Light-emitting module, lighting fixture, and method for manufacturing light-emitting module

Abstract

To provide a light-emitting module capable of arranging a lighting fixture that is configured more simply, and to provide a lighting fixture and a method for manufacturing a light-emitting module.SOLUTION: A light-emitting module includes: a plurality of light-emitting devices; and a single mounting substrate in which one or more substrate parts having a preset substrate external dimension are incorporated and to which the plurality of light-emitting devices are mounted, thereby reducing the number of light-emitting modules to be attached to such as a lighting fixture.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a light-emitting module, a lighting fixture, and a method for manufacturing a light-emitting module, and more particularly to improving the efficiency of manufacturing a light-emitting module. [Background technology]

[0002] Conventionally, there are lighting fixtures configured by housing one or more light-emitting modules, each equipped with multiple LEDs that serve as light sources, in a unit body (see, for example, Patent Document 1). When selling lighting fixtures, lighting fixtures are often offered in a lineup of multiple classes with different outputs, such as luminous flux values. In such cases, lighting fixtures with higher outputs are offered in a lineup by adjusting the number of light-emitting modules housed in the unit body, for example by increasing the number of light-emitting modules. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2017-073261 Summary of the Invention [Problem to be solved by the invention]

[0004] However, since each light-emitting module is configured independently, when a lighting fixture is constructed by combining multiple light-emitting modules, the number of wiring members and fixing members increases, resulting in a problem of a complex lighting fixture configuration.

[0005] Therefore, an object of the present invention is to provide a light-emitting module and a lighting device that can provide a range of lighting devices with simpler configurations, as well as a method for manufacturing the light-emitting module. [Means for solving the problem]

[0006] The light-emitting module according to the present disclosure comprises a plurality of light-emitting elements and a single mounting board on which the plurality of light-emitting elements are mounted, the mounting board being integrally formed of one or more substrate parts having predetermined board outer dimensions.

[0007] Furthermore, a lighting fixture according to the present disclosure includes the above-described light-emitting module and a mounting portion to which one light-emitting module is attached.

[0008] The method for manufacturing a light-emitting module according to the present disclosure includes an original substrate manufacturing process in which a plurality of substrate portions, which are the smallest unit of the substrate outer dimensions of the mounting substrate on which light-emitting elements are mounted, are integrally formed to obtain an original substrate, and a dividing groove process in which dividing grooves or dividing through holes are formed at the boundaries between the substrate portions on the upper and lower surfaces of the original substrate to match the size of the mounting substrate formed based on the number of light-emitting elements to be mounted. [Effects of the Invention]

[0009] According to the present disclosure, by configuring a light-emitting module using a single mounting board that integrates one or more substrate sections, with the substrate section being the smallest unit of the substrate shape, depending on the output, it is possible to reduce the number of light-emitting modules that need to be attached to the mounting section of a lighting fixture, etc. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a diagram showing an example of the configuration of a light-emitting module 1 according to a first embodiment. [Figure 2] 2A to 2C are diagrams illustrating examples of light-emitting modules 1 according to each class in the first embodiment. [Figure 3] 3 is a diagram showing a flow of a manufacturing process for the light-emitting module 1 according to the first embodiment. [Figure 4] 5A to 5C are diagrams illustrating the effects of the light-emitting module 1 according to the first embodiment. [Figure 5] FIG. 11 is an external perspective view of a lighting fixture 1000 according to a third embodiment. [Figure 6]FIG. 10 is an exploded perspective view of a lighting device 1000 according to a third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] A light-emitting module 1 and a lighting device 1000 according to an embodiment of the present disclosure will be described below with reference to the drawings. The configurations of the components shown in the specification are merely illustrative and are not limited to these descriptions. Furthermore, in the following figures, including FIG. 1, the relative dimensional relationships and shapes of the components may differ from those in the actual product. In the drawings, identical reference numerals denote identical or equivalent components, and this rule applies throughout the specification. To facilitate understanding, directional terms or orientations are used as appropriate. However, these notations are used for convenience of explanation and do not limit the placement, direction, or orientation of devices, devices, or components. Examples of terms that represent directions or orientations include up, down, right, left, front, back, front, and back.

