Light source unit and lighting fixture

Abstract

The manufacturing process will be simplified compared to conventional methods. [Solution] The light source unit comprises a substrate 221, a power supply device, a mounting member 21 on which the substrate 221 is attached to a first surface and the power supply device is attached to a second surface, and a connecting member that electrically connects the power supply circuit and the substrate 221. The mounting member 21 is provided with a first through hole 213 that penetrates from the first surface to the second surface. The substrate 221 has a second through hole 2210 that faces the first through hole 213 when viewed from the thickness direction of the mounting member 21. The connecting member comprises two rod-shaped conductors 50, a holder 53 positioned between the substrate 221 and the printed circuit board 40 to guide the two conductors 50, and two terminal members that are connected one-to-one with the two conductors 50. The holder 53 faces the first through hole 213 and the second through hole 2210 and has an insertion opening 531 into which the two conductors 50 are inserted.

Description

Technical Field

[0001] The present invention relates to a light source unit and a lighting fixture, and more particularly to a light source unit including a light source and a power supply device, and a lighting fixture including the light source unit.

Background Art

[0002] As a conventional example of a light source unit, a light emitting unit described in Patent Document 1 is exemplified. The light emitting unit described in Patent Document 1 includes a long substrate on which a plurality of light emitting elements (light emitting diodes) are mounted, a long support member for supporting the substrate, a power supply unit, and a long light transmissive cover.

[0003] The substrate is attached to the lower surface of the support member. The light transmissive cover is attached to the lower surface of the support member and transmits light emitted from the plurality of light emitting elements. The power supply unit includes a power supply substrate having a lighting circuit (power supply circuit) for the light emitting elements, a housing (power supply box) for housing the power supply substrate therein, and wiring for supplying power from the power supply circuit to the light emitting elements. This wiring is electrically connected to the substrate through a through hole (through portion) provided in the support member.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] An object of the present invention is to provide a light source unit and a lighting fixture capable of simplifying the manufacturing process as compared with conventional examples.

Means for Solving the Problems

[0006] A light source unit according to one aspect of the present invention comprises a substrate having a solid-state light-emitting element, a power supply device having a power supply circuit for supplying power to the solid-state light-emitting element, a plate-shaped mounting member having a first surface and a second surface which is the back surface of the first surface, the substrate being attached to the first surface and the power supply device being attached to the second surface, and a connecting member for electrically connecting the power supply circuit and the substrate. The mounting member is provided with a first through-hole that penetrates from the first surface to the second surface. The power supply circuit has a printed circuit board having two output terminals for outputting the power generated by the power supply circuit. The substrate has a second through-hole that faces the first through-hole when viewed from the thickness direction of the mounting member. The connecting member has two rod-shaped conductors, a holder disposed between the substrate and the printed circuit board for guiding the two conductors, and two terminal members that are connected one-to-one with the two conductors. The holder has an insertion opening that faces the first through-hole and the second through-hole and into which the two conductors are inserted.

[0007] A light source unit according to one aspect of the present invention comprises a substrate having a solid-state light-emitting element, a power supply device having a power supply circuit for supplying power to the solid-state light-emitting element, a plate-shaped mounting member having a first surface and a second surface which is the back surface of the first surface, the substrate being attached to the first surface and the power supply device being attached to the second surface, and a connecting member for electrically connecting the power supply circuit and the substrate. The mounting member is provided with a first through-hole that penetrates from the first surface to the second surface. The power supply circuit has a printed circuit board having an output terminal portion for outputting the power generated by the power supply circuit. The substrate has a second through-hole that faces the first through-hole when viewed from the thickness direction of the mounting member. The connecting member has a rod-shaped conductor, a holder disposed between the substrate and the printed circuit board for guiding the conductor, and a first terminal member and a second terminal member connected to the conductor. The holder has an insertion opening that faces the first and second through-holes and into which the conductor is inserted. The first terminal member is configured to electrically and mechanically connect the end of the conductor to the output terminal portion via the second terminal member.

[0008] A lighting fixture according to one aspect of the present invention comprises a light source unit and a fixture body that supports the light source unit. [Effects of the Invention]

[0009] The light source unit and lighting fixture of the present invention have the advantage of simplifying the manufacturing process compared to conventional examples. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is an exploded perspective view of a light source unit and lighting fixture according to one embodiment of the present invention. [Figure 2] Figure 2 is a cross-sectional view of the same lighting fixture. [Figure 3] Figure 3 is a circuit diagram of the power supply circuit of the power supply unit for the light source unit shown above. [Figure 4] Figure 4 is a plan view of the power supply unit shown above. [Figure 5] Figure 5 is an exploded perspective view of a portion of the light source unit, including the connecting members. [Figure 6] Figure 6A is a front view of the first terminal member of the light source unit shown above. Figure 6B is a top view of the first terminal member shown above. Figure 6C is a rear view of the first terminal member shown above. Figure 6D is a right side view of the first terminal member shown above. [Figure 7] Figure 7 is an exploded perspective view of the second terminal member and holder of the same light source unit. [Figure 8] Figure 8 is a cross-sectional view of a portion of the light source unit, including the connecting member. [Figure 9] Figure 9 is a partially omitted cross-sectional view of the same light source unit. [Figure 10] Figure 10 is a partially omitted cross-sectional view of the same light source unit. [Figure 11] Figure 11 is a partially omitted top view of the same light source unit. [Figure 12] Figure 12 is a bottom view of the main components of the light source unit shown above.

Best Mode for Carrying Out the Invention

[0011] A light source unit and a lighting fixture according to an embodiment of the present invention will be described in detail with reference to the drawings. However, each of the drawings described in the following embodiments is a schematic diagram, and the ratio of the size and thickness of each component does not necessarily reflect the actual dimensional ratio. In the following description, unless otherwise specified, the up-down, left-right, and front-back directions of the light source unit and the lighting fixture are defined in the orientation shown in FIG. 1. Note that the configurations described in the following embodiments are merely examples of the present invention. The present invention is not limited to the following embodiments, and various modifications can be made according to the design and the like as long as the effects of the present invention can be achieved.

[0012] The lighting fixture 1 of the present embodiment is a lighting fixture attached to the ceiling 100. However, the lighting fixture of the embodiment may be a lighting fixture attached to a location other than the ceiling, such as a wall.

