Substrate sheet for card-type lamp unit, card-type lamp unit and vehicle lamp

Abstract

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

Description

[Technical Field]

[0001] The present invention relates to a substrate sheet for a card-type lamp unit having an external connector insertion portion and a heat sink with a different linear expansion coefficient, a card-type lamp unit, and a vehicle lamp. [Background technology]

[0002]

[0024]

[0025] and Figure 3 of the specification of Patent Document 1 describe a card-type light source made of resin, which has a large number of LEDs mounted on an element mounting portion and a connector portion protruding from the element mounting portion. If a board to be connected to the LEDs is formed in such a card-type light source, it is conceivable that the heat generated in the board when the light is turned on can be dissipated by integrating a metal plate (heat dissipation member) or the like with the back surface of the board.

[0003] Furthermore, a card-type light source such as that disclosed in Patent Document 1 is generally formed as a substrate sheet together with a frame body connected via a number of connecting ends, and is then cut out from the frame body by cutting the connecting ends. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] WO2019 / 117190 Summary of the Invention [Problem to be solved by the invention]

[0005] When mounting LEDs on a substrate sheet having a card-shaped light source as in Patent Document 1, or when integrating a heat dissipation member such as a metal plate on the back surface of the resin card-shaped light source of the substrate sheet to form a metal base substrate, the substrate sheet must be heat treated. Such heat treatment causes "warping" due to bending stress in the formed metal base substrate due to the difference in linear expansion coefficient between the resin card-shaped light source and the metal plate.

[0006] Because the metal base substrate formed as a substrate sheet is integrated with the frame body via numerous connecting ends, the outer periphery of the metal base substrate connected to the frame body by the connecting ends does not warp due to the frame body's restriction of deformation. However, since the connecting ends with the frame body become burrs after cutting, if connecting ends were formed between the outer periphery of the connector portion and the frame body, warping would not occur, but would adversely affect the insertion and removal of the connector portion from an external connector. Therefore, since connecting ends cannot be formed between the connector portion and the frame body, a substrate sheet having a metal base substrate with a connector portion formed as a substrate sheet has the problem of warping occurring near the portion where the connector portion is formed during heat treatment.

[0007] In view of the above problems, the present application provides a substrate sheet having a metal base substrate with a connector portion, a card-type lighting unit, and a vehicle lighting fixture, which are less likely to warp near the connector portion even when subjected to heat treatment. [Means for solving the problem]

[0008] In a substrate sheet of a card-type lighting unit, the substrate sheet has a polygonal substrate body having an outer periphery and a connector-forming edge, an external connector insertion portion formed on the connector-forming edge, a heat dissipation member integrated into the substrate body and having a linear expansion coefficient different from that of the substrate body, and a light-emitting element light source connected to a control circuit for turning the light on and off, and a frame body that integrates the card-type lighting unit via a connecting end portion formed on the outer periphery of the polygonal substrate body, and a connecting end portion with the frame body is provided on the connector-forming edge.

[0009] (Function) By connecting the connector forming portion to the frame body via the connecting end portion, even if bending stress occurs near the connector forming portion when the substrate sheet is subjected to heat treatment, warping is restricted by the frame body.

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

[0011] (Operation) If a control circuit that controls the on / off of multiple light-emitting element light sources were placed outside the card-type lighting unit, it would be necessary to provide a metal conductive path for each of the multiple light-emitting element light sources in the external connector insertion section. However, the present invention mounts the control circuit on the circuit board main body of the card-type lighting unit, eliminating the need to provide a conductive path for each light-emitting element in the external connector insertion section.

[0012] Furthermore, it is desirable that the substrate sheet of the card-type lighting unit has a plurality of the card-type lighting units, and each card-type lighting unit has an interconnecting end portion that interconnects each connector-forming edge with each other, instead of the connecting end portion with the frame body.

[0013] (Operation) In the substrate sheet, the connector-forming sides of the plurality of card-type lighting units are connected by the interconnecting end portions, so that warping occurring in the vicinity of each connector-forming side is mutually restricted.

[0014] The card-type lamp unit is formed by cutting the connecting end portion and separating it from the frame of the substrate sheet, and the separated card-type lamp unit is provided in a vehicle lamp. [Effects of the Invention]

[0015] According to the substrate sheet of the card-type lighting unit, warping is unlikely to occur in the vicinity of the external connector insertion portion relative to the frame body even when heat treatment is performed.

[0016] The substrate sheet of the card-type lighting fixture unit eliminates the need to form a conductive path in the external connector insertion section that connects the control circuit for turning the light on and off to each of the multiple light-emitting elements, so the width of the external connector insertion section can be narrowed and the connector forming edge can be made wider, so that the connecting end of the connector forming edge can be made thicker or more numerous, thereby better preventing warping that occurs near the external connector insertion section.