[0012] Embodiment 1 Fig. 1 is a diagram showing an example of the configuration of a light emitting module 1 according to embodiment 1. The light emitting module 1 in Fig. 1 shows a light emitting module used in a high-output class lighting fixture or the like (hereinafter referred to as a high-output class light emitting module, etc.). As shown in Fig. 1, the light emitting module 1 according to embodiment 1 has a plurality of light emitting elements 10 and a mounting substrate 20.

[0013] The light emitting element 10 serving as the light source is an electronic component that emits light when supplied with power. The light emitting element 10 in the first embodiment is, for example, a light emitting diode (hereinafter referred to as LED) element. However, the light emitting element 10 is not limited to an LED element, and may be a solid-state laser element, a semiconductor laser element, an organic EL element, or the like. The number of light emitting elements 10 varies depending on the class, and a light emitting module in a high-power class has a greater number of light emitting elements 10 than a light emitting module in a low-power class.

[0014] The mounting substrate 20 mounts the light emitting elements 10. As will be described later, the mounting substrate 20 is obtained by dividing the original substrate 40 into multiple pieces. The mounting substrate 20 in the first embodiment is configured by laminating, for example, an insulating layer 21 made of an insulating material such as epoxy resin and copper foil on a base substrate made of a metal material such as aluminum. Then, by processing the copper foil, a metal printed wiring 22 is formed on the mounting substrate 20. A connector 23 is provided on the metal printed wiring 22. The connector 23 is, for example, a connection terminal to which a harness 30, which is an electrical wiring to an external device that receives a power supply, is connected. Here, the insulating layer 21 may have multiple layers that are applied multiple times during the manufacturing process, for example, as a pinhole prevention measure. The mounting substrate 20 may also be made of other materials, such as a glass cloth-glass nonwoven fabric substrate epoxy resin copper-clad laminate or a glass cloth substrate epoxy resin copper-clad laminate.

[0015] Furthermore, the mounting board 20 in the first embodiment has one or more rectangular board portions 24 with preset board outer dimensions. Therefore, when the mounting board 20 has multiple board portions 24, the board outer dimensions of each board portion are the same. Each board portion 24 is the smallest structural unit of the board that becomes the mounting board 20. Each board portion 24 has a connector 23, a screw mounting hole 25, and a screw notch 26. The screw mounting hole 25 is a through-hole through which a fastener such as a screw or a screw (not shown) is inserted for attachment. The screw notch 26 is a notch through which a fastener such as a screw or a screw (not shown) is inserted for attachment.

[0016] The mounting board 20 in the first embodiment is formed by integrating a number of board units 24 corresponding to the class. The mounting board 20 in the light-emitting module 1 in FIG. 1 is a light-emitting module of a high-output class, and therefore has two board units 24. By integrating a number of board units 24 corresponding to the class into a single mounting board 20, it is possible to configure the light-emitting module 1 while ensuring the board area required for the number of light-emitting elements 10 used in each class. Furthermore, the single mounting board 20 can also be integrated with the connectors 23, screw mounting holes 25, and screw notches 26.

[0017] Here, it is assumed that two corners in the short direction of the substrate portion 24 have different shapes. The difference in the shapes of the corners is not particularly limited. For example, as shown in FIG. 1, one corner may have a rounded shape and the other may have a chamfered shape. This relationship also applies when multiple substrate portions 24 are integrated, resulting in different corner shapes. Having two corners in the short direction of the substrate portion 24 that are different can prevent mistakes in mounting the light-emitting module 1 in the wrong position when manufacturing a lighting fixture.

