Manufacturing method for lighting fixtures and parts of lighting fixtures

Abstract

To provide a lighting device which can achieve reduction of manufacturing costs for a watertight structure, and to provide a manufacturing method of a component of the lighting device.SOLUTION: A lighting device 100 includes: a device body 1 which houses a lighting component 2; and a fixing part 3 which fixes the lighting component 2 to the device body 1. The device body 1 has a metallic fixing plate 10 to which the fixing part 3 is fixed. The fixing plate 10 includes projection parts 11 each of which is open to the inner side of the device body 1 so that the fixing part 3 is fitted therein, protrudes to the outer side of the device body 1, and has a bottomed cylindrical shape. Recessed parts 12, each of which is recessed to the inner side of the device body 1, are respectively provided at areas, which are located around the projection parts 11, on a surface of the fixing plate 10 facing the outer side of the device body 1.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a lighting fixture and a method for manufacturing parts of a lighting fixture, and more particularly, to a lighting fixture having a waterproof structure and a method for manufacturing parts of a lighting fixture.

Background Art

[0002] Patent Document 1 describes a road lamp (lighting fixture). This road lamp (hereinafter referred to as a conventional example) includes a base case body (lamp body) and a lower cover body that is screwed and fixed to the lower surface of the base case body. A light source unit and a power source for the light source unit are provided inside between the base case body and the lower cover body.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in the above conventional example, the screw for fixing the lower cover body to the base case body penetrates the base case body. Therefore, in the above conventional example, in order to prevent rainwater from entering the inside of the base case body through the portion where the screw penetrates, a waterproof structure such as a waterproof packing and a pressing plate for pressing the waterproof packing is separately required. Therefore, in the above conventional example, there is a risk of increasing the manufacturing cost due to the waterproof structure. In addition, the waterproof packing may not be able to maintain its sealing performance due to aging deterioration or the like, and in this case, there is a risk of causing a failure of the lighting fixture.

[0005] In view of the above circumstances, an object of the present disclosure is to provide a lighting fixture and a method for manufacturing parts of a lighting fixture that can reduce the manufacturing cost for a waterproof structure.

Means for Solving the Problems

[0006] A lighting fixture according to one aspect of the present disclosure comprises a fixture body for housing lighting components and a fixing portion for fixing the lighting components to the fixture body. The fixture body has a metal fixing plate to which the fixing portion is fixed. The fixing plate includes a bottomed cylindrical projection that opens toward the inside of the fixture body so as to fit the fixing portion and protrudes toward the outside of the fixture body. On the surface of the fixing plate facing toward the outside of the fixture body, a recess is provided around the projection that is recessed toward the inside of the fixture body.

[0007] Furthermore, a method for manufacturing a component of a lighting fixture according to one aspect of the present disclosure is a method for manufacturing a metal fixing plate used in a lighting fixture using a press die. The press die comprises a first die, a second die facing the first die and having a punch hole, a punch provided in the first die so as to be able to move back and forth and which enters into the punch hole, and a knock portion provided in the punch hole so as to be able to move back and forth. A convex portion is provided around the punch hole of the second die that protrudes toward the first die. In this manufacturing method, a plate-shaped base material to form the fixing plate is sandwiched between the first die and the second die, and while pressing the convex portion against the base material to form a recess, the base material is sandwiched between the punch and the knock portion, and the punch is used to partially punch out the base material, thereby forming a bottomed cylindrical projection on the base material. [Effects of the Invention]

[0008] A method for manufacturing lighting fixtures and components of lighting fixtures according to one aspect of this disclosure can reduce the manufacturing cost for a watertight structure. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1A is a perspective view showing a lighting fixture according to one embodiment of the present disclosure as seen from the rear, and Figure 1B is a plan cross-sectional view showing the main part of the same lighting fixture (part A in Figure 1A). [Figure 2]Figures 2A to 2C are cross-sectional views showing, in order, the method for manufacturing the main components of the lighting fixture described above. [Figure 3] Figure 3 is a perspective view showing the same lighting fixture as described above, viewed from the front. [Figure 4] Figure 4 is an exploded perspective view showing the same lighting fixture. [Figure 5] Figure 5 is a rear view showing the same lighting fixture. [Figure 6] Figure 6 is a perspective view showing an enlarged view of portion A of Figure 1A. [Modes for carrying out the invention]

[0010] Hereinafter, a method for manufacturing a lighting fixture 100 and a component of the lighting fixture 100 (specifically, a metal fixing plate 10) according to one embodiment of the present disclosure shown in Figures 1 to 6 will be described in detail with reference to the drawings. Each figure is a schematic diagram, and the size and thickness ratios of each component do not necessarily reflect the actual dimensional ratios. Furthermore, one embodiment is merely an example of the present disclosure. The present disclosure can be modified in various ways as long as the effects of the present disclosure can be achieved.

