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CN111819392B - Light source unit and method for manufacturing mounting member for the same - Google Patents

Light source unit and method for manufacturing mounting member for the same Download PDF

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Publication number
CN111819392B
CN111819392B CN201980017947.4A CN201980017947A CN111819392B CN 111819392 B CN111819392 B CN 111819392B CN 201980017947 A CN201980017947 A CN 201980017947A CN 111819392 B CN111819392 B CN 111819392B
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CN
China
Prior art keywords
substrate
mounting surface
base plate
light
heat sink
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Active
Application number
CN201980017947.4A
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Chinese (zh)
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CN111819392A (en
Inventor
野末修平
高木伸
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Koito Manufacturing Co Ltd
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Koito Manufacturing Co Ltd
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Publication of CN111819392A publication Critical patent/CN111819392A/en
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Publication of CN111819392B publication Critical patent/CN111819392B/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/147—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/19—Attachment of light sources or lamp holders
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
    • F21S45/40—Cooling of lighting devices
    • F21S45/42—Forced cooling
    • F21S45/43—Forced cooling using gas
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/502—Cooling arrangements characterised by the adaptation for cooling of specific components
    • F21V29/503—Cooling arrangements characterised by the adaptation for cooling of specific components of light sources
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/60—Cooling arrangements characterised by the use of a forced flow of gas, e.g. air
    • F21V29/67—Cooling arrangements characterised by the use of a forced flow of gas, e.g. air characterised by the arrangement of fans

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Optics & Photonics (AREA)
  • Fastening Of Light Sources Or Lamp Holders (AREA)

Abstract

The light source unit (LU) is provided with: a first substrate (50) and a second substrate (60) on which light-emitting elements (55, 63) are mounted, respectively; a heat sink (80) having a first mounting surface (86) on which at least a part of the first substrate (50) is mounted and a second mounting surface (91) on which at least a part of the second substrate (60) is mounted; and grease (24) interposed between the first substrate (50) and the first mounting surface (86) and between the second substrate (60) and the second mounting surface (91). The first substrate (50) and the second substrate (60) are mounted on the heat sink (80) with a predetermined gap therebetween. The heat sink (80) has a flow member recess (96) capable of accommodating a part of the grease (24) between the edge of the first mounting surface (86) on the second substrate (60) side in the region overlapping the first substrate (50) and the edge of the second mounting surface (91) on the first substrate (50) side in the region overlapping the second substrate (60).

Description

Light source unit and method for manufacturing mounting member for the same
Technical Field
The present invention relates to a light source unit and a method for manufacturing a mounting member for the light source unit.
Background
As a light source unit used in a device that irradiates light such as a lamp, a light source unit using a light emitting element such as a Light Emitting Diode (LED) as a light source is known. For example, patent document 1 listed below describes a light source unit including a plurality of substrates on which such light emitting elements are mounted, respectively.
The light source unit of patent document 1 includes three substrates on which light emitting elements are mounted, and a heat sink on which the three substrates are mounted. In this light source unit, three substrates are mounted in parallel on one heat sink.
Patent document 2 listed below describes a light source unit including a plurality of substrates on which light emitting elements are mounted, respectively. The light source unit of patent document 2 includes three substrates on which light emitting elements are mounted, and mounting members on which the three substrates are mounted. In the light source unit, three substrates are mounted in parallel on a mounting member, an angle formed by two adjacent substrates is smaller than 180 degrees, and the two adjacent substrates are connected by a lead wire.
In addition, for example, a light source unit of a vehicle headlamp, such as an automotive headlamp, is provided with a reflector or the like that reflects light emitted from a light emitting element in order to obtain a desired light distribution. For example, patent document 3 below discloses a light source unit including: the light emitting device includes a substrate on which the light emitting element is mounted, a reflector that reflects light emitted from the light emitting element, a mounting substrate, and a mounting member for mounting the reflector. In the light source unit, a through hole penetrating in a thickness direction of the substrate is formed in the substrate, and the mounting member has a rib substantially parallel to a normal line of a mounting surface on which the substrate is mounted. The rib of the mounting member is inserted into the through hole of the substrate, so that the position of the substrate relative to the mounting member is limited within a predetermined range, and the position of the light emitting element relative to the reflector mounted on the mounting member is limited within a predetermined range.
