Lighting fixture and manufacturing method of lighting fixture

Abstract

To provide a lighting fixture which has reduced labor and which has improved strength, and to provide a manufacturing method of the lighting fixture.SOLUTION: A lighting fixture includes: a fixture body having an opening on one surface; and a light source part arranged in the fixture body. The light source part includes: a light source module having a light source; a decorative frame made of one plate material and arranged on one surface side of the fixture body; and a diffusion cover installed on the decorative frame, and for diffusing the light from the light source. The decorative frame includes: a flange part constituted by a pair of first flat surface parts and a pair of second flat surface parts extending in parallel with each other, and formed in a rectangular frame shape in a plan view; a pair of hemming parts in which part of the pair of first flat surface parts is constituted double; a pair of holding parts extending to the upper side which is a vertical direction with respect to the pair of first flat surface parts from one end of the pair of hemming parts; and a rectangular opening part formed at a center part.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates to a lighting fixture that is attached to a ceiling to illuminate a room, and a method for manufacturing the lighting fixture. [Background technology]

[0002] Conventionally, lighting fixtures that are attached to a ceiling and illuminate a room have been provided (see, for example, Patent Document 1). The lighting fixture of Patent Document 1 includes a fixture body, a frame, a plurality of light source units, an electrical connection device, a power supply device, and a light-transmitting panel. The frame is made of a metal plate and has a frame portion and a flange portion attached to the lower end of the frame. The flange portion is composed of a main portion formed into a frame shape by providing a rectangular opening in the center of a rectangular metal plate, and an edge portion formed by bending the outer edge of the main portion upward. The frame body is assembled integrally by joining the flange portion to the lower end of the frame portion by, for example, welding, so that a portion of the main portion of the flange portion is positioned within the frame of the frame portion. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-110873 Summary of the Invention [Problem to be solved by the invention]

[0004] In the lighting fixture disclosed in Patent Document 1, the frame body has a frame portion and a flange portion, which are joined by welding, which is a time-consuming process. In addition, when the frame portion and the flange portion are joined by welding, the strength of the connection is weak, and if the fixture is painted, there is a problem that the paint may crack.

[0005] The present disclosure is intended to solve such problems, and aims to provide a lighting fixture and a method for manufacturing a lighting fixture that reduces the effort required and improves strength. [Means for solving the problem]

[0006] The lighting fixture disclosed herein comprises a fixture body having an opening on one side, and a light source unit arranged within the fixture body, the light source unit comprising a light source module having a light source, a decorative frame made of a single plate and arranged on the one side of the fixture body, and a diffusion cover installed on the decorative frame and diffusing light from the light source, the decorative frame being composed of a pair of first planar portions and a pair of second planar portions extending parallel to each other, a flange portion formed in a rectangular frame shape in a planar view, a pair of hemming portions formed by doubling portions of the pair of first planar portions, a pair of rectangular plate-shaped holding portions extending upward from one end of the pair of hemming portions in a direction perpendicular to the pair of first planar portions, and a rectangular opening formed in the center.

[0007] Further, a method for manufacturing a lighting fixture according to the present disclosure includes a lighting fixture comprising: a fixture body having an opening on one surface; and a light source unit arranged within the fixture body, the light source unit comprising a light source module having a light source; a decorative frame made of a single plate material and arranged on the one surface side of the fixture body; and a diffusion cover installed on the decorative frame and diffusing light from the light source, the decorative frame being composed of a pair of first flat surfaces and a pair of second flat surfaces extending parallel to each other, and including a flange portion formed in a rectangular frame shape in a plan view; a pair of hemming portions formed by doubling portions of the pair of first flat surfaces; and a rectangular plate-like hemming portion extending upward from one end of the pair of hemming portions in a direction perpendicular to the pair of first flat surfaces. a first step of bending the pair of first flat portions downward at a right angle at a position that extends in the same direction as the pair of first flat portions and that is a boundary between the holding portions and the hemming portion; and a second step of bending the pair of first flat portions upward halfway at a position that extends in the same direction as the pair of first flat portions and that is a boundary between the hemming portion and the first flat portion, after the first step. [Effects of the Invention]

