Method for manufacturing a vehicle lighting device

Abstract

To provide a vehicular lighting device, a vehicular lighting fixture and a manufacturing method of the vehicular lighting device capable of miniaturizing a frame portion and improving light extraction efficiency.SOLUTION: A vehicular lighting device includes: a socket; a substrate 21 disposed at one end portion side of the socket; at least one light emitting element 22 disposed on the substrate; a frame portion 23 disposed on the substrate, having a frame shape, surrounding the light emitting element, and including a resin; and a sealing portion 24 disposed inside of the frame portion and covering the light emitting element. In a direction orthogonal to a central axis 23b of the frame portion, a dimension between inner walls of the frame portion at a substrate-side end portion, of the frame portion is smaller than a dimension between the inner walls of the frame portion at an end portion of a side opposite to the substrate side, of the frame portion. When a cross-section of the frame portion is projected to a plane including the central axis of the frame portion and in parallel with the central axis, a contour of the inner walls of the frame portion has at least one convex curve projecting to a central axis side and a concave curve projecting to a side opposite to the central axis side at least one by one.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] An embodiment of the present invention comprises: car The present invention relates to a method for manufacturing a dual-purpose lighting device. [Background technology]

[0002] 2. Description of the Related Art Vehicle lighting devices equipped with light-emitting diodes are becoming increasingly popular in place of vehicle lighting devices equipped with filaments, from the viewpoints of energy saving and longer life. In recent years, there has been a demand for miniaturization of vehicle lighting devices. To this end, a vehicle lighting device has been proposed that includes a substrate, a chip-shaped light-emitting diode mounted on the substrate, a frame that surrounds the light-emitting diode, and a sealing portion that is provided inside the frame and covers the light-emitting diode.

[0003] If a frame is provided surrounding the light-emitting diode, the light emitted from the light-emitting diode and incident on the inner wall of the frame can be reflected toward the front side of the vehicle lighting device, thereby improving the light extraction efficiency.

[0004] In recent years, there has been a demand for further miniaturization and higher luminous flux of vehicle lighting devices, and therefore there has been a demand for the development of technology that can further reduce the size of the frame and further improve the light extraction efficiency. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2018-37197 Summary of the Invention [Problem to be solved by the invention]

[0006] The problem to be solved by the present invention is to reduce the size of the frame and improve the light extraction efficiency. car A method for manufacturing a dual-purpose lighting device is provided. [Means for solving the problem]

[0007] Vehicle lighting device according to an embodiment Manufacturing method teeth, The method includes the steps of providing at least one light-emitting element on a substrate, providing a frame on the substrate that surrounds the light-emitting element, and providing a sealing portion inside the frame that covers the light-emitting element. The step of providing a frame that surrounds the light-emitting element includes the steps of applying softened resin in a linear pattern to form a first resin portion that surrounds the light-emitting element, applying softened resin in a linear pattern to form a second resin portion outside the first resin portion or inside the first resin portion, and applying softened resin in a linear pattern to form a third resin portion above and between the position where the first resin portion was applied and the position where the second resin portion was applied. In a direction perpendicular to the central axis of the frame, the dimension between the inner walls of the frame at the end of the frame facing the substrate is smaller than the dimension between the inner walls of the frame at the end of the frame facing away from the substrate. When a cross section of the frame is projected onto a plane that includes the central axis of the frame and is parallel to the central axis, the outline of the inner wall of the frame has at least one convex curve that protrudes toward the central axis and one concave curve that protrudes away from the central axis. The convex curve is located closer to the substrate than the concave curve. [Effects of the Invention]

[0008] According to the embodiment of the present invention, it is possible to reduce the size of the frame and improve the light extraction efficiency. car A method for manufacturing a dual-use lighting device may be provided. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a schematic exploded view illustrating a vehicle lighting device according to an embodiment of the present invention; [Figure 2] 2 is a cross-sectional view of the vehicle lighting device taken along line AA in FIG. 1. [Figure 3] 5(a) to 5(c) are schematic cross-sectional views illustrating a frame portion according to a comparative example. [Figure 4] 3 is a schematic cross-sectional view illustrating a frame portion according to the present embodiment. FIG. [Figure 5] 3A and 3B are schematic cross-sectional views illustrating optical elements. [Figure 6] 10A and 10B are schematic cross-sectional views illustrating a frame portion according to another embodiment. [Figure 7] FIG. 2 is a schematic partial cross-sectional view illustrating a vehicle lamp. [Figure 8]10(a) and 10(b) are schematic cross-sectional views illustrating the formation of a frame portion. [Figure 9] 10(a) and 10(b) are schematic cross-sectional views illustrating the formation of a frame portion. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments will be illustrated with reference to the drawings. In the drawings, like components are designated by like reference numerals and detailed descriptions thereof will be omitted where appropriate.

