Optical member, lighting fixture, and method for manufacturing the lighting fixture

Abstract

To provide an optical member etc. which can be stored and / or transported stably.SOLUTION: An optical member 100 is a plate-like optical member having major surfaces 110a and 110b and includes: multiple lenses 120 protruding from the major surface 110a; a protrusion 130 for a night light which protrudes from the major surface 110a and whose height from the major surface 110a is higher than those of the multiple lenses 120; a protrusion 141 protruding from one of the major surfaces 110a and 110b; and a protrusion 142 protruding from the other of the major surfaces 110a and 110b. A tip of the protrusion 142 is provided with a recessed part 145 having a size such that a part of the protrusion 141 may be inserted. The protrusion 141 overlaps with the recessed part 145 in a plan view.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to an optical member, a lighting device, and a method for manufacturing a lighting device. [Background technology]

[0002] Conventionally, ceiling lights, which are lighting fixtures arranged on a ceiling, are known. For example, a ceiling light disclosed in Patent Document 1 includes a fixture body, a light-emitting module attached to the fixture body, a light-transmitting lens cover that covers the light-emitting module, and a light-diffusing cover that covers the lens cover. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2018-181602 A Summary of the Invention [Problem to be solved by the invention]

[0004] After the lens cover of the conventional ceiling light is produced, it is stored or transported to a place where the ceiling light is assembled. During storage or transportation, the lens covers are stacked. In this case, the lens covers have uneven surfaces, so they cannot be stacked stably.

[0005] Therefore, an object of the present invention is to provide an optical member that can be stably stored and / or transported, a lighting device including the optical member, and a method for manufacturing the lighting device. [Means for solving the problem]

[0006] An optical member according to one aspect of the present invention is a plate-shaped optical member having a first main surface and a second main surface opposite to the first main surface, and includes a plurality of lenses protruding from the first main surface, a first convex portion protruding from the first main surface and having a height from the first main surface greater than that of the plurality of lenses, a second convex portion protruding from one of the first main surface and the second main surface, and a third convex portion protruding from the other of the first main surface and the second main surface. A recess is provided at a tip of the third convex portion, the recess being large enough to allow a portion of the second convex portion to be inserted therein. The second convex portion overlaps the recess in a plan view.

[0007] A lighting device according to one aspect of the present invention includes the optical member according to the above aspect, a device body, a substrate attached to the device body, and a light-emitting module having a plurality of light-emitting elements arranged on a main surface of the substrate, wherein the plurality of lenses correspond one-to-one to the plurality of light-emitting elements.

[0008] A method for manufacturing a lighting device according to an embodiment of the present invention includes the steps of manufacturing a plurality of optical members according to the embodiment, stacking the plurality of optical members vertically, transporting the stacked plurality of optical members, and assembling a lighting device using one of the transported plurality of optical members. In the stacking step, a part of the second convex portion of one of the optical members is inserted into the concave portion of another of the optical members. Effect of the Invention

[0009] According to the present invention, it is possible to provide an optical member etc. that can be stably stored and / or transported. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view showing an external appearance of a lighting fixture according to an embodiment. [Diagram 2] FIG. 2 is an exploded perspective view of the lighting fixture according to the embodiment. [Diagram 3] FIG. 3 is a perspective view showing the structural relationship between the light-emitting module, the optical member, and the device body according to the embodiment. [Figure 4] FIG. 4 is a plan view of the optical member according to the embodiment. [Diagram 5] FIG. 5 is a side view of the optical member according to the embodiment. [Figure 6] FIG. 6 is an end view of the optical member according to the embodiment when cut at the position indicated by the line VI-VI in FIG. [Figure 7] FIG. 7 is an end view of a mounting portion for optical members when a plurality of optical members according to the embodiment are stacked. [Figure 8] FIG. 8 is a side view showing a state in which a plurality of optical members according to the embodiment are stacked. [Figure 9] FIG. 9 is an end view showing a modified example of the mounting portion for the optical member according to the embodiment. [Figure 10] FIG. 10 is a flowchart showing a method for manufacturing a lighting device according to an embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] In the following, an optical member, a lighting device, and a method for manufacturing a lighting device according to an embodiment of the present invention will be described in detail with reference to the drawings. Note that each of the embodiments described below shows a specific example of the present invention. Therefore, the numerical values, shapes, materials, components, arrangement and connection forms of the components, steps, and order of steps shown in the following embodiments are merely examples and are not intended to limit the present invention. Therefore, among the components in the following embodiments, components that are not described in the independent claims will be described as optional components.

[0012] In addition, each figure is a schematic diagram and is not necessarily illustrated precisely. Therefore, for example, the scales in each figure do not necessarily match. In addition, in each figure, substantially the same configurations are given the same reference numerals, and duplicated explanations are omitted or simplified.

[0013] Furthermore, in this specification, terms indicating the relationship between elements, such as parallel and orthogonal, terms indicating the shape of elements, such as circular and rectangular, and numerical ranges are not expressions that only express a strict meaning, but are expressions that include a substantially equivalent range, for example, a difference of about a few percent.

[0014] In this specification and the drawings, the X-axis, the Y-axis, and the Z-axis represent the three axes of a three-dimensional orthogonal coordinate system.

[0015] In this specification, unless otherwise specified, "plan view" means viewing the main surface of the substrate of the light emitting module from the front. The Z axis is defined to coincide with the normal line of the main surface of the substrate. Therefore, "plan view" means viewing from the Z axis direction (specifically, the Z axis positive direction).

[0016] In addition, in this specification, ordinal numbers such as "first" and "second" do not refer to the number or order of components, unless otherwise specified, but are used for the purpose of avoiding confusion and distinguishing between components of the same type.

[0017] (Embodiment) [Overall configuration of lighting fixtures] First, the overall configuration of a lighting device 1 according to an embodiment will be described with reference to FIGS.