[0011] (One embodiment) (1) Overview A lighting fixture 100 according to one embodiment shown in Figures 1A and B comprises a fixture body 1 that houses lighting components 2, and a fixing part 3 that fixes the lighting components 2 to the fixture body 1. The fixture body 1 has a metal fixing plate 10 to which the fixing part 3 is fixed. The fixing plate 10 includes a bottomed cylindrical projection 11 that opens toward the inside of the fixture body 1 so that the fixing part 3 fits into it, and protrudes toward the outside of the fixture body 1. On the surface of the fixing plate 10 facing toward the outside of the fixture body 1, a recess 12 is provided around the projection 11 that is recessed toward the inside of the fixture body 1.

[0012] In one embodiment of the lighting fixture 100 having the above configuration, the fixing part 3 for fixing the lighting component 2 can be fitted onto the bottomed cylindrical projection 11 that does not penetrate the fixing plate 10, thereby fixing the lighting component 2 to the fixing plate 10. Therefore, in one embodiment of the lighting fixture 100, other members for sealing the through-holes in the fixing plate 10 in a watertight manner can be omitted, thereby reducing the manufacturing cost for a watertight structure.

[0013] In addition, in the lighting fixture 100 of one embodiment, a recess 12 is provided around the projection 11 of the fixing plate 10. Therefore, when forming the projection 11 by press-forming (drawing) a part of the fixing plate 10, the peripheral wall portion 111 of the bottomed cylindrical projection 11 can be made thicker by the amount of the recess 12. As a result, in the lighting fixture 100 of one embodiment, the mounting strength of the fixing portion 3 to the projection 11 is easily ensured, and the fixing state of the lighting component 2 to the fixing plate 10 is easily stabilized.

[0014] Furthermore, the manufacturing method for the components of the lighting fixture 100 according to one embodiment shown in Figures 1A, B and 2A-C is a method for manufacturing a metal fixing plate 10 used in the lighting fixture 100 using a press die 4. The press die 4 has a first die 40, a second die 41 facing the first die 40 and provided with a punch hole 410, a punch 42 provided in the first die 40 so as to be able to move back and forth and enter the punch hole 410, and a knock portion 43 provided in the punch hole 410 so as to be able to move back and forth. A convex portion 411 is provided around the punch hole 410 of the second die 41, projecting toward the first die 40. In this manufacturing method, a plate-shaped base material 10a that will form the fixing plate 10 is sandwiched between a first mold 40 and a second mold 41, and while pressing a convex portion 411 against the base material 10a to form a concave portion 12, the base material 10a is sandwiched between a punch 42 and a knock portion 43, and the base material 10a is partially punched out by the punch 42 into the punching hole 410, thereby forming a bottomed cylindrical projection 11 on the base material 10a.

[0015] In the manufacturing method of the components of the lighting fixture 100 according to one embodiment having the above configuration, by using a press die 4 (first die 40, second die 41, punch 42, and knock part 43), a metal fixing plate 10 having a protrusion 11 and a recess 12 can be easily manufactured from a plate-like base material 10a. Therefore, in this manufacturing method, it is possible to easily manufacture a component (fixing plate 10) of the lighting fixture 100 that can reduce the manufacturing cost for a watertight structure.

[0016] (2) Details Subsequently, the lighting fixture 100 according to one embodiment shown in FIGS. 1 to 6 will be described in more detail. The lighting fixture 100 is used, for example, for illuminating lighting light in an outdoor parking lot, a ground, etc. In the following description, unless otherwise specified, the up-down, front-back, and left-right directions indicated by arrows in FIG. 1 are defined as the up-down, front-back, and left-right directions of the lighting fixture 100.

[0017] As shown in FIGS. 1A, 1B, 3, and 4, the lighting fixture 100 includes an instrument body 1, lighting components 2, a fixing part 3, a frame 5, an arm 6, a seal member 7, and a lens unit 8. In this embodiment, the lighting components 2 include a light source part 2a that emits lighting light and a power supply device 2b that supplies power to the light source part 2a. In this embodiment, the fixing part 3 is a male screw 30.

[0018] (2-1) Instrument body The instrument body 1 is a housing that houses the lighting components 2. The instrument body 1 has a rectangular box-shaped housing part 13 with an open front surface, a rectangular frame-shaped flange part 14 that protrudes outward from the opening edge of the front surface of the housing part 13, and a protruding wall 15 that protrudes forward from the outer peripheral edge of the flange part 14.

[0019] The housing part 13, the flange part 14, and the protruding wall 15 that constitute the instrument body 1 are integrally formed by drawing and bending a metal plate (for example, a plate made of pure aluminum).

[0020] In this embodiment, the power supply device 2b is housed in the housing part 13, and the light source part 2a and the lens unit 8 are housed in the flange part 14 and the protruding wall 15.

