Substrate for vehicular light emitting unit, vehicular light emitting unit, and vehicular lamp fitting

Abstract

The objective of the present invention is to provide a substrate for a vehicular light emitting unit, a vehicular light emitting unit, and a vehicular lamp fitting with which it is possible to reduce the number of components and reduce cost.　In a substrate 2, a vehicular light emitting unit 1U, and a vehicular lamp fitting 100 according to the present invention, a first part 21 on which a light conversion layer 3 is formed and a second part 22 on which an excitation light source 4 and an optical member 5 are installed are composed of one substrate 2. As a result, the present invention makes it possible to reduce the number of components and reduce cost.

Description

Substrate for vehicle light emitting unit, vehicle light emitting unit, and vehicle lamp

[0001] The present invention relates to a substrate for a vehicle light emitting unit, a vehicle light emitting unit, and a vehicle lamp.

[0002] 2. Description of the Related Art A vehicle light emitting unit and a vehicle lamp that utilize secondary light of luminescence that is excited by excitation light and emits light are disclosed in, for example, Japanese Patent Application Laid-Open No. 2003-222999.

[0003] The vehicle lamp of Patent Document 1 includes a light source that emits excitation light, a reflector that reflects the excitation light from the light source, a light generating unit that has a light emitting layer that emits generated light when irradiated with the excitation light and a holding member that holds the light emitting layer, and a lens member that is arranged on the front side of the light emitting layer and irradiates the generated light from the light emitting layer in a forward direction when mounted on the vehicle.

[0004] JP 2023-98490 A

[0005] However, the vehicle lamp of Patent Document 1 has a heat sink that dissipates heat from the light source and a holding member for the light generating unit that are configured separately, so it has a large number of components and tends to be expensive.

[0006] SUMMARY OF THE INVENTION An object of the present invention is to provide a substrate for a vehicle light emitting unit, a vehicle light emitting unit, and a vehicle lamp that can reduce the number of components and lower costs.

[0007] In order to solve the problem, the substrate of a vehicle light emitting unit according to a first aspect of the present invention is a substrate of a vehicle light emitting unit, which comprises a first portion in which a light conversion layer is formed and a second portion in which an excitation light source is installed, and the first portion and the second portion are composed of a single substrate.

[0008] In the substrate of the vehicle light emitting unit of the present invention, the first portion and the second portion are preferably bent between the first portion and the second portion.

[0009] In the substrate of the vehicle light-emitting unit of this invention, it is preferable that the second part has an attachment portion to which the second part, the excitation light source, and the vehicle lamp are attached, and that the attachment portion is arranged in a portion excluding the portion between the light-emitting element of the excitation light source attached to the second part and the first part.

[0010] In the substrate of the vehicle light-emitting unit of this invention, it is preferable that the second part has a positioning portion for positioning the second part, the excitation light source, and the vehicle lamp, and that the positioning portion is arranged in a portion excluding the portion between the light-emitting element of the excitation light source attached to the second part and the first part.

[0011] In the substrate of the light emitting unit for a vehicle of the present invention, an optical member that irradiates the light conversion layer with excitation light from the excitation light source is preferably provided in the second portion.

[0012] In order to solve the above problem, a first aspect of the present invention provides a vehicle light emitting unit comprising a substrate having a first portion and a second portion, a light conversion layer formed in the first portion, and an excitation light source installed in the second portion, wherein the light conversion layer converts excitation light irradiated from the excitation light source into secondary light and irradiates the secondary light in a predetermined direction, and the first portion and the second portion of the substrate are composed of a single substrate.

[0013] In the vehicle light emitting unit of the present invention, the first portion and the second portion are preferably bent at a position between the first portion and the second portion.

[0014] In the vehicle light-emitting unit of the present invention, it is preferable that the second part has an attachment portion to which the second part, the excitation light source, and the vehicle lamp are attached, and that the attachment portion is arranged in a portion excluding the portion between the light-emitting element of the excitation light source attached to the second part and the first part.

[0015] In the vehicle light-emitting unit of the present invention, it is preferable that the second part has a positioning portion for positioning the second part, the excitation light source, and the vehicle lamp, and that the positioning portion is arranged in a portion excluding the portion between the light-emitting element of the excitation light source attached to the second part and the first part.

[0016] In the light emitting unit for a vehicle of the present invention, it is preferable that an optical member that irradiates the light conversion layer with excitation light from the excitation light source is installed in the second portion.

[0017] In order to solve the problem, the vehicle lamp of a first aspect of the present invention comprises a lamp housing and a lamp lens that form a space, a vehicle light emitting unit that is arranged in the space, and a mounting portion that is also arranged in the space, wherein a second portion of the substrate of the vehicle light emitting unit is attached to the mounting portion, and the light conversion layer of the vehicle light emitting unit irradiates secondary light toward the lamp lens.

[0018] In the vehicle lamp of the present invention, it is preferable that a shielding member be disposed between the optical member of the vehicle light emitting unit and the lamp lens.

[0019] The substrate for the vehicle light emitting unit, the vehicle light emitting unit, and the vehicle lamp of the present invention can reduce the number of components and reduce costs.