Further, for example, patent document 4 below discloses a light source unit including: the light emitting device includes a substrate on which the light emitting element is mounted, a reflector that reflects light emitted from the light emitting element, a mounting substrate, and a mounting member for mounting the reflector. In the light source unit, the substrate is placed on the placement surface of the mounting member, and is pressed against the placement surface from the side opposite to the placement surface by the reflector, and is fixed to the mounting member. The reflector presses the substrate against the mounting surface with a force substantially perpendicular to the mounting surface.
Further, since the light emitting element tends to have a reduced light emitting efficiency and a reduced lifetime due to heat generation during light emission or to change the wavelength of light emitted from the light emitting element, the light emitting element is sometimes cooled using a heat dissipating member such as a heat sink. For example, patent document 5 discloses a light source unit including: a heat sink having a base plate and a plurality of fins formed on one surface of the base plate; and a substrate on which the light emitting element is mounted and which is placed on the other surface of the base plate of the heat sink.
Patent document 1: japanese patent laid-open publication No. 2013-254603
Patent document 2: japanese patent laid-open publication No. 2015-207367
Patent document 3: japanese patent laid-open publication No. 2016-149373
Patent document 4: japanese patent laid-open publication No. 2011-119094
Patent document 5: japanese patent laid-open publication No. 2013-110068
Disclosure of Invention
A first aspect of the present invention provides a light source unit, comprising: a first substrate and a second substrate on which light emitting elements are mounted, respectively; a heat sink having a first mounting surface on which at least a part of the first substrate is mounted and a second mounting surface on which at least a part of the second substrate is mounted; a fluid member interposed between the first substrate and the first mounting surface and between the second substrate and the second mounting surface, the fluid member having fluidity; the first substrate and the second substrate are mounted on the heat sink with a predetermined space therebetween, and the heat sink has a recess capable of receiving a part of the flow member between an edge of the first mounting surface and an edge of the second mounting surface, wherein the edge of the first mounting surface is an edge of the second substrate side of a region of the first mounting surface overlapping the first substrate, and the edge of the second mounting surface is an edge of the first substrate side of a region of the second mounting surface overlapping the second substrate.
In the light source unit, as described above, the heat sink has the recess capable of accommodating a part of the flow member between the edge of the first placement surface on the second substrate side in the region overlapping with the first substrate and the edge of the second placement surface on the first substrate side in the region overlapping with the second substrate. Therefore, a part of the flow member facing the second substrate among the remaining flow members pushed out from between the first substrate and the first mounting surface can be accommodated in the recess. In addition, a part of the flow member facing the first substrate among the remaining flow members pushed out from between the second substrate and the second placement surface can be accommodated in the recess. Therefore, a part of the remaining flow member accumulated between the first substrate and the second substrate can be prevented from adhering to the surface of the first substrate on the side opposite to the first mounting surface side or the surface of the second substrate on the side opposite to the second mounting surface side. Therefore, the remaining flow member can be prevented from adhering to the light emitting element mounted on the first substrate or the light emitting element mounted on the second substrate. Therefore, the light source unit capable of suppressing the malfunction can be provided. The flow member is not limited to a member having fluidity at all times, and includes a member having fluidity at least when the first substrate is placed on the first placement surface and when the second substrate is placed on the second placement surface. Therefore, the fluid component includes an uncured fluid component in which the first substrate or the second substrate is not cured even after being placed on the placement surface, such as grease or an adhesive, and a curable fluid component in which the first substrate or the second substrate is curable after being placed on the placement surface, such as an adhesive made of a thermosetting resin.
Preferably, at least a part of the recess is located in a region where a distance between an edge of the second substrate side of a region of the first mounting surface overlapping with the first substrate and an edge of the first substrate side of a region of the second mounting surface overlapping with the second substrate is smallest.