[0021] A power supply unit 2b is mounted on the front surface (i.e., the inner bottom surface) of the bottom wall 130 of the housing section 13. The bottom wall 130 is provided with a through-hole (not shown) through which a power cable 22 connected to the power supply unit 2b passes. The power supply unit 2b is fixed to the bottom wall 130 by a male screw 30 (see Figure 1B).

[0022] In this embodiment, the bottom wall 130 constitutes a metal fixing plate 10. As shown in Figures 1A, 1B, and 6, the bottom wall 130 includes a bottomed cylindrical projection 11 that opens toward the inside (i.e., the front side) of the fixture body 1 so that the fixing part 3 fits into it, and protrudes toward the outside (i.e., the rear side) of the fixture body 1. On the surface of the bottom wall 130 facing outward from the fixture body 1 (i.e., the rear surface), a recess 12 is provided around the projection 11 that is recessed toward the inside (i.e., the front side) of the fixture body 1.

[0023] In this embodiment, the recess 12 is an annular groove surrounding the projection 11. More specifically, the recess 12 is an annular groove.

[0024] The bottomed cylindrical projection 11 has a substantially disc-shaped bottom wall portion 110 and a peripheral wall portion 111 that is integral with the outer peripheral edge of the bottom wall portion 110. The inner circumferential surface of the peripheral wall portion 111 is cylindrical, and its inner diameter is constant along the entire length in the projection direction (i.e., the front-to-back direction) of the projection 11. The outer circumferential surface of the peripheral wall portion 111 is frustoconical, and its outer diameter is larger in the part closer to the recess 12. Therefore, the peripheral wall portion 111 is made thicker in the part closer to the recess 12 (i.e., the base end side in the projection direction).

[0025] The recess 12 and the projection 11 are located adjacent to each other. In this embodiment, the outer circumferential surface of the peripheral wall portion 111 of the projection 11 and the inner circumferential surface 120 of the recess 12 are continuous and flush with each other.

[0026] In this embodiment, the bottom wall 130 includes four protrusions 11, as shown in Figures 1A and 5. The four protrusions 11 are positioned at locations corresponding to the mounting positions of the power supply unit 2b.

[0027] As shown in Figure 4, through holes 140 are provided at the four corners of the rectangular frame-shaped flange portion 14 and at the center of each of the four frames in the longitudinal direction, penetrating the flange portion 14 in the thickness direction (more specifically, the front-to-back direction).

[0028] In this embodiment, as shown in Figures 1A, 4, and 5, the upper and lower frames of the rectangular flange portion 14 each constitute a metal fixing plate 10. Each of the upper and lower frames of the flange portion 14 includes a bottomed cylindrical projection 11 and a recess 12, similar to the bottom wall portion 110.

[0029] In this embodiment, each of the upper and lower frames of the flange portion 14 is provided with two projections 11. On each of the upper and lower frames of the flange portion 14, the two projections 11 are located between the four corner insertion holes 140 and the central insertion hole 140.

[0030] (2-2) Light source section As shown in Figure 4, the light source unit 2a is an LED module 20 on which at least one LED (Light-Emitting Diode) 200 is mounted on a substrate 201. A mounting plate 21 is attached to the LED module 20.

[0031] In this embodiment, the LED module 20 comprises a rectangular substrate 201 and a plurality of LEDs 200 mounted on the front surface of the substrate 201. Each of the plurality of LEDs 200 is a package-type white LED for illumination. The substrate 201 is, for example, a metal base substrate based on an aluminum plate. The plurality of LEDs 200 are mounted on the surface of the substrate 201 in multiple rows and at approximately equal intervals along the vertical (up and down) and horizontal (left and right) directions.

[0032] The mounting plate 21 is formed, for example, from an aluminum plate into a rectangular flat plate shape. The vertical (top and bottom) and horizontal (left and right) lengths of the mounting plate 21 are longer than the vertical and horizontal lengths of the substrate 201. When the LED module 20 is screwed to the front of the mounting plate 21, the outer periphery of the mounting plate 21 protrudes around the LED module 20. A pair of through holes 210 are provided on the upper and lower edges of the outer periphery of the mounting plate 21.

[0033] The light source unit 2a is secured to the flange portion 14 by screwing the male screws 30 into the four projections 11 of the flange portion 14 through the four insertion holes 210 of the mounting plate 21, with the outer circumference of the mounting plate 21 overlapping the front surface of the flange portion 14.

[0034] (2-3) Power supply device The power supply unit 2b is a device unit that supplies power to the light source unit 2a. A power cable 22 is connected to the power supply unit 2b. The power supply unit 2b includes, for example, a switching power supply circuit and converts AC power supplied from the power system through the power cable 22 into DC power. As shown in Figure 1, the power cable 22 is routed out from a through hole in the bottom wall 130 of the housing unit 13 to the rear of the housing unit 13. The power cable 22 is fixed to the outer surface (rear surface) of the bottom wall 130 by a cable gland 23. The cable gland 23 fixes the power cable 22 to the fixture body 1 and seals the gap between the power cable 22 and the through hole in the bottom wall 130 of the housing unit 13.