[0013] The lighting fixture 1 of the present embodiment includes a light source unit 2 and a fixture body 10 as shown in FIGS. 1 and 2. The fixture body 10 is fixed to a suspension bolt 200 and directly attached to the ceiling 100. The light source unit 2 is detachably attached to the fixture body 10.

[0014] The fixture body 10 is formed into a long and flat box shape with an opening on the upper surface (the surface facing the ceiling 100) by bending a sheet metal. A rectangular recess 11 for accommodating the light source unit 2 is provided over the entire length in the longitudinal direction (left-right direction) of the fixture body 10 on the lower surface of the fixture body 10 on the side opposite to the ceiling 100 (lower side). Inclined portions 12 are provided on both sides of the recess 11 in the short-side direction (front-back direction) of the fixture body 10. The inclined portions 12 extend from the open edge of the recess 11 in the short-side direction (front-back direction) of the fixture body 10 and incline upward toward the outside.

[0015] A hole 111A for passing the power cord 30 is provided substantially at the center in the longitudinal direction (left - right direction) of the bottom plate 111 of the recess 11. Further, holes 111B for passing the suspension bolts 200 are provided at positions near both ends in the longitudinal direction (left - right direction) of the bottom plate 111, respectively. And a terminal block 25 is attached to the lower surface of the bottom plate 111. The terminal block 25 is electrically connected to the power cord 30. Three electric wires 250 including a ground wire are drawn out from the terminal block 25. Further, plug connectors 251 are electrically connected to the tips of these three electric wires 250.

[0016] As shown in FIGS. 2 and 5, the light source unit 2 includes a light source portion, a mounting member 21, a cover 23, a power supply device 4, and a connection member 5. The light source portion includes a plurality (for example, two) of LED modules 22.

[0017] The plurality of LED modules 22 are arranged side by side in the longitudinal direction (left - right direction). Each LED module 22 has a substrate 221 formed in a rectangular plate shape long in the longitudinal direction (left - right direction). The substrate 221 has a long rectangular flat insulating substrate and a conductor (copper foil) for wiring printed on the surface of the insulating substrate. On the surface (lower surface) of the insulating substrate, a plurality of LEDs (light - emitting diodes) 220 are mounted (arranged) in a row along the longitudinal direction (left - right direction). Two input terminal portions 222 electrically connected to the connection member 5 are provided in any one of the plurality of LED modules 22 (see FIG. 5). Note that the insulating substrate constituting the substrate 221 is preferably a resin - made insulating substrate such as a glass cloth - based epoxy resin substrate.

[0018] At the end portions of each LED module 22 facing the adjacent LED module 22, a pair of connectors 224 for power supply are respectively mounted (see FIG. 2). And by electrically connecting the pair of connectors 224 of both adjacent LED modules 22 to each other, the lighting power is relayed from one LED module 22 to the other LED module 22.

[0019] The mounting member 21 is formed in a U-shape by bending sheet metal. The mounting member 21 comprises a long, rectangular base plate 211 and a pair of side plates 212 extending upward from both ends of the base plate 211 in the short direction (front-to-back direction). As shown in Figure 2, the tips (upper ends) of the pair of side plates 212 are each provided with a pair of inclined portions 212A that are inclined outward, moving away from each other, along their entire length. The LED module 22 described above is fixed to the mounting member 21 by a plurality of hooks 216 formed by cutting and bending a part of the base plate 211 of the mounting member 21 (see Figure 5). Each of these hooks 216 is arranged on both sides of the base plate 211 in the short direction (front-to-back direction) and spaced apart along the longitudinal direction (left-to-right direction) of the base plate 211. The substrate 221 has multiple grooves 2211 into which one-to-one corresponding hooks 216 from among the multiple hooks 216 are inserted (see Figure 5). Each of the multiple grooves 2211 is formed to be spaced apart along the longitudinal direction (left-to-right direction) of the substrate 221. In other words, the substrate 221 is inserted between the hooks 216 inserted into the corresponding grooves 2211 and the base plate 211 and fixed to the mounting member 21 (see Figure 9). However, at least two of the multiple hooks 216 that are closest to the center in the longitudinal direction of the mounting member 21 (fixing hooks 216A) fix the substrate 221 to the mounting member 21. The multiple hooks 216, excluding the fixing hooks 216A, prevent the substrate 221 from coming off the mounting member 21.

[0020] The mounting member 21 has a pair of hook fittings 214 that extend towards one end in the short direction (front-back direction) at positions near both ends in the longitudinal direction (left-right direction), and a pair of hook springs 215 that are positioned at the other end in the short direction (see Figure 1).

[0021] The cover 23 is formed in the shape of a long box with an opening on the top surface (the surface facing the mounting member 21) and is made of a light-diffusing material (for example, milky white acrylic resin). The cover 23 has a convex lens-shaped curved surface portion 231 such that the amount of downward protrusion increases from both ends towards the center in the front-to-back direction (width direction) (see Figure 2).

[0022] As shown in Figure 2, extensions 232 are provided at both ends of the cover 23 in the front-rear direction. Each extension 232 is positioned so as to overlap with the opening edge of the recess 11 of the fixture body 10 in the vertical direction when the light source unit 2 is attached to the fixture body 10. On the inside of the extension 232 in the short direction (front-rear direction) of the cover 23, a protruding wall portion 233 is provided along the entire length, projecting upward (towards the mounting member 21). A projection 233A is provided at the tip of each protruding wall portion 233, projecting inward. Near the base of each protruding wall portion 233, a support piece 233B projects inward.

[0023] The power supply unit 4 comprises a power supply circuit 49 formed by mounting electronic components on a printed circuit board 40, and a case 42 that houses the power supply circuit 49. A circuit diagram of the power supply circuit 49 is shown in Figure 3. The power supply circuit 49 includes a power input section 400, a filter circuit 401, a rectifier section 402, a boost circuit 403, a buck circuit 404, an output terminal section 405, a main control circuit 406, a control power supply circuit 407, a dimming control circuit 408, a power off control circuit 409, and a signal input section 410.