[0018] FIG 1 is a perspective view showing the appearance of a lighting fixture 1 according to an embodiment. FIG 2 is an exploded perspective view of the lighting fixture 1 according to an embodiment. The upward direction (positive direction of the Z axis) in FIG 1 and FIG 2 corresponds to the direction of a floor surface (not shown) facing the ceiling. In other words, the lighting fixture 1 in FIG 1 and FIG 2 is shown upside down from its normal use. The same applies to FIG 3 and FIG 5 to FIG 9 described later.

[0019] As shown in FIG. 1, the lighting fixture 1 of the present embodiment is, for example, a ceiling light attached to a ceiling. The lighting fixture 1 according to the present embodiment includes a fixture body 10 and a light-emitting module 20 attached to the fixture body 10. The light-emitting module 20 includes a substrate 21 and a plurality of light-emitting elements 22 arranged on a main surface of the substrate 21. In the present embodiment, a plurality of circuit components 81 are further arranged on the main surface of the substrate 21, and the plurality of circuit components 81 constitute a power supply circuit 80. The lighting fixture 1 further includes a reflective sheet 40, a circuit cover 60, an optical member 100, a lighting cover 70, and a fixture attachment portion 90, which are arranged along the light-emitting module 20. A decorative plate 71 is attached to the outer periphery of the lighting cover 70.

[0020] [Main unit] 1, the device body 10 is a disk-shaped member made of sheet metal such as an aluminum plate or a steel plate. The surface of the device body 10 on which the light-emitting module 20 and the like are arranged is coated with, for example, a white paint having a high light reflectance or a reflective metal material is vapor-deposited.

[0021] A circular opening is formed in the center of the fixture body 10, and a substantially cylindrical support part 19 (see FIG. 2) is disposed extending from the periphery of the opening toward the light emitting module 20. The support part 19 is a member made of, for example, resin, and has a structure that allows it to be fitted into the fixture attachment part 90. The fixture attachment part 90 is detachably attached to a ceiling-side attachment member (hook-on ceiling body) installed on the ceiling. In other words, the fixture body 10 is detachably attached to the ceiling via the fixture attachment part 90.

[0022] In the device body 10, a step portion 11 is formed around the support portion 19, and further outside the step portion 11, a ring-shaped mounting surface portion 12 is formed. When the light-emitting module 20 is attached to the device body 10, the back surface of the substrate 21 contacts the mounting surface portion 12, and the lead of the circuit component 81 protruding from the back surface of the substrate 21 is housed in the space within the step portion 11.

[0023] The mounting surface 12 is provided with a restricting protrusion 13 that restricts the mounting position of the light emitting module 20. The mounting surface 12 is also provided with a recess 14 for avoiding contact with the mounting portion 140 of the optical member 100, and a recess 15 for avoiding contact with a protrusion 160 (see FIG. 5) of the optical member 100.

[0024] [Light emitting module] 2, the light emitting module 20 includes a substrate 21, a plurality of light emitting elements 22 arranged on the main surface (front surface) of the substrate 21, and a plurality of circuit components 81 arranged on the substrate 21. The substrate 21 has a polygonal outer shape in a plan view (from the main surface side of the substrate 21), and has a circular opening 23 formed in the center. The outer shape of the substrate 21 in a plan view is expressed as, for example, a rectangle with the tips of the four corners cut off (hereinafter, simply referred to as a "rectangle").

[0025] The substrate 21 is a so-called printed circuit board on which metal wiring is patterned, and in this embodiment, a resin substrate having a conductor pattern (metal wiring) on ​​one side is used as the substrate 21. Examples of such substrates include a glass epoxy substrate and a composite substrate epoxy resin substrate (CEM-3).

[0026] Each of the light-emitting elements 22 in this embodiment is, for example, an LED element in which an LED chip is packaged. That is, the mounting structure of the light-emitting module 20 is an SMD (Surface Mount Device) structure in which an LED element in which an LED chip is packaged is mounted on the main surface of the substrate 21.

[0027] The plurality of light-emitting elements 22 includes two or more types of light-emitting elements that emit light with different color temperatures. The plurality of light-emitting elements 22 includes, for example, a light-emitting element with a high color temperature (e.g., 6500K) and a light-emitting element with a low color temperature (e.g., 2700K). The light emission of the light-emitting element with the high color temperature and the light-emitting element with the low color temperature are controlled independently. This enables dimming and color adjustment.

[0028] The multiple light-emitting elements 22 are connected in series, for example, with each light-emitting element being of the same type. Alternatively, multiple groups (light-emitting element groups) of n (n is an integer of 2 or more) light-emitting elements 22 connected in series may be formed, and these multiple light-emitting element groups may be connected in parallel. Note that all of the multiple light-emitting elements 22 may be light-emitting elements of the same type. These multiple light-emitting elements 22 are arranged in multiple rings around the opening 23 of the substrate 21, for example, as shown in FIG. 2. The multiple light-emitting elements 22 arranged in multiple rings in this manner constitute a light-emitting section in the light-emitting module 20.

[0029] A plurality of circuit components 81 are arranged in a region of the central portion (peripheral portion of the opening 23) of the substrate 21 in a plan view, and these plurality of circuit components 81 constitute a power supply circuit 80 that supplies power for light emission to the plurality of light-emitting elements 22. The power supply circuit 80 converts AC power supplied via a cable (not shown) extending from the device main body 10, for example, into DC power suitable for light emission of the plurality of light-emitting elements 22 and supplies the converted power. As a result, the plurality of light-emitting elements 22 emit light. Each of the plurality of circuit components 81 that constitute the power supply circuit 80 is, for example, a capacitance element such as an electrolytic capacitor or a ceramic capacitor, a resistance element, a coil element, a choke coil (choke transformer), a noise filter, and a semiconductor element such as a diode or an integrated circuit element.

[0030] In this manner, the power supply circuit 80 and an annular light-emitting section (plurality of light-emitting elements 22) are arranged on the main surface of the substrate 21 so as to surround the power supply circuit 80. In the present embodiment, the light-emitting element 30 for use as a night light is further arranged on the main surface of the substrate 21 between the power supply circuit 80 and the light-emitting element 22.

