) are used.
By using the LED chips 6 and controlling the lighting independently as shown in FIG. 6, the LED chip 6 can be formed as a combination of a tail lamp and a stop lamp. By using an emitting LED chip, it can also be formed as a turn signal lamp.

Furthermore, not only as a rear combination lamp as described above, but also a reflection type LED lamp assembly provided with this reflector can provide a high on-axis (front) brightness. It can be embodied in various uses as a lamp for lighting or lighting.
In those cases, the cover lens can be omitted as appropriate.

In these cases, the number and arrangement of the concave portions (concave curved reflecting surfaces) provided in the reflector should be appropriately designed, including a single case, depending on the specific application and the like. Can be. For example, by arranging four recesses vertically and horizontally, it is possible to form a light emitting surface having a square shape as a whole. The type and number of LED chips used are not limited to red LED chips emitting red light, LED chips emitting amber light, green LED chips emitting green light, and blue LEDs emitting blue light. Each color LED chip such as an LED chip can be used alone or in combination of two or more. Then, for example, red LE constituting the three primary colors of light
By using three types of LED chips, a D chip, a green LED chip, and a blue LED chip, and by configuring a lead frame so that these can be controlled independently of each other, a substantially mixed color including white mixed color is obtained. In this way, all emission colors can be obtained.

[0061]

As described above, the light emitting diode lamp assembly according to the first aspect includes the concave portion which is concavely curved and curved in a spherical shape, and the inner surface of the concave portion formed as the concave curved surface is formed as a reflective surface. A reflector, a plurality of lead frames attached to the reflector and having tips extending along the plane of the opening of the recess to the center of the opening, and electrically connected to the lead frame; A light emitting diode chip attached to the surface of the lead frame on the side of the recess at the center of the opening of the light emitting diode chip, sealing the light emitting diode chip and its electrical connection, and
A resin mold made of a light-transmitting resin that mechanically couples the plurality of lead frames to each other.

Therefore, according to this light emitting diode lamp assembly, the light emitted from the light emitting diode chip, that is, 180 degrees from the light emitting diode chip bonded to the surface of the lead frame on the side of the recess at the center of the opening of the recess. Radiation light radiated radially over the entire range of the solid angle is substantially entirely reflected directionally forward by the inner surface of the concave portion formed of a concave curved surface formed as a reflective surface. Can be. Therefore, it is possible to obtain a light-emitting surface having high and uniform on-axis (front) brightness and having a wide area corresponding to the size of the opening of the recess. In addition, since the light emitted from the light emitting diode chip is efficiently used as illumination light, a light emitting surface having a predetermined brightness can be formed at a low cost by using a smaller number of light emitting diode chips.
Further, since the lead frame has substantially no weight, and the resin mold can be formed in a minimum size having substantially no weight enough to surround the periphery of the light emitting diode chip, the whole is simplified. It can be formed lightweight with a simple structure.

According to a second aspect of the present invention, there is provided a light emitting diode lamp assembly further comprising a cover lens in addition to the light emitting diode lamp assembly of the first aspect, further comprising a concave portion which is curved and concaved in a spherical shape. A reflector having a concave curved surface, the inner surface of which is formed as a reflective surface; and a plurality of lead frames attached to the reflector, the leading ends of which extend along the plane of the opening of the recess to the center of the opening. And electrically connected to the lead frame,
A light emitting diode chip mounted on the surface of the lead frame on the side of the recess at the center of the opening of the recess, sealing the light emitting diode chip and its electrical connection, and the plurality of lead frames; And a cover lens that covers the front surface of the reflector.

Therefore, according to this light emitting diode lamp assembly, since the cover lens is further provided, in addition to the effect of the first aspect, each part such as the reflecting surface of the reflector, the lead frame, and the light emitting diode chip is protected from wind and rain. There is an effect that the radiation light reflected by the reflection surface and traveling toward the front side can be appropriately dispersed.

Further, a light emitting diode lamp assembly according to a third aspect of the present invention is the light emitting diode lamp assembly according to the second aspect, wherein the light emitting portion is constituted by a plurality in particular, and is curved and recessed in a spherical shape. With multiple recesses,
A reflector having a concave curved surface, the inner surface of which is formed as a reflective surface, attached to the reflector,
A plurality of lead frames whose tips extend along the plane of each opening of the plurality of recesses to the center of the opening; and the lead frame is electrically connected to the lead frame, and the lead frame is located at the center of the opening of the recess. A light-emitting diode chip mounted on the surface of the concave portion side; and a light-transmitting material for sealing the light-emitting diode chip and its electrical connection portion and mechanically coupling the plurality of lead frames to each other. And a cover lens that covers the front side of the reflector.