[0020] FIG. 1 is a longitudinal cross-sectional view showing a substrate of a vehicle light emitting unit, a vehicle light emitting unit, and a vehicle lamp according to a first embodiment of the present invention in use. FIG. 2 is a longitudinal cross-sectional view showing a substrate of a vehicle light emitting unit and a vehicle light emitting unit in use. FIG. 3 is a plan view showing a substrate with holes drilled. FIG. 4 is a side view showing a substrate with holes drilled, as viewed from the arrow IV in FIG. 3. FIG. 5 is a plan view showing a substrate with a light conversion layer formed on a first portion. FIG. 6 is a side view showing a substrate with a light conversion layer formed on a first portion, as viewed from the arrow VI in FIG. 5. FIG. 7 is a plan view showing a substrate in which a first portion and a second portion are bent. FIG. 8 is a side view showing a substrate in which a first portion and a second portion are bent, as viewed from the arrow VIII in FIG. 7. FIG. 9 is a plan view showing a state in which a second portion of the substrate is attached to a mounting member. FIG. 10 is a side view showing a state in which the second portion of the substrate is attached to a mounting member, as viewed from the arrow X in FIG. 9. Fig. 11 is a plan view showing a state in which the excitation light source is installed on the second portion of the substrate. Fig. 12 is a side view showing a state in which the excitation light source is installed on the second portion of the substrate, as viewed from arrow XII in Fig. 11 . Fig. 13 is a plan view showing a state in which the second portion of the substrate, the excitation light source, and the optical member are fastened together to the mounting member. Fig. 14 is a side view showing a state in which the second portion of the substrate, the excitation light source, and the optical member are fastened together to the mounting member, as viewed from arrow XIV in Fig. 13 . Fig. 15 is a cross-sectional view showing a state in which a substrate for a vehicle light emitting unit, a vehicle light unit, and a vehicle lamp according to a second embodiment of the present invention are used. Fig. 16 is a vertical cross-sectional view showing a state in which a substrate for a vehicle light emitting unit, a vehicle light unit, and a vehicle lamp according to a first modified embodiment of the present invention are used. Fig. 17 is a front view showing a state in which the substrate for a vehicle light emitting unit and a vehicle light emitting unit are used, as viewed from arrow XVII in Fig. 16 . FIG. 18 is a cross-sectional view showing a second modified example of the substrate of the vehicle light emitting unit, the vehicle light emitting unit, and the vehicle lamp according to the present invention in a used state.

[0021] Hereinafter, embodiments of a substrate for a vehicle light emitting unit, a vehicle light emitting unit, and a vehicle lamp according to the present invention will be described with reference to the drawings. Note that the present invention is not limited to these embodiments. Furthermore, the components in the following embodiments include those that are easily replaceable by those skilled in the art, or those that are substantially the same.

[0022] In this specification, the terms "front," "rear," "up," "down," "left," and "right" refer to the front, rear, top, bottom, left, and right of the substrate of the vehicular light emitting unit, the vehicular light emitting unit, and the vehicular lamp according to the present invention when mounted on a vehicle. The terms "front," "back," "up," "down," and "left" refer to the directions when the substrate of the vehicular light emitting unit, the vehicular light emitting unit, and the vehicular lamp are mounted on a vehicle and are viewed from the driver's seat in the direction of travel of the vehicle. The front-rear direction is the direction of travel of the vehicle, i.e., the forward and backward directions, the up-down direction is the vertical direction, and the left-right direction is the horizontal direction of the vehicle. The direction in which light is emitted from the vehicular light emitting unit and the vehicular lamp is the front direction, and the direction opposite to the front direction is the rear direction.

[0023] The drawings are schematic diagrams showing the substrate of the vehicle light emitting unit, the vehicle light emitting unit, and the vehicle lamp according to the present invention, and therefore only show the main components of the substrate of the vehicle light emitting unit, the vehicle light emitting unit, and the vehicle lamp according to the present invention, and omit illustration of components other than the main components. Also, some hatching has been omitted. Furthermore, in the drawings, the symbols "F" represent "front," "B" represent "rear," "U" represent "up," "D" represent "down," "L" represent "left," and "R" represent "right."

[0024] 1 to 14 show a substrate of a vehicle light emitting unit, a vehicle light emitting unit, and a vehicle lamp according to a first embodiment of the present invention. The configurations of the substrate of the vehicle light emitting unit, the vehicle light emitting unit, and the vehicle lamp according to the first embodiment will be described below.

[0025] (Description of Vehicle Lamp 100) The vehicle lamp 100 according to the first embodiment is a rear combination lamp that is attached to each of the left and right sides of the rear of the vehicle, and emits light toward the rear of the vehicle. Therefore, in the first embodiment, the front direction is the rear direction, and the back direction is the forward direction. Note that the vehicle is not shown in the drawings.

[0026] The vehicular lamp 100 shown in Figure 1 is a left-side vehicular lamp 100 mounted on the left rear side of a vehicle. The left-side vehicular lamp 100 will be described below. Note that the right-side vehicular lamp mounted on the right rear side of a vehicle has the same configuration as the left-side vehicular lamp 100, but is laterally reversed, and therefore will not be described here.

[0027] As shown in FIG. 1, the vehicle lamp 100 according to the first embodiment includes an outer housing 101 as a lamp housing, an outer lens 102 as a lamp lens, and a vehicle light emitting unit 1U as a tail lamp unit.

[0028] The outer housing 101 is a light-impermeable member made of a resin material, etc. The outer lens 102 is a light-transmitting member made of a resin material, etc. The outer housing 101 and the outer lens 102 are fixed to each other, and a space, i.e., a lamp space 103, is formed inside the outer housing 101 and the outer lens 102.

[0029] In this example, the outer lens 102 is a colorless and transparent outer cover or the like. The outer lens 102 may be a red lens. The outer lens 102 has a curved shape that protrudes outward from a lamp space 103 disposed inside the outer lens 102, i.e., from the lamp space 103 toward the opposite side of the outer lens 102. The outer lens 102 is inclined from front to back as it goes from top to bottom.

[0030] The vehicle light emitting unit 1U is disposed in the vertical center of the lamp space 103. Other lamp units are also disposed in the lamp space 103. The other lamp units are signal lamps and illuminating lamps such as stop lamps, tail stop lamps, turn signal lamps, backup lamps, and tail fog lamps.

[0031] A mounting portion 104 such as a base and a shielding member 105 are arranged within the lamp space 103. The mounting portion 104 is attached to the outer housing 101 directly or via another member such as a bracket. In this example, the mounting portion 104 has a rectangular plate shape. One surface 106 of the mounting portion 104 forms a horizontal plane. The vehicle light emitting unit 1U is positioned on the one surface 106 of the mounting portion 104 by positioning means and is attached by mounting screws 107 as mounting means.