The remaining flow members tend to gradually accumulate from a region where the distance between the edge of the second substrate side of the region of the first mounting surface overlapping the first substrate and the edge of the first substrate side of the region of the second mounting surface overlapping the second substrate is the smallest. In the light source unit, the recess is located in such a region, and therefore, it is possible to appropriately suppress adhesion of a part of the remaining flow member to the surface of the first substrate on the side opposite to the first mounting surface and the surface of the second substrate on the side opposite to the second mounting surface. Therefore, it is possible to appropriately suppress adhesion of a part of the remaining flow member to the light emitting element mounted on the first substrate and the light emitting element mounted on the second substrate.
Preferably, at least a part of the concave portion is located between a first straight line passing through one end of the light emitting element of at least one of the first substrate and the second substrate in a direction perpendicular to a direction from the first substrate side toward the second substrate side and being parallel to the direction from the first substrate side toward the second substrate side, and a second straight line passing through the other end of the light emitting element of at least one of the first substrate and the second substrate in a direction perpendicular to the direction from the first substrate side toward the second substrate side and being parallel to the first straight line.
With this configuration, it is possible to prevent a portion of the remaining flow member from adhering to a surface of the first substrate on the side opposite to the first mounting surface, from a portion closer to the light-emitting element mounted on the first substrate, among the edges of the second substrate side in a plan view of the first substrate. In addition, it is possible to prevent a portion closer to the light emitting element mounted on the second substrate from adhering to a surface of the second substrate opposite to the second mounting surface side, from among the edges of the first substrate side in a plan view of the second substrate. Therefore, it is possible to appropriately suppress adhesion of a part of the remaining flow member to the light emitting element mounted on the first substrate or the light emitting element mounted on the second substrate.
Preferably, the heat sink has two surfaces arranged from the first mounting surface side toward the second mounting surface side between an edge of the second substrate side in a region of the first mounting surface overlapping with the first substrate and an edge of the first substrate side in a region of the second mounting surface overlapping with the second substrate, an angle formed by the two surfaces is smaller than 180 degrees, and the recess is formed between and connected to the two surfaces.
In the light source unit, as described above, the heat sink has two surfaces arranged from the first mounting surface side toward the second mounting surface side between the edge of the second substrate side in the region of the first mounting surface overlapping the first substrate and the edge of the first substrate side in the region of the second mounting surface overlapping the second substrate. Therefore, a part of the remaining flow member extending from the first substrate side toward the second substrate side can be pushed out onto the first mounting surface side of the two surfaces. On the other hand, a part of the remaining flow member from the second substrate side toward the first substrate side can be pushed out onto the second mounting surface side of the two surfaces. Further, in a state where the flow member is positioned on both surfaces forming an angle smaller than 180 degrees and the both surfaces are visible from the upper side, the flow member on at least one surface tends to face between the both surfaces, and the flow member is likely to be accumulated between the both surfaces. As a state where both surfaces can be seen from above, for example, a state where both surfaces intersect in a substantially V-shape is given. In the light source unit, as described above, the angle formed by the two surfaces is smaller than 180 degrees, and the concave portion is formed between the two surfaces and connected to the two surfaces. Therefore, at least one of the remaining flow member pushed out to the surface on the first mounting surface side and the remaining flow member pushed out to the surface on the second mounting surface side is easily directed to the recess. Therefore, the recess can appropriately accommodate a part of at least one of the flow member from the first substrate side toward the second substrate side and the flow member from the second substrate side toward the first substrate side. Therefore, the remaining flow member can be appropriately prevented from adhering to at least one of the light-emitting element mounted on the first substrate and the light-emitting element mounted on the second substrate.
Alternatively, the concave portion may include a first concave portion that is concave toward the side opposite to the first substrate side with respect to the first mounting surface, and a second concave portion that is concave toward the side opposite to the second substrate side with respect to the second mounting surface with respect to the first concave portion.
With this configuration, compared to the case where there is one recess, it is possible to suppress adhesion of a part of the remaining flow member accumulated between the first substrate and the second substrate to the surface of the first substrate on the side opposite to the first mounting surface side or to the surface of the second substrate on the side opposite to the second mounting surface side. Therefore, the remaining flow member can be prevented from adhering to the light emitting element mounted on the first substrate or the light emitting element mounted on the second substrate.
A normal line of the first substrate extending to the first mounting surface may intersect a normal line of the second substrate extending to the second mounting surface.