[0011] (Vehicle lighting device) The vehicle lighting device 1 according to this embodiment can be installed in, for example, an automobile, a railway vehicle, etc. Examples of the vehicle lighting device 1 installed in an automobile include those used as front combination lights (for example, an appropriate combination of daytime running lamps (DRLs), position lamps, turn signal lamps, etc.) and rear combination lights (for example, an appropriate combination of stop lamps, tail lamps, turn signal lamps, backup lamps, fog lamps, etc.). However, the uses of the vehicle lighting device 1 are not limited to these.

[0012] FIG. 1 is a schematic exploded view illustrating a vehicle lighting device 1 according to the present embodiment. FIG. 2 is a cross-sectional view of the vehicle lighting device 1 taken along line AA in FIG. As shown in FIGS. 1 and 2, a vehicle lighting device 1 includes, for example, a socket 10, a light-emitting module 20, a power supply unit 30, and a heat transfer unit 40.

[0013] The socket 10 includes, for example, a mounting portion 11, a bayonet 12, a flange 13, heat dissipation fins 14, and a connector holder 15. The mounting portion 11 is provided on one surface 13a of the flange 13. The outer shape of the mounting portion 11 can be columnar. The outer shape of the mounting portion 11 is, for example, cylindrical. The mounting portion 11 has, for example, a recess 11a that opens at the end opposite to the flange 13 side.

[0014] The bayonet 12 is provided, for example, on the side surface of the mounting portion 11. The bayonet 12 protrudes toward the outside of the vehicle lighting device 1. The bayonet 12 faces the flange 13. A plurality of bayonets 12 may be provided. The bayonet 12 is used when mounting the vehicle lighting device 1 to, for example, a housing 101 of a vehicle lamp 100 described below. The bayonet 12 can be used for a twist lock.

[0015] The flange 13 has, for example, a plate shape. The flange 13 has, for example, a substantially circular plate shape. The flange 13 has a surface 13a and a surface 13b opposite to the surface 13a. The side surface of the flange 13 is located outward from the side surface of the bayonet 12 to the vehicle lighting device 1.

[0016] The heat dissipation fins 14 are provided, for example, on the surface 13b of the flange 13. At least one heat dissipation fin 14 can be provided. For example, as shown in FIG. 2, the socket 10 can be provided with a plurality of heat dissipation fins 14. The plurality of heat dissipation fins 14 can be arranged side by side in a predetermined direction. The heat dissipation fins 14 are, for example, plate-shaped or cylindrical.

[0017] The connector holder 15 is provided, for example, on the surface 13b of the flange 13. The connector holder 15 can be provided alongside the heat dissipation fins 14. The connector holder 15 is cylindrical, and a connector 105 having a seal member 105a therein is inserted into the connector holder 15.

[0018] The socket 10 has the function of holding the light-emitting module 20 and the power supply unit 30, and the function of conducting heat generated in the light-emitting module 20 to the outside. Therefore, the socket 10 is preferably made of a material with high thermal conductivity. For example, the socket 10 can be made of a metal such as an aluminum alloy.

[0019] In recent years, it has become desirable for the socket 10 to be lightweight and capable of efficiently dissipating heat generated in the light-emitting module 20. Therefore, it is more preferable that the socket 10 be formed from, for example, a highly thermally conductive resin. The highly thermally conductive resin includes, for example, a resin and a filler using an inorganic material. The highly thermally conductive resin is, for example, a resin such as PET (Polyethylene terephthalate) or nylon mixed with a filler using carbon, aluminum oxide, or the like.

[0020] If the socket 10 contains a highly thermally conductive resin and has the mounting portion 11, bayonet 12, flange 13, heat dissipation fins 14, and connector holder 15 integrally molded, the heat generated in the light-emitting module 20 can be efficiently dissipated. The weight of the socket 10 can also be reduced. In this case, the mounting portion 11, bayonet 12, flange 13, heat dissipation fins 14, and connector holder 15 can be integrally molded using injection molding or the like. Alternatively, the socket 10 and the heat transfer portion 40 can be integrally molded using insert molding, or the socket 10, power supply portion 30, and heat transfer portion 40 can be integrally molded.

[0021] The light emitting module 20 (substrate 21) is provided on one end side of the socket 10. The light emitting module 20 includes, for example, a substrate 21, a light emitting element 22, a frame 23, a sealing portion 24, and an element 25.

[0022] The substrate 21 is adhered to the surface 40a of the heat transfer unit 40. In this case, the adhesive is preferably an adhesive with high thermal conductivity. For example, the adhesive may be an adhesive mixed with a filler using an inorganic material.