[0032] As shown in Figures 9 and 10, two protrusions 108 serving as positioning means are provided on both side edges of one surface 106 of the mounting portion 104. In this example, the protrusions 108 are cylindrical or conical. Note that the shape of the protrusions 108 is not limited to the shape in this example. A screw hole 109 serving as mounting means is provided in the center of one surface 106 of the mounting portion 104. Note that if the mounting screw 107 is a tapping screw, a pilot hole can be formed instead of the screw hole 109.

[0033] The shielding member 105 is made of a light-impermeable material, and is attached to the outer housing 101, similar to the attachment portion 104. The shielding member 105 is disposed between the outer lens 102 and at least the optical member 5 of the vehicle light emitting unit 1U, and covers the optical member 5 so that the optical member 5 cannot be seen from the outer lens 102.

[0034] (Explanation of Vehicle Light Emitting Unit 1U) As shown in Fig. 1, the vehicle light emitting unit 1U is disposed in a lamp space 103 as a space, is positioned on a mounting portion 104 by a positioning means, and is attached by a mounting means such as a mounting screw 107. In this example, the vehicle light emitting unit 1U is a tail lamp unit, and includes a substrate 2, a light conversion layer 3, an excitation light source 4, and an optical member 5, as shown in Figs.

[0035] (Description of Substrate 2) The substrate 2 is made of a material with high thermal conductivity, such as FR4 or an aluminum substrate. As shown in Figures 1 to 14, the substrate 2 has a first portion 21 and a second portion 22. Because the substrate 2 is made of a material with high thermal conductivity, it has a high heat dissipation effect. In this example, the substrate 2 has a rectangular shape with one corner removed when viewed from above, as shown in Figure 3.

[0036] The first portion 21 and the second portion 22 are formed from a single substrate 2. That is, the first portion 21 and the second portion 22 are integrally formed. The first portion 21 and the second portion 22 are bent at a predetermined angle θ° between the first portion 21 and the second portion 22 at a distance 20 as shown in FIG. 8 . The bending angle θ° between the first portion 21 and the second portion 22 is set to an angle at which the excitation light L1 from the optical member 5 is irradiated to the light conversion layer 3 with high efficiency. In this example, the bending angle θ° is in the range of approximately 30° to approximately 75°, preferably in the range of approximately 45° to approximately 60°. Note that the bending angle θ° is not limited to this range.

[0037] The first portion 21 has a rectangular shape with one corner removed, and the second portion 22 has a rectangular shape. The shapes of the first portion 21 and the second portion 22 can be any shape based on the layout of the light conversion layer 3, the excitation light source 4, and the optical member 5, the design of the light-emitting surface of the tail lamp unit, i.e., the design of the light conversion layer 3, etc.

[0038] The light conversion layer 3 is formed on one surface of the first portion 21. The first portion 21 is a holding member or holding substrate that holds the light conversion layer 3. One surface of the first portion 21 faces the outer lens 102. Therefore, the light conversion layer 3 also faces the outer lens 102.

[0039] 13 and 14 , the second part 22, together with the excitation light source 4 and the optical member 5, is positioned on the mounting portion 104 by a positioning means, and is attached by an attachment means such as an attachment screw 107. The second part 22 is an attachment substrate on which the excitation light source 4 is attached, and also serves as a heat sink that dissipates heat generated in the excitation light source 4.

[0040] 3 and 4 , the second part 22 has, as positioning means, first and second elongated holes 221 and 222 each having an oval shape, and first and second circular holes 223 and 224 each having a circular shape, on both left and right edges of the second part 22 relative to the space 20 between the first part 21. The first elongated hole 221 and the first circular hole 223 are provided to correspond to the two protrusions 108 of the mounting portion 104.

[0041] 3 and 4, a semicircular piece 225 serving as an attachment means is provided in the center of the front edge of the second portion 22 opposite the gap 20. A circular through-hole 226 is provided in the piece 225. Note that the piece 225 and the circular through-hole 226 may be provided on both left and right edges of the second portion 22 relative to the gap 20, as shown by the two-dot chain lines in FIGS. 3 and 4. The attachment screw 107 passes through the through-hole 226 of this piece 225, shown by the solid line and the two-dot chain line.

[0042] The second portion 22 has a positioning portion 23 and an attachment portion 24. The positioning portion 23 is a portion where the second portion 22, the excitation light source 4, the optical member 5, and the attachment portion 104 are positioned by a positioning device. In this example, the positioning portion 23 is a portion of the second portion 22 where the first elongated hole 221, the second elongated hole 222, the first round hole 223, and the second round hole 224 are provided, on both left and right edges of the space 20. The attachment portion 24 is a portion where the second portion 22, the excitation light source 4, and the optical member 5 are attached to the attachment portion 104 by an attachment device. In this example, the attachment portion 24 is a portion of the second portion 22 where the piece portion 225 is provided, on the front edge opposite the space 20. For convenience, the boundaries between the positioning portion 23 and the attachment portion 24 and other portions of the second portion 22 are indicated by dashed lines in FIGS. 3 and 4 .

[0043] 2 and 3 , the positioning portion 23 and the mounting portion 24 are disposed in a portion of the second portion 22 excluding the area between the light-emitting element 41 of the excitation light source 4 attached to the second portion 22 and the gap 20. That is, the first elongated hole 221, the second elongated hole 222, the first round hole 223, the second round hole 224 of the positioning portion 23, and the piece 225 of the mounting portion 24 are not disposed between the light-emitting element 41 of the excitation light source 4 attached to the second portion 22 and the gap 20. This allows the light-emitting element 41 of the excitation light source 4 to be positioned close to the gap 20, thereby shortening the light-guiding distance of the excitation light L1 in the light-guiding portion 53 of the optical member 5. Note that in FIG. 3 , the light-emitting element 41 of the excitation light source 4 attached to the second portion 22 is indicated by a dashed line.