With this configuration, the angle formed by the first mounting surface and the second mounting surface is smaller than 180 degrees. Therefore, as described above, the excess flow member is easily accumulated between the first mounting surface and the second mounting surface, that is, between the first substrate and the second substrate. Therefore, the light source unit is useful when the angle formed by the first mounting surface and the second mounting surface is smaller than 180 degrees.
The light-emitting element of at least one of the first substrate and the second substrate may be located on one substrate on which the light-emitting element is mounted, on the other substrate side of the one substrate.
With this configuration, the remaining flow member accumulated between the first substrate and the second substrate is easily attached to at least one of the light emitting elements of the first substrate and the second substrate. Therefore, the light source unit is useful when the light emitting element of at least one of the first substrate and the second substrate is located on the other substrate side of the one substrate on which the light emitting element is mounted.
In addition, a second aspect of the present invention provides a light source unit including: a first substrate and a second substrate on which light emitting elements are mounted, respectively; a mounting member having a first mounting surface on which at least a part of the first substrate is mounted and a second mounting surface on which at least a part of the second substrate is mounted; a flexible printed circuit board having a first connection portion connected to a mounting surface of the first substrate on which the light-emitting element is mounted and a second connection portion connected to a mounting surface of the second substrate on which the light-emitting element is mounted; the first board and the second board are mounted on the mounting component with a predetermined space therebetween, a normal line of the first mounting surface extending toward the first board side intersects with a normal line of the second mounting surface extending toward the second board side, and the flexible printed circuit board is bent in a convex shape toward the mounting component between the first board and the second board and passes through at least one of a region on the first mounting surface side of the first connection portion and a region on the second mounting surface side of the second connection portion.
In this light source unit, as described above, the normal line extending to the first substrate side of the first mounting surface intersects the normal line extending to the second substrate side of the second mounting surface, and therefore the angle formed by the first substrate and the second substrate is smaller than 180 degrees. The flexible printed circuit board is bent in a convex shape toward the mounting member between the first substrate and the second substrate and passes at least one of a region on the first mounting surface side of the first connection portion and a region on the second mounting surface side of the second connection portion. Therefore, a force pressing the substrate side to which the connection portion is connected can act on at least one of the first connection portion and the second connection portion. Therefore, at least one of the first connection portion and the second connection portion can be prevented from peeling off from the substrate to which the connection portion is connected, and occurrence of a connection failure between the first substrate and the second substrate can be prevented. Therefore, a light source unit in which defects can be suppressed can be obtained.
In the light source unit according to the second aspect, it is preferable that at least one of the first substrate and the second substrate is formed with a notch extending from an outer edge of the other substrate to a predetermined position in a plan view of the one substrate, and the flexible printed circuit board passes through the notch.
In order to flex the flexible printed circuit board, the flexible printed circuit board needs to have a certain length, and thus the first substrate is separated from the second substrate to some extent. In this light source unit, as described above, the notch extending from the outer edge of the other substrate side to a predetermined position in a plan view of the one substrate is formed in at least one of the first substrate and the second substrate, and the flexible printed circuit board passes through the notch. Therefore, the flexible printed circuit board can be bent between the first substrate and the second substrate without extending the distance between the first substrate and the second substrate. Therefore, compared to a case where the notch is not formed in at least one of the first substrate and the second substrate, the distance between the first substrate and the second substrate can be shortened, and the light source unit can be downsized.
In the light source unit according to the second aspect, when a notch is formed in at least one of the first substrate and the second substrate, the light emitting element mounted on the one substrate is preferably disposed on the other substrate side with respect to an edge of the notch on a side opposite to the other substrate side in a plan view of the one substrate.
As described above, when the notch is not formed in at least one of the first substrate and the second substrate, the first substrate and the second substrate need to be separated from each other to some extent in order to bend the flexible printed circuit board. Therefore, the light-emitting element mounted on the first substrate and the light-emitting element mounted on the second substrate are also separated from each other to some extent. In this light source unit, the light emitting element mounted on one substrate is disposed on the other substrate side with respect to the edge of the cutout on the side opposite to the other substrate side in a plan view of the one substrate. Therefore, as compared with the case where the notch is not formed in at least one of the first substrate and the second substrate, the distance between the first substrate and the second substrate can be shortened as described above, and the distance between the light-emitting element mounted on the first substrate and the light-emitting element mounted on the second substrate can also be shortened. Therefore, the optical member such as a reflector that reflects the light emitted from the two light emitting elements can be downsized.