[0024] The power input section 400 consists of a receptacle connector. A plug connector 251 (see Figure 1), which is electrically connected to the wire 250 drawn out from the terminal block 25, is plugged into the power input section 400. The filter circuit 401 has a common-mode choke coil 4010 and an across-the-line capacitor 4011. The rectifier section 402 has a diode bridge. The rectifier section 402 full-wave rectifies the AC voltage (AC current) input from the AC power supply 3 via the filter circuit 401 and the power input section 400, and outputs a pulsating voltage (pulsating current) from the DC output terminal.

[0025] The boost circuit 403 is a conventionally known boost chopper circuit (power factor correction circuit). The boost circuit 403 comprises a choke coil L1, a switching element Q1, a rectifier element D1, and a smoothing capacitor C1. The boost circuit 403 converts the pulsating voltage output from the rectifier section 402 into a DC voltage higher than the peak value of the pulsating voltage (for example, a DC voltage of 400V).

[0026] The step-down circuit 404 is a conventionally known step-down chopper circuit (buck converter). The step-down circuit 404 comprises a switching element Q2, an inductor L2, a rectifier element D2, a resistor R1, and a smoothing capacitor C2. The step-down circuit 404 steps down the DC voltage (first DC voltage) output from the step-up circuit 403 to a DC voltage (second DC voltage) suitable for the load, the LED module 22. Each of the pair of output terminals 405 is a land formed on the upper surface of the printed circuit board 40. Each output terminal 405 is electrically connected to the corresponding output terminal of the pair of output terminals (both ends of the smoothing capacitor C2) of the step-down circuit 404.

[0027] The main control circuit 406 is configured to switch the switching element Q1 of the boost circuit 403 and the switching element Q2 of the buck circuit 404, respectively, in order to maintain a constant output voltage of the boost circuit 403. Furthermore, the main control circuit 406 is configured to match the output current of the buck circuit 404 to a target value. The control power supply circuit 407 is configured to generate a control voltage (for example, a DC voltage of about 15V to 3V) from the output voltage of the boost circuit 403. The main control circuit 406 operates on the control voltage supplied by the control power supply circuit 407.

[0028] The signal input unit 410 consists of a receptacle connector. Control signals transmitted via the signal line are input to the dimming control circuit 408 and the dimming control circuit 409 via the signal input unit 410.

[0029] The off-control circuit 409 is configured to generate an off-signal to turn off the lit LED module 22 in response to a control signal and output it to the main control circuit 406. When the main control circuit 406 receives the off-signal, it is configured to stop the switching of the switching element Q2, stop the step-down circuit 404, and turn off the LED module 22.

[0030] The dimming control circuit 408 is configured to generate a dimming signal in response to a control signal and output it to the main control circuit 406. The dimming signal is a signal for instructing the light output (dimming level) of the LED module 22. The dimming level is expressed as the ratio [%] of the average power supplied to the LED module 22 per unit time to the rated power, with the light output of the LED module 22 when the rated power is supplied being 100%. For example, when the average power supplied to the LED module 22 per unit time is half the rated power, the dimming level is 50%. In other words, if the dimming level instructed by the control signal is 50%, the dimming control circuit 408 generates a dimming signal that instructs the step-down circuit 404 to supply the average power per unit time to the LED module 22 to half the rated power. The main control circuit 406 is configured to adjust the duty cycle of the switching element Q2 in response to the dimming signal received from the dimming control circuit 408. To explain in more detail, the dimming control circuit 408 is configured to detect the output current of the step-down circuit 404 from the voltage across resistor R1 and to generate a dimming signal so that the average value of the output current matches a target value corresponding to the dimming level.

[0031] The printed circuit board 40 comprises a long, rectangular, flat insulating substrate and a wiring conductor (copper foil) printed on the back of the insulating substrate. So-called leaded components such as connectors, smoothing capacitors, and common mode choke coils 4010 are mounted on the top surface (bottom surface) of the printed circuit board 40 (see Figure 4). Surface-mount components such as a rectifier unit 402, a main control circuit 406, a dimming control circuit 408, and a power-off control circuit 409 are mounted on the top surface (top surface) of the printed circuit board 40. The power input unit 400 is mounted on the surface of the longitudinal (left-right) end of the printed circuit board 40. The power input unit 400 has a terminal piece 4001 for frame grounding. The terminal piece 4001 is electrically connected to the grounding contact of the power input unit 400. The terminal piece 4001 has a circular hole that penetrates through the thickness direction (vertical direction) of the terminal piece 4001. Furthermore, through-holes are provided at the ends of the printed circuit board 40 that connect to the holes of the terminal pieces 4001. The signal input section 410 is mounted on the surface of the other end of the printed circuit board 40 in the longitudinal direction (left-right direction). The insulating substrate constituting the printed circuit board 40 is preferably a resin insulating substrate, such as a paper-based phenolic resin substrate.

[0032] As shown in Figures 2 and 4, case 42 includes a bottom plate 420, a pair of first side plates 421A and 421B rising from the edge of the bottom plate 420 along its short side, and a pair of second side plates 422A and 422B rising from the edge of the bottom plate 420 along its longitudinal side. That is, case 42 is formed in the shape of a long box with the surface facing the bottom plate 420 (the bottom surface) open. Case 42 is equipped with a fixing plate 423 that protrudes outward from the tip of one of the pair of second side plates 422A and 422B, which is a second side plate 422A. The fixing plate 423 is formed in the shape of a trough, as shown in Figure 2. In addition, a screw fastening portion 424 is provided at one end (the left end) in the longitudinal direction of the bottom plate 420. The screw fastening portion 424 is formed in the shape of a bridge that protrudes downward from the bottom plate 211. The screw fastening portion 424 is also provided with screw holes.

[0033] The printed circuit board 40 is housed in the case 42 with its back facing the bottom plate 420, and is secured to the case 42 by four claws 4220 cut out from a pair of second side plates 422A and 422B (see Figure 4). The power input socket 400 protrudes outside the case 42 through a rectangular window opening provided in the first side plate 421B. Also, a screw 4002 inserted through a hole in the terminal piece 4001 passes through a through-hole in the printed circuit board 40 and is screwed into a screw hole in the screw fastening portion 424 of the case 42 (see Figure 9).