[0044] 5 and 6, the light conversion layer 3 is formed on one surface of the first portion 21 of the substrate 2, i.e., the surface facing the outer lens 102. As shown in FIGS. 1 and 2, the light conversion layer 3 converts the excitation light L1 irradiated from the optical member 5 and the excitation light L1 reflected from the first portion 21 into secondary light L2, and irradiates the secondary light L2 from the front of the light conversion layer 3 toward the outer lens 102.

[0045] The front surface of the light conversion layer 3 forms a light emitting surface. The front light emitting surface of the light conversion layer 3 is inclined upward at an angle θ° with respect to the horizontal. The front light emitting surface of the light conversion layer 3 is made of a designed surface of any shape. In Figures 1 and 2, the excitation light L1 is indicated by a solid arrow, and the secondary light L2 is indicated by a hollow arrow.

[0046] The light conversion layer 3 may be made of either an organic or inorganic light emitting material. That is, the material of the light conversion layer 3 is made of at least one of an organic fluorescent material, an organic phosphorescent material, and an inorganic fluorescent material. The thickness of the light conversion layer 3 is determined based on some relative relationship in the conversion of the excitation light L1 to the secondary light L2, and is not particularly limited.

[0047] 11 and 12, the excitation light source 4 has a printed circuit board 40, a light-emitting element 41, and a connector 42. The light-emitting element 41 and other electronic components are mounted on the printed circuit board 40, and the connector 42 and other electric components are also attached to the printed circuit board 40.

[0048] In this example, the printed circuit board 40 is made of a material with high thermal conductivity, such as FR4 or an aluminum substrate. The printed circuit board 40 has a rectangular shape, similar to the second portion 22 of the substrate 2. Positioning means are provided on both left and right edges of the printed circuit board 40: first and second oblong slots 401 and 402, and first and second circular slots 403 and 404. Furthermore, a mounting piece 405 is provided at the center of the front edge of the printed circuit board 40 as mounting means. The mounting piece 405 has a mounting hole 406, which is a partially cut-out portion of the circle. The mounting piece 405 and the mounting hole 406 of the printed circuit board 40 correspond to the pieces 225 and the holes 226 of the second portion 22 of the substrate 2.

[0049] The first elongated hole 401, the second elongated hole 402, the first round hole 403, and the second round hole 404, which are positioning means for the printed circuit board 40, are provided to correspond to the first elongated hole 221, the second elongated hole 222, the first round hole 223, and the second round hole 224, which are positioning means for the board 2. The mounting through-hole 406, which is the mounting means for the printed circuit board 40, is provided to correspond to the through-hole 226, which is the mounting means for the board 2.

[0050] In this example, the light emitting elements 41 have a rectangular shape. However, the shape of the light emitting elements 41 is not limited to a rectangular shape. Three light emitting elements 41 are mounted near the center in the left-right direction on the rear side of the printed circuit board 40, between the first elongated hole 401 and the second round hole 404 on the left side and the second elongated hole 402 and the first round hole 403 on the right side. However, the number of mounted light emitting elements 41 is not limited to three. Furthermore, the rear side of the printed circuit board 40 corresponds to the space 20 between the boards 2.

[0051] As described above, the long sides of the three light-emitting elements 41 are arranged parallel to the rear edge of the printed circuit board 40. Furthermore, the first elongated hole 401, the second elongated hole 402, the first round hole 403, and the second round hole 404, which are positioning means for the printed circuit board 40, and the mounting piece 405 and mounting through-hole 406, which are mounting means, are arranged on both the left and right sides and the front side of the three light-emitting elements 41. As a result, the first elongated hole 401, the second elongated hole 402, the first round hole 403, and the second round hole 404, which are positioning means for the printed circuit board 40, and the mounting piece 405 and mounting through-hole 406, which are mounting means, are not arranged between the long sides of the three light-emitting elements 41 and the rear edge of the printed circuit board 40.

[0052] In this example, the light-emitting element 41 is a blue LED. The light-emitting element 41 emits excitation light L1 with a dominant wavelength ranging from approximately 350 nm to approximately 500 nm. Note that a light source other than a blue LED, such as an LD (semiconductor laser), may also be used as the light-emitting element 41. In this example, the excitation light L1 is blue light with a dominant wavelength of approximately 450 nm. Furthermore, the directivity angle of the excitation light L1 is wide, e.g., 180°.

[0053] (Explanation of Optical Member 5) The optical member 5 is a light-transmitting member (such as a resin member), and in this example is made of a colorless and transparent resin material such as acrylic resin, PC (polycarbonate), PMMA (polymethyl methacrylate, methacrylic resin), etc. The optical member 5 is a lens member, or what is called a light guide.

[0054] 1 , 2 , 13 , and 14 , the optical member 5 is attached to the second portion 22 of the substrate 2, and irradiates the light conversion layer 3 with excitation light L1 from the light emitting element 41 of the excitation light source 4. In this example, the optical member 5 has a positioning portion 50, an attachment portion 51, an incident portion 52, a light guiding portion 53, and an exit portion 54. The optical member 5 has a plate-shaped lower portion made up of the positioning portion 50, the attachment portion 51, and a part of the incident portion 52, and an plate-shaped upper portion made up of the remaining portion of the incident portion 52, the light guiding portion 53, and the exit portion 54.

[0055] The positioning portion 50 is composed of two pins 500 that are integrally provided on both sides of the lower surface of the lower portion. The pins 500 correspond to the second elongated hole 222 and the second round hole 224 of the second portion 22 of the substrate 2, and the second elongated hole 402 and the second round hole 404 of the printed circuit board 40.