In the light source unit according to the second aspect, it is preferable that the mounting member has a recess between the first substrate and the second substrate, the recess being recessed toward a side opposite to the flexible printed circuit substrate side with respect to at least one of the first mounting surface and the second mounting surface, and the flexible printed circuit substrate passes through the recess.
With this configuration, the amount of deflection of the flexible printed circuit board can be increased as compared with the case where the mounting member does not have the recess. Therefore, at least one of the first connection portion and the second connection portion can be appropriately pressed by the substrate side to which the connection portion is connected. Therefore, it is possible to further suppress peeling of at least one of the first connecting portion and the second connecting portion from the substrate to which the connecting portion is connected.
In the light source unit according to the second aspect, the flexible printed circuit board is preferably not in contact with the mounting member.
For example, in the case where the light source unit is used for a vehicle lamp, the light source unit vibrates due to vibration of the vehicle. When the light source unit vibrates and the flexible printed circuit board and the mounting member come into contact with each other, the flexible printed circuit board and the mounting member tend to rub against each other. The flexible printed circuit board and the mounting member rub against each other, and thus, there is a possibility that a defect such as disconnection of a wiring formed on the flexible printed circuit board occurs. In this light source unit, since the flexible printed circuit board and the mounting member are not in contact with each other as described above, friction between the flexible printed circuit board and the mounting member due to vibration of the light source unit or the like can be suppressed. Therefore, it is possible to suppress a failure such as disconnection of the wiring formed on the flexible printed circuit board.
In the light source unit according to the second aspect, the flexible printed circuit board may have a plurality of wires extending from the first connection portion to the second connection portion, and a slit may be formed between the wires adjacent to each other.
With this configuration, at least a part of the wirings adjacent to each other can be spatially separated by the slit. Therefore, even if the wiring is moved, it is possible to reduce the occurrence of a defect due to a short circuit, as compared with the case where no slit is formed between the mutually adjacent wirings.
In the light source unit according to the second aspect, the light source unit may further include two flexible printed circuit boards, and the center of gravity of at least one of the first substrate and the second substrate may be located between the connection portions of the two flexible printed circuit boards connected to the one substrate.
With this configuration, in a state where the first substrate and the second substrate are connected by the two flexible printed circuit boards and before these substrates are mounted on the mounting member, stress generated in the first connecting portion and the second connecting portion of the two flexible printed circuit boards can be suppressed. Specifically, for example, when one substrate is suspended from the other substrate, the occurrence of warpage in the flexible printed circuit board can be suppressed. Therefore, stress generated in at least one of the first connection portion and the second connection portion of the two flexible printed circuit boards can be suppressed. Therefore, in a state before the first substrate and the second substrate are mounted on the mounting member, at least one of the first connecting portion and the second connecting portion can be prevented from peeling off from the substrate to which the connecting portion is connected. Therefore, as compared with a case where the center of gravity of at least one of the first substrate and the second substrate is not located between the connection portions to which the two flexible printed circuit substrates connected to the one substrate are connected, handling of these substrates becomes easy, and productivity of the light source unit is improved.
A third aspect of the present invention provides a light source unit, comprising: a substrate on which a light emitting element is mounted and which has a through hole penetrating in a plate thickness direction; and a mounting member having a mounting surface on which at least a part of the substrate is mounted, a rib that is inclined with respect to a normal line of the mounting surface and is inserted into the through hole of the substrate, and an abutment surface that abuts against a part of a side surface of the substrate, wherein at least one of an outer peripheral surface of one side and an outer peripheral surface of the other side of the rib in a direction perpendicular to an extending direction of the rib in a plan view of the mounting surface abuts against a part of an inner peripheral surface of the substrate that defines the through hole, and a tangent line to the abutment surface and the part of the side surface of the substrate in the plan view of the mounting surface are not parallel to the extending direction of the rib.