[0031] The light emitting element 30 for the night light is, for example, an LED element having a similar configuration to the light emitting element 22. The color temperature of the light emitted by the light emitting element 30 for the night light is, for example, an incandescent color, but may also be a daylight color. A bullet-shaped LED may also be used as the light emitting element 30 for the night light. An insulating cover 50 (see FIG. 2) and a night light convex portion 130 of the optical member 100 described later are arranged on the front side (the positive Z-axis direction side) of the light emitting element 30 for the night light.

[0032] [Reflective sheet] The reflective sheet 40 is disposed between the light emitting module 20 and the optical member 100. The reflective sheet 40 is a sheet-like member formed of, for example, resin, and reflects light that travels directly or indirectly from the multiple light emitting elements 22 toward the reflective sheet 40.

[0033] 2, the reflection sheet 40 has a plurality of through holes 41 formed therein to expose each of the plurality of light-emitting elements 22 to the optical member 100. When viewed from the front (positive direction of the Z axis), each light-emitting element 22 is exposed from the reflection sheet 40, and light emitted from the light-emitting element 22 travels toward the optical member 100 without being blocked by the reflection sheet 40. Furthermore, light traveling directly or indirectly from the light-emitting element 22 toward the reflection sheet 40 is reflected by the reflection sheet 40 and travels toward the optical member 100. In other words, the reflection sheet 40 suppresses light loss between the light-emitting element 22 and the optical member 100.

[0034] [Circuit cover] The circuit cover 60 is a member that covers a plurality of circuit components 81 (power supply circuits 80) arranged on the substrate 21. In this embodiment, the circuit cover 60 is made of a metal such as iron or aluminum, and is non-flammable. An insulating sheet made of, for example, resin may be arranged on the inner surface of the circuit cover 60. This allows the inner surface of the circuit cover 60 to be closer to the circuit components 81 inside the circuit cover 60, and as a result, the height (width in the Z-axis direction) of the circuit cover 60 can be reduced. Furthermore, the circuit cover 60 may be made of, for example, a flame-retardant resin instead of a metal. This allows, for example, the circuit cover 60 to be made smaller or lighter.

[0035] In this embodiment, the circuit cover 60 is attached to the fixture body 10 together with the optical member 100 and the light emitting module 20 by, for example, a plurality of screws (not shown).

[0036] [Optical components] 2, the optical member 100 is a light-emitting portion cover that covers a plurality of light-emitting elements 22 of the light-emitting module 20. The optical member 100 is formed using a translucent (e.g., transparent) resin material such as a transparent acrylic resin. In a plan view, the optical member 100 has a circular outer shape with a hole (opening 111) in the center, that is, has a shape generally called a doughnut shape.

[0037] The optical member 100 has a plurality of lenses 120. The plurality of lenses 120 are provided in one-to-one correspondence with the plurality of light-emitting elements 22. The lenses 120, for example, expand the light distribution angle of the light from the corresponding light-emitting element 22. That is, the lenses 120 have a function of diverging light. In this way, by arranging the lenses 120 in correspondence with each of the light-emitting elements 22, for example, it is possible to precisely control the diffusion of light from each of the plurality of light-emitting elements 22. The specific shape of the optical member 100 will be described later.

[0038] [Lighting cover] The lighting cover 70 is an example of a diffusion cover, and is attached to the fixture body 10 to cover the main surface of the light-emitting module 20. Specifically, the lighting cover 70 is a member that covers the side of the fixture body 10 on which the light-emitting module 20 and the like are attached, and is made of a translucent resin. The lighting cover 70 is also called a globe. The lighting cover 70 is made of, for example, a milky white resin, and can diffuse the light from each light-emitting element 22 and emit it to the outside.

[0039] The lighting cover 70 has a circular outer shape in a plan view. The lighting cover 70 is attached to the fixture body 10 in a freely detachable manner. In this embodiment, a circular decorative plate 71 corresponding to the outer shape (circular shape) of the lighting cover 70 in a plan view is attached to the outer periphery of the lighting cover 70. The decorative plate 71 is fixed to the lighting cover 70 by a plurality of screws (not shown) or the like. The lighting cover 70 is attached to and detached from the fixture body 10 with the decorative plate 71 fixed.

[0040] [Specific configuration of optical components] Next, a specific configuration of the optical member 100 will be described with reference to FIGS.

[0041] Fig. 3 is a perspective view showing the structural relationship between the light-emitting module 20, the optical member 100, and the device body 10 according to the present embodiment. Fig. 4 is a plan view of the optical member 100 according to the present embodiment. Fig. 5 is a side view of the optical member 100 according to the present embodiment. Fig. 6 is an end view of the optical member 100 according to the present embodiment when cut at the position represented by the line VI-VI in Fig. 4.

[0042] The optical member 100 is a plate-like member having principal surfaces 110a and 110b. The principal surface 110a is an example of a first principal surface, and is the principal surface on the lighting cover 70 side. The principal surface 110b is an example of a second principal surface, and is the principal surface opposite to the principal surface 110b. The principal surface 110b is the principal surface on the light-emitting module 20 and fixture body 10 side.

[0043] As shown in FIGS. 3 to 5, the optical member 100 includes a flat portion 110, a plurality of lenses 120, a night-light convex portion 130, a plurality of mounting portions 140, a recess 150, and a protrusion 160. As shown in FIG.

[0044] The planar portion 110 is a portion located outside the multiple lenses 120 in a plan view. The planar portion 110 has a flat plate shape with a predetermined thickness. The planar portion 110 is a portion that does not overlap the light emitting module 20 in a plan view.

[0045] In this embodiment, the outer shape of the optical member 100 in a planar view is circular. Specifically, the outer shape of the optical member 100 in a planar view is substantially the same as the outer shape of the mounting surface portion 12 of the device body 10. In contrast, the outer shape of the light-emitting module 20 in a planar view is rectangular. Therefore, when the optical member 100 is arranged so as to cover the light-emitting module 20, four bow-shaped portions (flat portions 110) that do not overlap the light-emitting module 20 are formed.