[0017] According to the substrate sheet of the card-type lighting unit, the warping that occurs near each connector forming edge of multiple card-type lighting units is mutually restricted, thereby further strengthening the prevention of warping that occurs near the external connector insertion portion.

[0018] In addition, it is possible to obtain a card-type lighting unit and a vehicle lighting fixture that have the above-mentioned effects. [Brief explanation of the drawings]

[0019] [Figure 1] 1 is a front view of a vehicle lamp having a card-type lamp unit according to a first embodiment. [Figure 2] 2 is a cross-sectional view taken along line II in FIG. 1 and an enlarged cross-sectional view of the cross-sectional view. [Figure 3] 1 is a schematic cross-sectional view of a card-type lighting unit and a power supply connector. [Figure 4] FIG. 10 is a schematic explanatory diagram of a substrate sheet on which a plurality of card-type lighting units are arranged on the side. [Figure 5] 10 is a schematic explanatory diagram of a substrate sheet formed so that the external connector insertion portions of a plurality of card-type lighting fixture units are arranged opposite each other; FIG. [Figure 6] FIG. 10 is a schematic explanatory diagram of a substrate sheet on which a plurality of modified card-type lighting units are arranged sideways. [Figure 7] 10A and 10B are schematic explanatory diagrams of substrate sheets formed so that external connector insertion portions are arranged opposite each other for a number of modified examples of the card-type lighting fixture unit. DETAILED DESCRIPTION OF THE INVENTION

[0020] A preferred embodiment of a vehicle lamp of the present invention will be described below with reference to Figures 1 and 2, and a preferred embodiment of a card-type lamp unit of the present invention will be described with reference to Figure 3. In each figure, the vehicle lamp, card-type lamp unit, and substrate sheet will be described with reference to the directions (front side: back side: left end side: right end side: tip side: base end side = Fr:Re:Le:Ri:Lo:Up).

[0021] A vehicle lamp 1 according to a first embodiment shown in FIGS. 1 and 2 comprises a lamp body 2, a front cover 3, and a lamp unit 4. The lamp body 2 has an opening on the front side of a vehicle (not shown). The front cover 3 is made of a translucent resin, glass, or the like, and is attached to the opening of the lamp body 2 to form a lamp chamber S therein. The lamp unit 4 shown in FIG. 1 is composed of a card-type lamp unit 5 having light-emitting element light sources 6 made up of light-emitting elements 6a to 6g such as LED light sources or laser diodes, an optical unit 7, a heat dissipation unit 8, and a power supply connector 9, and is disposed inside the lamp chamber S.

[0022] 1 to 3 is composed of a substrate body 10 which is a glass epoxy substrate, an external connector insertion portion 11 formed as a card edge connector, and a metal plate 16 which is a heat dissipation member integrally formed on the back surface of the substrate body 10 and the external connector insertion portion 11. As an example, the external connector insertion portion 11 is formed to protrude upward from a connector forming edge 12 which is the outer peripheral edge portion on the upper end side of the rectangular plate-shaped substrate body 10.

[0023] 3, it is more preferable that the metal plate 16 integrally formed on the back surface of the board main body 10 and the external connector insertion portion 11 is not formed on the back surface of the external connector insertion portion 11, but is instead formed integrally only on the back surface of the board main body 10. In this case, since the external connector insertion portion 11 does not have the metal plate 16 on its back surface, the metal plate 16 will not peel off from the external connector insertion portion 11, which is made of a glass epoxy board, when it is inserted into or removed from the power supply connector 9. Furthermore, if the metal plate 16 is not provided on the back surface of the external connector insertion portion 11, burrs generated on the outer periphery of the metal plate 16 during processing will not protrude from the outer periphery of the external connector insertion portion 11. This prevents damage to the power supply connector 9 due to burrs and also prevents burrs broken off from the metal plate 16 from adhering to the conductive paths on the board main body 10 or the connector insertion portion 11 and causing a short circuit.