In this light source unit, as described above, at least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the rib is in contact with a part of the inner peripheral surface of the substrate defining the through hole in the direction perpendicular to the extending direction of the rib when the mounting surface is viewed in plan. Therefore, the position of the substrate relative to the mounting member in the direction perpendicular to the direction in which the ribs extend when the mounting surface is viewed in plan can be limited to a predetermined range. As described above, the tangent line of the contact surface between the part of the side surface of the substrate and the part of the side surface of the substrate in the plan view of the mounting surface is not parallel to the extending direction of the rib. Therefore, the position of the substrate relative to the mounting member in the extending direction of the rib can be limited within a predetermined range when the mounting surface is viewed in plan. Therefore, the position of the substrate with respect to the mounting member can be restricted within a predetermined range, and the outer peripheral surface of the rib can be prevented from coming into contact with at least one of the inner peripheral surface of the substrate defining the through hole, the vicinity of the edge on the mounting surface side, and the vicinity of the edge on the opposite side to the mounting surface side. Therefore, the influence of the unevenness formed in the vicinity of the edge on the mounting surface side or the vicinity of the edge on the opposite side to the mounting surface side on the inner peripheral surface of the substrate defining the through hole can be suppressed. Therefore, the position of the light emitting element with respect to an optical member such as a reflector that reflects light emitted from the light emitting element can be limited within a predetermined range. Therefore, a light source unit capable of forming a desired light distribution can be provided.
The contact surface may not always contact a part of the side surface of the substrate, and may contact the substrate when the substrate moves along the mounting surface. In addition, at least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the rib may not always abut against a part of the inner peripheral surface of the substrate defining the through hole in a direction perpendicular to the extending direction of the rib when the mounting surface is viewed in plan. The outer peripheral surfaces of the ribs may abut against each other when the substrate moves along the mounting surface.
In the light source unit according to the third aspect, it is preferable that the mounting member further includes a rib reinforcing portion connected to a surface on which the rib is formed and an outer peripheral surface of the rib on a side inclined with respect to the mounting surface.
With this configuration, the strength of the rib can be improved and damage to the rib can be suppressed, as compared with the case where the rib reinforcing portion is not provided. Therefore, the positional deviation of the substrate with respect to the mounting member can be suppressed, and the change in the light distribution can be suppressed.
In the light source unit according to the third aspect, it is preferable that the mounting member further includes a projection on which the abutment surface is formed, and the rib projects in a direction normal to the mounting surface beyond the projection.
With this configuration, the rib can be inserted into the through hole of the substrate before the substrate abuts against the protrusion. Therefore, the position of the substrate with respect to the mounting member can be restricted to some extent by the rib inserted into the through hole, and the substrate can be mounted on the mounting surface in such a restricted state. Therefore, the substrate can be easily placed on the placement surface.
In the light source unit according to the third aspect, the mounting member may further include a second mounting surface on which at least a part of a second substrate on which the light emitting element is mounted, the second mounting surface being not parallel to the mounting surface, and the second mounting surface being visible when viewed from the extending direction of the rib.
When a mounting member having two mounting surfaces that are not parallel to each other is formed by die molding, a normal line of at least one of the mounting surfaces is not parallel to a die opening direction. Therefore, when the rib is formed on the mounting surface with the normal line not parallel to the mold opening direction, the rib tends to extend in the mold opening direction and to be inclined with respect to the normal line of the mounting surface from the viewpoint of productivity. Since the second mounting surface can be seen when viewed from the extending direction of the rib, the mounting member can be molded by die molding in which the die opening direction is set as the extending direction of the rib. Therefore, even if the mounting member has two mounting surfaces that are not parallel to each other, the reduction in productivity of the mounting member is suppressed, and the position of the substrate with respect to the mounting member is limited within a predetermined range by using the rib inclined with respect to the normal line of the mounting surface, as described above.