[0046] The lenses 120 protrude from the principal surface 110a as shown in Fig. 5 and Fig. 6. The lenses 120 have a dome shape protruding from the principal surface 110a in the positive direction of the Z axis. The lenses 120 have substantially the same height h1 from the principal surface 110a. Note that the "height of the lens from the principal surface" refers to the distance in the direction normal to the principal surface between the principal surface and the part of the lens farthest from the principal surface.

[0047] The lenses 120 correspond one-to-one to the light-emitting elements 22 arranged on the main surface of the substrate 21. That is, when focusing on one light-emitting element 22, one of the lenses 120 is arranged in front of it (positive direction of the Z axis). Light emitted by the light-emitting element 22 is diffused by the corresponding lens 120 and emitted forward (positive direction of the Z axis).

[0048] The lens 120 having such an optical function is disposed at a position facing each of the plurality of light-emitting elements 22 arranged in a multiple ring shape in the Z-axis direction. That is, the plurality of lenses 120 are arranged in a multiple ring shape like the plurality of light-emitting elements 22, as shown in Fig. 4. The outline of the set of the plurality of lenses 120 in a plan view is roughly rectangular, like the substrate 21.

[0049] The night-light convex portion 130 is an example of a first convex portion protruding from the main surface 110a. As shown in FIG. 5, the height h2 of the night-light convex portion 130 from the main surface 110a is higher than the height h1 of the lenses 120 from the main surface 110a. Specifically, the height h2 of the night-light convex portion 130 from the main surface 110a is higher than any of the heights h1 of the lenses 120 from the main surface 110a. Note that the "height of the convex portion from the main surface" is the distance between the main surface and the part of the convex portion farthest from the main surface in the normal direction to the main surface. Also, the height h2 of the night-light convex portion 130 from the main surface 110a is higher than the height h4 of the convex portion 142 of the mounting portion 140 from the main surface 110a.

[0050] In this embodiment, as shown in FIG. 5, the night-light convex portion 130 has a cover portion 131 and a base portion 132.

[0051] The cover portion 131 is a portion that overlaps with the night-light light emitting element 30 in a plan view. The cover portion 131 protrudes obliquely upward from the upper surface of the base portion 132 toward the center of the optical member 100. As shown in Figs. 3 and 4, the cover portion 131 protrudes from the inner peripheral end portion toward the center of the optical member 100 so as to cover a part of the opening 111 of the optical member 100. The distance between the tip portion of the cover portion 131 and the main surface 110a is the height h2 of the night-light convex portion 130.

[0052] The pedestal portion 132 is a portion that supports the cover portion 131. The pedestal portion 132 is provided along the edge of the opening portion 111 of the optical member 100. That is, the pedestal portion 132 is located between the multiple lenses 120 that are provided in an annular shape and the opening portion 111 in a plan view.

[0053] The placement section 140 is used to stack the optical members 100. The specific configuration of the placement section 140 will be described later.

[0054] As described above, the optical member 100 is fixed to the device body 10 together with the light emitting module 20 and the circuit cover 60 by a plurality of screws or the like. A configuration for regulating the optical member 100 and the substrate 21 of the light emitting module 20 to the correct positions relative to the device body 10 during this fixing operation is provided in the device body 10 or the like.

[0055] Specifically, as shown in Fig. 2, the instrument body 10 has a restricting protrusion 13. The substrate 21 is provided with a cutout 24 into which the restricting protrusion 13 is inserted. The restricting protrusion 13 engages with the cutout 24 of the substrate 21, thereby determining the position and orientation of the substrate 21 relative to the instrument body 10 to the correct position and orientation.

[0056] The height of the restricting protrusion 13 is greater than the thickness of the substrate 21. For this reason, the optical member 100 is formed with a recess 150 into which the restricting protrusion 13 is inserted. The recess 150 is formed in a recessed shape from the main surface 110b of the optical member 100. The recess 150 forms a space to prevent contact between the restricting protrusion 13 and the optical member 100. The recess 150 may be used to position the optical member 100 by contacting the restricting protrusion 13. Two sets of the restricting protrusion 13, the notch 24, and the recess 150 are provided, but only one set or three or more sets may be provided.

[0057] 4 and 5, a protrusion 160 is provided on the main surface 110b of the optical member 100. The protrusion 160 is inserted into a through hole 25 (see FIG. 3) provided in the substrate 21 of the light-emitting module 20 and into a recess 15 (see FIG. 3) of the device body 10, in that order. In a plan view, the size and shape of the through hole 25 are substantially the same as the size and shape of the protrusion 160. By inserting the protrusion 160 into the through hole 25, the position of the optical member 100 relative to the light-emitting module 20 (substrate 21) can be regulated to a regular position.

[0058] In addition, the recess 15 of the instrument body 10 is larger than the protrusion 160 in a plan view. In other words, the recess 15 forms a space for preventing contact between the protrusion 160 and the instrument body 10. A through hole may be provided instead of the recess 15. Although two sets of the protrusion 160, the through hole 25, and the recess 15 are provided in the embodiment, only one set or three or more sets may be provided.

[0059] [Placement section] Next, a specific configuration of the mounting portion 140 for the optical member 100 will be described.

[0060] As shown in FIGS. 5 and 6, the placement portion 140 has protrusions 141 and 142.

[0061] The protrusion 141 is an example of a second protrusion protruding from one of the principal surfaces 110a and 110b. In the present embodiment, the protrusion 141 protrudes from the principal surface 110b. The protrusion 141 is a protrusion having a truncated cone shape.

[0062] The protruding portion 142 is an example of a third protruding portion protruding from the other of the main surfaces 110a and 110b. As shown in Fig. 6, a recessed portion 145 having a size that allows a part of the protruding portion 141 to be inserted therein is provided at the tip of the protruding portion 142. In other words, the protruding portion 142 is an annular protruding portion surrounding the recessed portion 145.