[0035] (2-4) slots As shown in Figures 3 and 4, the frame 5 has a frame body 50 with a window 500 in the center, and four peripheral wall portions 51 that protrude rearward from the outer edge of the frame body 50. The frame body 50 and the four peripheral wall portions 51 that make up the frame 5 are integrally formed by punching and bending a metal plate (for example, a plate made of pure aluminum).

[0036] The frame body 50 is rectangular in shape. The frame body 50 has a window 500 on its inside. Multiple through holes 501 are provided in each of the top, bottom, left, and right portions of the frame body 50, through which bolts 90 that fix the frame body 50 to the flange portion 14 of the fixture body 1 are inserted. The arrangement of the multiple through holes 501 in the frame body 50 corresponds to the arrangement of the multiple through holes 140 in the flange portion 14.

[0037] One nut 93 is fixed to the lower part of each of the left and right peripheral wall portions 51 of the four peripheral wall portions 51. Each nut 93 is, for example, a crimp nut (also called a piercing nut or rivet nut) and is fixed by crimping into a through hole provided in the peripheral wall portion 51.

[0038] (2-5) Arm The arm 6 has a fixing portion 60 that is fixed to the object to be fixed (base) and a pair of arm portions 61. The fixing portion 60 and the pair of arm portions 61 are integrally formed by punching and bending a metal plate (for example, a sheet of pure aluminum).

[0039] The fixing part 60 is formed in the shape of a trapezoidal plate. The fixing part 60 is provided with three circular mounting holes 600 arranged in a row. For example, one anchor bolt embedded in a concrete base or the like is inserted through each of these three mounting holes 600, and a nut is tightened on each anchor bolt to fix the fixing part 60 to the object to be fixed (base).

[0040] The pair of arm portions 61 are formed in a roughly L-shape and protrude diagonally upward and backward from the pair of slanted sides (sides corresponding to the legs of a trapezoid) of the fixing portion 60. Each of the pair of arm portions 61 is provided with one insertion hole 610 at its tip (see Figure 4).

[0041] The arm 6 is attached to the frame 5 with two bolts 92. More specifically, the bolts 92, which are inserted through the insertion holes 610 of each arm portion 61, are screwed into nuts 93 fixed to the left and right peripheral walls 51 of the frame 5, thereby rotatably attaching each arm portion 61 to each peripheral wall 51.

[0042] (2-6) Sealing member The sealing member 7 shown in Figure 4 is formed in the shape of a rectangular frame using silicone rubber. The sealing member 7 may also be made of an elastic material other than silicone rubber. In this embodiment, each of the top, bottom, left, and right frames of the sealing member 7 has a U-shaped cross-section perpendicular to the longitudinal direction, opening inwards towards the frame.

[0043] Each of the four frames of the sealing member 7 is provided with multiple notches 70 through which bolts 90 are inserted. The arrangement of the multiple notches 70 in the four frames corresponds to the arrangement of the multiple insertion holes 501 in the frame 5 and the multiple insertion holes 140 in the flange portion 14.

[0044] (2-7) Lens Unit The lens unit 8 comprises a unit body 81 provided with a plurality of lenses 80, and a cover portion 82 that covers the plurality of lenses 80. The plurality of lenses 80, the unit body 81, and the cover portion 82 are integrally formed from a light-transmitting synthetic resin material (for example, polycarbonate resin or acrylic resin).

[0045] The unit body 81 is rectangular in shape. Multiple lenses 80 are provided on the remaining portion of the unit body 81, excluding the rectangular frame-shaped outer periphery 810. The multiple lenses 80 correspond one-to-one with the multiple LEDs 200 of the LED module 20. In other words, the light distribution of the light emitted from each LED 200 is controlled by each lens 80 that corresponds one-to-one with each LED 200.

[0046] Multiple notches 811 are provided on the outer periphery 810. The arrangement of the multiple notches 811 on the outer periphery 810 corresponds to the arrangement of the multiple notches 70 on the sealing member 7. The sealing member 7 is fitted into the outer periphery 810.

[0047] The cover portion 82 is located in front of the central part of the unit body 81. The cover portion 82 covers multiple lenses 80. As shown in Figure 3, the cover portion 82 protrudes forward from the window 500 of the frame 5.

[0048] (2-8) Assembly of lighting fixtures Next, we will explain an example of the assembly procedure for lighting fixture 100. However, the assembly procedure described below is just one example, and the order of some of the steps may be changed.

[0049] First, the worker performing the assembly work electrically connects the power cable 22 to the power supply unit 2b, pulls the power cable 22 out of the housing 13 through the through hole in the bottom wall 130 of the housing 13 of the main body of the device 1, and then attaches the power supply unit 2b to the front of the bottom wall 130.