[0023] The substrate 21 has a plate-like shape. The planar shape of the substrate 21 is, for example, a rectangle. The substrate 21 can be formed from, for example, an inorganic material such as ceramics (e.g., aluminum oxide or aluminum nitride), or an organic material such as paper phenol or glass epoxy. The substrate 21 may also be a metal core substrate in which the surface of a metal plate is coated with an insulating material. When the light emitting element 22 generates a large amount of heat, it is preferable to form the substrate 21 using a material with high thermal conductivity from the perspective of heat dissipation. Examples of materials with high thermal conductivity include ceramics such as aluminum oxide or aluminum nitride, highly thermally conductive resins, and metal core substrates. The substrate 21 may have a single-layer structure or a multi-layer structure.

[0024] Furthermore, a wiring pattern 21a is provided on the surface of the substrate 21. The wiring pattern 21a is made of, for example, a material containing silver as a main component or a material containing copper as a main component.

[0025] It is also possible to provide a covering portion that covers the wiring pattern 21a, a film-like resistor (to be described later), etc. The covering portion may contain, for example, a glass material.

[0026] The light emitting element 22 may be, for example, a light emitting diode, an organic light emitting diode, a laser diode, or the like.

[0027] The light emitting element 22 is provided on the substrate 21 (the side opposite to the heat transfer section 40). The light emitting element 22 is electrically connected to the wiring pattern 21a. At least one light emitting element 22 can be provided. When a plurality of light emitting elements 22 are provided, the plurality of light emitting elements 22 can be connected in series with each other.

[0028] The light-emitting element 22 may be a chip-type light-emitting element. If the light-emitting element 22 is a chip-type light-emitting element, the light-emitting module 20 can be made smaller, and therefore the vehicle lighting device 1 can be made smaller. The chip-type light-emitting element 22 can be mounted on the wiring pattern 21a by COB (Chip On Board). The chip-type light-emitting element 22 may be, for example, an upper electrode type light-emitting element, a top and bottom electrode type light-emitting element, or a flip-chip type light-emitting element.

[0029] The number, size, arrangement, etc. of the light-emitting elements 22 are not limited to those exemplified, and can be changed as appropriate depending on the size, use, etc. of the vehicle lighting device 1.

[0030] The frame portion 23 has a frame shape and is provided on the substrate 21. The frame portion 23 surrounds the light-emitting element 22. The frame portion 23 has, for example, a function of defining the formation area of ​​the sealing portion 24 and a function of a reflector. The frame portion 23 is formed, for example, from a resin. The resin can be, for example, a thermoplastic resin such as PBT (polybutylene terephthalate), PC (polycarbonate), PET, nylon, PP (polypropylene), PE (polyethylene), or PS (polystyrene). In this case, the resin can contain titanium oxide particles or be a white resin. This makes it easier to reflect light incident on the frame portion 23, thereby improving the light extraction efficiency. The frame portion 23 will be described in detail later.

[0031] The sealing portion 24 is provided inside the frame portion 23. The sealing portion 24 is provided so as to cover the area surrounded by the frame portion 23. The sealing portion 24 is provided so as to cover the light-emitting element 22. The sealing portion 24 contains a light-transmitting resin. The sealing portion 24 is formed, for example, by filling the inside of the frame portion 23 with resin. The filling of the resin is performed, for example, using a dispenser or the like. The resin to be filled is, for example, a silicone resin or the like.

[0032] Furthermore, the sealing portion 24 may contain a phosphor. The phosphor may be, for example, a YAG-based phosphor (yttrium-aluminum-garnet-based phosphor). However, the type of phosphor may be changed as appropriate to obtain a predetermined emission color depending on the application of the vehicle lighting device 1.

[0033] The element 25 can be a passive element or an active element used to configure a light-emitting circuit having the light-emitting element 22. The element 25 is provided, for example, on the periphery of the frame portion 23 and electrically connected to the wiring pattern 21a. At least one element 25 can be provided.

[0034] The element 25 may be, for example, a resistor 25a and a control element 25b. However, the type of element 25 is not limited to the exemplified ones, and can be changed as appropriate depending on the configuration of the light-emitting circuit having the light-emitting element 22. For example, in addition to the above-mentioned ones, the element 25 may also be a capacitor, a positive temperature coefficient thermistor, a negative temperature coefficient thermistor, an inductor, a surge absorber, a varistor, a transistor such as an FET or a bipolar transistor, an integrated circuit, an arithmetic element, or the like.

[0035] The resistor 25a is provided on the substrate 21. The resistor 25a is electrically connected to the wiring pattern 21a. The resistor 25a may be, for example, a surface-mount resistor, a resistor with leads (metal oxide film resistor), or a film resistor formed by screen printing or the like. The resistor 25a illustrated in FIG. 1 is a film resistor.