[0018] FIG. 2 is a diagram illustrating an example of a light emitting module 1 according to each class of the first embodiment. FIGS. 2(a) to 2(d) respectively show light emitting modules 1 in a high-output class with a large luminous flux value to a low-output class with a small luminous flux value. For example, as shown in FIGS. 2(a) and 2(b), a light emitting module 1 in a high-output class has a mounting substrate 20 formed by two substrate units 24. The mounting substrates 20 in FIGS. 2(a) and 2(b) have the same size, but differ in the number of light emitting elements 10, etc. Furthermore, as shown in FIGS. 2(c) and 2(d), a light emitting module in a low-output class has a mounting substrate 20 formed by a single substrate unit 24. The mounting substrates 20 in FIGS. 2(c) and 2(d) also have the same size, but differ in the number of light emitting elements 10, etc.

[0019] FIG. 3 is a diagram showing the flow of the manufacturing process of the light-emitting module 1 according to the first embodiment. FIG. 3(a) is a diagram showing an original substrate 40 integrated with substrate portions 24 manufactured from the shape of a mold. As shown in FIG. 3(a), the original substrate 40 is manufactured using a mold, with multiple substrate portions 24 integrated together. Therefore, the original substrate 40 also becomes an aggregate of multiple mounting substrates 20 integrated together. Here, FIG. 3(a) shows a mold for the original substrate 40 in which four substrate portions 24 are integrally formed, but the number of substrate portions 24 integrally formed is not particularly limited. Furthermore, holes that serve as screw mounting holes 25 and screw notches 26 are formed in the original substrate 40, corresponding to each substrate portion 24.

[0020] Next, in order to divide the original substrate 40 into a plurality of mounting substrates 20, dividing grooves 41 are formed on the upper and lower surfaces of the original substrate 40 at portions that define boundaries between the substrate portions 24 of the two mounting substrates 20. Here, in the first embodiment, the dividing grooves 41 are V-shaped grooves. As shown in FIG. 3(b-1), when manufacturing a mounting substrate 20 for a high-power light-emitting module 1, the original substrate 40 is divided into two, so two dividing grooves 41 are provided in the original substrate 40. On the other hand, as shown in FIG. 3(b-2), when manufacturing a mounting substrate 20 for a low-power light-emitting module 1, the original substrate 40 is divided into four, so four dividing grooves 41 are provided in the original substrate 40. This allows a plurality of mounting substrates 20 of the same shape to be manufactured from a single original substrate 40.

[0021] Furthermore, as shown in FIGS. 3(c-1) and 3(c-2), the copper foil of the original substrate 40 is processed to form metal printed wiring 22 and connectors 23 on the mounting substrate 20. Furthermore, light emitting elements 10 are mounted. In FIGS. 3(c-1) and 3(c-2), the light emitting elements 10 are shown on one mounting substrate 20 of the original substrate 40, but in reality, the light emitting elements 10 are mounted on all mounting substrates. Then, the original substrate 40 is divided along the dividing grooves 41 to manufacture light emitting modules 1 according to the class, as shown in FIGS. 3(d-1) and 3(d-2). The holes formed on the dividing grooves 41 are divided to form screw notches 26.

[0022] As described above, according to the first embodiment, the substrate section 24 is the smallest unit of the substrate shape, and the light-emitting module 1 is configured using a single mounting substrate 20 that integrates one or more substrate sections 24, for example, depending on the output of the lighting fixture to which the light-emitting module 1 is to be attached. This makes it possible to adjust the number of light-emitting elements 10 that can be mounted on a single mounting substrate 20, and increase the number of light-emitting elements 10 per light-emitting module 1, thereby making it possible to reduce the number of light-emitting modules 1 that are attached to the mounting section of a lighting fixture in the high-output class, for example.

[0023] FIG. 4 is a diagram illustrating the effect of the light-emitting module 1 according to the first embodiment. As shown in FIG. 4(b), when attempting to achieve light-emitting capability in a high-power class using light-emitting modules corresponding to two low-power classes, it is necessary to use multiple light-emitting modules. In this case, since each light-emitting module is independent, each light-emitting module needs to be attached to a mounting plate (not shown) of the lighting fixture using fasteners (not shown) such as screws, and also needs to be connected to a lighting device (not shown) using a harness 30. By configuring the light-emitting module 1 according to the first embodiment shown in FIG. 4(a) using a single mounting board 20, it is possible to reduce the number of screws, connectors 23, and harnesses 30 required for attaching the light-emitting module 1.