[0034] As shown in Figure 2, the power supply unit 4 is mounted on the upper surface (second surface) of the mounting member 21 of the light source unit 2 with the bottom plate 420 of the case 42 facing upwards. Specifically, the case 42 is fixed to the mounting member 21 by screwing the second side plate 422B and the fixing plate 423 to the pair of side plates 212 of the mounting member 21, respectively. When mounted on the mounting member 21, the opening of the case 42 is closed by the bottom plate 211 of the mounting member 21. The terminal piece 4001 of the power input section 400 is electrically connected to the case 42 via the screw 4002. Therefore, when the light source unit 2 is mounted on the fixture body 10, the ground potential of the power supply circuit 49 becomes equal to the potential of the fixture body 10 via the case 42 and the mounting member 21 which is electrically connected to the case 42.

[0035] As shown in Figure 5, the connecting member 5 comprises two conductors 50, two first terminal members 51, and two second terminal members 52. Each of the two conductors 50 is formed in the shape of a thin rod (for example, a cylindrical shape) from a conductive material such as copper or a copper alloy. The length of each of these two conductors 50 is preferably about several tens of millimeters.

[0036] The two first terminal members 51 are formed to be the same shape and dimensions as each other. Therefore, the following description will focus on one first terminal member 51. As shown in Figures 6A to 6D, the first terminal member 51 has a plate material 510 made of a rectangular metal plate. The plate material 510 is formed into a trough shape by bending both ends along the longitudinal direction X1 of the plate material 510 in the same direction along the thickness direction X3 (see Figure 6A). As shown in Figure 6A, the first terminal member 51 has an insertion hole 511 that penetrates the center of the plate material 510 (the center of the longitudinal direction X1 and the short direction X2). Preferably, the first terminal member 51 has a plurality (for example, three) of support pieces 512 and a plurality (for example, three) of guide pieces 513. Each of the three support pieces 512 is formed integrally with the plate material 510 by cutting and bending the plate material 510 into a pentagonal shape. The tips 5120 of each of the three support pieces 512 face the insertion hole 511. Furthermore, the three support pieces 512 are arranged at equal intervals surrounding the insertion hole 511 (see Figures 6A and 6C). Each of the three guide pieces 513 is formed integrally with the plate material 510 by cutting and bending the plate material 510 into a trapezoidal shape. The tips of each of the three guide pieces 513 face the insertion hole 511. Furthermore, the three guide pieces 513 are positioned one by one between the three support pieces 512 so as they surround the insertion hole 511 (see Figures 6A and 6C). Note that each of the three support pieces 512 and the three guide pieces 513 is configured to incline away from the plate material 510 along the thickness direction X3 of the plate material 510 as they approach the insertion hole 511 (see Figures 6B and 6D).

[0037] Each of these two first terminal members 51 is electrically connected in a one-to-one correspondence with two input terminal portions 222 provided on the substrate 221. Each of the two input terminal portions 222 consists of a land formed around a second through-hole 2210 that penetrates the substrate 221 in the thickness direction (vertical direction) on the surface (bottom surface) of the substrate 221 (see Figure 5). Each of the two input terminal portions 222 is electrically connected to a plurality of LEDs 220 via a conductor formed on the surface (bottom surface) of the substrate 221. Furthermore, each of the two first terminal members 51 corresponds one-to-one with the two input terminal portions 222, and it is preferable that the plate material 510 of each first terminal member 51 is soldered to the corresponding input terminal portion 222. Each first terminal member 51 is electrically connected to the corresponding input terminal section 222 by inserting its three support pieces 512 and three guide pieces 513 into the second through-hole 2210 of the corresponding input terminal section 222 (see Figure 9).

[0038] The two second terminal members 52 are formed to be identical in shape and dimensions. Therefore, the following description will focus on one of the second terminal members 52. However, in the following description, the up / down, left / right, and front / back directions of the second terminal member 52 are defined in Figures 7 and 8.

[0039] As shown in Figures 7 and 8, the second terminal member 52 has a first spring piece 520A, a second spring piece 520B, a first main piece 521A, a second main piece 521B, a connecting piece 522, a flexible piece 523, a terminal piece 524, and three hooking claws 525. The first main piece 521A and the second main piece 521B are each formed in the shape of a rectangular plate. The connecting piece 522 is also formed in the shape of a rectangular plate. The connecting piece 522 is connected to the first main piece 521A and the second main piece 521B at both ends in the front-rear direction. In other words, the first main piece 521A and the second main piece 521B are mechanically connected via the connecting piece 522 so that they face each other in the front-rear direction. The first spring piece 520A is formed in the shape of a rectangular plate and protrudes downward from the lower end of the first main piece 521A. The first spring piece 520A is curved in a U shape when viewed from the left-right direction. The second spring piece 520B is formed in the shape of a rectangular plate and protrudes downward from the lower end of the second main piece 521B. The second spring piece 520B is curved in a U-shape when viewed from the left and right directions. In other words, the first spring piece 520A and the second spring piece 520B are formed so that the distance between them decreases towards their tips. The flexing piece 523 is formed in the shape of a narrow rectangular plate. The flexing piece 523 protrudes from the upper end of the second main piece 521B in the front-to-back direction, approaching the first main piece 521A. The terminal piece 524 is formed in the shape of an elongated rectangular plate. The terminal piece 524 protrudes upward from the tip of the flexing piece 523. The three hooking claws 525 are provided in the center of the first main piece 521A, the second main piece 521B, and the connecting piece 522, respectively. Each of the three hooking claws 525 is cut and bent so that its upper end faces outward. Preferably, the first spring piece 520A, the second spring piece 520B, the first main piece 521A, the second main piece 521B, the connecting piece 522, the flexible piece 523, the terminal piece 524, and the three hooking claws 525 are integrally formed by processing a metal plate such as copper or a copper alloy.