[0063] The convex portion 141 overlaps with the concave portion 145 in a plan view. Therefore, when two optical members 100 are stacked, the convex portion 141 and the concave portion 145 are located at the same position in a plan view, and a part of the convex portion 141 is inserted into the concave portion 145. Specifically, the protrusion 144 provided at the tip of the convex portion 141 is inserted into the concave portion 145 (see FIG. 7).

[0064] In this embodiment, the tip of the convex portion 141 includes a flat surface 143 and a protrusion 144, as shown in FIG.

[0065] The protrusion 144 protrudes from the flat surface 143. In a plan view, the protrusion 144 is located at the center of the convex portion 141 and is surrounded by the annular flat surface 143. As shown in Fig. 6, a recess is provided at the tip of the protrusion 144. This makes it possible to reduce the thickness of the protrusion 144, and makes it possible to suppress molding defects such as sink marks when the optical member 100 is formed by injection molding using a resin material.

[0066] The projection 144 has a size that allows it to be inserted into the recess 145. On the other hand, the flat surface 143 has a size that does not allow it to be inserted into the recess 145. FIG. 7 is an end view of the mounting portion 140 of the optical member 100 when a plurality of optical members 100 according to the present embodiment are stacked. As shown in FIG. 7, when two optical members 100 are stacked, the flat surface 143 of the upper optical member 100 is placed on the convex portion 142 of the lower optical member 100. At this time, the projection 144 of the upper optical member 100 is inserted into the concave portion 145 of the lower optical member 100, and the lateral movement of the projection 144 is restricted by the convex portion 142. This makes it possible to prevent the stacked optical members 100 from collapsing.

[0067] In this embodiment, as shown in Fig. 4, the optical member 100 includes four mounting portions 140. The four mounting portions 140 are arranged in rotationally symmetric positions with the center (central axis J) of the optical member 100 as the center of rotation in a plan view. Specifically, the four mounting portions 140 are arranged in rotationally symmetric positions by 90 degrees. In other words, the positions of the four mounting portions 140 are the same regardless of whether the optical member 100 is rotated by 90 degrees, 180 degrees, or 270 degrees around the central axis J. This allows the optical members 100 to be rotated and stacked.

[0068] A specific method for stacking the optical members 100 will be described below with reference to FIG.

[0069] Fig. 8 is a side view showing a state in which a plurality of optical members 100 according to this embodiment are stacked. Fig. 8 shows three optical members 100A to 100C stacked in this order, and a fourth optical member 100D being further stacked.

[0070] 8, the optical members 100A to 100D are placed in order with their orientations rotated 180 degrees each. Therefore, the night-light convex portion 130A of the optical member 100A and the night-light convex portion 130C of the optical member 100C overlap in a plan view, and the night-light convex portion 130B of the optical member 100B and the night-light convex portion 130D of the optical member 100D overlap in a plan view. The night-light convex portions 130A and 130C do not overlap the night-light convex portions 130B and 130D in a plan view.

[0071] When the optical member 100D is stacked on the optical member 100C, the convex portions 141D of the four mounting portions 140D of the optical member 100D are placed on the convex portions 142C of the four mounting portions 140C of the optical member 100C. Specifically, the protrusions 144D of the convex portions 141D are inserted into the recesses 145 (not shown in FIG. 8) of the convex portions 142C, and the flat surfaces 143D of the convex portions 141D are placed on the convex portions 142C.

[0072] Since the optical members 100D can be supported at four points, the optical members 100D can be stacked stably. The bottom optical member 100A can be stably placed on a flat surface by the convex portions 141A of the four placement portions 140A.

[0073] As shown in Fig. 8, the cover portion 131A of the night-light convex portion 130A of the lowest optical member 100A is inserted into the openings 111 (not shown in Fig. 8) of the second-stage optical member 100B and the third-stage optical member 100C. This prevents the cover portion 131A of the night-light convex portion 130A from contacting other optical members 100. Similarly, the cover portion 131B of the second-stage night-light convex portion 130B, the cover portion 131C of the third-stage night-light convex portion 130C, and the cover portion 131D of the fourth-stage night-light convex portion 130D can also avoid contacting other optical members 100.

[0074] In this embodiment, the night-light convex portion 130 overlaps with the night-light convex portion 130 of the optical member 100 two levels above in plan view, so it is necessary to ensure the height of the mounting portion 140 so that the two night-light convex portions 130 do not come into contact with each other. As shown in FIG. 6, the height of the mounting portion 140 corresponds to the sum of the height h3 of the convex portion 141 and the height h4 of the convex portion 142. By providing convex portions on both the main surfaces 110a and 110b of the optical member 100, the height required for the mounting portion 140 can be distributed. In other words, it is possible to prevent a high convex portion from being formed on only one of the main surfaces 110a and 110b.

[0075] A height h4 of the convex portion 142 from the principal surface 110a is higher than a height h1 from the principal surface 110a of the plurality of lenses 120. This makes it difficult for the surface of the lens 120 to come into contact with the other optical members 100 when the optical members 100 are stacked, thereby suppressing damage to the lens 120 and suppressing deterioration in the light distribution characteristics.

[0076] A height h3 of the convex portion 141 from the principal surface 110b is higher than a height h4 of the principal surface 110a of the convex portion 142. This allows the convex portion 142 on the light exit side to be lowered, thereby preventing the convex portion 142 from interfering with the light exiting from the lens 120.

[0077] In this embodiment, since the convex portion 141 of the mounting portion 140 protrudes from the main surface 110b toward the instrument body 10, the instrument body 10 is provided with a concave portion 14 to avoid contact with the convex portion 141, as shown in Fig. 3. The concave portion 14 of the instrument body 10 is larger than the convex portion 141 in a plan view. A through hole may be provided instead of the concave portion 14.