[0008] According to the lighting fixture and the manufacturing method of the lighting fixture disclosed herein, the decorative frame has a flange portion formed in a rectangular frame shape in a plan view and a pair of rectangular plate-shaped retaining portions extending upward from one end of a pair of hemming portions in a direction perpendicular to the pair of first flat portions, and the decorative frame is made of a single plate material. Therefore, there is no need to join the flange portion and the retaining portions by welding as in the conventional method, which reduces the labor and improves the strength. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is an exploded perspective view showing a schematic overall configuration of a lighting fixture according to a first embodiment. [Figure 2] 1 is a perspective view showing a configuration of a lighting fixture according to a first embodiment. [Figure 3] 3 is an exploded perspective view of a lower portion of a light source unit including a part of a light source section according to the first embodiment. FIG. [Figure 4] 10 is an exploded perspective view of an upper portion of a light source unit including the remaining portion of the light source section and a power supply according to the first embodiment. FIG. [Figure 5] FIG. 2 is a plan view of the decorative frame according to the first embodiment. [Figure 6] FIG. 6 is an enlarged view of the portion indicated by the arrow A in FIG. 5. [Figure 7] 6 is an enlarged view of a modified example of the portion indicated by the arrow A in FIG. 5. [Figure 8] 1 is a perspective view showing a first step of a manufacturing method for a decorative frame according to the first embodiment. FIG. [Figure 9] 10 is a perspective view showing a second step of the manufacturing method of the decorative frame according to the first embodiment. FIG. [Figure 10] FIG. 2 is a perspective view showing the completed state of the decorative frame according to the first embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] An embodiment of a lighting fixture 1 according to the present disclosure will be described below with reference to the drawings. In each drawing, identical or equivalent components are designated by the same reference numerals, and this applies throughout the entire specification. Furthermore, throughout the entire specification, the direction from the floor to the ceiling, i.e., the Z1 direction of the Z direction, will sometimes be referred to as the "upper direction," and the ceiling side will sometimes be referred to as the "upper side." Similarly, the perpendicular direction from the ceiling to the floor, i.e., the Z2 direction, will sometimes be referred to as the "downward direction," and the floor side will sometimes be referred to as the "lower side." The X and Y directions are perpendicular to the Z direction. Furthermore, in the following description, the terms "inside" and "outside" (including the inside, outside, inner surface, and outer surface) may be used to describe positional relationships and directions. Unless otherwise specified, the central portion of the lighting fixture 1 is referred to as the "inside," and the outer side of the lighting fixture 1 is referred to as the "outside." Note that the relative dimensions or shapes of the components in each drawing may differ from those of the actual components.

[0011] Embodiment 1 FIG. 1 is an exploded perspective view showing a schematic overall configuration of a lighting fixture 1 according to embodiment 1. FIG. 2 is a perspective view showing the configuration of the lighting fixture 1 according to embodiment 1. Below, an outline of the mounting structure of the lighting fixture 1 and the light source unit 100 to the ceiling C will be described using FIGS. 1 and 2. The lighting fixture 1 emits light and has a fixture body 30 and a light source unit 100 having a light source section 10. The lighting fixture 1 is a ceiling-embedded lighting fixture. The lighting fixture 1 is formed in a rectangular shape when viewed in the Z direction (hereinafter referred to as a plan view).

[0012] The fixture body 30 is formed in the shape of a rectangular box that is open at the bottom. A light source unit 100 that is rectangular in plan view is disposed inside the fixture body 30. The light source unit 100 is attached to the fixture body 30 by V-springs 19 that are fixed to a decorative frame 11 (described later) of the light source section 10. Two V-springs 19 are fixed to each of a pair of first flat portions 11a1 (see FIG. 3 described later) that extend in the longitudinal direction (X direction) of the flange portion 11a of the decorative frame 11 that is formed in a rectangular frame shape. The lighting fixture 1 is configured to be attached to the fixture body 30 by attaching the V-springs 19 of the light source unit 100 to V-spring mounting brackets (not shown) that are fixed to the fixture body 30.

[0013] The lighting fixture 1 is installed so as to be embedded in an embedding hole H provided in a ceiling C. A suspension bolt B is suspended from the embedding hole H in the ceiling C. The lighting fixture 1 is embedded in the embedding hole H with the fixture body 30 suspended from the suspension bolt B. The lighting fixture 1 is installed on the ceiling so that the portion excluding the flange portion 11a is embedded in the embedding hole H and the lower end surface A of the flange portion 11a is exposed along the ceiling surface.

[0014] The outline of the mounting structure of the lighting fixture 1 to the ceiling C has been explained above, but the mounting structure is not limited to the above and can be changed as appropriate.

[0015] Fig. 3 is an exploded perspective view of a lower portion of light source unit 100 including a part of light source section 10 according to embodiment 1. Fig. 4 is an exploded perspective view of an upper portion of light source unit 100 including the remaining portion of light source section 10 according to embodiment 1 and power supply section 20. The configuration of light source unit 100 of lighting fixture 1 will be described in detail below with reference to Figs. 3 and 4.

[0016] The light source unit 100 includes a light source section 10 and a power supply section 20 disposed above the light source section 10. The light source section 10 includes a decorative frame 11, a diffusion cover 12, a protective cover 13, a first light source module 14, a light source module holding member 15, a second light source module 16, a scattering plate 17, and an elastic member 18.