[0040] Each of these two second terminal members 52 is electrically connected in a one-to-one correspondence to two output terminal sections 405 provided on the printed circuit board 40 of the power supply unit 4. Each of the two output terminal sections 405 is composed of a land. Each land is formed on the back surface (top surface) of the printed circuit board 40 around two through-holes 43 that penetrate the printed circuit board 40 in the thickness direction (vertical direction) (see Figure 8). The terminal piece 524 of each second terminal member 52 is inserted through the through-hole 43 of the output terminal section 405 that corresponds in a one-to-one correspondence to the other output terminal section 405. Then, the terminal piece 524 of each second terminal member 52 is soldered to the output terminal section 405 on the back surface of the printed circuit board 40. In this way, the two second terminal members 52 are electrically connected in a one-to-one correspondence to the two output terminal sections 405 provided on the printed circuit board 40 of the power supply unit 4.

[0041] Here, the two second terminal members 52 are each held in an electrically insulating holder 53. As shown in Figure 7, the holder 53 is made of a rectangular parallelepiped-shaped synthetic resin molded body. The holder 53 electrically insulates and mechanically holds the two second terminal members 52. The holder 53 has two housing sections 530 (see Figure 7). Each of the two housing sections 530 houses a one-to-one corresponding second terminal member 52 from the two second terminal members 52 (see Figure 8). The upper surfaces of the two housing sections 530 are open. The terminal pieces 524 of each of the two second terminal members 52 protrude from the openings on the upper surface of the holder 53 (see Figure 8). Two insertion openings 531 are open on the lower surface of the holder 53 (see Figures 5 and 8). Each of the two sockets 531 is connected to the corresponding housing section 530 of the two housing sections 530 (see Figure 8). The inner surfaces of the two sockets 531 have inclined surfaces that slope toward the housing sections 530. Each of the two second terminal members 52 is prevented from coming loose from the housing section 530 by hooking the tips of their three hooking claws 525 onto the inner wall surface of the housing section 530 (see Figure 8). However, a portion (lower end portion) of the first spring piece 520A and the second spring piece 520B of the second terminal member 52 housed in the corresponding housing section 530 protrudes into the corresponding socket 531 (see Figure 8).

[0042] Incidentally, as shown in Figures 7 and 8, the holder 53 has a pair of fixing parts 532. The pair of fixing parts 532 are formed in a columnar shape and protrude upward from both the left and right ends on the upper surface of the holder 53. The pair of fixing parts 532 are press-fitted one by one into each of the two fixing holes 44 provided in the printed circuit board 40. In other words, the holder 53 is fixed to the printed circuit board 40 by the press-fitting of the pair of fixing parts 532 into the two fixing holes 44 of the printed circuit board 40 (see Figure 8).

[0043] Next, the assembly process of the light source unit 2 will be described. Each of the two first terminal members 51 is electrically connected to the corresponding input terminal 222 of the two input terminals 222 of the substrate 221 by soldering. Similarly, each of the two second terminal members 52 is electrically connected to the corresponding output terminal 405 of the two output terminals 405 of the printed circuit board 40 by soldering. Furthermore, holders 53, each holding one of the two second terminal members 52, are mechanically fixed to the printed circuit board 40.

[0044] First, the worker performing the assembly attaches the power supply unit 4 to the second surface (top surface) of the mounting member 21 such that the opening surface (bottom surface) of the case 42 is covered by the bottom plate 211 of the mounting member 21. With the power supply unit 4 attached to the mounting member 21, the first through hole 213 provided in the bottom plate 211 and the holder 53 mounted on the printed circuit board 40 overlap when viewed from the thickness direction (vertical direction) of the printed circuit board 40.

[0045] Next, the worker fixes the LED module 22 to the first surface (bottom surface) of the bottom plate 211 of the mounting member 21. At this time, the two first terminal members 51 attached to the substrate 221 of the LED module 22 are positioned so as to overlap with the corresponding insertion opening 531 of the two insertion openings 531 of the holder 53 when viewed from the thickness direction (up and down direction) of the substrate 221 (see Figure 8). In other words, the first through hole 213 is blocked by the substrate 221 of the LED module 22 on the first surface (bottom surface) side of the bottom plate 211 (see Figure 9). Therefore, the light source unit 2 of this embodiment does not require a member to block the first through hole 213 (for example, tape with adhesive applied to one side), and costs can be reduced by reducing the number of parts and manufacturing processes.

[0046] The worker then inserts each of the two conductors 50 into the corresponding through-hole 511 of the two first terminal members 51. At this time, the upper end (second end 501) of the conductor 50 is guided into the through-hole 511 by the lower surfaces (inclined surfaces) of the three support pieces 512 and three guide pieces 513 that are arranged to surround the through-hole 511. As a result, the worker can easily insert the conductor 50 into the through-hole 511. However, each of the three support pieces 512 bends (elastically deforms) in the direction in which the conductor 50 is inserted (upward) when its tip portion 5120 contacts the conductor 50.

[0047] When the operator inserts the conductor 50 into the insertion hole 511, the upper end (second end 501) of the conductor 50 passes through the insertion opening 531 of the holder 53 and is inserted between the first spring piece 520A and the second spring piece 520B of the second terminal member 52, which correspond one-to-one. In other words, the second ends 501 of each of the two conductors 50 are sandwiched from the front and rear directions by the first spring piece 520A and the second spring piece 520B, thereby electrically connecting each conductor 50 to the second terminal member 52, which corresponds one-to-one (see Figure 8). In addition, the first ends 500 of each of the two conductors 50 are sandwiched by the three support pieces 512, thereby electrically connecting each conductor 50 to the first terminal member 51, which corresponds one-to-one (see Figure 8). As a result, each of the two input terminals 222 of the LED module 22 is electrically connected to the corresponding output terminal 405 of the two output terminals 405 of the power supply unit 4 (power supply circuit 49) by the connecting member 5 (see Figure 8).

[0048] Finally, the worker attaches the cover 23 to the mounting member 21 with the opening side of the mounting member 21 facing upward. At this time, a pair of projections 233A provided on a pair of protruding wall portions 233 of the cover 23 catch on a pair of inclined portions 212A on a pair of side plates 212 of the mounting member 21, and the cover 23 is attached to the mounting member 21. The light source unit 2 is assembled through the assembly process described above.

[0049] As described above, the light source unit 2 is configured such that the electrical connection between the power supply unit 4 and the LED module 22 is completed simply by inserting the two conductors 50 into the corresponding insertion holes 511 of the first terminal member 51. Therefore, the manufacturing process of the light source unit 2 can be simplified compared to conventional examples such as the light-emitting unit described in Patent Document 1.

