Baseboard sheet of card-type lamp unit, card-type lamp unit and vehicle lamp

Abstract

To relate to an external connector insertion part, a baseboard sheet of a card-type lamp unit having heat radiation plates having different linear expansion coefficients, the card-type lamp unit and a vehicle lamp.SOLUTION: A baseboard sheet 20 of a card-type lamp unit 5 has: the card-type lamp unit 5 having a polygonal baseboard main body 10 having external peripheries 10b to 10d, and a connector forming side 12, an external connector insertion part 11 formed at the connector forming side 12, a heat radiation member 16 integrated with the baseboard main body 10, and different in a linear expansion coefficient of the baseboard main body 10, and a light emitting light source 6 connected to a turn-on / off control circuit 13; and a frame body 23 which is integrated with the card-type lamp unit 5 via a connecting end part 10e formed at an external peripheral side of the baseboard main body 10. Connecting end parts 21, 22 of the frame body 23 are arranged at the connector forming side 12.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to a substrate sheet of a card-type lighting unit having an external connector insertion portion and a heat dissipation plate with different linear expansion coefficients, a card-type lighting unit, and a vehicle lighting device.

Background Art

[0002] In paragraphs

[0024] and

[0025] of the specification of Patent Document 1 and FIG. 3, a resin card-type light source having a large number of LEDs mounted on an element mounting portion and a connector portion protruding from the element mounting portion is described. In the case of forming a substrate connected to the LED in such a card-type light source on which such an LED is mounted, it is conceivable to dissipate heat generated in the substrate during lighting by integrating a metal plate (heat dissipation member) or the like on the back surface or the like of the substrate.

[0003] In addition, a card-type light source such as that of Patent Document 1 is generally formed as a substrate sheet together with a frame body connected via a large number of connecting ends, and is cut out from the frame body by cutting the connecting ends.

Prior Art Documents

Patent Documents

[0004] <管理编号: <管理编号:

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] <管理编号:管理编号: When an LED is mounted on a substrate sheet having the card-type light source of Patent Document 1, or when a heat dissipation member such as a metal plate is integrated on the back surface of the resin card-type light source of the substrate sheet to form a metal base substrate, such a substrate sheet needs to be heat-treated. Such heat treatment causes "warpage" due to bending stress in the formed metal base substrate due to the difference in the linear expansion coefficients of the resin card-type light source and the metal plate. <管理编号:管理编号: <管理编号:管理编号:

[0006] <管理编号:管理编号: The metal base substrate, formed as a substrate sheet, is integrated with the frame via numerous connecting ends. Therefore, the outer periphery of the metal base substrate, which is connected to the frame by the connecting ends, does not warp due to the frame's restriction of deformation. However, the connecting ends to the frame become burrs after cutting. If connecting ends were formed between the outer periphery of the connector and the frame, while warping would not occur, it would negatively affect the insertion and removal of the connector from the external connector. Consequently, connecting ends cannot be formed between the connector and the frame. Therefore, substrate sheets with a metal base substrate and a connector have the problem of warping occurring near the connector area during heat treatment.

[0007] In view of the above problems, this application provides a substrate sheet having a metal base substrate with a connector portion, a card-type lighting unit, and a vehicle lighting device that are less prone to warping near the connector portion even when heat treatment is applied. [Means for solving the problem]

[0008] A card-type luminaire unit comprising a polygonal substrate body having an outer perimeter and a connector-forming edge, an external connector insertion portion formed on the connector-forming edge, a heat dissipation member integrated with the substrate body having a different coefficient of thermal expansion than the substrate body, and a light-emitting element light source connected to a control circuit for turning the light on and off, and a frame body integrating the card-type luminaire unit via connecting ends formed on the outer perimeter of the polygonal substrate body, wherein a connecting end for connection to the frame body is provided on the connector-forming edge.

[0009] (Function) Because the connector forming portion is connected to the frame via the connecting end, even if bending stress occurs near the connector forming portion when the substrate sheet is heat-treated, the frame restricts warping.

[0010] Furthermore, in the circuit board sheet of the card-type lighting unit, it is desirable that multiple light-emitting elements constituting the light-emitting element source are provided on the circuit board body, and that the control circuit for turning the light on and off is mounted on the circuit board body.

[0011] (Function) If a control circuit for controlling the on / off state of multiple light-emitting elements is placed outside the card-type lighting unit, it is necessary to provide a metal conductive path for each of the multiple light-emitting elements at the external connector insertion point. The present invention mounts the control circuit on the main circuit board of the card-type lighting unit, eliminating the need to install a conductive path for each light-emitting element at the external connector insertion point.