[0050] At this time, the male screw 30 is driven into the housing of the power supply unit 2b from the inside of the main body 1 of the device, and the threads of the male screw 30 are screwed into the inner surface of the peripheral wall portion 111 of the projection 11 of the bottom wall 130, thereby forming a tap groove on the inner surface of the peripheral wall portion 111. As a result, the power supply unit 2b is attached to the front of the bottom wall 130.

[0051] Next, the worker secures the power cable 22 to the rear surface (outer bottom surface) of the bottom wall 130 of the housing 13 using the cable gland 23.

[0052] Next, the worker places the mounting plate 21 of the light source unit 2a onto the flange portion 14 of the fixture body 1, and attaches the mounting plate 21 of the light source unit 2a to the front surface of the flange portion 14.

[0053] At this time, the male screw 30 is driven from the inside of the fixture body 1 into the four insertion holes 210 of the mounting plate 21, and the threads of the male screw 30 are screwed into the inner circumferential surface of the four projections 11 of the flange portion 14, thereby forming tap grooves on the inner circumferential surface of the peripheral wall portion 111. As a result, the light source portion 2a is attached to the front surface of the flange portion 14.

[0054] Before attaching the light source unit 2a to the flange unit 14, the worker electrically connects the output wires drawn from the power supply unit 2b to the connector mounted on the circuit board 201 of the LED module 20.

[0055] Next, the worker fits the sealing member 7 onto the outer circumference 810 of the unit body 81 of the lens unit 8. Then, the worker places the lens unit 8 with the sealing member 7 fitted onto the front surface of the flange portion 14, and then places the frame 5 over the sealing member 7 from the front.

[0056] Next, the worker inserts the bolts 90 from the front into the multiple insertion holes 501 in the frame body 50 of the frame 5 and the multiple insertion holes 140 in the flange portion 14. Then, the worker fastens two nuts 91 to each bolt 90 inserted into the insertion hole 140 of the flange portion 14, thereby fixing the frame 5 to the flange portion 14 of the fixture body 1.

[0057] Next, the worker inserts one bolt 92 into each of the insertion holes 610 of the pair of arm sections 61 and screws the bolts 92 into the nuts 93 fixed to the left and right peripheral wall sections 51, thereby attaching the arms 6 to the frame 5.

[0058] The assembly of lighting fixture 100 is completed by following the steps above.

[0059] (2-9) Method for manufacturing a fixing plate Next, the manufacturing method of the components of the lighting fixture 100 in this embodiment (specifically, the fixing plate 10) will be described. In this embodiment, as shown in Figures 2A to C, the fixing plate 10 (i.e., the bottom wall 130 and flange portion 14) is manufactured by press-forming (more specifically, drawing) a plate-shaped base material 10a using a press mold 4.

[0060] In this embodiment, the base material 10a is made of aluminum. The thickness of the base material 10a is, for example, about 2 mm. The base material 10a can be made of any material that can be press-formed, and is not limited to aluminum; it may be made of other metal materials such as hot-dip galvanized steel sheet.

[0061] As shown in Figures 2A and 2B, the press die 4 comprises a first die 40, a second die 41 facing the first die 40 and having a punch hole 410, and a punch 42 mounted on the first die 40 so as to be movable back and forth and which enters the punch hole 410. The press die 4 further has a knock portion 43 mounted on the punch hole 410 so as to be movable back and forth. The second die 41 is provided with a convex portion 411 that protrudes toward the first die 40 around the punch hole 410.

[0062] More specifically, the first type 40 presses against one side of the base material 10a in the thickness direction (more specifically, the side facing the inside (i.e., the front) of the device body 1). The first type 40 is provided with an installation hole 400 into which a punch 42 is installed so as to be able to move back and forth. The installation hole 400 opens at least towards the second type 41 side. The punch 42 is installed so as to be able to move back and forth in the direction in which the first type 40 and the second type 41 face each other. The punch 42 is cylindrical.

[0063] The second type 41 presses against the other side of the base material 10a in the thickness direction (specifically, the side facing outward (i.e., rear) of the device body 1). The second type 41 has a pressing surface 412 that presses against the base material 10a. The second type 41 is provided with a punch hole 410 into which the punch 42 enters together with the deformed base material 10a.

[0064] The punch hole 410 opens at least towards the first mold 40. In this embodiment, the punch hole 410 is a circular cross-section hole, and its diameter is larger than the diameter of the punch 42. The punch 42 is inserted into the punch hole 410 such that its central axis passes through the center of the punch hole 410. A predetermined gap is formed between the inner circumferential surface of the punch hole 410 and the punch 42 inserted inside it.

[0065] Of the pressing surface 412 of the second type 41, a protrusion 411 is provided around the punch hole 410, projecting toward the first type 40. In this embodiment, the protrusion 411 is an annular (more specifically, circular) projection. The protrusion 411 is located adjacent to the punch hole 410, and the inner circumferential surface 413 of the protrusion 411 is flush and continuous with the inner circumferential surface of the punch hole 410.