[0056] The mounting portion 51 is made up of the central portion on the front side of the lower portion. The mounting portion 51 is provided with a circular through-hole 510. The through-hole 510 corresponds to the through-hole 226 of the second portion 22 of the substrate 2 and the mounting through-hole 406 of the printed circuit board 40.

[0057] The incident section 52 is composed of a rear portion of the lower section and a front portion of the upper section. The incident section 52 has a first incident surface 521, a second incident surface 522, a first reflecting surface 523, and a second reflecting surface 524. The first incident surface 521 and the second incident surface 522 allow the excitation light L1 from the light-emitting element 41 to be incident thereon. The first reflecting surface 523 reflects the excitation light L1 incident from the first incident surface 521 toward the second reflecting surface 524. The second reflecting surface 524 reflects the excitation light L1 incident from the second incident surface 522 and the excitation light L1 reflected from the first reflecting surface 523 toward the light-guiding section 53.

[0058] The light guide 53 is configured from the upper portion between the incident portion 52 and the exit portion 54. The light guide 53 guides the excitation light L1 from the incident portion 52 side to the exit portion 54 side in the horizontal direction.

[0059] The exit section 54 is composed of the rear part of the upper section. The exit section 54 has a reflecting surface 540 and an exiting surface 541. The reflecting surface 540 reflects the excitation light L1 guided by the light-guiding section 53 toward the exiting surface 541. The exiting surface 541 emits the excitation light L1 reflected from the reflecting surface 540 toward the light conversion layer 3 of the first portion 21 of the substrate 2.

[0060] (Description of Manufacturing Process of Vehicle Light Emitting Unit 1U) Hereinafter, a manufacturing process of the vehicle light emitting unit 1U will be described with reference to FIGS. 3 to 14. FIG.

[0061] 3 and 4, the substrate 2 of the vehicle light emitting unit 1U is cut to a predetermined shape and size in a cutting process. Furthermore, the first elongated hole 221, the second elongated hole 222, the first round hole 223, the second round hole 224, and the through hole 226 are drilled in the substrate 2 at predetermined positions in a drilling process. The excitation light source 4 and the optical member 5 of the vehicle light emitting unit 1U and the outer housing 101 of the vehicle lamp 100 are manufactured separately from the substrate 2 of the vehicle light emitting unit 1U.

[0062] Next, as shown in FIGS. 5 and 6, the light conversion layer 3 is formed on the first portion 21 of the substrate 2 that has been cut and drilled.

[0063] Then, as shown in Figures 7 and 8, the substrate 2 having a first portion 21 on which the optical conversion layer 3 is formed and the other second portion 22 is bent at a predetermined angle θ° between the first portion 21 and the second portion 22 20, as shown in Figure 8.

[0064] 8, the first portion 21 on which the light conversion layer 3 is formed may be further folded. By further folding the first portion 21, the inclination angle of the front surface of the light conversion layer 3 changes from one step to two steps of the angle θ° shown in FIG. 8, so that the angle and range at which the excitation light L1 from the optical member 5 is irradiated onto the front surface of the light conversion layer 3 can be adjusted.

[0065] Furthermore, the step of bending the first portion 21 and the second portion 22 of the substrate 2 shown in Figures 7 and 8 may be a step subsequent to or prior to the step of forming the light conversion layer 3 shown in Figures 5 and 6.

[0066] 9 and 10 , the second portion 22 of the circuit board 2 is installed on the mounting portion 104 of the outer housing 101. At this time, the two protrusions 108 of the mounting portion 104 are inserted into the first elongated hole 221 and the first round hole 223 of the second portion 22. This determines the relative positions of the mounting portion 104 and the circuit board 2.

[0067] 11 and 12, the excitation light source 4 is installed on the second portion 22 of the substrate 2. At this time, the two protrusions 108 of the mounting portion 104 pass through the first elongated hole 221 and the first round hole 223 of the second portion 22 and are inserted into the first elongated hole 401 and the first round hole 403 of the printed circuit board 40 of the excitation light source 4. This determines the relative positions of the mounting portion 104, the substrate 2, and the excitation light source 4.

[0068] 13 and 14, the optical member 5 is mounted on the printed circuit board 40 of the excitation light source 4. At this time, the two pins 500 of the optical member 5 are inserted into the second elongated hole 402 and the second round hole 404 of the printed circuit board 40 of the excitation light source 4, and into the second elongated hole 222 and the second round hole 224 of the second portion 22 of the substrate 2. This determines the relative positions of the mounting portion 104, the substrate 2, the excitation light source 4, and the optical member 5.

[0069] 13 and 14 , the mounting screw 107 passes through the through-hole 510 of the optical member 5, the mounting hole 406 of the printed circuit board 40 of the excitation light source 4, and the hole 226 of the second portion 22 of the board 2, and is screwed into the screw hole 109 of the mounting portion 104. This fixes the mounting portion 104, the board 2, the excitation light source 4, and the optical member 5 together. At this time, the vehicle light emitting unit 1U is attached by being sandwiched between the mounting portion 104 and the head of the mounting screw 107. In other words, the vehicle light emitting unit 1U is attached to the mounting portion 104 in a positioned state.

[0070] (Explanation of Operation of First Embodiment) The operation of the substrate 2, the vehicle light emitting unit 1U, and the vehicle lamp 100 according to the first embodiment will be described.

[0071] When the light-emitting element 41 of the excitation light source 4 is turned on, excitation light L1 is emitted from the light-emitting element 41. This excitation light L1 enters the optical element 5 from the incident portion 52 of the optical element 5. The excitation light L1 that has entered the optical element 5 is guided from the incident portion 52 to the exit portion 54 through the light-guiding portion 53 of the optical element 5. The excitation light L1 that has been guided to the exit portion 54 is irradiated from the exit portion 54 onto the light conversion layer 3 in the first portion 21 of the substrate 2.