[0012] Furthermore, it is desirable that the substrate sheet of the card-type lighting unit has a plurality of such card-type lighting units, and that each card-type lighting unit has interconnecting ends that connect each connector-forming edge to each other, instead of the connecting ends with the frame.

[0013] (Function) In the substrate sheet, the connector-forming edges of multiple card-type lighting units are connected by interconnecting ends, thereby mutually restricting warping that occurs near each connector-forming edge.

[0014] Furthermore, the card-type lighting unit is formed by separating it from the substrate sheet frame via cutting the connecting end, and the separated card-type lighting unit is installed in a vehicle lighting fixture. [Effects of the Invention]

[0015] According to the circuit board sheet of the card-type lighting unit, even after heat treatment, warping is less likely to occur near the external connector insertion part relative to the frame.

[0016] According to the circuit board sheet of the card-type lighting unit, it is no longer necessary to form conductive paths connecting the control circuit for turning the lights on and off to each of the multiple light-emitting elements in the external connector insertion area. As a result, the width of the external connector insertion area can be narrowed, and the connector forming edge can be made wider. By making the connecting ends of the connector forming edge thicker or providing more of them, it is possible to strengthen the prevention of warping that occurs near the external connector insertion area.

[0017] According to the substrate sheet of the card-type lighting unit, by mutually regulating the warpage generated near each connector forming side of a plurality of card-type lighting units, it is possible to further strengthen the prevention of warpage occurring near the external connector insertion part.

[0018] And a card-type lighting unit having each of the above effects can be obtained as a vehicle lighting device.

Brief Description of the Drawings

[0019] [Figure 1] Front view of a vehicle lighting device having a card-type lighting unit according to the first embodiment. [Figure 2] [[ID=I5]]Cross-sectional view taken along the line I-I in FIG. 1 and enlarged cross-sectional view of the cross-sectional view. [Figure 3] Schematic cross-sectional view of a card-type lighting unit and a power supply connector. [Figure 4] Schematic explanatory view of a substrate sheet in which a plurality of card-type lighting units are arranged side by side. [Figure 5] Schematic explanatory view of a substrate sheet formed such that the external connector insertion parts of a plurality of card-type lighting units are arranged to face each other. [Figure 6] Schematic explanatory view of a substrate sheet in which a plurality of modified examples of a card-type lighting unit are arranged side by side. [Figure 7] Schematic explanatory view of a substrate sheet formed such that the external connector insertion parts face each other with respect to a plurality of modified examples of a card-type lighting unit.

Modes for Carrying Out the Invention

[0020] Hereinafter, a preferred embodiment of the vehicle lighting device of the present invention will be described based on FIGS. 1 and 2, and a preferred embodiment of the card-type lighting unit of the present invention will be described based on FIG. 3. In each figure, the directions of the vehicle lighting device, the card-type lighting unit, and the substrate sheet printed circuit board will be described as (front side: back side: left end side: right end side: front end side: base end side = Fr: Re: Le: Ri: Lo: Up).

[0021] The vehicle light fixture 1 of the first embodiment shown in Figures 1 and 2 comprises a lamp body 2, a front cover 3, and a light fixture unit 4. The lamp body 2 has an opening on the front side of the vehicle (not shown). The front cover 3 is made of a light-transmitting resin or glass and is attached to the opening of the lamp body 2 to form a light chamber S on the inside. The light fixture unit 4 shown in Figure 1 consists of a card-type light fixture unit 5 having a light-emitting element light source 6 consisting of light-emitting elements 6a to 6g such as LED light sources or laser diodes, an optical unit 7, a heat dissipation unit 8, and a power supply connector 9, and is arranged inside the light chamber S.

[0022] The card-type lighting unit 5 shown in Figures 1 to 3 consists of a substrate body 10 which is a glass epoxy substrate, an external connector insertion part 11 formed as a card edge connector, and a metal plate 16 which is a heat dissipation member integrally formed on the back surfaces of the substrate body 10 and the external connector insertion part 11. For example, the external connector insertion part 11 is formed to protrude upward from the connector forming edge 12, which is the outer peripheral edge of the upper end of the rectangular plate-shaped substrate body 10.