[0050] Furthermore, in the light source unit 2, each of the two first terminal members 51 has three support pieces 512 provided on the plate material 510. Each of these three support pieces 512 is integrally formed with the plate material 510 so as to surround the insertion hole 511. In addition, each of the three support pieces 512 is elastically deformed by being pressed by the conductor 50 (or its first end 500) inserted through the insertion hole 511. Moreover, each of the three support pieces 512 is electrically connected to the conductor 50 at its tip portion 5120, which is pressed by the first end 500 of the conductor 50. In other words, even if the conductor 50 is tilted relative to the insertion hole 511 of the plate material 510, the elastic force of the multiple (for example, three) support pieces 512 allows each tip portion 5120 of the support piece 512 to come into contact with the conductor 50. As a result, the light source unit 2 can widen the allowable range of misalignment between the two first terminal members 51 and the two second terminal members 52, which correspond to each other one-to-one. Moreover, the stress applied to the solder joining each of the plate materials 510 of the two first terminal members 51 to each of the two input terminal sections 222 is less affected by the tilt of the conductor 50. Therefore, compared to the case where the first terminal members 51 and the conductor 50 are fixed by soldering or the like, cracks are less likely to occur in the solder joining the first terminal members 51 (plate material 510) and the input terminal section 222.

[0051] Incidentally, the substrate 221 of the LED module 22 expands due to the heat radiated from the lit LED 220 and the heat radiated from the power supply circuit 49. Furthermore, the coefficient of linear expansion of the synthetic resin (e.g., epoxy resin) forming the substrate 221 (insulating substrate) is several tens of times larger than the coefficient of linear expansion of the metal (e.g., galvanized steel plate or stainless steel plate) forming the mounting member 21. Each of the multiple grooves 2211 provided in the substrate 221 is configured such that the length along the longitudinal direction of the substrate 221 is greater than the length along the longitudinal direction of the base portion of the hook portion 216. In other words, the substrate 221 can expand and contract along its longitudinal direction relative to the mounting member 21 by the difference in length between the grooves 2211 along the longitudinal direction of the substrate 221 and the hook portion 216. Therefore, even if the thermal expansion of the substrate 221 is greater than the thermal expansion of the mounting member 21, the substrate 221 stretches longitudinally relative to the mounting member 21, thereby reducing the stress applied to the substrate 221 from the hook portion 216 of the mounting member 21.

[0052] However, if the substrate 221 expands due to thermal expansion and stretches longitudinally relative to the mounting member 21, the relative positions of the first terminal member 51 fixed to the substrate 221 and the second terminal member 52 indirectly fixed to the mounting member 21 via the case 42 will shift. As described above, the connecting member 5 can maintain an electrical connection via the conductor 50 even if the positions of the two first terminal members 51 and the two second terminal members 52, which correspond to each other one-to-one, shift to some extent. However, if the amount of expansion (stretching) of the substrate 221 relative to the mounting member 21 exceeds the allowable range of misalignment between the first terminal member 51 and the second terminal member 52 in the connecting member 5, it may not be possible to maintain an electrical connection via the conductor 50.

[0053] On the other hand, the printed circuit board 40 of the power supply unit 4 also expands due to the heat radiated from the lit LED 220 and the heat radiated from the power supply circuit 49. However, the insulating substrate that makes up the printed circuit board 40 and the insulating substrate that makes up the substrate 221 are made of the same type of material (for example, synthetic resins such as epoxy resin and phenolic resin). In other words, the difference in the coefficient of linear expansion between the substrate 221 and the printed circuit board 40, which are made of the same type of material, is very small compared to the difference in the coefficient of linear expansion between the substrate 221 and the printed circuit board 40 and the mounting member 21, which are made of different types of materials such as synthetic resin and metal.

[0054] Furthermore, both the circuit board 221 and the printed circuit board 40 expand (stretch) more as they move away from their respective fixing positions on the mounting member 21. In addition, if the fixing positions of the circuit board 221 and the printed circuit board 40 as seen from the connecting member 5 are on different sides in the longitudinal direction of the mounting member 21, the longitudinal positional misalignment of the input terminal section 222 and the output terminal section 405 on the mounting member 21 becomes larger.

[0055] In contrast, in the light source unit 2 of this embodiment, the fixing position F1 of the substrate 221 relative to the mounting member 21 and the fixing position F2 of the printed circuit board 40 relative to the mounting member 21 are on the same side in the longitudinal direction of the mounting member 21 when viewed from the connecting member 5 (see Figure 9). In other words, the substrate 221 and the printed circuit board 40 expand and contract in the same direction in the longitudinal direction of the mounting member 21 when they expand and contract due to heat. Here, the difference between the shortest distance Z1 between the fixing position F1 and the conductor 50 and the shortest distance Z2 between the fixing position F2 and the conductor 50 is defined as Z3 (=|Z1-Z2|). In the light source unit 2, since the substrate 221 and the printed circuit board 40 expand and contract in the same direction, the amount of change in the difference Z3 due to the expansion and contraction of the substrate 221 and the printed circuit board 40 can be reduced. Therefore, the light source unit 2 can reduce the positional misalignment of the input terminal section 222 and the output terminal section 405 in the longitudinal direction of the mounting member 21. As a result, the light source unit 2 can reduce the stress on the wiring (input terminal section 222, output terminal section 405, and connecting member 5) from the power supply unit 4 to the LED module 22.

[0056] Next, the installation procedure for lighting fixture 1 will be explained. First, as shown in Figure 1, the installer inserts the power supply wire 30 and signal wire, which have been pre-wired in the ceiling cavity, into the hole 111A of the fixture body 10, and then passes each suspension bolt 200, which is exposed on the room side, through the corresponding hole 111B. After that, the installer screws nuts 300 onto each suspension bolt 200 to fix the fixture body 10 to the ceiling 100. Then, the installer connects the power supply wire 30 to the terminal block 25, and then plugs the plug connector 251 of the terminal block 25 into the power input section 400 (see Figure 4) of the power supply unit 4. Subsequently, the installer electrically connects the signal wire to the signal input section 410 (see Figure 4) of the power supply unit 4.