[0036] The film resistor is made of, for example, ruthenium oxide (RuO2). The film resistor is formed by, for example, screen printing and firing. If the resistor 25a is a film resistor, the contact area between the resistor 25a and the substrate 21 can be increased, thereby improving heat dissipation. Furthermore, multiple resistors 25a can be formed at once, thereby improving productivity. Furthermore, variations in the resistance values ​​of the multiple resistors 25a can be suppressed.

[0037] Here, since there is variation in the forward voltage characteristics of the light-emitting element 22, if the voltage applied between the anode terminal and the ground terminal is constant, variation occurs in the brightness (luminous flux, luminance, luminous intensity, illuminance) of the light emitted from the light-emitting element 22. Therefore, to keep the brightness of the light emitted from the light-emitting element 22 within a predetermined range, the value of the current flowing through the light-emitting element 22 is controlled to be within a predetermined range by using the resistor 25a connected in series to the light-emitting element 22. In this case, the resistance value of the resistor 25a is changed to keep the value of the current flowing through the light-emitting element 22 within the predetermined range.

[0038] If the resistor 25a is a surface-mount resistor or a resistor with leads, the resistor 25a should have an appropriate resistance value depending on the forward voltage characteristics of the light-emitting element 22. If the resistor 25a is a film resistor, the resistance value can be increased by removing a portion of the resistor 25a. For example, a portion of the film resistor can be easily removed by irradiating it with laser light. The number and size of the resistors 25a are not limited to those illustrated, and can be changed as appropriate depending on the number and specifications of the light-emitting elements 22.

[0039] The control element 25b is provided on the substrate 21. The control element 25b is electrically connected to the wiring pattern 21a. The control element 25b is provided, for example, to prevent a reverse voltage from being applied to the light-emitting element 22 and to prevent pulse noise from being applied from the reverse direction to the light-emitting element 22. The control element 25b is, for example, a surface-mounted diode or a diode with leads. The control element 25b illustrated in FIG. 1 is a surface-mounted diode.

[0040] The power supply unit 30 includes, for example, a plurality of power supply terminals 31 and a holding unit 32 . The plurality of power supply terminals 31 may be rod-shaped. One end of each of the plurality of power supply terminals 31 protrudes from the bottom surface 11a1 of the recess 11a. The plurality of power supply terminals 31 are arranged, for example, lined up in a predetermined direction. One end of each of the plurality of power supply terminals 31 is soldered to the wiring pattern 21a provided on the substrate 21. The other end of each of the plurality of power supply terminals 31 is exposed inside the hole of the connector holder 15. The connector 105 is fitted into the plurality of power supply terminals 31 exposed inside the hole of the connector holder 15. The plurality of power supply terminals 31 are formed of a metal such as a copper alloy. The shape, arrangement, material, etc. of the plurality of power supply terminals 31 are not limited to those exemplified and can be changed as appropriate.

[0041] For example, if the socket 10 is made of a metal such as an aluminum alloy or a highly thermally conductive resin containing a carbon-based filler, the socket 10 will be electrically conductive. Therefore, the retaining portion 32 is provided to insulate the multiple power supply terminals 31 from the electrically conductive socket 10. The retaining portion 32 also has the function of holding the multiple power supply terminals 31. The retaining portion 32 is made of, for example, an insulating resin. For example, the retaining portion 32 can be press-fitted into a hole in the socket 10 or adhered to the inner wall of the hole. Note that if the socket 10 is made of, for example, a highly thermally conductive resin containing an aluminum oxide-based filler, the socket 10 will be electrically insulating. In such a case, the retaining portion 32 can be omitted.

[0042] The heat transfer section 40 is plate-shaped and is provided between the socket 10 and the light-emitting module 20 (substrate 21). A surface 40a of the heat transfer section 40 is exposed from the end of the socket 10 on the side where the light-emitting module 20 is provided. The heat transfer section 40 can be embedded in the bottom surface 11a1 of the recess 11a, or can be adhered to the bottom surface 11a1 of the recess 11a, or can be adhered to a convex pedestal provided on the bottom surface 11a1 of the recess 11a.

[0043] The heat transfer section 40 is provided to facilitate the transfer of heat generated in the light-emitting module 20 to the socket 10. For this reason, the heat transfer section 40 is preferably formed from a material with high thermal conductivity (for example, a metal such as aluminum, an aluminum alloy, copper, or a copper alloy).

[0044] The heat transfer section 40 can be omitted. However, in recent years, there has been a demand for higher luminous flux in the vehicle lighting device 1, and the current flowing through the light-emitting element 22 tends to increase. This has resulted in an increase in the amount of heat generated in the light-emitting module 20. Furthermore, in recent years, there has been a demand for smaller vehicle lighting devices 1, and the cross-sectional area of ​​the mounting section 11 tends to become smaller. If the cross-sectional area of ​​the mounting section 11 becomes smaller, it becomes more difficult for the heat generated in the light-emitting module 20 to be transferred to the heat dissipation fins 14, and heat dissipation via the heat dissipation fins 14 may become more difficult. Therefore, in consideration of the need for higher luminous flux and smaller size in the vehicle lighting device 1, it is preferable to provide the heat transfer section 40.