[0078] In FIG. 8, an example in which the optical members 100 are alternately stacked by rotating them by 180 degrees is shown, but the present invention is not limited thereto. For example, the optical members 100 may be stacked in order while rotating them by 90 degrees at a time. In this case, the night-light convex portion 130 overlaps with the night-light convex portion 130 of the optical member four levels above in a plan view. Therefore, three optical members 100 are arranged between the night-light convex portions 130 that overlap in a plan view, so that the distance can be increased by the thickness of the optical members 100, and the height of the mounting portion 140 can be reduced. By reducing the height of the mounting portion 140, the deterioration of the light distribution characteristics of the optical members 100 can be suppressed. In addition, the recess 14 of the fixture body 10 for avoiding contact with the mounting portion 140 can be made smaller.

[0079] In addition, in FIG. 8, the second optical member 100B may be placed on the base 132A of the night-light convex portion 130A. In this case, the optical member 100B can be supported more stably. In addition, the number of mounting portions 140B provided on the optical member 100B can be reduced. For example, the optical member 100B may have only one mounting portion 140B. The optical member 100B can be stably supported by the base 132A and the one mounting portion 140B. Similarly, the bases 132B, 132C, and 132D can support the optical member 100 placed thereon when the optical member 100 is placed thereon.

[0080] Moreover, a ring-shaped protrusion 142 may be provided on the main surface 110b. Fig. 9 is an end view showing a mounting portion 240 of an optical member 200 according to a modified example of the present embodiment. The mounting portion 240 has a shape obtained by turning the mounting portion 140 shown in Fig. 6 upside down.

[0081] Specifically, the placement portion 240 has protrusions 241 and 242 as shown in FIG.

[0082] The protruding portion 241 is an example of a second protruding portion, and protrudes from the main surface 110a. The protruding portion 241 has an inverted shape of the protruding portion 141 of the mounting portion 140 in Fig. 6, and is provided with a flat surface 243 and a projection 244 at its tip.

[0083] The protruding portion 242 is an example of a third protruding portion, and protrudes from the main surface 110b. A recessed portion 245 having a size into which a part of the protruding portion 241 (specifically, the protrusion 244) can be inserted is provided at the tip of the protruding portion 242. In other words, the protruding portion 242 is an annular protruding portion surrounding the recessed portion 245.

[0084] In this modification, the height of the convex portion 242 protruding from the main surface 110b is higher than the height of the convex portion 241 protruding from the main surface 110a. In other words, the convex portion 241 protruding from the main surface 110a is configured to be lower. This makes it difficult for the convex portion 241 to obstruct the light emitted from the multiple lenses 120, and it is possible to suppress deterioration of the optical characteristics of the optical member 200.

[0085] [Manufacturing method] Next, a method for manufacturing the lighting fixture 1 will be described with reference to Fig. 10. Fig. 10 is a flowchart showing a method for manufacturing the lighting fixture 1 according to the present embodiment. Fig. 10 shows a method for manufacturing a plurality of lighting fixtures 1.

[0086] 10, first, a plurality of optical members 100 are manufactured (S10). For example, the optical members 100 are manufactured by injection molding using a resin material.

[0087] Next, the manufactured optical members 100 are stacked one on top of the other (S20). Specifically, a part of the convex portion 141 of one optical member 100 is inserted into the concave portion 145 of the other optical member 100. More specifically, as described with reference to FIG. 7, the protrusion 144 of the convex portion 141 of the upper optical member 100 is inserted into the concave portion 145 of the convex portion 142 of the lower optical member 100, and the flat surface 143 is placed on the convex portion 142. The protrusion 144 is caught by the convex portion 142 to restrict lateral movement, so that the stacked optical members 100 are unlikely to collapse and can be stored stably.

[0088] Next, the stacked optical members 100 are transported (S30). Specifically, the stacked optical members 100 are transported as they are (in a stacked state) to a work site where the lighting device 1 is assembled. As in the case of storage, the protrusions 144 are hooked onto the convex portions 142 to restrict lateral movement, so the stacked optical members 100 are less likely to collapse and can be transported stably.

[0089] Next, the lighting fixture 1 is assembled using one of the transported optical members 100 (S40). Note that components other than the optical member 100 (such as the fixture body 10 and the light-emitting module 20) are also manufactured in the same manner as the optical member 100, and then transported to a work site where the lighting fixture 1 is assembled. The lighting fixture 1 can be manufactured by assembling the components in a predetermined order.

[0090] [Effects, etc.] As described above, the optical member 100 according to the present embodiment is a plate-shaped optical member 100 having a main surface 110a and a main surface 110b opposite to the main surface 110a, and includes a plurality of lenses 120 protruding from the main surface 110a, a night-light convex portion 130 protruding from the main surface 110a and having a height from the main surface 110a higher than the plurality of lenses 120, a convex portion 142 protruding from one of the main surfaces 110a and 110b, and a convex portion 141 protruding from the other of the main surfaces 110a and 110b. A recess 145 having a size that allows a part of the convex portion 141 to be inserted is provided at the tip of the convex portion 142. The convex portion 141 overlaps the recess 145 in a plan view.

[0091] As a result, when two optical members 100 are stacked, a part of the convex portion 141 of the upper optical member 100 can be inserted into the concave portion 145 of the convex portion 142 of the lower optical member 100. The convex portion 141 is engaged with the concave portion 145 of the convex portion 142, thereby restricting the lateral position of the upper optical member 100. As a result, the optical members 100 are less likely to collapse during storage and / or transportation, and can be transported and / or stored stably.

[0092] In addition, when two optical members 100 are stacked, it is necessary to secure a space between the two optical members 100 so that the lower night-light convex portion 130 does not push up the upper optical member 100. This space depends on the total height of the convex portion 141 and the convex portion 142. In other words, in the optical member 100 according to the present embodiment, the height for forming the necessary space is allocated to the convex portion 141 and the convex portion 142 and secured. Therefore, it is not necessary to provide a high convex portion on either one of the main surfaces 110a and 110b. By lowering the height of the convex portion provided on the main surface 110a, the convex portion is less likely to interfere with the light emitted from the multiple lenses 120, and the deterioration of the optical characteristics of the optical member 100 can be suppressed. In addition, by lowering the height of the convex portion provided on the main surface 110b, the convex portion is less likely to interfere with the attachment to the device body 10, and handling becomes easier.