[0017] (Decorative Frame 11) The decorative frame 11 is configured in a frame-like shape that penetrates in the Z direction. The decorative frame 11 is attached so as to cover the rectangular lower end of the fixture body 30. The decorative frame 11 is plate-shaped extending in the XY plane and has a flange portion 11a formed in a rectangular frame shape in a planar view. The flange portion 11a is configured with a pair of first flat portions 11a1 extending in the longitudinal direction (X direction) and a pair of second flat portions 11a2 extending in the lateral direction (Y direction). The decorative frame 11 further has a pair of hemming portions 11c formed by doubling parts of the pair of first flat portions 11a1, a pair of rectangular plate-shaped holding portions 11b extending upward (Z1 direction) from one end of the pair of hemming portions 11c, and a rectangular opening 11d formed in the center. The pair of holding portions 11b face each other in the Y direction, and the above-mentioned V-spring 19 is fixed to them. The decorative frame 11 is configured to have a flange portion 11a, a holding portion 11b, and a hemming portion 11c, for example, by bending a single metal plate material with an opening in the center (having an opening portion 11d). Note that the decorative frame 11 is not limited to being made of metal.

[0018] (Diffusion Cover 12) The diffusion cover 12 is formed in a rectangular frame shape in a plan view. The diffusion cover 12 diffuses light from a light source (a first light source module 14, described below). The diffusion cover 12 is installed on the flange portion 11a of the decorative frame 11. The diffusion cover 12 is made of, for example, a white resin, such as milky white. The diffusion cover 12 is formed in a truncated quadrangular pyramid shape with open top and bottom sides. Therefore, each of the four side surfaces of the diffusion cover 12 is inclined at a predetermined angle relative to the vertical direction. Each of the four side surfaces of the diffusion cover 12 is made of a trapezoidal diffusion plate 12a, and the length of the upper side is shorter than the length of the lower side. Furthermore, since each of the four side surfaces of the diffusion cover 12 is inclined, the position of the upper side is positioned more inward than the position of the lower side when viewed from the Z direction. As a result, the internal space of the diffusion cover 12 tapers downward. As described above, the diffusion cover 12 is formed by combining four trapezoidal diffusion plates 12a. However, the method of formation is not limited to this, and the diffusion cover 12 may be formed by integral molding.

[0019] Of the four diffusion plates 12a constituting the diffusion cover 12, three of the diffusion plates 12a have light-emitting surfaces 12a1, and the remaining diffusion plate 12a has a non-light-emitting surface 12a2. The three light-emitting surfaces 12a1 are arranged in a U-shape to match the U-shaped first light source module 14 described below. The three light-emitting surfaces 12a1 are surfaces that emit white light emitted from the first light source module 14.

[0020] A light-shielding sheet (not shown) is attached to the outer surface of the diffusion plate 12a having the non-light-emitting surface 12a2, so that light does not leak from the non-light-emitting surface 12a2.

[0021] In this way, the diffusion cover 12 has a configuration in which three light-emitting surfaces 12a1 that emit white light emitted from the first light source module 14 are combined with one non-light-emitting surface 12a2 that does not emit light. As a result, the light emitted from the diffusion cover 12 comes from three directions, and it is possible to create a visual effect with a sense of depth, as if light from outside is shining through a window frame in the sunlight or through a window frame in the shade.

[0022] An outwardly extending fixing portion 12b is provided on the upper end surface of the diffusion cover 12. The fixing portion 12b is a portion to which the protective cover 13 is fixed, and is formed in a rectangular ring shape in a plan view.

[0023] (Protective cover 13) The protective cover 13 is a transparent, light-transmitting cover formed in a plate shape, and is made of a transparent resin material such as acrylic. The protective cover 13 is rectangular in plan view. The protective cover 13 is adhered and fixed to the fixing portion 12b of the diffusion cover 12 with an adhesive. The protective cover 13 is not limited to a structure in which it is fixed to the fixing portion 12b, and may be formed by integral molding with the diffusion cover 12. The protective cover 13 is disposed so as to cover the upper opening of the diffusion cover 12, and together with the diffusion cover 12, it closes the lower opening of the fixture body 30.

[0024] The protective cover 13 is disposed opposite the light-emitting surface 17a, which is the lower surface of the scattering plate 17. The protective cover 13 is disposed at a distance from the light-emitting surface 17a in a direction perpendicular to the light-emitting surface 17a of the scattering plate 17 (Z direction). The protective cover 13 transmits light emitted from the light-emitting surface 17a on the lower side of the scattering plate 17. The protective cover 13 is a cover for preventing external foreign matter from adhering to the scattering plate 17 and for preventing scratches on the surface due to external forces. Examples of external foreign matter include dust, water, and sebum that adheres during installation.

[0025] (First light source module 14) The first light source module 14 is formed in a U-shape in plan view. That is, the first light source module 14 is configured to form three of the four sides of a rectangle. The first light source module 14 has three plate-shaped substrates 14a and a light source 14b configured with a white LED provided on each of the three substrates 14a, with the angle between adjacent substrates being 90°. In this way, the first light source module 14 is an optical module having light sources 14b.

[0026] The first light source module 14 emits white light as a first light from the light sources 14b provided on each of the three substrates 14a toward the inside of the U-shape. In this way, the first light source module 14 emits white light from the three directions that make up the U-shape. The first light source module 14 is fixed to a first holding portion 15a of the light source module holding member 15 (described later) and is disposed outside the diffusion cover 12, and emits white light toward the diffusion cover 12.