[0045] Next, the frame portion 23 will be further described. 3(a) to 3(c) are schematic cross-sectional views illustrating frame portions 123a to 123c according to the comparative example.

[0046] The frame portion 123a shown in FIG. 3(a) is formed by, for example, injection molding or cutting, and is bonded to the substrate 21. Furthermore, when forming the frame portion 123a by injection molding or the like, the inner wall 123a1 of the frame portion 123a can be inclined with respect to the upper surface of the substrate 21. In this case, when a cross section of the frame portion 123a is projected onto a plane that includes and is parallel to the central axis 123a2 of the frame portion 123a, the outline of the inner wall 123a1 of the frame portion 123a is a straight line. The frame portion 123a having such an inner wall 123a1 can easily emit light incident on the inner wall 123a1 to the outside of the sealing portion 24. This can improve the light extraction efficiency.

[0047] In recent years, there has been a demand for a smaller light-emitting module 20 in order to reduce the size of the vehicle lighting device 1. In order to reduce the size of the light-emitting module 20, it is necessary to reduce the size of the frame portion 123a. However, when the frame portion 123a is reduced in size, the thickness of the frame portion 123a (the distance between the inner wall 123a1 and the outer wall) is reduced, and the rigidity of the frame portion 123a is reduced. If the rigidity of the frame portion 123a is reduced, there is a risk that the shape of the frame portion 123a may be distorted or the position of the frame portion 123a may be displaced when the frame portion 123a is bonded to the substrate 21.

[0048] 3(b) and 3(c) are formed directly on the substrate 21 using, for example, a dispenser. For example, resin softened with a solvent or the like is supplied linearly onto the substrate 21, and then cured to form the frame-shaped frame portions 123b and 123c. In this way, even if the thickness of the frame portions 123b and 123c is reduced, it is possible to prevent the shape of the frame portions 123b and 123c from being distorted or the position of the frame portions 123b and 123c from being shifted.

[0049] The inner walls 123b1, 123c1 of the frame portions 123b, 123c formed in this manner have convex curved surfaces. In this case, as shown in Figures 3(b) and 3(c), when the cross sections of the frame portions 123b, 123c are projected onto a plane that includes the central axes 123b2, 123c2 of the frame portions 123b, 123c and is parallel to the central axes 123b2, 123c2, the outlines of the inner walls of the frame portions 123b, 123c form a single convex curve.

[0050] 3(b) and 3(c), the angle of incidence of light reflected by the inner walls 123b1 and 123c1 of the frame portions 123b and 123c at the interface between the sealing portion 24 and the outside air becomes large, making total reflection more likely to occur, which may result in a decrease in the light extraction efficiency.

[0051] Although the shapes of the frame portions 123b and 123c can be controlled to some extent by the viscosity of the softened resin, forming the frame portions 123b and 123c by a single application may result in large variations in the shapes of the inner walls 123b1 and 123c1, which may result in variations in the light extraction efficiency for each vehicle lighting device 1.

[0052] FIG. 4 is a schematic cross-sectional view illustrating the frame portion 23 according to the present embodiment. 4, in a direction perpendicular to central axis 23b of frame 23, the dimension between the inner walls of frame 23 at the end of frame 23 facing substrate 21 is smaller than the dimension between the inner walls of frame 23 at the end of frame 23 opposite substrate 21. Furthermore, when a cross section of frame 23 is projected onto a plane that includes central axis 23b of frame 23 and is parallel to central axis 23b, the outline of inner wall 23a of frame 23 has at least one convex curve that protrudes toward central axis 23b and one concave curve that protrudes away from central axis 23b. For example, the convex curve is located closer to substrate 21 than the concave curve.

[0053] If the contour of inner wall 23a of frame portion 23 has a convex curve and a concave curve, it is possible to reduce the probability that the angle of incidence will be large (probability that total reflection will occur) when light reflected on inner wall 23a of frame portion 23 is incident on the interface between sealing portion 24 and the outside air. Therefore, it is possible to improve the light extraction efficiency compared to the case of frames 123b and 123c.

[0054] Furthermore, as will be described later, frame portion 23 can be formed directly on substrate 21 using, for example, a dispenser. Therefore, even if the thickness of frame portion 23 is reduced, distortion of the shape of frame portion 23 and displacement of frame portion 23 can be suppressed compared to the case of frame portion 123a. Furthermore, as will be described later, since the resin is applied to the frame portion 23 in multiple steps, it is possible to reduce variations in the shape of the inner wall 23a, and therefore it is possible to suppress variations in the light extraction efficiency for each vehicle lighting device 1. The formation of the frame portion 23 will be described in detail later.