[0066] When the thickness of the base material 10a is about 2 mm, the protruding length of the convex portion 411 from the pressing surface 412 is, for example, about 0.5 mm. In this case, the outer diameter of the male screw 30 is, for example, 3.0 mm.

[0067] In this embodiment, a knock portion 43 is provided in the punch hole 410 so as to be able to move forward and backward. The knock portion 43 moves (retracts) within the punch hole 410 of the second mold 41 when it is pushed by the punch 42 inserted into the punch hole 410 and the deformed base material 10a. The knock portion 43 is also biased toward the first mold 40 by a spring or the like.

[0068] In the manufacturing method of this embodiment, first, as shown in Figure 2A, the base material 10a is placed between the first mold 40 and the second mold 41.

[0069] Next, as shown in Figure 2B, the base material 10a is sandwiched between the first mold 40 and the second mold 41, and the convex portion 411 is pressed against the base material 10a to form a concave portion 12. With the base material 10a sandwiched between the punch 42 and the knock portion 43, the punch 42 is used to partially punch out the base material 10a into the punching hole 410, thereby forming a bottomed cylindrical projection 11 on the base material 10a.

[0070] At this time, as the base material 10a is pressed by the protrusion 411 and the punch 42 pushes the base material 10a into the punch hole 410, the portion of the base material 10a pressed by the protrusion 411 easily spreads to the peripheral wall portion 111 of the projection 11 adjacent to the protrusion 411. Therefore, in this manufacturing method, the peripheral wall portion 111 of the bottomed cylindrical projection 11 (especially the portion on the base end side of the projection 11) can be made thicker.

[0071] Next, as shown in Figure 2C, the first mold 40, the second mold 41, the punch 42, and the knocking part 43 are separated from the base material 10a (i.e., demolded). This forms a fixed plate 10 with recesses 12 formed around the projection 11.

[0072] (3) Effects In the lighting fixture 100 of this embodiment described above, the protrusions 11 and recesses 12 can be formed on the bottom wall 130 and flange portion 14 of the housing portion 13 of the fixture body 1, respectively, using the manufacturing method shown in Figures 2A to C. In the lighting fixture 100 of this embodiment, the male screws 30 for fixing the light source 2a and power supply unit 2b can be fitted and fixed to the bottomed cylindrical protrusions 11 that do not penetrate the bottom wall 130 and flange portion 14. Therefore, in the lighting fixture 100 of this embodiment, other members (such as gaskets or retaining plates to hold gaskets) that seal the through holes (holes through which the male screws 30 pass) in the bottom wall 130 and flange portion 14 in a watertight manner can be omitted, thereby reducing the manufacturing cost for a watertight structure.

[0073] In addition, in the lighting fixture 100 of this embodiment, recesses 12 are provided around the projection 11 of the bottom wall 130 and flange portion 14. Therefore, in the lighting fixture 100 of this embodiment, when forming the projection 11 by press working (drawing) a part of the bottom wall 130 and flange portion 14, the peripheral wall portion 111 of the bottomed cylindrical projection 11 can be made thicker by the amount of the recess 12. Consequently, in the lighting fixture 100 of this embodiment, the mounting strength of the male screw 30 to the projection 11 is easily ensured, and the fixing state of the light source unit 2a and power supply unit 2b to the bottom wall 130 and flange portion 14 is easily stabilized.

[0074] Furthermore, in the lighting fixture 100 of this embodiment, the recess 12 is located adjacent to the projection 11. Therefore, in the lighting fixture 100 of this embodiment, the portion of the base material 10a that is pushed aside by forming the recess 12 can easily reach the peripheral wall portion 111 of the projection 11, and the thickness of the projection 11, especially the base end portion, can be increased.

[0075] In this embodiment of the lighting fixture 100, the male screw 30 bites into the peripheral wall portion 111 of the projection 11 to form a tapping groove. Therefore, if the peripheral wall portion 111 is thick, it is easier to ensure the mounting strength of the male screw 30 to the projection 11.

[0076] Furthermore, in the lighting fixture 100 of this embodiment, an annular recess 12 is formed around the projection 11, so the volume displaced by the formation of the recess 12 in the base material 10a is large, making it easier to make the peripheral wall portion 111 of the projection 11 thicker. Moreover, in the lighting fixture 100 of this embodiment, because the recess 12 (protrusion 411) is annular, the thickness of the peripheral wall portion 111 of the projection 11 tends to increase in the circumferential direction, making it easier to suppress variations in the thickness of the peripheral wall portion 111 in the circumferential direction.

[0077] (4) Variations Next, we will describe some variations of the manufacturing method for the lighting fixture 100 and its components according to the above-described embodiment. Note that the following variations can be combined as appropriate.

[0078] The recess 12 is not limited to an annular groove provided to surround the projection 11. For example, the recess 12 may be a single recess located around the projection 11, or it may be a plurality of recesses spaced apart from each other to surround the projection 11.