[0027] The lighting fixture 1 can be used as a lighting fixture in which white light from the first light source module 14 is emitted from the light-emitting surface 12a1 of the diffusion cover 12 and illuminates an area diagonally downward from the light-emitting surface 12a1. Note that the blue light emitted from the light-emitting surface 17a of the scattering plate 17, which will be described later, is intended to create a visual effect similar to that of a blue sky, and its luminous flux is insufficient when used for lighting. On the other hand, the light emitted from the light-emitting surface 12a1 satisfies the luminous flux required for lighting. Thus, the light intensity of the white light emitted from the light-emitting surface 12a1 differs from the light intensity of the blue light emitted from the light-emitting surface 17a of the scattering plate 17, and the light intensity of the white light is stronger than the light intensity of the blue light.

[0028] The white light emitted from the light-emitting surface 12a1 does not have to be white light of a single color temperature. Specifically, the first light source module 14 may be configured to include two types of white LEDs with different color temperatures. In this way, the first light source module 14 may include only one type of white LED as the white LED, or may include two types of white LEDs, one for daylight and one for warm colors. When the first light source module 14 includes two types of white LEDs, the dimming rates of the two types of white LEDs can be changed to emit white light of various color temperatures and various luminous fluxes from the light-emitting surface 12a1.

[0029] Furthermore, the white LEDs for daylight and the white LEDs for warm colors may be switched depending on the time of day. Specifically, for example, the white LEDs for daylight may be used during the daytime hours from 8:00 AM to 5:00 PM, and the white LEDs for warm colors may be used during other hours. This type of color tone adjustment according to time may also be performed in the second light source module 16. Note that these time periods are merely examples and are not limited to these, and may be set as appropriate.

[0030] The light distribution of the white LED used in first light source module 14 is a wide-angle type. By using a wide-angle type LED in first light source module 14, the luminous intensity of the light emitted from diffusion cover 12 can be made less likely to change even if the tilt angle of light-emitting surface 12a1 of diffusion cover 12 is changed. Therefore, the same type of white LED module can be used for diffusion covers 12 with different tilt angles.

[0031] Here, first light source module 14 has light source 14b configured with a white LED, but the color of light emitted from light source 14b is not limited, and may be changed as appropriate depending on the application of lighting fixture 1. Furthermore, light source 14b is not limited to an LED, and other light-emitting elements or light-emitting devices may be used.

[0032] (Light source module holding member 15) The light source module holding member 15 is formed in a rectangular frame shape in a plan view. The light source module holding member 15 is a portion that holds the first light source module 14 and the second light source module 16. The light source module holding member 15 is formed to extend in the Z direction and has a rectangular frame-shaped first holding portion 15a that holds the first light source module 14, and a rectangular frame-shaped second holding portion 15b that is formed to extend inward from the Z1 side end of the first holding portion 15a and holds the second light source module 16.

[0033] The first holding portion 15a is formed to extend in the Z direction and the X direction and has a pair of long side surface portions 15a1 facing each other in the Y direction, and a pair of short side surface portions 15a2 facing each other in the X direction. The first light source module 14 is fixed to the inside of a U-shaped portion of the first holding portion 15a formed by the pair of long side surface portions 15a1 and one of the pair of short side surface portions 15a2.

[0034] The second holding portion 15b extends inward from the Z1-side end of the first holding portion 15a, and its tip forms a lower guide plate 15b2. The lower guide plate 15b2 has a rectangular ring shape in plan view. A convex portion (not shown) that protrudes in the Z2 direction is formed on the surface of the lower guide plate 15b2 facing the Z1 direction, and the end face (top surface) of the convex portion serves as a support surface on which the scattering plate 17 is placed. The convex portion has a rectangular ring shape in plan view, and supports the outer periphery of each of the four sides of the scattering plate 17 from below.

[0035] The second holding portion 15b has a pair of longitudinal portions that face each other in the Y direction and extend in the X direction, and has a pair of fixing portions 15b1 to which the second light source module 16 is fixed. The pair of fixing portions 15b1 are configured in the shape of rectangular plates that extend in the X direction and the Z direction, and the second light source module 16 is fixed to the inner surface side of the pair of fixing portions 15b1.

[0036] (Second light source module 16) The second light source module 16 is configured as a plate with its longitudinal direction in the X direction, and two second light source modules 16 are provided facing each other in the Y direction. The second light source module 16 includes a long, plate-shaped substrate 16a with its longitudinal direction in the X direction and a plurality of light sources 16b configured with blue LEDs provided on the substrate 16a. Thus, the second light source module 16 is an optical module including the light sources 16b. The second light source module 16 emits blue light as the second light. The second light source module 16 emits the blue light from the light sources 16b toward a scattering plate 17 (described below). Note that, although the second light source module 16 includes the light sources 16b configured with blue LEDs in this example, the color of the light emitted from the light sources 16b is not limited and may be changed as appropriate depending on the application of the lighting device 1. Furthermore, the light sources 16b are not limited to LEDs and may be other light-emitting elements or light-emitting devices.