[0055] FIG. 5 is a schematic cross-sectional view illustrating the optical element 26. As shown in FIG. As shown in FIG. 5, an optical element 26 can be provided on the sealing portion 24. The optical element 26 illustrated in FIG. 5 is a convex lens, but it may also be a concave lens or a light guide. The optical element 26 can be formed from, for example, glass or a translucent resin. If the optical element 26 is formed from glass or a translucent resin, the difference between the refractive index of the sealing portion 24 and the refractive index of the optical element 26 is smaller than the difference between the refractive index of the sealing portion 24 and the outside air (air). Therefore, the probability of total reflection occurring at the interface between the sealing portion 24 and the optical element 26 can be made smaller than the probability of total reflection occurring at the interface between the sealing portion 24 and the outside air. As a result, the light extraction efficiency can be further improved.

[0056] FIG. 6 is a schematic cross-sectional view illustrating a frame portion 33 according to another embodiment. As shown in Figure 6, similar to the frame portion 23 described above, in a direction perpendicular to the central axis 33b of the frame portion 33, the dimension between the inner walls of the frame portion 33 at the end of the frame portion 33 on the side of the substrate 21 is smaller than the dimension between the inner walls of the frame portion 33 at the end of the frame portion 33 opposite the side of the substrate 21. Furthermore, when a cross section of frame 33 is projected onto a plane that includes central axis 33b of frame 33 and is parallel to central axis 33b, the contour of inner wall 33a of frame 33 includes convex curved line 33a1 that protrudes toward central axis 33b and concave curved line 33a2 that protrudes toward the opposite side from central axis 33b. Furthermore, multiple convex curved lines 33a1 and multiple concave curved lines 33a2 are provided alternately. The number of convex curved lines 33a1 is greater than the number of concave curved lines 33a2.

[0057] In this way, it is possible to further reduce the probability that the angle of incidence becomes large (probability that total reflection occurs) when light reflected on the inner wall 33a of the frame portion 33 enters the interface between the sealing portion 24 and the outside air. Therefore, it is possible to further improve the light extraction efficiency compared to the case of the frame portion 23. Furthermore, as will be described later, since the resin is applied to the frame portion 33 in multiple steps, it is possible to further reduce variations in the shape of the inner wall 33a, and therefore it is possible to further suppress variations in the light extraction efficiency for each vehicle lighting device 1.

[0058] (vehicle lighting fixtures) Next, the vehicle lamp 100 will be illustrated. In the following, as an example, a case will be described in which the vehicular lamp 100 is a front combination light installed in an automobile. However, the vehicular lamp 100 is not limited to a front combination light installed in an automobile. The vehicular lamp 100 may be any vehicular lamp that is installed in an automobile, a railroad car, or the like.

[0059] FIG. 7 is a schematic partial cross-sectional view illustrating the vehicle lamp 100. As shown in FIG. As shown in FIG. 7, the vehicle lamp 100 includes, for example, the vehicle lighting device 1, a housing 101, a cover 102, an optical element 103, a seal member 104, and a connector 105.

[0060] The vehicle lighting device 1 is attached to the housing 101. The housing 101 holds the mounting portion 11. The housing 101 is box-shaped with one end open. The housing 101 is formed, for example, from a light-opaque resin. The bottom surface of the housing 101 is provided with a mounting hole 101a into which the portion of the mounting portion 11 provided with the bayonet 12 is inserted. A recess is provided around the periphery of the mounting hole 101a into which the bayonet 12 provided on the mounting portion 11 is inserted. Note that although the case where the mounting hole 101a is directly provided in the housing 101 has been exemplified, a mounting member having the mounting hole 101a may also be provided on the housing 101.

[0061] When attaching the vehicle lighting device 1 to the vehicle lamp 100, the portion of the mounting portion 11 where the bayonet 12 is provided is inserted into the mounting hole 101a, and the vehicle lighting device 1 is rotated. Then, for example, the bayonet 12 is held in a fitting portion provided on the periphery of the mounting hole 101a. This type of attachment method is called a twist lock.

[0062] The cover 102 is provided so as to cover the opening of the housing 101. The cover 102 is made of a light-transmitting resin or the like. The cover 102 may also have a function such as a lens.

[0063] Light emitted from the vehicle lighting device 1 is incident on the optical element 103. The optical element 103 reflects, diffuses, guides, and collects the light emitted from the vehicle lighting device 1, and forms a predetermined light distribution pattern. For example, the optical element 103 illustrated in FIG. 7 is a reflector. In this case, the optical element 103 reflects the light emitted from the vehicle lighting device 1 and forms a predetermined light distribution pattern.