[0072] The blue excitation light L1 irradiated from the optical member 5 onto the light conversion layer 3 is converted into red secondary light L2 by the light conversion layer 3. The secondary light L2 is emitted from the front light-emitting surface of the light conversion layer 3, passes through the outer lens 102, and is emitted to the outside in a predetermined light distribution pattern, in this example, the light distribution pattern of a tail lamp.

[0073] (Explanation of Effects of First Embodiment) Effects of the substrate 2, the vehicle light emitting unit 1U, and the vehicle lamp 100 according to the first embodiment will be described.

[0074] In the substrate 2 according to the first embodiment, the first portion 21 where the light conversion layer 3 is formed and the second portion 22 where the excitation light source 4 and the optical member 5 are disposed are configured from a single substrate 2. As a result, the substrate 2, the vehicle light emitting unit 1U, and the vehicle lamp 100 according to the first embodiment can reduce the number of components and the cost, compared to the vehicle lamp of Patent Document 1, in which the heat sink that dissipates heat from the light source and the holding member for the light generating unit are configured separately.

[0075] In the substrate 2 according to the first embodiment, the first portion 21 and the second portion 22 are bent at the boundary between the first portion 21 and the second portion 22. As a result, in the substrate 2, the vehicle light emitting unit 1U, and the vehicle lamp 100 according to the first embodiment, the first portion 21 in which the light conversion layer 3 is formed and the second portion 22 in which the excitation light source 4 and the optical member 5 are disposed are configured from a single substrate 2. Even with this configuration, by bending the first portion 21 and the second portion 22 at an arbitrary predetermined angle θ°, the excitation light L1 from the optical member 5 in the second portion 22 can be highly efficiently irradiated onto the light conversion layer 3 in the first portion 21.

[0076] In the substrate 2 according to the first embodiment, the second portion 22 has an attachment portion 24 to which the second portion 22, the excitation light source 4, and the attachment target portion 104 are attached. The attachment portion 24 is disposed in a portion excluding the area between the first portion 21 and the light-emitting element 41 of the excitation light source 4 attached to the second portion 22. As a result, in the substrate 2, the vehicular light emitting unit 1U, and the vehicular lamp 100 according to the first embodiment, the attachment portion 24 is not disposed between the light-emitting element 41 of the excitation light source 4 and the first portion 21, and therefore the light-emitting element 41 can be placed close to the first portion 21. As a result, the substrate 2, the vehicular light emitting unit 1U, and the vehicular lamp 100 according to the first embodiment can irradiate the excitation light L1 to the light conversion layer 3 with high efficiency.

[0077] In the substrate 2 according to the first embodiment, the second portion 22 has a positioning portion 23 that positions the second portion 22, the excitation light source 4, and the mounting portion 104 relative to each other. The positioning portion 23 is disposed in a portion excluding the portion between the first portion 21 and the light-emitting element 41 of the excitation light source 4 that is mounted on the second portion 22. As a result, in the substrate 2, the vehicular light emitting unit 1U, and the vehicular lamp 100 according to the first embodiment, the positioning portion 23 is not disposed between the light-emitting element 41 of the excitation light source 4 and the first portion 21, and therefore the light-emitting element 41 can be positioned close to the first portion 21. As a result, the substrate 2, the vehicular light emitting unit 1U, and the vehicular lamp 100 according to the first embodiment can irradiate the excitation light L1 to the light conversion layer 3 with high efficiency.

[0078] In the substrate 2 according to the first embodiment, an optical member 5 that irradiates the excitation light L1 from the excitation light source 4 onto the light conversion layer 3 is provided in the second portion 22. As a result, the substrate 2, the vehicular light emitting unit 1U, and the vehicular lamp 100 according to the first embodiment can irradiate the excitation light L1 from the excitation light source 4 onto the light conversion layer 3 via the optical member 5 with high efficiency.

[0079] In the vehicle lamp 100 according to the first embodiment, a shielding member 105 is disposed between the optical member 5 and the outer lens 102. As a result, in the vehicle lamp 100 according to the first embodiment, the optical member 5 is covered and hidden by the shielding member 105, so that the optical member 5 is not visible when looking into the lamp space 103 from the outer lens 102. This makes it possible for the vehicle lamp 100 according to the first embodiment to highlight the light-emitting surface of the light conversion layer 3, thereby improving the degree of freedom in designing the light conversion layer 3.

[0080] (Explanation of the configuration, operation, and effect of the second embodiment) Fig. 15 shows a substrate, a vehicle light emitting unit, and a vehicle lamp according to the second embodiment of the present invention. In Fig. 15, the same reference numerals as those in Figs. 1 to 14 indicate the same components.

[0081] In the substrate 2 according to the first embodiment, the first portion 21 is disposed rearward relative to the second portion 22, and the first portion 21 is bent obliquely downward at the space 20 between the first portion 21 and the second portion 22. In contrast, in the substrate 2A according to the second embodiment, the first portions 21A, 21A are disposed on both the left and right sides of the second portion 22A, and the first portions 21A, 21A are bent obliquely rearward at the space 20 between the second portion 22A.

[0082] In the vehicle light emitting unit 1U according to the first embodiment, the optical member 5 is disposed above the first portion 21 and irradiates the excitation light L1 onto the lower light conversion layer 3. In contrast, in the vehicle light emitting unit 1UA according to the second embodiment, the optical member 5A is disposed between the first portions 21A, 21A on both the left and right sides and irradiates the excitation light L1 onto the left and right light conversion layers 3.

[0083] The substrate 2A, vehicle light-emitting unit 1UA, and vehicle lamp 100A of embodiment 2 are configured as described above, and therefore can achieve the same functions and effects as the substrate 2, vehicle light-emitting unit 1U, and vehicle lamp 100 of embodiment 1.

[0084] Although not shown, the vehicle light-emitting unit 1UA of embodiment 2 may also be configured, like the vehicle light-emitting unit 1U of embodiment 1, so that the positioning portion and the mounting portion are positioned in the area excluding the area between the light-emitting element of the excitation light source 4 attached to the second part 22A and the gap 20.