[0037] The second light source module 16 is fixed to a pair of fixing portions 15b1 of the second holding portion 15b of the light source module holding member 15. The second light source module 16 is fixed to the second holding portion 15b by clamping the upper end portions of the substrate 16a and the fixing portions 15b1 of the second holding portion 15b with clip-shaped fixing members 41.

[0038] (Scatter board 17) The scattering plate 17 is made of a transparent resin material such as acrylic and has a plate shape. The scattering plate 17 is formed into a rectangular shape in a plan view. The scattering plate 17 has a light-emitting surface 17a, which is the lower surface and serves as the surface from which light from the light source 16b is emitted, a back surface 17b, which is the upper surface and faces opposite to the light-emitting surface 17a, two opposing end surfaces 17c extending in the longitudinal direction, and two opposing end surfaces 17d extending in the lateral direction.

[0039] The scattering plate 17 is configured so that the outer peripheries of its four sides are supported by a support surface (not shown) of the lower guide plate 15b2 to determine its position in the vertical direction (Z direction), and so that light emitted from the light source 16b of the second light source module 16 is incident on the end surface 17c. The scattering plate 17 is supported on the support surface with a gap S between it and the protective cover 13.

[0040] The scattering plate 17 transmits the light emitted from the second light source module 16 and emits blue light from the light-emitting surface 17a, which serves as the emission surface. The scattering plate 17 contains scatterers, which are particles that scatter light. The scatterers contain, for example, silica.

[0041] The back surface 17b of the scattering plate 17 is smooth to allow for total reflection. The back surface 17b of the scattering plate 17 is preferably mirror-finished. If the back surface 17b of the scattering plate 17 is scratched during the assembly of the lighting fixture 1, total reflection will be less likely to occur at the scratched area. As a result, the part of the lower surface corresponding to the scratched area of ​​the back surface 17b may appear whitish, which may prevent the appearance of a blue sky. Therefore, in order to prevent scratches on the back surface 17b of the scattering plate 17, the upper surface of the scattering plate 17 may be covered with a reflective sheet.

[0042] Here, when covering the back surface 17b of the scattering plate 17 with a reflective sheet, if the reflective sheet is attached without leaving any gap between the back surface 17b of the scattering plate 17 and the reflective sheet, total reflection is less likely to occur on the back surface 17b of the scattering plate 17. To ensure total reflection of light on the back surface 17b of the scattering plate 17, an air layer is required between the scattering plate 17 and the reflective sheet. To form the air layer, the reflective surface of the reflective sheet facing the back surface 17b of the scattering plate 17 is matte-finished. Matte-finishing is a process that creates fine irregularities like frosted glass. By matte-finishing the reflective surface of the reflective sheet, an air layer can be created between the scattering plate 17 and the reflective sheet. Furthermore, an adhesive portion may be provided on the edge of the reflective sheet in order to fix the reflective sheet to the scattering plate 17.

[0043] (Elastic member 18) The elastic member 18 is a frame-shaped packing and is disposed between the rear surface 17b of the scattering plate 17 and a rear cover 23, which will be described later. The elastic member 18 functions as a buffer material when the lighting device 1 is shaken by an earthquake or the like.

[0044] (Power supply section 20) The power supply section 20 has a power supply unit 21, a control unit 22, and a rear cover 23. The power supply unit 21 supplies power to each of the first light source module 14 and the second light source module 16 to cause the light source 14b and the light source 16b to emit light. The control unit 22 is a device that controls the light emission of the first light source module 14 and the second light source module 16. The power supply unit 21 and the control unit 22 are housed in a power supply housing section 23a of the rear cover 23, and are fixed to the interior of the fixture body 30 together with the rear cover 23.

[0045] (Method of manufacturing decorative frame 11) FIG. 5 is a plan view of the decorative frame 11 according to the first embodiment. FIG. 6 is an enlarged view of the portion viewed from the arrow A in FIG. 5. FIG. 7 is an enlarged view of a modified example of the portion viewed from the arrow A in FIG. 5. FIG. 8 is a perspective view showing a first step of the manufacturing method of the decorative frame 11 according to the first embodiment. FIG. 9 is a perspective view showing a second step of the manufacturing method of the decorative frame 11 according to the first embodiment. FIG. 10 is a perspective view showing the completed state of the decorative frame 11 according to the first embodiment. The structure and manufacturing method of the decorative frame 11 will be described below with reference to FIGS. 5 to 10.

[0046] As shown in FIGS. 5 and 6, slits 11e extending in the Y direction and slit margins 11f extending further in the Y direction from the slits 11e are formed at the four corners (indicated by dashed lines in FIG. 5) of the opening 11d of the decorative frame 11. The slits 11e are formed to allow the pair of first flat portions 11a1 to be bent. The slit margins 11f are formed to facilitate bending the pair of first flat portions 11a1. As shown in FIG. 6, the slit margins 11f have a rectangular shape. Alternatively, as shown in FIG. 7, the slit margins 11f have an arc-shaped (fan-shaped) shape. A rectangular slit margin 11f facilitates punching, while an arc-shaped (fan-shaped) slit margin 11f provides improved design. As shown in FIGS. 6 and 7, the width W1 of the slits 11e is 1 mm or more to facilitate workability. The length W2 of the slit margin 11f is 1 mm or less to facilitate design.