[0079] The fixing part 3 is not limited to a male screw 30. The fixing part 3 can be any part that fits into the bottomed cylindrical projection 11 and can be fixed to the projection 11, for example, it may be a projection that protrudes from the lighting component 2 and is configured to fit into the projection 11.

[0080] The lighting component 2 is not limited to the light source unit 2a and the power supply unit 2b; it may also include only the light source unit 2a, or it may further include other electrical components.

[0081] Furthermore, the lighting fixture 100 is not limited to the structure shown in Figures 1A and 3. The lighting fixture 100 is not limited to those used outdoors, but may also be used indoors.

[0082] Furthermore, the lighting fixture 100 may be configured such that only one of the light source unit 2a and the power supply unit 2b is fixed to the bottomed cylindrical projection 11.

[0083] Furthermore, the arrangement of the projection 11 and the recess 12 is not limited to the arrangement shown in Figures 1B and 6. For example, the recess 12 may be positioned at a distance from the projection 11.

[0084] (summary) As described above in the embodiment and its modified form, the lighting fixture (100) of the first embodiment has the following configuration.

[0085] In other words, the lighting fixture (100) of the first embodiment comprises a fixture body (1) that houses lighting components (2), and a fixing part (3) that fixes the lighting components (2) to the fixture body (1). The fixture body (1) has a metal fixing plate (10) to which the fixing part (3) is fixed. The fixing plate (10) includes a bottomed cylindrical projection (11) that opens toward the inside of the fixture body (1) so as to fit the fixing part (3), and protrudes toward the outside of the fixture body (1). On the surface of the fixing plate (10) that faces toward the outside of the fixture body (1), a recess (12) is provided around the projection (11) that is recessed toward the inside of the fixture body (1).

[0086] In the first embodiment of the lighting fixture (100) having the above configuration, a fixing part (3) for fixing the lighting component (2) can be fitted into a bottomed cylindrical projection (11) that does not penetrate the fixing plate (10), thereby fixing the lighting component (2) to the fixing plate (10). Therefore, in the first embodiment of the lighting fixture (100), other members for sealing the through hole in the fixing plate (10) in a watertight manner can be omitted, thereby reducing the manufacturing cost for a watertight structure. In addition, in the first embodiment of the lighting fixture (100), a recess (12) is provided around the projection (11) of the fixing plate (10). Therefore, in the first embodiment of the lighting fixture (100), when forming the projection (11) by press working (drawing) a part of the fixing plate (10), the peripheral wall portion (111) of the bottomed cylindrical projection (11) can be made thicker by the amount of the recess (12). Therefore, in the lighting fixture (100) of the first embodiment, the mounting strength of the fixing part (3) to the projection (11) is easily secured, and the fixing state of the lighting component (2) to the fixing plate (10) is easily stabilized.

[0087] Furthermore, as described above in one embodiment and its modified form, the lighting fixture (100) of the second embodiment additionally includes the following configuration in addition to the configuration of the first embodiment.

[0088] In other words, in the second embodiment of the lighting fixture (100), the recess (12) is an annular groove provided so as to surround the projection (11).

[0089] In the second embodiment of the lighting fixture (100) having the above configuration, when forming the projection (11) by press-forming (drawing) a part of the fixing plate (10), it is easier to make the peripheral wall portion (111) of the projection (11) thicker by the amount of the annular recess (12). Also, in the second embodiment of the lighting fixture (100), the peripheral wall portion (111) of the projection (11) tends to increase in thickness in the circumferential direction, making it easier to ensure greater mounting strength of the fixing portion (3) to the projection (11).

[0090] Furthermore, as described above in one embodiment and its modified form, the lighting fixture (100) of the third embodiment additionally includes the following configuration in addition to the configuration of the first or second embodiment.

[0091] In other words, in the lighting fixture (100) of the third embodiment, the fixing part (3) is a male screw (30).

[0092] In the third embodiment of the lighting fixture (100) having the above configuration, the male screw (30) bites into the inner circumferential surface of the bottomed cylindrical projection (11), making it easier to ensure the mounting strength of the fixing part (3) to the projection (11).

[0093] Furthermore, as described in the embodiment and its modified form above, the lighting fixture (100) of the fourth embodiment additionally includes the following configuration in addition to the configuration of any one of the first to third embodiments.

[0094] In other words, in the fourth embodiment of the lighting fixture (100), the lighting component (2) includes a light source unit (2a) that emits illumination light. The light source unit (2a) is an LED module (20) in which at least one LED (200) is mounted on a substrate (201). The LED module (20) is fixed to a fixing plate (10).

[0095] In the lighting fixture (100) of the fourth embodiment having the above configuration, damage to the LED module (20) due to short circuits can be suppressed, resulting in a more reliable lighting fixture (100).

[0096] Furthermore, as described above in one embodiment and its modified form, the lighting fixture (100) of the fifth embodiment additionally includes the following configuration in addition to the configuration of any one of the first to fourth embodiments.