[0057] Then, the installer hooks the ends of a pair of hook fittings 214 into a pair of insertion holes 112A provided in one side plate 112 of the fixture body 10, and then hooks a pair of hook springs 215 onto a hook portion 1120 provided in the other side plate 112 of the fixture body 10. When the installer rotates the light source unit 2 so as to lift it using the hook fittings 214 as a pivot point, the hook springs 215 return to their original position while remaining hooked onto the hook portion 1120, and the spring force of the hook springs 215 holds the light source unit 2 to the fixture body 10. The lighting fixture 1 is installed on the ceiling 100 using the above procedure.

[0058] In the light source unit 2, the fixing position F1 of the substrate 221 and the fixing position F2 of the printed circuit board 40 are on the opposite side of the connecting member 5 from the longitudinal center (center line α1) of the printed circuit board 40 (see Figure 9). In the light source unit 2, it is easier to ensure an insulating distance between the member that fixes the substrate 221 (hooking part 216A) and the member that fixes the printed circuit board 40 (screw 4002) and the connecting member 5.

[0059] Furthermore, in the light source unit 2, at least a portion of the range G1 in which the substrate 221 is fixed to the mounting member 21 overlaps with the range G2 in which the printed circuit board 40 is fixed to the mounting member 21, when viewed from the short side direction (front-to-back direction) of the mounting member 21 (see Figure 10). The range G1 in which the substrate 221 is fixed to the mounting member 21 is the range in which the hook portion 216A faces the lower surface of the substrate 221. On the other hand, the range G2 in which the printed circuit board 40 is fixed to the mounting member 21 is the range in which the head of the screw 4002 is in contact with the lower surface of the printed circuit board 40. If at least a portion of range G1 overlaps with range G2 in this way, the amount of change in the difference Z3 due to the expansion and contraction of the substrate 221 and the printed circuit board 40 can be further reduced.

[0060] Furthermore, in the light source unit 2, the substrate 221 and the printed circuit board 40 are formed from insulating substrates made of synthetic resin. Therefore, the difference in the coefficients of linear expansion between the substrate 221 and the printed circuit board 40 is reduced, which further reduces the amount of change in the difference Z3 due to the expansion and contraction of the substrate 221 and the printed circuit board 40.

[0061] In the light source unit 2, the connecting member 5 includes a conductor 50 formed in the shape of a rod, a first terminal member 51, and a second terminal member 52. The first terminal member 51 has a plate material that is conductive and has an insertion hole 511 that penetrates in the thickness direction. The plate material is electrically connected to the input terminal portion 222 by overlapping the hole that penetrates the input terminal portion 222 with the insertion hole 511 when viewed from the thickness direction of the substrate 221. The first terminal member 51 is configured to electrically and mechanically connect the first end 500 of the conductor 50 to the input terminal portion 222. The second terminal member 52 is configured to electrically and mechanically connect the second end 501 of the conductor 50 to the output terminal portion 405 through the first through hole 213. In the light source unit 2, since the connecting member 5 is configured as described above, the workability of electrically connecting the input terminal portion 222 of the substrate 221 and the output terminal portion 405 of the printed circuit board 40 using the connecting member 5 can be improved.

[0062] Here, the positions of the fixing position F2 (screw fastening portion 424) of the printed circuit board 40 and the output terminal portion 405 (terminal piece 524) may be offset in the short-side direction (front-to-back direction) of the mounting member 21 (see Figure 11). In other words, the positions of the fixing position F2 of the printed circuit board 40 and the output terminal portion 405 (terminal piece 524) do not need to be aligned in a straight line along the longitudinal direction of the mounting member 21.

[0063] Furthermore, as shown in Figure 12, the area G1 in which the substrate 221 is fixed to the mounting member 21 may overlap with the input terminal portion 222 (first terminal member 51) of the substrate 221 when viewed from the short side direction (front-to-back direction) of the mounting member 21. In the light source unit 2, if the area G1 in which the substrate 221 is fixed to the mounting member 21 overlaps with the input terminal portion 222 (first terminal member 51) of the substrate 221, changes in the position of the input terminal portion 222 due to the expansion and contraction of the substrate 221 can be suppressed.

[0064] As is clear from the embodiments described above, the light source unit (2) according to the first aspect of the present invention comprises a long substrate (221) having a solid-state light-emitting element (LED 220) and an input terminal section (222) electrically connected to the solid-state light-emitting element (LED 220). The light source unit (2) comprises a power supply device (4) having a power supply circuit (49) that supplies power to the solid-state light-emitting element (LED 220). The light source unit (2) comprises a mounting member (21) to which the substrate (221) and the power supply device (4) are attached, and a connecting member (5) that electrically connects the power supply circuit (49) and the input terminal section (222). The power supply circuit (49) has a printed circuit board (40). The printed circuit board (40) is formed in the shape of a long plate from the same material as the substrate (221) and has an output terminal section (405) that outputs power generated by the power supply circuit (49). The mounting member (21) is formed in the shape of a long plate having a first surface and a second surface which is the back surface of the first surface. A circuit board (221) is attached to the first surface, and a power supply unit (4) is attached to the second surface. Furthermore, the mounting member (21) is provided with a through hole (213) that penetrates from the first surface to the second surface. The input terminal section (222) and the output terminal section (405) are positioned so as to overlap with the through hole (213) when viewed from the thickness direction of the mounting member (21). The connecting member (5) is configured to electrically connect the input terminal section (222) and the output terminal section (405) through the through hole (213). The fixing position (F1) of the circuit board (221) relative to the mounting member (21) and the fixing position (F2) of the printed circuit board (40) relative to the mounting member (21) are on the same side in the longitudinal direction of the mounting member (21) when viewed from the connecting member (5).

[0065] In the light source unit (2) according to the first embodiment, the substrate (221) and the printed circuit board (40) expand and contract in the same direction, so that the longitudinal displacement of the mounting members (21) of the input terminal section (222) and output terminal section (405) due to the expansion and contraction of the substrate (221) and the printed circuit board (40) can be reduced. As a result, the light source unit (2) can reduce the stress on the wiring (input terminal section 222, output terminal section 405 and connecting member 5) from the power supply unit (4) to the solid-state light-emitting element (LED 220).