[0047] Next, a manufacturing method of the decorative frame 11 will be described. The manufacturing method of the decorative frame 11 consists of a first step and a second step. As shown in Fig. 8, in the first step, a pair of first flat portions 11a1 of the decorative frame 11 having the opening 11d are bent 90° (at a right angle) in the Z2 direction at a position (dashed line in Fig. 8) that is a boundary between the holding portion 11b extending in the X direction and the hemming portion 11c (see the hollow arrow in Fig. 8). Next, in the second step, after the first step, as shown in Fig. 9, the pair of first flat portions 11a1 extending in the X direction of the flange portion 11a are bent 180° (half a circumference) in the Z1 direction at a position (viewed from arrow B in Fig. 9) that is a boundary between the hemming portion 11c extending in the X direction and the first flat portion 11a1 (see the hollow arrow in Fig. 9). Here, slits 11f are formed at the four corners of the opening 11d of the decorative frame 11, making it easier to bend the pair of first flat portions 11a1 at the boundary between the hemming portion 11c and the first flat portion 11a1. As described above, by performing the first and second steps, a pair of hemming portions 11c, each of which is formed by doubling a portion of the pair of first flat portions 11a1, and a pair of rectangular plate-shaped retaining portions 11b extending in the Z1 direction from one end of the pair of hemming portions 11c are formed in the decorative frame 11, as shown in FIG. 10. Note that, in the first step, the pair of first flat portions 11a1 are bent 90° (at a right angle) in the Z2 direction, but this does not have to be strictly 90°. Furthermore, in the second step, the pair of first flat portions 11a1 are bent 180° (half a circumference) in the Z1 direction, but this does not have to be strictly 180°.

[0048] As described above, by forming the slits 11e and the slit margins 11f at the four corners of the opening 11d of the decorative frame 11, it is not necessary to weld the separate retaining portion 11b to the flange portion 11a. The retaining portion 11b can be integrally formed with the flange portion 11a, and post-welding finishing is also unnecessary. This reduces the number of processing steps and reduces manufacturing effort. Furthermore, since manual welding and finishing are no longer necessary, yields are improved and quality is stabilized. Furthermore, since the decorative frame 11 can be constructed from a single sheet of metal, there are no joints between the parts, improving the design compared to welding parts. Furthermore, sheet metal parts that would have been discarded when forming the opening 11d can be effectively reused as the retaining portion 11b. Furthermore, the decorative frame 11 can be processed using common processing machines such as a bender, enhancing versatility.

[0049] As described above, the lighting fixture 1 according to embodiment 1 comprises a fixture body 30 having an opening on one side thereof, and a light source unit 10 arranged within the fixture body 30. The light source unit 10 comprises a light source module having a light source, a decorative frame 11 made of a single plate material and arranged on one side of the fixture body 30, and a diffusion cover 12 installed on the decorative frame 11 and diffusing light from the light source. The decorative frame 11 comprises a pair of first flat surfaces 11a1 and a pair of second flat surfaces 11a2 extending parallel to each other, a flange portion 11a formed in a rectangular frame shape in plan view, a pair of hemming portions 11c formed by doubling a portion of the pair of first flat surfaces 11a1, a pair of rectangular plate-like holding portions 11b extending upward from one end of the pair of hemming portions 11c in a direction perpendicular to the pair of first flat surfaces 11a1, and a rectangular opening 11d formed in the center.

[0050] Furthermore, a manufacturing method of lighting fixture 1 according to embodiment 1 includes a lighting fixture including fixture body 30 having an opening on one surface thereof and light source unit 10 arranged within fixture body 30, light source unit 10 including a light source module having a light source, decorative frame 11 made of a single plate material and arranged on one surface side of fixture body 30, and diffusion cover 12 installed on decorative frame 11 and diffusing light from the light source, decorative frame 11 including a pair of first flat surface portions 11a1 and a pair of second flat surface portions 11a2 extending parallel to each other, flange portion 11a formed in a rectangular frame shape in plan view, a pair of hemming portions 11c formed by doubling a part of pair of first flat surface portions 11a1, and a rectangular plate-like hemming portion 11b extending upward from one end of the pair of hemming portions 11c in a direction perpendicular to the pair of first flat surface portions 11a1. A manufacturing method for a lighting fixture (1) having a pair of holding portions (11b) and a rectangular opening (11d) formed in the center, with slits (11e) extending in the direction in which the pair of second flat portions (11a2) extend and slit margins (11f) extending further from the slits (11e) in the same direction as the slits (11e) is formed at the four corners of the opening (11d) of the decorative frame (11), the manufacturing method comprising: a first step of bending the pair of first flat portions (11a1) downward at a right angle at a position that is a boundary between the holding portions (11b) and the hemming portion (11c) that extends in the same direction as the pair of first flat portions (11a1); and a second step of bending the pair of first flat portions (11a1) upward halfway at a position that is a boundary between the hemming portion (11c) and the first flat portion (11a1) that extends in the same direction as the pair of first flat portions (11a1) after the first step.