[0097] In other words, in the fifth embodiment of the lighting fixture (100), the lighting component (2) includes a light source unit (2a) that emits illumination light and a power supply unit (2b) that supplies power to the light source unit (2a). The power supply unit (2b) is fixed to the fixing plate (10).

[0098] In the fifth embodiment of the lighting fixture (100) having the above configuration, damage to the power supply unit (2b) due to short circuits can be suppressed, resulting in a more reliable lighting fixture (100).

[0099] Furthermore, as described above in one embodiment and its modified form, the method for manufacturing the components of the lighting fixture (100) of the sixth embodiment comprises the following configuration.

[0100] In other words, the manufacturing method for a component of the lighting fixture (100) according to the sixth embodiment is a method for manufacturing a metal fixing plate (10) used in the lighting fixture (100) using a press die (4). The press die (4) has a first die (40), a second die (41) facing the first die (40) and having a punch hole (410), and a punch (42) that is movable back and forth in the first die (40) and enters the punch hole (410). The press die (4) further has a knock portion (43) that is movable back and forth in the punch hole (410). A convex portion (411) is provided around the punch hole (410) of the second die (41) that protrudes toward the first die (40). In this manufacturing method, a plate-shaped base material (10a) that will form the fixing plate (10) is sandwiched between a first mold (40) and a second mold (41), and a convex portion (411) is pressed against the base material (10a) to form a concave portion (12). While the base material (10a) is sandwiched between a punch (42) and a knock portion (43), the base material (10a) is pushed into the punch hole (410) with the punch (42) to partially punch it out, thereby forming a bottomed cylindrical projection (11) on the base material (10a).

[0101] In the manufacturing method for the components of the sixth embodiment of the lighting fixture (100) having the above configuration, a metal fixing plate (10) having a bottomed cylindrical projection (11) and a recess (12) located around it can be easily manufactured from a plate-shaped base material (10a) using a press mold (4) (first mold 40, second mold 41, punch 42, and knock part 43). Therefore, this manufacturing method makes it possible to easily manufacture components (fixing plate 10) of the lighting fixture (100) that can reduce the manufacturing cost for a watertight structure.

[0102] Although the present disclosure has been described above based on the embodiments shown in the attached drawings, the present disclosure is not limited to the above embodiments and their modifications, and any appropriate design changes are possible within the scope intended by the present disclosure. [Explanation of Symbols]

[0103] 1. Main body of the device 10 Fixed plate 10a Base material 11 Protrusion 12 recesses 2 Lighting components 2a Light source section 2b Power supply 20 LED modules 200 LED 201 circuit board 3 Fixed part 30 Male screw 4 Press molds 40 Type 1 41 Type 2 410 Holes 411 Convex part 42 punches 43 Knock part 100 lighting fixtures

Claims

1. The fixture body that houses the lighting components, A fixing part for fixing the lighting component to the fixture body, Equipped with, The aforementioned device body is The aforementioned fixing part has a metal fixing plate to which it is fixed, The aforementioned fixing plate is It includes a bottomed cylindrical projection that opens toward the inside of the device body so as to fit the fixing part, and protrudes toward the outside of the device body, On the surface of the fixing plate facing outward from the main body of the device, a recess is provided around the projection that is recessed toward the inside of the main body of the device. Lighting fixtures.

2. The fixing plate is exposed to the outside, The lighting fixture according to claim 1.

3. The recess is an annular groove provided so as to surround the projection. A lighting fixture according to claim 1 or 2.

4. The fixing part is a male screw, A lighting fixture according to claim 1 or 2.

5. The lighting component includes a light source that emits illumination light, The light source unit is an LED module in which at least one LED is mounted on a substrate. The LED module is fixed to the fixing plate. A lighting fixture according to claim 1 or 2.

6. The lighting component is It includes a light source unit that emits illumination light and a power supply unit that supplies power to the light source unit, The power supply unit is fixed to the fixing plate. A lighting fixture according to claim 1 or 2.

7. A method for manufacturing a component of a lighting fixture, comprising using a press mold to manufacture a metal fixing plate used in a lighting fixture, The aforementioned press mold is, Type 1 and Opposite the first type, there is a second type which has a hole provided, A punch is provided in the first type so as to be able to move forward and backward, and which enters into the punching hole, It has a knocking part that is provided to move back and forth in the aforementioned hole, The area around the hole in the second type is provided with a protrusion that extends toward the first type. The plate-shaped base material forming the fixing plate is sandwiched between the first mold and the second mold, and while pressing the protrusions against the base material to form recesses, the base material is sandwiched between the punch and the knocking part, and the punch pushes the base material into the punching hole to partially punch it out, thereby forming a bottomed cylindrical projection on the base material. Manufacturing method for lighting fixture components.

8. The fixing plate is exposed to the outside, A method for manufacturing a component of a lighting fixture according to claim 7.

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