[0024] As shown in FIG. 3 , a light-emitting element light source 6 consisting of light-emitting elements 6a-6g and a control circuit 13 for turning the light-emitting elements 6a-6g on and off are mounted on the surface 10a of a substrate main body 10 of the card-type lighting unit 5. The control circuit 13 includes a switch circuit 13a that independently switches the light-emitting elements 6a-6g on and off, and multiple electronic components 13c-13f, including a power supply circuit. The switch circuit 13a and the multiple electronic components 13c-13f are electrically connected to terminals 13g formed on the surface of the external connector insertion portion 11 via metal conductive paths 13b. The multiple light-emitting elements 6a-6g are electrically connected to the switch circuit 13a via metal element conductive paths 13h, each of which corresponds to the number of light-emitting elements 6a-6g. The light-emitting elements 6a-6g may be mounted directly on a metal plate 16 through through-holes bored through the front and rear surfaces of the substrate main body 10, rather than on the surface of the substrate main body 10. In this embodiment, seven light-emitting elements are mounted, and therefore they must be connected to the switch circuit 13 via seven or more element conductive paths. The number of light-emitting elements mounted is not limited to seven, and may be one or any other number. As shown in Figures 1 and 3, the control circuit 13 mounted on the surface 10a of the substrate body 10 is concealed from the front by an extension reflector 15.

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

[0026] 1 and 2, the heat dissipation unit 8 is supported relative to the lamp body 2 via an aiming mechanism 14. The aiming mechanism 14 includes a pivot fulcrum 14a fixed to the lamp body 2, and an aiming screw 14b for adjusting tilt in the up-down direction and an aiming screw 14c for adjusting tilt in the left-right direction, which are respectively rotatably supported by the lamp body 2. The main body 8a of the heat dissipation unit 8 is supported so as to be swingable relative to the pivot fulcrum 14a, and tilts up, down, left, and right based on the rotation of the aiming screw 14b for adjusting tilt in the up-down direction and the aiming screw 14c for adjusting tilt in the left-right direction.

[0027] The power supply connector 9 shown in FIGS. 1 to 3 is composed of a connector main body 9a, a socket 9b for an external connector socket 11, and a power supply cable 9c for receiving power from a power source (not shown).

[0028] 1 to 3, the card-type lighting unit 5 is electrically connected to and held by attaching the external connector insertion portion 11 to the insertion port 9b of the power supply connector 9, with the metal plate 16 integrated into the back surface of the board body 10 in contact with the surface 8d of the main body 8a of the heat dissipation unit 8. At this time, the light-emitting element light source 6 is directed forward and positioned near the rear focal point of the projection lens 7a. Note that, although the power supply connector 9 is inserted from above the connector insertion portion 11 arranged to protrude upward from the board body 10 in FIGS. 1 and 2, the power supply connector 9 may also be inserted from below into the connector insertion portion 11 arranged to protrude downward from the board body 10.

[0029] 1 to 3, a card-type lighting unit 5 receives power from a power source (not shown) via a power supply connector 9 to a control circuit 13 and a light-emitting element light source 6, and turns on and off the light-emitting elements 6a to 6g independently under the control of a switch circuit 13a. The light source unit 4 in Fig. 1 is held inside the lamp body 2 by an aiming mechanism 14 in a state in which it can tilt up, down, left, and right.

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

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

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

[0033] 3, the control circuit 13 for turning the light on and off, including the switch circuit 13a for turning the light on and off, is not installed externally but is mounted on the board body 10, eliminating the need to form terminal portions 13g corresponding to the element conductive paths 13h connected to each of the plurality of light-emitting elements in the external connector insertion portion 11, thereby reducing the number of terminal portions 13g. Therefore, according to the board sheet 20 of the card-type lighting unit 5 shown in FIG. 4, the width W1 of the external connector insertion portion 11 can be made narrower, thereby ensuring wider widths W2 and W3 of the left and right connector forming edges 12. Therefore, by widening the widths of the connecting ends 21 and 22 of the connector forming edges 12 or by providing more connecting ends 21 and 22 on the left and right sides, it is possible to more effectively prevent warping of the frame body 23 that occurs near the external connector insertion portion 11.

[0034] The card-type lighting unit 5 of FIG. 4 is formed by cutting off the connecting end portions 21 and 22 and all of the connecting end portions 10e from the frame body 23.

[0035] Next, a board sheet 25, which is a modification of the board sheet 20 in FIG. 4, in which the external connector insertion portions 11 of the plurality of card-type lighting units 5 are arranged to face each other, will be described with reference to FIG.