[0024] Furthermore, by dividing the original substrate 40 according to the number of substrate portions 24, different classes of mounting substrates 20 can be manufactured from the original substrate 40. This allows the mounting substrates 20 of the light-emitting modules 1 and the molds used for manufacturing the substrates to be standardized.

[0025] Furthermore, the original substrate 40 has V-shaped dividing grooves 41 on the upper and lower surfaces of the boundary between the substrate portions 24 that are between the two mounting substrates 20 to be divided, making it easy to divide the original substrate 40.

[0026] Furthermore, the original substrate 40 has a hole that spans between adjacent substrate portions 24. This hole serves as a screw attachment hole 25 when not separated by the separating groove 41, and serves as a screw notch 26 when separated.

[0027] Furthermore, the mounting board 20 and the original board 40 are made from a substrate in which copper foil, which will become the insulating layer 21 and the metal printed wiring 22, is laminated on a metal plate, a glass cloth-glass nonwoven fabric substrate epoxy resin copper-clad laminate, or a glass cloth substrate epoxy resin copper-clad laminate. This makes it possible to form the mounting board 20 with printed wiring.

[0028] Furthermore, the two corners that form a pair aligned in the short direction of each substrate portion 24 and the mounting substrate 20 have different shapes. This makes it possible to prevent the light-emitting module 1 from being mounted in the wrong direction when it is attached to a lighting fixture.

[0029] Embodiment 2 In the first embodiment described above, the dividing groove 41 is formed in the original substrate 40 to facilitate division into the respective mounting substrates 20, but this is not limiting. For example, instead of the dividing groove 41, a dividing through hole or the like may be formed in the original substrate 40 at a portion that will be the boundary between the substrate portions of the two mounting substrates to be divided. The through hole may be a slit (long hole) or the like.

[0030] Embodiment 3 FIG. 5 is an external perspective view of a lighting device 1000 according to a third embodiment. FIG. 6 is an exploded perspective view of the lighting device 1000 according to the third embodiment. In the third embodiment, a lighting device 1000 having the light-emitting module 1 described in the first and second embodiments will be described. Here, the surface of the lighting device 1000 that emits light will be referred to as the top surface, and the surface opposite to the top surface will be referred to as the bottom surface. The direction from the top surface to the bottom surface or the direction from the bottom surface to the top surface will be referred to as the up-down direction. Furthermore, the direction perpendicular to the up-down direction, namely, the long side direction of the light source unit 200, will be referred to as the left-right direction. The direction perpendicular to the up-down direction and the left-right direction, namely, the short side direction of the light source unit 200, will be referred to as the depth direction.

[0031] Illumination device 1000 in the third embodiment is, for example, a floodlight used for outdoor lighting. As shown in Fig. 5 , illumination device 1000 includes support part 100 attached to a mounting base or a mounting part (not shown) such as a pole, light source unit 200 held by support part 100, and electric wire 300 connected to light source unit 200.

[0032] <Support part 100> 5 and 6, the support part 100 is, for example, a member formed into a U-shape by bending a metal plate, and has a fixed part 110 having a plurality of mounting holes 111 formed therein and two arms 120 extending perpendicularly from both ends of the fixed part 110. The support part 100 is fixed to a mounting target by passing fasteners (not shown), such as bolts, through the plurality of mounting holes 111 formed in the fixed part 110. Furthermore, the arms 120 are fixed to the side of the light source unit 200 by fasteners 130, such as bolts, so that the support part 100 is attached to the light source unit 200 so as to be rotatable about the fasteners 130 as an axis.

[0033] <Light source unit 200> 6, the light source unit 200 includes a light source section 2000 that emits light, a power supply section 3000 that supplies power to the light source section 2000, a main body section 4000 that holds the light source section 2000 and the power supply section 3000, and a drop prevention section 5000 that is attached to the main body section 4000. The light source section 2000 includes a cover frame 210, a cover 220, a lens 230, a light-emitting module 1, and an attachment plate 240.