Therefore, according to this light emitting diode lamp assembly, in particular, the reflector is provided with a plurality of recesses, and the LED chips are electrically connected to the lead frames in the respective recesses, and are sealed with a resin mold. Since the plurality of light emitting portions are provided as a unit, the light emitting portion can be easily replaced as a unit when the LED chip stops emitting light, in addition to the effect of the second aspect.

[Brief description of the drawings]

FIG. 1 is a plan view showing a light emitting diode lamp assembly according to an embodiment of the present invention, with a part cut away.

FIG. 2 is a sectional view taken along line XX of FIG.

FIG. 3 is a sectional view taken along the line YY of FIG. 1;

FIG. 4 is an enlarged plan view showing a mounting portion of a light emitting diode chip of the light emitting diode lamp assembly of FIG. 1;

FIG. 5 is an explanatory view showing an optical path of light emitted from a light emitting diode chip of the light emitting diode lamp assembly of FIG. 1;

FIG. 6 is an enlarged plan view showing a mounting portion of a light emitting diode chip of another embodiment of the light emitting diode lamp assembly of FIG. 1;

FIG. 7 is a plan view showing a reflector of the first alternative embodiment of the light-emitting diode lamp assembly of FIG. 1;

FIG. 8 is a cross-sectional view showing the reflector of FIG. 7 cut at the center along the length direction.

FIG. 9 is a cross-sectional view showing the reflector of FIG. 7 cut at a center of a concave portion at right angles to a longitudinal direction.

FIG. 10 is a perspective view showing a reflector of a second alternative embodiment of the light emitting diode lamp assembly of FIG. 1;

FIG. 11 is a cross-sectional view showing the reflector of FIG. 10 cut at the center along the length direction.

FIG. 12 is a perspective view showing a reflector of a third alternative embodiment of the light emitting diode lamp assembly of FIG. 1;

FIG. 13 is a partial cross-sectional view showing the reflector of FIG. 12 at the center along the length direction.

FIG. 14 is a cross-sectional view showing a reflector according to still another embodiment of the fourth embodiment, cut at the center along the length direction.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base 2 Cover lens 3 LED lamp assembly 4 Reflector 4b Depression 4c Reflection surface 5 Lead frame 6 LED chip 7 Resin mold 10, 20, 30 Reflector

Claims (3)

[Claims] 1. A reflector having a concave portion curved and concaved in a spherical shape and having a concave curved surface, the inner surface of which is formed as a reflective surface, and a reflector attached to the reflector, and a tip of the concave portion. A plurality of lead frames extending along the plane of the opening to the center of the opening, electrically connected to the lead frame, and attached to the surface of the lead frame on the side of the recess at the center of the opening of the recess; A light-emitting diode chip, and a resin mold made of a light-transmissive resin that seals the light-emitting diode chip and its electrical connection, and mechanically couples the plurality of lead frames to each other. A light emitting diode lamp assembly, comprising: 2. A reflector having a concave portion curved and concaved in a spherical shape, wherein the inner surface of the concave portion formed of a concave curved surface is formed as a reflection surface, and a reflector attached to the reflector, and a tip of the concave portion is provided. A plurality of lead frames extending along the plane of the opening to the center of the opening, electrically connected to the lead frame, and attached to the surface of the lead frame on the side of the recess at the center of the opening of the recess; A light emitting diode chip, a resin mold made of a light transmissive resin that seals the light emitting diode chip and its electrical connection part, and mechanically couples the plurality of lead frames to each other; A light emitting diode lamp assembly comprising: a cover lens that covers a front side of a reflector. 3. A reflector having a plurality of concave portions curved and concaved in a spherical shape, the reflector having a concave curved surface, the inner surface of which is formed as a reflective surface, and a reflector attached to the reflector and having a plurality of tips. A plurality of lead frames extending along the plane of the opening of the recess to the center of the opening; and the recess of the lead frame being electrically connected to the lead frame and at the center of the opening of the plurality of recesses. A light-emitting diode chip mounted on the surface of the unit, and a light-transmitting resin that seals the light-emitting diode chip and its electrical connection, and mechanically couples the plurality of lead frames to each other. A light emitting diode lamp assembly comprising: a resin mold; and a cover lens that covers a front side of the reflector.