[0093] Moreover, for example, the protrusion 141 protrudes from the main surface 110b, and the protrusion 142 protrudes from the main surface 110a.

[0094] As a result, by reducing the height of the convex portion 142, the convex portion 142 is less likely to interfere with the light emitted from the multiple lenses 120, and it is possible to suppress deterioration of the optical characteristics of the optical member 100. Furthermore, by reducing the height of the convex portion 141, the convex portion 141 is less likely to interfere with attachment to the device body 10, making it easier to handle.

[0095] Furthermore, for example, the height h3 of the protrusion 141 from the main surface 110b is greater than the height h4 of the protrusion 142 from the main surface 110a.

[0096] As a result, since the convex portions 142 are low, the convex portions 142 are less likely to obstruct the light emitted from the lenses 120, and deterioration of the optical characteristics of the optical member 100 can be suppressed.

[0097] Also, for example, the height h2 of the night-light convex portion 130 from the main surface 110a is higher than the height h4 of the convex portion 142 from the main surface 110a.

[0098] As a result, since the night-light convex portion 130 is higher than the convex portion 142, the convex portion 142 is less likely to obstruct the light emitted from the night-light convex portion 130, and deterioration of the optical characteristics of the optical member 100 can be suppressed.

[0099] Also, for example, the height h4 of the convex portion 142 from the principal surface 110a is higher than the height h1 of the multiple lenses 120 from the principal surface 110a.

[0100] As a result, the lenses 120 are lower than the convex portion 142, so that when the optical members 100 are stacked, the lenses 120 do not come into contact with the optical members 100. As a result, the lenses 120 are less likely to be damaged, and deterioration of the optical properties of the optical members 100 can be suppressed.

[0101] Furthermore, for example, the tip of the convex portion 141 includes a flat surface 143 and a protrusion 144 protruding from the flat surface 143. The recess 145 is sized so that the protrusion 144 can be inserted therein.

[0102] As a result, when two optical members 100 are stacked, the protrusion 144 of the convex portion 141 of the upper optical member 100 can be inserted into the concave portion 145 of the convex portion 142 of the lower optical member 100. Furthermore, when the protrusion 144 is inserted into the concave portion 145, the flat surface 143 of the convex portion 141 abuts against the convex portion 142, so that the upper optical member 100 can be stably stacked on the lower optical member 100.

[0103] For example, the optical member 100 includes a plurality of pairs of the convex portions 141 and 142.

[0104] As a result, when two optical members 100 are stacked, the upper optical member 100 can be supported at multiple positions, allowing for more stable storage and transportation.

[0105] Also, for example, the multiple pairs of convex portions 141 and 142 are arranged in rotationally symmetric positions with the center of the optical member 100 as the center of rotation in a plan view.

[0106] This allows stacking multiple optical members 100 with different orientations. For example, by stacking multiple optical members 100 alternately while rotating them by 180 degrees, it is possible to prevent the night-light convex portion 130 from hitting the upper optical member 100.

[0107] Furthermore, for example, the lighting fixture 1 according to this embodiment includes an optical member 100, a fixture body 10, a substrate 21 attached to the fixture body 10, and a light-emitting module 20 having a plurality of light-emitting elements 22 arranged on a main surface of the substrate 21. The plurality of lenses 120 are in one-to-one correspondence with the plurality of light-emitting elements 22.

[0108] This makes it difficult for the optical member 100 to be damaged during transportation and / or storage, thereby improving the reliability and yield of the lighting fixture 1.

[0109] Moreover, for example, the light emitting module 20 further includes a night light light emitting element 30 disposed on the main surface of the substrate 21. The night light convex portion 130 overlaps the night light light emitting element 30 in a plan view.

[0110] This allows the lighting fixture 1 to function as a night light.

[0111] Moreover, the manufacturing method of the lighting device 1 according to this embodiment includes the steps of manufacturing a plurality of optical members 100, stacking the plurality of optical members 100 vertically, transporting the stacked plurality of optical members 100, and assembling the lighting device 1 using one of the transported plurality of optical members 100. In the stacking step, a part of the convex portion 141 of one optical member 100 is inserted into the concave portion 145 of another optical member 100.

[0112] This makes it difficult for the optical members to be damaged during transportation and / or storage, and therefore makes it possible to manufacture highly reliable lighting fixtures 1 with a high yield.

[0113] (others) While the optical member, the lighting device, and the method for manufacturing the lighting device according to the present invention have been described based on the above-mentioned embodiment, the present invention is not limited to the above-mentioned embodiment.

[0114] For example, in the above embodiment, the night-light convex portion 130 is shown as an example of the first convex portion, but the present invention is not limited to this. For example, the first convex portion may be a convex portion for regulating the position of the optical member 100.

[0115] Also, for example, the heights h1 to h4 of the convex portions are not limited to the above-mentioned relationship in magnitude. For example, the height h1 of the lens 120, the height h2 of the night-light convex portion 130, and the height h4 of the convex portion 142 may be equal to each other. Also, the height h4 of the convex portion 142 may be lower than the height h1 of the lens 120. Also, the height h3 of the convex portion 141 and the height h4 of the convex portion 142 may be equal to each other. Or, the height h3 of the convex portion 141 may be lower than the height h4 of the convex portion 142.

[0116] Furthermore, for example, a rectangular substrate 21 with the tips of the four corners cut off has been exemplified as the substrate 21 of the light-emitting module 20, but the outer shape of the substrate 21 of the light-emitting module 20 in a planar view is not limited to this. For example, the outer shape of the substrate 21 in a planar view may be a polygonal shape other than a rectangle, such as a triangular shape or a pentagonal shape. Furthermore, the outer shape of the substrate 21 in a planar view may be a circle or an ellipse.