[0034] The cover frame 210 is made of a steel plate processed into a rectangular frame shape. The cover frame 210 holds the cover 220 and is attached to the main body 4000 with fasteners 211 such as screws. The cover 220 is made of rectangular tempered glass, and water-tight packings 221 are provided on the four sides of the cover 220. The lens 230 is disposed on the optical axis of the light-emitting module 1 and controls the direction of travel of the light emitted from the light-emitting module 1. The lens 230 is attached to a mounting plate 240 with fasteners 231 such as screws.

[0035] The light-emitting module 1 is the same as that described in the first and second embodiments. In particular, the light-emitting module 1 in the third embodiment has a plurality of light-emitting elements 10 arranged in a matrix. The light-emitting elements 10 are, for example, surface-mount or COB-type LED elements that emit daylight white light. Here, the arrangement of the light-emitting elements 10 is not limited to a matrix, and they may be arranged radially on the mounting substrate 20. The light-emitting module 1 is attached to the mounting plate 240 by fasteners 232 such as screws. The mounting plate 240 is made of, for example, a metal plate made of aluminum, and is attached to the mounting portion 411 of the main body 4000 by fasteners 241 such as screws with the lens 230 and the light-emitting module 1 attached thereto.

[0036] The power supply unit 3000 has a lighting device 310 and a lighting board 320. The lighting device 310 is electrically connected to a plurality of light-emitting elements 10 by wiring (not shown), and supplies power to light the plurality of light-emitting elements 10. The lighting board 320 holds the lighting device 310, and is attached to the main body unit 4000 by fasteners (not shown), such as screws. An electric wire 300 is connected to a terminal block of the lighting board 320, and power from an external commercial power source is supplied to the lighting device 310 via the electric wire 300.

[0037] 6, main body 4000 has housing 410 and fin section 420. Housing 410 and fin section 420 of main body 4000 are integrally formed by aluminum die casting.

[0038] Housing 410 has a box shape with an open top. Mounting portion 411 for mounting mounting plate 240 is provided inside housing 410. In addition, flange 412 for mounting cover 220 and cover frame 210 is provided around the opening of housing 410.

[0039] <Wire 300> The electric wire 300 is a lead wire or a cabtyre cable, one end of which is connected to a power supply unit 3000 housed inside the housing 410, and the other end of which is drawn out to the outside of the housing 410 and connected to a commercial power source or the like.

[0040] As described above, lighting fixture 1000 in embodiment 3 is configured using light-emitting module 1 described in embodiment 1 etc. Therefore, the number of wires connecting light-emitting module 1 and lighting device 310 etc. can be reduced, and lighting fixture 1000 can be easily assembled.

[0041] Various aspects of the present disclosure are summarized below as appendices.

[0042] (Appendix 1) A plurality of light-emitting elements; a single mounting substrate on which one or more substrate parts having preset substrate outer dimensions are integrally formed and on which a plurality of the light emitting elements are mounted; A light emitting module comprising: (Appendix 2) The mounting substrate is divided into a plurality of pieces from an original substrate, The light-emitting module according to claim 1, wherein the original substrate has a V-shaped dividing groove on the upper and lower surfaces of the boundary between the substrate portions of the two mounting substrates to be divided. (Appendix 3) The mounting substrate is divided into a plurality of pieces from an original substrate, 2. The light-emitting module according to claim 1, wherein the original substrate has a through-hole for division at a boundary between the substrate portions of the two mounting substrates to be divided. (Appendix 4) 4. The light-emitting module according to claim 1, wherein the substrate portion has screw holes for receiving screws. (Appendix 5) The light-emitting module according to any one of claims 1 to 4, wherein the mounting substrate, which is integrally formed from a plurality of the substrate portions, has a hole extending between adjacent substrate portions through which a fixing member for attaching the mounting substrate is inserted. (Appendix 6) The light-emitting module according to any one of appendices 1 to 5, wherein the mounting substrate is made of a substrate in which an insulating layer and copper foil are laminated on a metal plate, a glass cloth-glass nonwoven fabric substrate epoxy resin copper-clad laminate, or a glass cloth substrate epoxy resin copper-clad laminate. (Appendix 7) 7. The light emitting module according to claim 1, wherein a pair of corners arranged in a lateral direction of the mounting substrate have different shapes. (Appendix 8) A light-emitting module according to any one of Supplementary Note 1 to Supplementary Note 7; a mounting portion to which one of the light-emitting modules is mounted; A lighting fixture comprising: (Appendix 9) 9. The lighting fixture according to claim 8, wherein the mounting portion is made of sheet metal. (Appendix 10) an original substrate manufacturing process for integrally forming a plurality of substrate portions, which are the minimum unit of the substrate outer dimensions of a mounting substrate on which light-emitting elements are mounted, to obtain an original substrate; a dividing groove process of forming dividing grooves or dividing through holes at portions that become boundaries between the substrate portions on the upper and lower surfaces of the original substrate in accordance with the size of the mounting substrate that is formed based on the number of light-emitting elements to be mounted; A method for manufacturing a light emitting module having the above structure. [Explanation of symbols]