[0036] The board sheet 25 in Fig. 5 is formed by integrally forming a plurality (six in this embodiment, but not limited to six) of card-type lighting units 5, each with an external connector insertion portion 11 arranged opposite to each other. The card-type lighting unit 5 in Fig. 5 is structurally the same as the board sheet 20 in Fig. 4 in that it is formed integrally with the frame body 26 or an adjacent card-type lighting unit 5 via a plurality of connecting ends 10e (not limited to two in this embodiment, but may be one) formed on each of the left end side 10b, the right end side 10c, and the bottom end side 10d of the board body 10. 5, in a pair of card-type lighting units 5 in which the external connector insertion portions 11 are arranged opposite to each other, a mutual coupling end portion 27 is provided between the left connector forming piece 12a of one card-type lighting unit 5 and the connector forming piece 12b of the opposing card-type lighting unit 5, and a mutual coupling end portion 28 is provided between the right connector forming piece 12b of one card-type lighting unit 5 and the connector forming piece 12a of the opposing card-type lighting unit 5. In the pair of card-type lighting units 5 in which the external connector insertion portions 11 are arranged opposite to each other, the connector forming pieces 12a, 12b are integrally formed with each other via the mutual coupling ends 27, 28 in addition to the multiple coupling ends 10e that integrate the left end edge 10b, the right end edge 10c, and the bottom end edge 10d of the board main body 10 into the frame body 26.

[0037] According to the substrate sheet 25 of Figure 5, in addition to the multiple connecting ends 10e that integrate the three sides of the substrate main body 10, namely the left end edge 10b, the right end edge 10c and the bottom end edge 10d, into the frame body 26, in particular, the interconnecting ends 27, 28 that integrate the left and right connector forming edges 12a, 12b of the card-type lighting unit 5, which have the external connector insertion portions 11 arranged opposite each other, mutually restrict warping that occurs in each opposing connector molding portion 11 even when heat treatment is performed, thereby further strengthening the prevention of warping that occurs near each external connector insertion portion 11.

[0038] The card-type lighting unit 5 of FIG. 5 is formed by cutting off the interconnecting end portions 27 and 28 and the plurality of connecting end portions 10e from the frame body 26, respectively.

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

[0040] 6 is the card-type lighting unit 5 of FIG. 3, in which the connector insertion portion 11 protruding above the connector forming piece 12 is replaced with a connector insertion portion 36 whose upper end is flush with the connector forming edge 37. The card-type lighting unit 34 has a common configuration with the card-type lighting unit 5 of FIG. 5, except that the shape of the connector insertion portion 37 and the arrangement of the control circuit 13 electrically connected to the light-emitting element light source 6 are different.

[0041] The board sheet 35 shown in Fig. 6 is formed by laterally arranging the card-type lighting units 34 of Fig. 6 within a frame body 40, and the board sheet 35 has connecting ends 38, 39 to the frame body 40 on the left and right sides of the connector-forming edge 12 of the board body 10, which is closest to the external connector insertion portion 36, and the card-type lighting units 34 are integrated with the frame body 40 via the connecting ends 38, 39, thereby preventing warping of the frame body 40 due to internal stress during heat treatment. The card-type lighting units 34 of Fig. 6 are each formed by cutting off the connecting ends 38, 39 and all of the multiple connecting ends 10e from the frame body 40.

[0042] The substrate sheet of FIG. 7 is the card-type lighting unit 34 of FIG. 6, which is integrated with the frame body 50 with the external connector insertion portion 36 disposed opposite.

[0043] 7, in a pair of card-type lighting units 34 whose external connector insertion portions 36 face each other, a mutually connecting end portion 46 is provided between the left connector forming piece 37a of one card-type lighting unit 34 and the right connector forming piece 37b of the opposing card-type lighting unit 34, and a mutually connecting end portion 47 is provided between the right connector forming piece 37b of one card-type lighting unit 34 and the left connector forming piece 37a of the opposing card-type lighting unit 34. In a pair of card-type lighting units 34 whose external connector insertion portions 36 face each other, the left and right connector forming pieces 37a, 37b are integrally formed with each other via the mutually connecting end portions 46, 47. According to the substrate sheet 45, the interconnecting ends 46, 47, which integrate the left and right connector forming edges 37a, 37b of the card-type lighting unit 34, which has the external connector insertion portions 36 arranged opposite each other, mutually restrict warping that occurs in the frame body 50 even when heat treatment is performed, thereby further strengthening the prevention of warping that occurs near each external connector insertion portion 36.

[0044] The card-type lamp unit 34 of FIG. 7 is formed by cutting off the interconnecting end portions 46 and 47 and all of the connecting end portions 10e from the frame body 50. [Explanation of symbols]

[0045] 5 Card-type lighting unit 6 Light-emitting element light source 6a~6g Light emitting element 0 Board body 10b~10d Outer periphery of the board body 11 External connector insertion part 12 Connector forming edge 12a Left connector forming piece 12b Right connector forming piece 13 Control circuit for turning on and off light emitting elements 16 Metal plate as heat dissipation material 20 PCB sheet 21,22 Connecting end 23 Frame 25 PCB sheet 26 Frame 27,28 interconnected ends

Claims

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

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

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

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

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

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