[0117] Furthermore, the substrate (module substrate) on which the multiple light-emitting elements 22 are arranged in the light-emitting module 20 does not have to be a single physical substrate like the substrate 21 according to the embodiment. For example, a single module substrate may be formed by connecting multiple substrates, each of which has one or more light-emitting elements 22 arranged thereon. For example, depending on the size required for the module substrate, it may be determined whether the module substrate is realized by a single substrate or by multiple substrates.

[0118] Furthermore, the substrate 21 of the light-emitting module 20 may be of a type other than the glass epoxy substrate and the composite substrate epoxy resin substrate (CEM-3) exemplified in the above embodiment. For example, a metal-based substrate made of a metal material with a resin-coated surface may be used. In this case, for example, heat from the multiple light-emitting elements 22 and multiple circuit components 81 arranged on the main surface of the substrate 21 is efficiently conducted to the fixture body 10 via the substrate 21.

[0119] Furthermore, power supply circuit 80 that supplies power for light emission to each light-emitting element 22 may be configured with a plurality of circuit components arranged on a board separate from board 21. Furthermore, power supply circuit 80 may be arranged outside lighting fixture 1. For example, power supply circuit 80 may be housed in a power supply box that supplies DC power to lighting fixture 1. This allows lighting fixture 1 to be made smaller and lighter, for example.

[0120] Furthermore, one or more circuit components 81 arranged on substrate 21 may form a different type of electric circuit (electronic circuit) from power supply circuit 80. For example, one or more circuit components 81 may form a control circuit that controls dimming or color adjustment of multiple light-emitting elements 22 in accordance with a signal transmitted from outside lighting device 1. Furthermore, power supply circuit 80 may include the above-mentioned control circuit.

[0121] In addition, the light emitting element 22 is an SMD type LED element, but is not limited thereto. For example, the light emitting module 20 may have a COB (Chip On Board) structure in which an LED chip is directly mounted on the substrate 21. In this case, the LED chips mounted on the substrate 21 are collectively or individually sealed with a sealing member containing a wavelength conversion material, thereby making it possible to obtain illumination light with a predetermined color temperature.

[0122] In the above-described embodiment and modified example, an LED element in which an LED chip is packaged has been exemplified as the light-emitting element 22. However, other types of solid-state light-emitting elements, such as semiconductor light-emitting elements such as semiconductor lasers, or EL elements such as organic EL (Electro Luminescence) or inorganic EL, may be adopted as the light-emitting element 22.

[0123] Furthermore, for example, the lighting fixture 1 may not include any components other than the fixture body 10, the light-emitting module 20, and the optical member 100. For example, the lighting fixture 1 may not include the reflective sheet 40, the circuit cover 60, the lighting cover 70, etc. The lighting fixture 1 may be realized as a lighting fixture other than a ceiling light.

[0124] In addition, the present invention also includes forms obtained by applying various modifications to each embodiment that a person skilled in the art may think of, and forms realized by arbitrarily combining the components and functions of each embodiment within the scope that does not deviate from the spirit of the present invention. [Explanation of symbols]

[0125] 1 Lighting equipment 10. Equipment body 20 Light Emitting Module 21 Substrate 22 Light emitting element 30 Light emitting element for night light 100, 100A, 100B, 100C, 100D, 200 Optical components 110a Main surface (first main surface) 110b Main surface (2nd main surface) 120 Lens 130, 130A, 130B, 130C, 130D Night light convex part (first convex part) 140, 140A, 140B, 140C, 140D, 240 Placement part 141, 141A, 141D, 242 convex part (second convex part) 142, 142C, 241 convex part (third convex part) 143, 143D, 243 flat surface 144, 144D, 244 protrusion 145, 245 recess

Claims

1. A plate-shaped optical member having a first main surface and a second main surface opposite to the first main surface, a plurality of lenses protruding from the first major surface; a first convex portion protruding from the first main surface and having a height from the first main surface greater than the height of the lenses; a second protrusion protruding from one of the first main surface and the second main surface; a third protrusion protruding from the other of the first main surface and the second main surface, a recess having a size into which a part of the second protrusion can be inserted is provided at a tip of the third protrusion, The second convex portion overlaps the concave portion in a plan view. Optical components.

2. The second protrusion protrudes from the second main surface, The third protrusion protrudes from the first main surface. The optical member according to claim 1 .

3. The height of the second convex portion from the second main surface is higher than the height of the third convex portion from the first main surface. The optical member according to claim 2 .

4. The height of the first convex portion from the first main surface is higher than the height of the third convex portion from the first main surface. The optical member according to claim 2 or 3.

5. a height of the third convex portion from the first principal surface is greater than a height of the lenses from the first principal surface; The optical member according to any one of claims 2 to 4.

6. The tip portion of the second protrusion includes a flat surface and a protrusion protruding from the flat surface, The recess has a size that allows the protrusion to be inserted therein. The optical member according to any one of claims 1 to 5.

7. A plurality of sets of the second protrusions and the third protrusions are provided. The optical member according to any one of claims 1 to 6.

8. The plurality of sets are arranged in rotational symmetry with respect to the center of the optical member as a rotation center in a plan view. The optical member according to claim 7.

9. The optical member according to any one of claims 1 to 8, The instrument body, A light emitting module having a substrate attached to the device body and a plurality of light emitting elements arranged on a main surface of the substrate, The lenses correspond one-to-one to the light-emitting elements. Lighting fixtures.

10. The light emitting module further includes a light emitting element for a night light disposed on the main surface of the substrate; The first convex portion overlaps the night light light emitting element in a plan view.

10. A lighting device according to claim 9.

11. A step of manufacturing a plurality of optical members according to any one of claims 1 to 8; stacking a plurality of the optical members one above the other; transporting a stack of a plurality of the optical elements; and assembling a lighting fixture using one of the transported optical members, In the stacking step, a part of the second convex portion of one of the optical members is inserted into the concave portion of the other optical member; A method for manufacturing lighting fixtures.

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