[0051] According to the lighting fixture 1 and the manufacturing method of the lighting fixture 1 according to the first embodiment, the decorative frame 11 has a flange portion 11a formed in a rectangular frame shape in a plan view, and a pair of rectangular plate-like retaining portions 11b extending upward from one end of a pair of hemming portions 11c in a direction perpendicular to a pair of first flat portions 11a1, and the decorative frame 11 is made of a single plate material. Therefore, there is no need to join the flange portion and the retaining portion by welding as in the conventional case, which reduces the effort and improves the strength.

[0052] In the method for manufacturing lighting device 1 according to embodiment 1, width W1 of slit 11e is equal to or greater than 1 mm.

[0053] According to the method for manufacturing the lighting device 1 of the first embodiment, the width W1 of the slit 11e is set to 1 mm or more, thereby improving workability.

[0054] In addition, in lighting device 1 according to embodiment 1, length W2 of slit margin 11f is 1 mm or less.

[0055] In the method for manufacturing lighting device 1 according to embodiment 1, length W2 of slit margin 11f is 1 mm or less.

[0056] According to the lighting fixture 1 and the method for manufacturing the lighting fixture 1 according to the first embodiment, the length W2 of the slit margin 11f is set to 1 mm or less, thereby improving the design.

[0057] In lighting device 1 according to embodiment 1, slit margin 11f has a rectangular shape.

[0058] In the method for manufacturing lighting device 1 according to embodiment 1, slit margin 11f has a rectangular shape.

[0059] According to the lighting fixture 1 and the manufacturing method for the lighting fixture 1 according to the first embodiment, the slit allowance 11f is formed in a rectangular shape, which makes it easier to perform punch processing.

[0060] In lighting device 1 according to embodiment 1, slit margin 11f has an arc shape.

[0061] In the method for manufacturing lighting device 1 according to embodiment 1, slit margin 11f has an arc shape.

[0062] According to the lighting fixture 1 and the method for manufacturing the lighting fixture 1 of the first embodiment, the slit margin 11f is formed in an arc shape, thereby improving the design.

[0063] Although the present disclosure has been described above based on the first embodiment, the present disclosure is not limited to the configuration of the first embodiment. For example, lighting device 1 may be provided with a light-shielding sheet to prevent light leakage from various components. Furthermore, although lighting device 1 is described in the first embodiment as being oriented with the Z direction facing up and down, it may be installed at an angle or attached to a wall, for example. In other words, we would like to emphasize that the gist (technical scope) of the present disclosure also includes various modifications, applications, and uses that may be made by a person skilled in the art as needed.

[0064] Various aspects of the present disclosure are described below.

[0065] (Appendix 1) a device body having an opening on one side; a light source unit disposed within the fixture body, The light source unit is a light source module having a light source; A decorative frame made of a single plate material and arranged on the one surface side of the fixture body; a diffusion cover that is placed on the decorative frame and that diffuses light from the light source, The decorative frame is a flange portion formed in a rectangular frame shape in a plan view, the flange portion including a pair of first flat portions and a pair of second flat portions extending parallel to each other; a pair of hemming portions formed by doubling portions of the pair of first flat portions; a pair of rectangular plate-shaped holding portions extending upward from one end of the pair of hemming portions in a direction perpendicular to the pair of first flat portions; A rectangular opening formed in the center thereof Lighting fixtures. (Appendix 2) Slits extending in the direction in which the pair of second flat portions extend are formed at four corners of the opening of the decorative frame. 1. A lighting fixture as described in Appendix 1. (Appendix 3) The length of the slit is 1 mm or less 1. A lighting fixture as described in Appendix 2. (Appendix 4) The slit has a rectangular shape. 1. A luminaire as described in Appendix 2 or 3. (Appendix 5) The slit has an arc shape. 1. A luminaire as described in Appendix 2 or 3. (Appendix 6) a device body having an opening on one side; a light source unit disposed within the fixture body, The light source unit is a light source module having a light source; A decorative frame made of a single plate material and arranged on the one surface side of the device body; a diffusion cover that is placed on the decorative frame and that diffuses light from the light source, The decorative frame is a flange portion formed in a rectangular frame shape in a plan view, the flange portion including a pair of first flat portions and a pair of second flat portions extending parallel to each other; a pair of hemming portions formed by doubling portions of the pair of first flat portions; a pair of rectangular plate-shaped holding portions extending upward from one end of the pair of hemming portions in a direction perpendicular to the pair of first flat portions; a rectangular opening formed in the center, a manufacturing method of a lighting fixture, in which slits extending in a direction in which the pair of second flat portions extend and slit margins extending further from the slits in the same direction as the slits are formed at four corners of the opening of the decorative frame, a first step of bending the pair of first flat portions downward at a right angle at a boundary between the holding portion and the hemming portion, the boundary extending in the same direction as the pair of first flat portions; and a second step of bending the pair of first flat portions upward halfway at a boundary between the hemming portion and the first flat portion, the boundary extending in the same direction as the pair of first flat portions, after the first step. Manufacturing method of lighting fixtures. (Appendix 7) The width of the slit is 1 mm or more. 6. A method for manufacturing a lighting fixture as described in Appendix 6. (Appendix 8) The length of the slit is 1 mm or less A method for manufacturing a lighting fixture according to appendix 6 or 7. (Appendix 9) The slit has a rectangular shape. A method for manufacturing a lighting fixture according to any one of Supplementary Notes 6 to 8. (Appendix 10) The slit has an arc shape. A method for manufacturing a lighting fixture according to any one of Supplementary Notes 6 to 8. [Explanation of symbols]