[0066] In the light source unit (2) according to the second embodiment, it is preferable that the fixing position (F1) of the substrate (221) and the fixing position (F2) of the printed circuit board (40) are on the opposite side of the connecting member (5) from the center (center line α1) in the longitudinal direction of the printed circuit board (40).

[0067] In the light source unit (2) according to the second embodiment, it becomes easier to ensure an insulating distance between the member that fixes the substrate (221) (hooking portion 216A) and the member that fixes the printed circuit board (40) (screw 4002) and the connecting member (5).

[0068] In the third embodiment of the light source unit (2), it is preferable that, in the first or second embodiment, at least a portion of the area in which the substrate (221) is fixed to the mounting member (21) overlaps with the area in which the printed circuit board (40) is fixed to the mounting member (21) when viewed from the short side direction of the mounting member (21).

[0069] In the third embodiment of the light source unit (2), the amount of change in the difference (Z3) due to the expansion and contraction of the substrate (221) and the printed wiring board (40) can be reduced, and the stress on the wiring (input terminal section 222, output terminal section 405 and connecting member 5) can be further reduced.

[0070] In the light source unit according to the fourth embodiment, in any of the first to third embodiments, the substrate (221) and the printed wiring board (40) are preferably formed from an insulating substrate made of synthetic resin.

[0071] In the light source unit (2) according to the fourth embodiment, the difference in the coefficients of linear expansion between the substrate (221) and the printed wiring board (40) becomes smaller. As a result, the light source unit (2) reduces the amount of change in the difference (Z3) due to the expansion and contraction of the substrate (221) and the printed wiring board (40), and further reduces the stress on the wiring (input terminal section 222, output terminal section 405 and connecting member 5).

[0072] In the fifth embodiment of the light source unit (2), in any of the first to fourth embodiments, the connecting member (5) preferably has a rod-shaped conductor (50), a first terminal member (51), and a second terminal member (52). The first terminal member (51) preferably has a plate material that is conductive and has a through hole (511) that penetrates in the thickness direction. The plate material is preferably electrically connected to the input terminal portion (222) by overlapping the hole penetrating the input terminal portion (222) with the through hole (511) when viewed from the thickness direction of the substrate (221). The first terminal member (51) is preferably configured to electrically and mechanically connect the first end (500) of the conductor (50) to the input terminal portion (222). The second terminal member (52) is preferably configured to electrically and mechanically connect the second end (501) of the conductor (50) to the output terminal portion (405) through a through hole (213).

[0073] In the fifth embodiment of the light source unit (2), the workability of electrically connecting the input terminal portion (222) of the substrate (221) and the output terminal portion (405) of the printed wiring board (40) using the connecting member (5) can be improved.

[0074] The lighting fixture (1) according to the sixth embodiment comprises a light source unit (2) according to any of the first to fifth embodiments and a fixture body (10) that supports the light source unit (2).

[0075] In the lighting fixture (1) according to the sixth embodiment, the stress on the wiring (input terminal section 222, output terminal section 405 and connecting member 5) from the power supply unit (4) to the solid-state light-emitting element (LED 220) can be reduced. [Explanation of symbols]

[0076] 1 Lighting fixtures 2 Light source units 4 Power supply 5. Connecting Members 10. Main body of the device 21 Mounting components 40 Printed circuit boards 49 Power supply circuit 50 Conductors 51 First terminal member 52 Second terminal member 53 Holder 213 First through hole 220 LEDs (Solid-State Light-Emitting Devices) 221 circuit board 222 Input terminal section 405 Output terminal section 531 outlet 2210 Second through hole

Claims

1. A substrate having a solid-state light-emitting element, A power supply device having a power supply circuit that supplies power to the solid-state light-emitting element, A mounting member having a plate-like shape with a first surface and a second surface which is the back surface of the first surface, wherein the substrate is attached to the first surface and the power supply device is attached to the second surface, A connecting member that electrically connects the power supply circuit and the circuit board, Equipped with, The mounting member is provided with a first through hole that penetrates from the first surface to the second surface. The power supply circuit has a printed circuit board having two output terminals that output the power generated by the power supply circuit. The substrate has a second through hole that faces the first through hole when viewed from the thickness direction of the mounting member, The aforementioned connecting member is Two conductive materials formed in a rod shape, A holder positioned between the substrate and the printed circuit board to guide the two conductors, Two terminal members connected one-to-one with the two aforementioned conductors, It has, The holder has an insertion opening into which the two conductors are inserted, facing the first through hole and the second through hole. Light source unit.

2. The aforementioned terminal member is designated as a second terminal member. The connecting member further comprises two first terminal members, The two first terminal members are configured to electrically and mechanically connect the ends of corresponding conductors among the two conductors to corresponding output terminals among the two output terminals via corresponding second terminals among the two second terminal members. The light source unit according to claim 1.

3. The substrate has two input terminals that are electrically connected to the solid-state light-emitting element. The light source unit according to claim 1 or 2, wherein the two input terminals are electrically connected one-to-one with the two conductors inserted through the second through-hole.

4. A substrate having a solid-state light-emitting element, A power supply device having a power supply circuit that supplies power to the solid-state light-emitting element, A mounting member having a plate-like shape with a first surface and a second surface which is the back surface of the first surface, wherein the substrate is attached to the first surface and the power supply device is attached to the second surface, A connecting member that electrically connects the power supply circuit and the circuit board, Equipped with, The mounting member is provided with a first through hole that penetrates from the first surface to the second surface. The power supply circuit has a printed circuit board having an output terminal section that outputs the power generated by the power supply circuit, The substrate has a second through hole that faces the first through hole when viewed from the thickness direction of the mounting member, The aforementioned connecting member is A conductor formed in the shape of a rod, A holder positioned between the substrate and the printed circuit board to guide the conductor, A first terminal member and a second terminal member connected to the conductor, It has, The holder has an insertion opening into which the conductor is inserted, facing the first through hole and the second through hole. The first terminal member is configured to electrically and mechanically connect the end of the conductor to the output terminal portion via the second terminal member. Light source unit.

5. A light source unit according to any one of claims 1 to 4, The fixture body supporting the light source unit, Equipped with, Lighting fixtures.

Images