[0023] Furthermore, it is more desirable that the metal plate 16, which is integrally formed on the back surface of the substrate body 10 and the external connector insertion part 11 as shown in Figure 3, be integrally formed only on the back surface of the substrate body 10, and not on the back surface of the external connector insertion part 11. In that case, by not having a metal plate 16 on the back surface of the external connector insertion part 11, the metal plate 16 will not peel off from the external connector insertion part 11, which is made of a glass epoxy substrate, when inserting or removing it from the power supply connector 9. In addition, if a metal plate 16 is not provided on the back surface of the external connector insertion part 11, burrs generated on the outer circumference of the metal plate 16 during processing will not protrude from the outer circumference of the external connector insertion part 11, thereby preventing damage to the power supply connector 9 due to burrs, and preventing burrs that have detached from the metal plate 16 from adhering to the conductive paths on the substrate body 10 or the connector insertion part 11 and causing a short circuit.

[0024] As shown in Figure 3, the surface 10a of the circuit board body 10 of the card-type lighting unit 5 is equipped with a light-emitting element light source 6 consisting of light-emitting elements 6a to 6g and a control circuit 13 for turning the light on and off. The control circuit 13 includes a switch circuit 13a that independently switches the light on and off of the light-emitting elements 6a to 6g, and a plurality of electronic components 13c to 13f including a power supply circuit. The switch circuit 13a and the plurality of electronic components 13c to 13f are electrically connected to terminals 13g formed on the surface of the external connector insertion part 11 via a metal conductive path 13b. The plurality of light-emitting elements 6a to 6g are electrically connected to the switch circuit 13a via metal conductive paths 13h formed in the same number as the number of elements installed. Note that the light-emitting elements 6a to 6g may be mounted directly on a metal plate 16 through through holes cut out on both sides of the circuit board body 10, rather than on the surface of the circuit board body 10. In this embodiment, since seven light-emitting elements are mounted, it is necessary to connect them to the switch circuit 13 via seven or more conductive paths for elements. Furthermore, the number of light-emitting elements is not limited to seven; it can be one or any other number. Also, as shown in Figures 1 and 3, the control circuit 13 mounted on the surface 10a of the substrate body 10 is concealed from view from the front by the extension reflector 15.

[0025] As shown in Figures 1 and 2, the optical unit 7 consists of a plano-convex, transparent or translucent projection lens 7a and a lens holder 7b that holds the projection lens 7a. The heat dissipation unit 8 consists of a metal body 8a, multiple metal heat dissipation fins 8b integrally protruding from the rear of the body 8a, and a heat dissipation fan 8c attached to the rear surface of the heat dissipation fins 8b. The heat dissipation fan 8c rotates when powered by a power source (not shown). The projection lens 7a is fixed to the surface of the body 8a of the heat dissipation unit 8 via the lens holder 7b.

[0026] As shown in Figures 1 and 2, the heat dissipation unit 8 is supported on the lamp body 2 via an aiming mechanism 14. The aiming mechanism 14 consists of a pivot point 14a fixed to the lamp body 2, and aiming screws 14b for vertical tilt adjustment and 14c for horizontal tilt adjustment, which are rotatably supported on the lamp body 2. The main body 8a of the heat dissipation unit 8 is supported to swing freely with respect to the pivot point 14a and tilts up, down, left, and right based on the rotation of the aiming screws 14b and 14c.

[0027] As shown in Figures 1 to 3, the power supply connector 9 consists of a connector body 9a, an insertion port 9b of an external connector insertion part 11, and a power supply cable 9c that receives power from a power source (not shown).

[0028] As shown in Figures 1 to 3, the card-type lighting unit 5 is electrically connected to and held by the power supply connector 9 when the external connector insertion part 11 is attached to the insertion port 9b of the power supply connector 9, with the metal plate 16 integrated on the back surface of the circuit board body 10 in contact with the surface 8d of the main body 8a of the heat dissipation unit 8. At this time, the light-emitting element light source 6 is directed forward and positioned near the rear focal point of the projection lens 7a. In Figures 1 and 2, the power supply connector 9 is inserted from above the connector insertion part 11 which is positioned to protrude above the circuit board body 10, but the power supply connector 9 may also be inserted from below into the connector insertion part 11 which is positioned to protrude below the circuit board body 10.

[0029] As shown in Figures 1 to 3, the card-type lighting unit 5 receives power from a power source (not shown) via a power connector 9 to the control circuit 13 and the light-emitting element light source 6, respectively. Based on the control by the switch circuit 13a, the light-emitting elements 6a to 6g are independently turned on and off. The light source unit 4 in Figure 1 is held inside the lamp body 2 in a state that allows it to tilt up, down, left, and right by the aiming mechanism 14.

[0030] Next, Figures 4 and 5 will illustrate a preferred embodiment of a substrate sheet capable of forming multiple card-type lighting units 5. Figure 4 shows a substrate sheet 20 on which multiple (three in this embodiment, but not limited to three) card-type lighting units 5 are integrally formed.