[0064] The seal member 104 is provided between the flange 13 and the housing 101. The seal member 104 has an annular shape and is made of an elastic material such as rubber or silicone resin.

[0065] When the vehicle lighting device 1 is attached to the vehicle lamp 100, the seal member 104 is sandwiched between the flange 13 and the housing 101. Therefore, the seal member 104 can seal the internal space of the housing 101. Furthermore, the elastic force of the seal member 104 presses the bayonet 12 against the housing 101. Therefore, the vehicle lighting device 1 can be prevented from detaching from the housing 101.

[0066] The connector 105 is fitted to the ends of the plurality of power supply terminals 31 exposed inside the connector holder 15. A power source (not shown) and the like are electrically connected to the connector 105. Therefore, by fitting the connector 105 to the ends of the plurality of power supply terminals 31, the power source (not shown) and the light-emitting element 22 can be electrically connected.

[0067] Furthermore, a seal member 105a is provided on the connector 105. When the connector 105 having the seal member 105a is inserted into the inside of the connector holder 15, the inside of the connector holder 15 is sealed so as to be watertight.

[0068] (Method of manufacturing a vehicle lighting device) Next, a method for manufacturing the vehicle lighting device 1 will be described. The socket 10 is formed by injection molding, die casting, or the like. The power supply section 30 is formed by press-fitting the plurality of power supply terminals 31 into holes in the insulating section 32 or by integrally molding the plurality of power supply terminals 31 and the insulating section 32 by insert molding.

[0069] In addition, the light emitting module 20 is manufactured. First, the light emitting element 22 and the element 25 are mounted in this order on the substrate 21 having the wiring pattern 21a.

[0070] Next, a frame 23 surrounding the light emitting element 22 is provided on the substrate 21 . 8(a) and (b) are schematic cross-sectional views illustrating the formation of the frame portion 23. FIG. As shown in FIG. 8(a), first, a frame-shaped resin portion 23d1 (corresponding to an example of a first resin portion) is formed on the substrate 21 so as to surround the light emitting element 22. Next, a frame-shaped resin portion 23d2 (corresponding to an example of a second resin portion) is formed on the substrate 21 so as to surround the resin portion 23d1, with the inner periphery of the resin portion 23d2 being in contact with the outer periphery of the resin portion 23d1. Next, a frame-shaped resin portion 23d3 (corresponding to an example of a third resin portion) is formed on the resin portions 23d1 and 23d2. At this time, the resin portion 23d3 can be formed on the contact portion between the resin portions 23d1 and 23d2.

[0071] Resin portions 23d1, 23d2, and 23d3 can be formed by, for example, applying a resin softened with a solvent or the like in a linear fashion using a dispenser, etc. Resin portions 23d1, 23d2, and 23d3 can also be formed by, for example, applying a heated resin in a linear fashion using a hot melt device, etc.

[0072] Furthermore, the materials of resin portion 23d1, resin portion 23d2, and resin portion 23d3 may be the same or different. For example, the reflectance of the material of resin portion 23d1 and resin portion 23d3 forming inner wall 23a of frame portion 23 can be higher than the reflectance of the material of resin portion 23d2. For example, the material of resin portion 23d1 and resin portion 23d3 can be a white resin or a resin containing titanium oxide particles.

[0073] The resin portions 23d1, 23d2, and 23d3 formed in the above manner are mixed together and integrated with each other over time, as shown in FIG. 8(b).

[0074] Although the above describes an example in which the resin portions are formed sequentially from the inside to the outside, the resin portions may be formed sequentially from the outside to the inside. Furthermore, when forming the resin portions, a small gap may be provided between the resin portions. In this manner, the frame portion 23 is formed, which includes the convex curve 23a1 and the concave curve 23a2 in the contour of the inner wall 23a.

[0075] Next, the inside of the frame portion 23 is filled with resin to form the sealing portion 24 . Furthermore, an optical element 26 can be provided on the sealing portion 24, if necessary. In this manner, the light emitting module 20 can be manufactured.

[0076] Next, the power supply unit 30, the heat transfer unit 40, and the light emitting module 20 are assembled in this order into the socket 10. In this manner, the vehicle lighting device 1 can be manufactured.

[0077] 9(a) and (b) are schematic cross-sectional views illustrating the formation of the frame portion 33. FIG. The frame portion 33 can be formed in the same manner as the frame portion 23 described above. For example, as shown in FIG. 9(a), first, a frame-shaped resin portion 33d1 (corresponding to an example of a first resin portion) is formed on the substrate 21 so as to surround the light emitting element 22. Next, a frame-shaped resin portion 33d2 (corresponding to an example of a second resin portion) is formed on the substrate 21 so as to surround the resin portion 33d1. At this time, the inner periphery of the resin portion 33d2 is in contact with the outer periphery of the resin portion 33d1. Thereafter, frame-shaped resin portions are successively formed on the substrate 21 in the same manner.