[0066] 1 Lighting fixture, 10 Light source part, 11 Decorative frame, 11a Flange part, 11a1 First flat part, 11a2 Second flat part, 11b Holding part, 11c Hemming part, 11d Opening, 11e Slit, 11f Slit margin, 12 Diffusion cover, 12a Diffusion plate, 12a1 Light-emitting surface, 12a2 Non-light-emitting surface, 12b Fixing part, 13 Protective cover, 14 First light source module, 14a Board, 14b Light source, 15 Light source module holding member, 15a First holding part, 15a1 Long side part, 15a2 Short side part, 15b Second holding part, 15b1 Fixing part, 15b2 Lower guide plate, 16 Second light source module, 16a Board, 16b Light source, 17 Scattering plate, 17a Light-emitting surface, 17b Back surface, 17c End surface, 17d end surface, 18 elastic member, 19 V spring, 20 power supply section, 21 power supply unit, 22 control unit, 23 rear cover, 23a power supply housing section, 30 fixture body, 41 fixing member, 100 light source unit, A bottom end surface, B hanging bolt, C ceiling, H embedding hole, S gap, W1 width.

Claims

1. a device body having an opening on one side; a light source unit disposed within the fixture body, The light source unit is a light source module having a light source; a decorative frame made of a single plate material and arranged on the one surface side of the fixture body; a diffusion cover that is placed on the decorative frame and that diffuses light from the light source, The decorative frame is a flange portion formed in a rectangular frame shape in a plan view, the flange portion including a pair of first flat portions and a pair of second flat portions extending parallel to each other; a pair of hemming portions formed by doubling portions of the pair of first flat portions; a pair of rectangular plate-shaped holding portions extending upward from one end of the pair of hemming portions in a direction perpendicular to the pair of first flat portions; A rectangular opening formed in the center thereof Lighting fixtures.

2. Slits extending in the direction in which the pair of second flat portions extend are formed at four corners of the opening of the decorative frame.

10. The lighting fixture of claim 1.

3. The length of the slit is 1 mm or less.

3. A lighting fixture according to claim 2.

4. The slit has a rectangular shape.

4. A lighting fixture according to claim 2 or 3.

5. The slit has an arc shape.

4. A lighting fixture according to claim 2 or 3.

6. a device body having an opening on one side; a light source unit disposed within the fixture body, The light source unit is a light source module having a light source; a decorative frame made of a single plate material and arranged on the one surface side of the fixture body; a diffusion cover that is placed on the decorative frame and that diffuses light from the light source, The decorative frame is a flange portion formed in a rectangular frame shape in a plan view, the flange portion including a pair of first flat portions and a pair of second flat portions extending parallel to each other; a pair of hemming portions formed by doubling portions of the pair of first flat portions; a pair of rectangular plate-shaped holding portions extending upward from one end of the pair of hemming portions in a direction perpendicular to the pair of first flat portions; a rectangular opening formed in the center, a method for manufacturing a lighting fixture, wherein slits extending in a direction in which the pair of second planar portions extend and slit margins extending further from the slits in the same direction as the slits are formed at four corners of the opening of the decorative frame, a first step of bending the pair of first flat portions downward at a right angle at a boundary between the holding portion and the hemming portion, the boundary extending in the same direction as the pair of first flat portions; a second step of bending the pair of first flat portions upward by half a circumference at a position that is a boundary between the hemming portion and the first flat portion and that extends in the same direction as the pair of first flat portions, after the first step; Manufacturing method of lighting fixtures.

7. The width of the slit is 1 mm or more. A method for manufacturing the lighting fixture according to claim 6.

8. The length of the slit is 1 mm or less. A method for manufacturing a lighting fixture according to claim 6 or 7.

9. The slit has a rectangular shape. A method for manufacturing a lighting fixture according to claim 6 or 7.

10. The slit has an arc shape. A method for manufacturing a lighting fixture according to claim 6 or 7.

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