[0085] (Explanation of the configuration, operation, and effect of Modification 1) Figures 16 and 17 show Modification 1 of the substrate, vehicular light emitting unit, and vehicular lamp according to the present invention. In Figures 16 and 17, the same reference numerals as in Figures 1 to 15 indicate the same parts. In Figure 16, light L3 from another light source 6 is indicated by a dashed grid arrow.

[0086] The substrates 2 and 2A, the vehicle light emitting units 1U and 1UA, and the vehicle lamps 100 and 100A according to the first and second embodiments use only the excitation light source 4. In contrast, the substrate 2B, the vehicle light emitting unit 1UB, and the vehicle lamp 100B according to the first modified example use the excitation light source 4 and another light source 6.

[0087] The substrate 2B according to the first modification, like the substrate 2 according to the first embodiment, has a first portion 21B disposed rearward of the second portion 22B, and the first portion 21B is bent downward relative to the second portion 22B. The second portion 22B of the substrate 2B according to the first modification has another light source 6 and an optical member 5B attached to it. The optical member 5B receives light L3 from the other light source 6 and emits it toward the outer lens 102. The other light source 6 is used as a light source for functions other than the tail lamp function, such as a stop lamp function, a turn signal lamp function, a backup lamp function, a rear fog lamp function, and a license lamp function. As a result, the light L3 from the other light source 6 is emitted from the exit surface of the optical member 5B, passes through the outer lens 102, and is irradiated to the outside in a predetermined light distribution pattern as another lamp function, as shown in the area indicated by the dashed grid in FIG. 17 .

[0088] In the substrate 2B, vehicular light emitting unit 1UB, and vehicular lamp 100B according to the first modification, the excitation light source 4 is disposed within the lamp space 103, rearward and downward of the light conversion layer 3 of the first portion 21B of the substrate 2B. The excitation light source 4 irradiates excitation light L1 onto the light conversion layer 3 of the first portion 21B of the substrate 2B. The light conversion layer 3 converts the excitation light L1 into secondary light L2 and irradiates the secondary light L2 toward the outer lens 102. As a result, the excitation light L1 from the excitation light source 4 is converted into secondary light L2 in the light conversion layer 3. As shown in the solid-line grid portion in FIG. 17 , the converted secondary light L2 is emitted from the light-emitting surface of the light conversion layer 3, passes through the outer lens 102, and is irradiated to the outside in a predetermined light distribution pattern as a tail lamp function.

[0089] The substrate 2B, vehicle light-emitting unit 1UB, and vehicle lamp 100B of variant example 1 have the above-described configuration and function, and can therefore achieve the same effects as the substrates 2, 2A, vehicle light-emitting units 1U, 1UA, and vehicle lamps 100, 100A of embodiments 1 and 2.

[0090] Although not shown, in the substrate 2B, vehicular light emitting unit 1UB, and vehicular lamp 100B according to Modification 1, similar to the substrate 2, 2A, vehicular light emitting unit 1U, 1UA, and vehicular lamp 100, 100A according to Embodiments 1 and 2, the positioning portion and the mounting portion may be configured to be disposed in a portion of the second portion 22B excluding the space between the light emitting element of the other light source 6 attached to the second portion 22B and the gap 20. In this case, it is possible to suppress light guiding loss of the light L3 in the light guiding portion of the optical member 5B, and therefore it is possible to irradiate the light L3 from the optical member 5B toward the outer lens 102 with high efficiency.

[0091] (Explanation of the configuration, operation, and effect of Modification 2) Fig. 18 shows the substrate, the vehicular light emitting unit, and the vehicular lamp according to Modification 2. In Fig. 18, the same reference numerals as those in Figs. 1 to 17 indicate the same parts.

[0092] In the substrate 2B according to the first modification, the first portion 21B disposed rearward relative to the second portion 22B is bent downward. In contrast, in the substrate 2C according to the second modification, the first portions 21C, 21C disposed on both the left and right sides of the second portion 22C are bent obliquely rearward, similar to the substrate 2A according to the second embodiment.

[0093] In the vehicle light emitting unit 1UC according to the second modification, similarly to the vehicle light emitting unit 1UB according to the first modification, another light source 6 and an optical member 5C are attached to the second portion 22C of the substrate 2C. As a result, similarly to the first modification, the optical member 5C receives light L3 from the other light source 6 and emits it toward the outer lens 102.

[0094] Furthermore, in the substrate 2C, vehicular light emitting unit 1UC, and vehicular lamp 100C according to Modification 2, the two excitation light sources 4, 4C are arranged on the left or right side behind the light conversion layers 3 of the first portions 21C, 21C on both the left and right sides of the substrate 2C within the lamp space 103. The two excitation light sources 4, 4C irradiate the light conversion layers 3 of the first portions 21C, 21C on both the left and right sides of the substrate 2C with excitation light L1. The light conversion layers 3 convert the excitation light L1 into secondary light L2 and irradiate the secondary light L2 toward the outer lens 102.

[0095] Although not shown, in the substrate 2C, vehicle light emitting unit 1UC, and vehicle lamp 100C according to variant example 2, similar to the substrate 2B, vehicle light emitting unit 1UB, and vehicle lamp 100B according to variant example 1, the positioning portion and the mounting portion may be configured to be arranged in the second part 22C excluding the space between the light emitting element of the other light source 6 mounted on the second part 22C and the gap 20.

[0096] (Explanation of Examples Other Than Embodiments 1 and 2 and Modifications 1 and 2) Note that in Embodiments 1 and 2 and Modifications 1 and 2, an example will be described in which vehicular light emitting units 1U, 1UA, 1UB, and 1UC including substrates 2, 2A, 2B, and 2C are arranged in a lamp space 103 formed by the outer housing 101 and outer lens 102 of vehicular lamps 100, 100A, 100B, and 100C. However, in the present invention, vehicular light emitting units 1U, 1UA, 1UB, and 1UC may be arranged in a lamp unit space formed by the inner housing and inner lens of the lamp unit, and this lamp unit may be arranged in the lamp space 103 formed by the outer housing 101 and outer lens 102 of vehicular lamps 100, 100A, 100B, and 100C.