[0043] 1 light emitting module, 10 light emitting element, 20 mounting board, 21 insulating layer, 22 metal printed wiring, 23 connector, 24 board portion, 25 screw mounting hole, 26 screw notch, 30 harness, 40 base board, 41 dividing groove, 100 support portion, 110 fixing portion, 111 mounting hole, 120 arm, 130, 211, 231, 232, 241 fixing device, 200 light source unit, 210 cover frame, 220 cover, 221 packing, 230 lens, 240 mounting plate, 300 electric wire, 310 lighting device, 320 lighting board, 410 housing, 411 mounting portion, 412 flange, 420 fin portion, 1000 lighting fixture, 2000 light source portion, 3000 power supply portion, 4000 Main body, 5000 fall prevention part.

Claims

1. A plurality of light-emitting elements; a single mounting substrate on which one or more substrate portions having preset substrate outer dimensions are integrally formed and on which a plurality of the light-emitting elements are mounted; A light emitting module comprising:

2. The mounting substrate is divided into a plurality of pieces from an original substrate, The light emitting module according to claim 1 , wherein the original substrate has V-shaped dividing grooves on the upper and lower surfaces of a portion that will be a boundary between the substrate portions of the two mounting substrates to be separated.

3. The mounting substrate is divided into a plurality of pieces from an original substrate, The light emitting module according to claim 1 , wherein the original substrate has a dividing through hole at a boundary between the substrate portions of the two mounting substrates to be divided.

4. 4. The light-emitting module according to claim 1, wherein the substrate portion has a screw mounting hole for mounting a screw.

5. The mounting substrate, which is integrally formed from a plurality of the substrate portions, has a hole extending between adjacent substrate portions through which a fixing member for attaching the mounting substrate is inserted.

6. The light-emitting module according to any one of claims 1 to 3, wherein the mounting substrate is made of a material selected from the group consisting of a substrate in which an insulating layer and copper foil are laminated on a metal plate, a glass cloth-glass nonwoven fabric substrate epoxy resin copper-clad laminate, and a glass cloth substrate epoxy resin copper-clad laminate.

7. 4. The light emitting module according to claim 1, wherein a pair of corners arranged in a lateral direction of the mounting substrate have different shapes.

8. A light emitting module according to any one of claims 1 to 3; a mounting portion to which one of the light-emitting modules is mounted; A lighting fixture comprising:

9. The lighting fixture according to claim 8 , wherein the mounting portion is made of sheet metal.

10. an original substrate manufacturing process for integrally forming a plurality of substrate portions, which are the minimum unit of the substrate outer dimensions of a mounting substrate on which light-emitting elements are mounted, to obtain an original substrate; a dividing groove process of forming dividing grooves or dividing through holes at portions that become boundaries between the substrate portions on the upper and lower surfaces of the original substrate in accordance with the size of the mounting substrate that is formed based on the number of the light-emitting elements to be mounted; A method for manufacturing a light emitting module having the above structure.

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