[0031] The card-type lighting unit 5 in Figure 4 is integrally formed with the frame 23 via connecting ends (21, 22) provided on the left and right connector connection sides 12 of the external connector insertion part 11. Furthermore, it is integrally formed with the frame 23 or adjacent card-type lighting unit 5 via multiple connecting ends 10e formed on the left edge 10b, right edge 10c, and bottom edge 10d of the circuit board body 10 (not limited to two locations in this embodiment, but may be just one location).

[0032] In the substrate sheet 20 of this embodiment shown in Figure 4, internal stress is generated during heat treatment that causes "warping" due to the difference in coefficients of thermal expansion between the substrate body 10, which is made of glass epoxy substrate, and the metal plate 16. However, according to the substrate sheet 20 of Figure 4, in addition to multiple connecting ends 10e that integrate the left edge 10b, right edge 10c, and bottom edge 10d of the substrate body 10 with the frame 23, connecting ends 21 and 22 to the frame 23 are provided on the left and right sides of the connector forming edge 12 of the substrate body 10, which is closest to the external connector insertion part 11, so that all four sides of the substrate body 10 are integrated with the frame 23. Therefore, the card-type lighting unit 5 is less prone to warping near the external connector insertion part 11 caused by internal stress during heat treatment, particularly due to the connecting ends 21 and 22.

[0033] Furthermore, in the card-type lighting unit 5 shown in Figure 3, the on / off control circuit 13, which includes a switch circuit 13a for turning the light on and off, is not installed externally but is mounted on the main board 10. Therefore, it is not necessary to form terminal portions 13g corresponding to the conductive paths 13h for elements connected to each of the multiple light-emitting elements on the external connector insertion portion 11, and the number of terminal portions 13g can be reduced. Accordingly, in the main board sheet 20 of the card-type lighting unit 5 shown in Figure 4, the width W1 of the external connector insertion portion 11 can be made narrower, and the widths W2 and W3 of the connector forming sides 12 on the left and right sides can be made wider, respectively. By making the connecting ends 21 and 22 of the connector forming sides 12 wider and thicker, or by providing two or more connecting ends 21 and 22 on the left and right sides, it is possible to strengthen the prevention of warping of the frame 23 that occurs near the external connector insertion portion 11.

[0034] The card-type lighting unit 5 in Figure 4 is formed by separating the connecting ends 21 and 22 and the multiple connecting ends 10e from the frame 23.

[0035] Next, Figure 5 will describe a modified substrate sheet 25, which is a modified version of the substrate sheet 20 in Figure 4, in which the external connector insertion parts 11 of multiple card-type lighting units 5 are arranged facing each other.

[0036] The substrate sheet 25 in Figure 5 integrally forms multiple (six in this embodiment, but not limited to six) card-type lighting units 5, each with an external connector insertion portion 11 arranged opposite to the others. The card-type lighting units 5 in Figure 5 are structurally the same as the substrate sheet 20 in Figure 4, in that they are integrally formed with the frame 26 or adjacent card-type lighting units 5 via connecting ends 10e, which are formed in multiple locations (not limited to two in this embodiment, but may be one) on the left edge 10b, right edge 10c, and bottom edge 10d of the substrate body 10. On the other hand, in the substrate sheet 25 of Figure 5, in a pair of card-type lamp units 5 with external connector insertion parts 11 facing each other, an interconnecting end 27 is provided between the connector forming piece 12a on the left side of one card-type lamp unit 5 and the connector forming piece 12b of the card-type lamp unit 5 facing it, and an interconnecting end 28 is provided between the connector forming piece 12b on the right side of one card-type lamp unit 5 and the connector forming piece 12a of the card-type lamp unit 5 facing it. The pair of card-type lamp units 5 with opposing external connector insertion parts 11 have multiple connecting ends 10e that integrate the left edge 10b, right edge 10c, and bottom edge 10d of the substrate body 10 with the frame body 26, and the interconnecting ends 27 and 28 form the connector forming pieces 12a and 12b of each other integrally.

[0037] As shown in Figure 5, the substrate sheet 25 has multiple connecting ends 10e that integrate the left edge 10b, right edge 10c, and bottom edge 10d of the substrate body 10 with the frame 26, and in particular, the interconnecting ends 27 and 28 that integrate the left and right connector forming edges 12a and 12b of the card-type lighting unit 5, which have opposing external connector insertion parts 11, mutually restrict warping that occurs in the opposing connector molding parts 11 even after heat treatment, thereby further strengthening the prevention of warping that occurs near each external connector insertion part 11.

[0038] The card-type lighting unit 5 in Figure 5 is formed by separating the interconnecting ends 27 and 28 and the multiple connecting ends 10e from the frame 26.