[0097] In addition, the substrates 2, 2A, 2B, and 2C, the vehicle light-emitting units 1U, 1UA, 1UB, and 1UC, and the excitation light sources 4, 4A, 4B, and 4C of the vehicle lamps 100, 100A, 100B, and 100C in the first and second embodiments and the first and second modifications are intended to be used as tail lamp light sources. However, in the present invention, the substrates 2, 2A, 2B, and 2C, the vehicle light-emitting units 1U, 1UA, 1UB, and 1UC, and the excitation light sources 4, 4A, 4B, and 4C of the vehicle lamps 100, 100A, 100B, and 100C may be used as light sources other than tail lamp light sources, such as stop lamp light sources, turn signal lamp light sources, backup lamp light sources, rear fog lamp light sources, and license lamp light sources. In this case, the other light sources 6 in the first and second modifications must be used as light sources for lamp functions other than the excitation light sources 4, 4A, 4B, and 4C. When the excitation light sources 4, 4A, 4B, and 4C are used as light sources for the tail lamp function, the stop lamp function, and the rear fog lamp function, the secondary light L2 is red light. When the excitation light sources 4, 4A, 4B, and 4C are used as light sources for the turn signal lamp function, the secondary light L2 is yellow-orange light. When the excitation light sources 4, 4A, 4B, and 4C are used as light sources for the backup lamp function and the license lamp function, the secondary light L2 is white light.

[0098] 100, 100A, 100B, 100C Vehicle lamp 101 Outer housing 102 Outer lens 103 Lamp space 104 Mounting portion 105 Shielding member 106 One surface 107 Mounting screw 108 Protrusion 109 Screw hole 1U, 1UA, 1UB, 1UC Vehicle light emitting unit 2, 2A, 2B, 2C Substrate 20 Space 21, 21A, 21B, 21C First portion 22, 22A, 22B, 22C Second portion 221 First elongated hole 222 Second elongated hole 223 First round hole 224 Second round hole 225 Piece portion 226 Through hole 23 Positioning portion 24 Mounting portion 3 Light conversion layer 4 Excitation light source 40 Printed circuit board 41 Light emitting element 42 Connector 401 First elongated hole 402 Second elongated hole 403 First round hole 404 Second round hole 405 Mounting piece portion 406 Mounting through-hole 5, 5A, 5B, 5C Optical member 50 Positioning portion 500 Pin 51 Mounting portion 510 Through-hole 52 Incident portion 521 First incident surface 522 Second incident surface 523 First reflecting surface 524 Second reflecting surface 53 Light guiding portion 54 Exit portion 540 Reflecting surface 541 Exit surface 6 Other light source B Back D Bottom F Front L Left L1 Excitation light L2 Secondary light L3 Light R Right U Top θ° Angle

Claims

1. A substrate for a light emitting unit for a vehicle, comprising: a first portion in which a light conversion layer is formed; and a second portion in which an excitation light source is installed, wherein the first portion and the second portion are formed from a single substrate.

2. The substrate of the vehicle light emitting unit according to claim 1, wherein the first portion and the second portion are bent between the first portion and the second portion.

3. The substrate of the vehicle light emitting unit described in claim 1, characterized in that the second part has an attachment part to which the second part, the excitation light source, and the vehicle lamp are attached, and the attachment part is arranged in a part excluding the part between the light emitting element of the excitation light source attached to the second part and the first part.

4. The substrate of the vehicle light emitting unit described in claim 1, characterized in that the second part has a positioning portion for positioning the second part, the excitation light source, and the vehicle lamp, and the positioning portion is arranged in a portion excluding the portion between the light emitting element of the excitation light source attached to the second part and the first part.

5. The substrate of the vehicle light emitting unit according to claim 1, characterized in that an optical member that irradiates the excitation light from the excitation light source onto the light conversion layer is installed in the second portion.

6. A light emitting unit for a vehicle comprising: a substrate having a first portion and a second portion; a light conversion layer formed on the first portion; and an excitation light source installed on the second portion, wherein the light conversion layer converts excitation light irradiated from the excitation light source into secondary light and irradiates the secondary light in a predetermined direction; and wherein the first portion and the second portion of the substrate are constituted by a single substrate.

7. The vehicle light emitting unit according to claim 6, wherein the first portion and the second portion are bent between the first portion and the second portion.

8. The vehicle light emitting unit described in claim 6, characterized in that the second part has an attachment part to which the second part, the excitation light source, and the vehicle lamp are attached, and the attachment part is arranged in a part excluding the part between the light emitting element of the excitation light source attached to the second part and the first part.

9. The vehicle light emitting unit described in claim 6, characterized in that the second part has a positioning portion that positions the second part, the excitation light source, and the vehicle lamp, and the positioning portion is arranged in a portion excluding the portion between the light emitting element of the excitation light source attached to the second part and the first part.

10. The vehicle light emitting unit according to claim 6, wherein an optical member that irradiates the excitation light from the excitation light source onto the light conversion layer is installed in the second portion.

11. A vehicle lighting fixture comprising: a lamp housing and a lamp lens that form a space; a vehicle light emitting unit according to any one of claims 6 to 10 that is disposed within the space; and an attachment portion that is disposed within the space; wherein the second portion of the substrate of the vehicle light emitting unit is attached to the attachment portion; and the light conversion layer of the vehicle light emitting unit irradiates the secondary light toward the lamp lens.

12. The vehicle lamp according to claim 11, wherein a shielding member is disposed between the optical member of the vehicle light emitting unit and the lamp lens.

Images