[0078] Next, a frame-shaped resin portion 33d3 (corresponding to an example of a third resin portion) is formed on the resin portions 33d1 and 33d2. At this time, the resin portion 33d3 can be formed on the contact portion between the resin portions 33d1 and 33d2. Thereafter, frame-shaped resin portions are formed sequentially in the same manner. Furthermore, on the layer including the resin portion 33d3 formed in this way, a layer including a resin portion can be formed in sequence.

[0079] The resin portion can be formed using, for example, a dispenser or a hot melt device, in the same manner as in the formation of the frame portion 23 described above. Furthermore, as in the case of the above-described frame 23, the reflectance of the material of the resin portion forming the inner wall 33a of the frame 33 can be made higher than the reflectance of the material of the resin portion forming the outer wall 33c. For example, the material of the resin portion forming the inner wall 33a of the frame 33 can be a white resin or a resin containing titanium oxide particles or the like.

[0080] The plurality of resin portions formed in this manner will mix together and become integrated over time, as shown in FIG. 9(b).

[0081] Although the above description exemplifies the case where the resin portions are formed sequentially from the inside to the outside, the resin portions may be formed sequentially from the outside to the inside. Although the case where the resin portions are sequentially brought into contact with each other has been exemplified, for example, the resin portions may be formed apart from each other and another resin portion may be formed between them so that the resin portions come into contact with each other. Furthermore, when the resin portions are formed, a small gap may be provided between the resin portions. In this manner, the frame portion 33 is formed, which includes a plurality of convex curves 33a1 and a plurality of concave curves 33a2 in the contour of the inner wall 33a.

[0082] As described above, the process of providing the frame portions 22 and 33 surrounding the light emitting element 22 can include the following processes. A process of applying the softened resin in a linear shape to form the resin portions 23d1 and 33d1 surrounding the light emitting element 22. A process of applying the softened resin in a linear shape to form the resin portions 23d2 and 33d2 on the outside of the resin portions 23d1 and 33d1 or on the inside of the resin portions 23d1 and 33d1. A process of applying softened resin in a linear shape to form resin portions 23d3 and 33d3 above and between the positions where resin portions 23d1 and 33d1 are applied and the positions where resin portions 23d2 and 33d2 are applied.

[0083] Although several embodiments of the present invention have been described above, these embodiments are presented by way of example only and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, modifications, etc. can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the invention and its equivalents as set forth in the claims. Furthermore, the above-described embodiments can be implemented in combination with each other. [Explanation of symbols]

[0084] 1 Vehicle lighting device, 10 Socket, 20 Light-emitting module, 21 Board, 22 Light-emitting element, 23 Frame portion, 23a Inner wall, 23a1 Convex curve, 23a2 Concave curve, 23b Central axis, 23c Outer wall, 23d1 to 23d3 Resin portion, 24 Sealing portion, 33 Frame portion, 33a Inner wall, 33a1 Convex curve, 33a2 Concave curve, 33d1 to 33d3 Resin portion, 100 Vehicle lighting fixture, 101 Housing

Claims

1. Providing at least one light-emitting element on a substrate; providing a frame portion surrounding the light-emitting element on the substrate; providing a sealing portion that covers the light-emitting element inside the frame portion; Equipped with The step of providing a frame portion surrounding the light-emitting element includes: applying the softened resin in a linear shape to form a first resin portion surrounding the light emitting element; applying the softened resin in a linear shape to form a second resin portion on the outside or inside of the first resin portion; applying the softened resin in a linear pattern to form a third resin portion above and between the position where the first resin portion is applied and the position where the second resin portion is applied; Including, In a direction perpendicular to the central axis of the frame portion, a dimension between inner walls of the frame portion at an end of the frame portion on the substrate side is smaller than a dimension between inner walls of the frame portion at an end of the frame portion on the opposite side to the substrate side, when a cross section of the frame is projected onto a plane that includes the central axis of the frame and is parallel to the central axis, the outline of the inner wall of the frame has at least one convex curve that protrudes toward the central axis and one concave curve that protrudes toward the opposite side from the central axis, The method for manufacturing a vehicle lighting device, wherein the convex curve is located closer to the substrate than the concave curve.

2. The method for manufacturing a vehicle lighting device according to claim 1 , wherein the convex curves and the concave curves are provided alternately in a plurality of positions, and the number of the convex curves is greater than the number of the concave curves.

3. The method for manufacturing a vehicle lighting device according to claim 1 or 2, further comprising the step of providing an optical element on the sealing portion.

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