[0039] Figure 6 shows a substrate sheet 35 in which card-type lighting units 34, which are modified versions of the card-type lighting unit 5, are formed in parallel on the side, and Figure 7 shows a substrate sheet 45 in which the external connector insertion parts 36 of the card-type lighting unit 34 are arranged opposite each other.

[0040] The card-type luminaire unit 34 in Figure 6 is a variation of the card-type luminaire unit 5 in Figure 3, in which the upper end of the connector insertion portion 36 is flush with the connector forming edge 37, replacing the connector insertion portion 11 that protrudes above the connector forming piece 12. The card-type luminaire unit 34 has the same configuration as the card-type luminaire unit 5 in Figure 5, except for the shape of the connector insertion portion 37 and the arrangement of the control circuit 13 electrically connected to the light-emitting element 6.

[0041] As shown in Figure 6, the substrate sheet 35 is formed by arranging the card-type lighting unit 34 of Figure 6 laterally with a frame 40. According to the substrate sheet 35, connecting ends 38 and 39 to the frame 40 are provided on the left and right sides of the connector-forming edge 12 of the substrate body 10, which is closest to the external connector insertion part 36, and the card-type lighting unit 34 is integrated with the frame 40 via the connecting ends 38 and 39, thereby preventing warping of the frame 40 due to internal stress during heat treatment. The card-type lighting unit 34 in Figure 6 is formed by separating the connecting ends 38 and 39 and multiple connecting ends 10e from the frame 40.

[0042] The substrate sheet in Figure 7 is an integrated version of the card-type lighting unit 34 in Figure 6, with the external connector insertion parts 36 positioned opposite each other and integrated into the frame 50.

[0043] In Figure 7, the substrate sheet 45 is provided with an interconnecting end 46 between the left connector forming piece 37a of one card-type lamp unit 34 and the right connector forming piece 37b of the opposing card-type lamp unit 34, and an interconnecting end 47 between the right connector forming piece 37b of one card-type lamp unit 34 and the left connector forming piece 37a of the opposing card-type lamp unit 34. The pair of card-type lamp units 34 with opposing external connector forming pieces 36 are integrally formed with their left and right connector forming pieces 37a and 37b via the interconnecting ends 46 and 47. According to the substrate sheet 45, the interconnected ends 46 and 47, which integrate the left and right connector forming edges 37a and 37b of the card-type lighting unit 34, which are arranged opposite each other, mutually restrict warping relative to the frame 50 even after heat treatment, thereby further strengthening the prevention of warping that occurs near each external connector insertion part 36.

[0044] The card-type lighting unit 34 in Figure 7 is formed by separating the interconnecting ends 46 and 47 and the multiple connecting ends 10e from the frame 50. [Explanation of symbols]

[0045] 5. Card-type lighting unit 6. Light-emitting light source 6a~6g Light-emitting elements 0 Main board 10b~10d Outer periphery of the main circuit board 11 External connector insertion part 12 Connector forming edge 12a Left connector forming piece 12b Connector forming piece on the right side 13 Control circuit for turning light-emitting elements on and off 16. Metal plate that serves as a heat dissipation component. 20 circuit board sheets 21,22 Connecting end 23 Frame 25 circuit board sheets 26 Frame 27, 28 Interconnected ends

Claims

1. a card-type lighting unit including a polygonal substrate body having an outer periphery and a connector forming side, an external connector insertion portion formed on the connector forming side, a heat dissipation member having a linear expansion coefficient different from that of the substrate body and integrated with the substrate body, and a light-emitting element light source connected to a control circuit for turning the light on and off; a frame body that is integrated with the card-type lighting unit via connecting ends formed on the outer periphery of the polygonal substrate body; In a substrate sheet of a card-type lighting unit having A substrate sheet for a card-type lighting unit, characterized in that a connection end portion for connection to a frame body is provided on the connector forming side.

2. A plurality of light emitting elements constituting the light emitting element light source are provided on the substrate body, 2. The board sheet of a card-type lamp unit according to claim 1, wherein the control circuit for turning the lamp on and off is mounted on a main board.

3. 3. A substrate sheet for a card-type lighting unit as described in claim 1 or 2, characterized in that it has a plurality of the card-type lighting units, and each card-type lighting unit has an interconnecting end portion that interconnects each connector-forming edge instead of the connecting end portion with the frame body.

4. 3. The card-type lamp unit according to claim 1, wherein the connecting end portion is cut off to separate the card-type lamp unit from the frame of the base sheet.

5. A vehicle lamp comprising the card-type lamp unit according to claim 4.

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