A fourth aspect of the present invention provides a method of manufacturing a mounting member on which a substrate is to be mounted, the method of manufacturing the mounting member including a mounting surface on which at least a part of the substrate is to be mounted, a rib inclined with respect to a normal to the mounting surface, and an abutment surface that abuts against a part of a side surface of the substrate, the abutment surface being not parallel to an extending direction of the rib when the mounting surface is viewed in plan, the method including: a die forming step of forming an intermediate member having a temporary placement surface covering the placement surface, a temporary contact surface covering the contact surface, and the rib by die forming; a cutting step of cutting the temporary mounting surface and the temporary contact surface to form the mounting surface and the contact surface; in the cutting step, at least a part of the mounting surface and at least a part of the contact surface are formed at the same time.
In the method of manufacturing the mounting member, since at least a part of the mounting surface and at least a part of the contact surface are formed at the same time in the cutting step as described above, productivity of the mounting member can be improved as compared with a case where at least a part of the mounting surface and at least a part of the contact surface are not formed at the same time.
A fifth aspect of the present invention provides a light source unit, comprising: a substrate on which a light emitting element is mounted; a mounting member having a mounting surface on which at least a part of the substrate is mounted and an abutting surface that abuts against a part of a side surface of the substrate; and a pressing member that is brought into contact with at least a contact portion on a mounting surface of the substrate on which the light-emitting element is mounted, and presses the substrate against the mounting surface and the contact surface.
In the light source unit, the substrate is pressed against the mounting surface and the contact surface by the pressing member. Therefore, even when the light source unit vibrates, the substrate can be prevented from floating from the mounting surface or from being displaced along the mounting surface to the side opposite to the pressing direction with respect to the contact surface. Therefore, the light-emitting element can be prevented from being positionally displaced with respect to an optical member such as a reflector that reflects light emitted from the light-emitting element. Therefore, a light source unit capable of forming a desired light distribution can be provided.
In the light source unit according to the fifth aspect, the contact surface may be positioned in a direction in which the pressing member presses the substrate against the contact surface, in a plan view of the substrate, further than the contact portion.
In the light source unit according to the fifth aspect, it is preferable that at least a part of the contact surface is located between a straight line that is parallel to a direction in which the pressing member presses the substrate against the contact surface and passes through one end of the contact portion in a direction perpendicular to the direction, and another straight line that is parallel to the straight line and passes through the other end of the contact portion, in a plan view of the substrate.
With this configuration, the force with which the pressing member presses the substrate against the contact surface is directed from the contact portion of the substrate with the pressing member toward the contact surface. Therefore, the pressing member can appropriately press the substrate against the contact surface, and even when the light source unit vibrates, the substrate can be appropriately prevented from deviating along the mounting surface to the side opposite to the pressing direction against the contact surface.
In the light source unit according to the fifth aspect, it is preferable that the substrate has two of the contact portions, and at least a part of the contact surface is located between a straight line parallel to a direction of a force with which the pressing member presses the substrate against the contact surface and passing through an end of one of the contact portions opposite to the other of the contact portions and another straight line parallel to the straight line and passing through an end of the other of the contact portions opposite to the one of the contact portions in a plan view of the substrate.
With this configuration, the support plate can appropriately press the substrate against the contact surface, compared to a case where the contact surface is located on the opposite side of the one straight line with respect to the one straight line or on the opposite side of the one straight line with respect to the other straight line in a plan view of the substrate. Therefore, even when the light source unit vibrates, the substrate can be appropriately prevented from being displaced along the mounting surface to the side opposite to the pressing direction with respect to the contact surface.
In the light source unit according to the fifth aspect, it is preferable that the pressing member has elasticity, and the substrate is pressed against the mounting surface and the contact surface by the elasticity of the pressing member.
With this configuration, even if the contact surface is separated from the part of the side surface of the substrate due to vibration of the light source unit or the like, the part of the side surface of the substrate can be brought into contact with the contact surface by the elastic force of the pressing member. That is, even if the substrate is displaced along the mounting surface to the side opposite to the pressing direction with respect to the contact surface due to vibration of the light source unit or the like, the substrate can be moved to substantially the same position as before the displacement.
A sixth aspect of the present invention provides a light source unit, comprising: a first substrate and a second substrate on which light emitting elements are mounted, respectively; and a heat sink having a first mounting surface on which at least a part of the first substrate is mounted and a second mounting surface on which at least a part of the second substrate is mounted, wherein the first substrate and the second substrate are mounted on the heat sink at a predetermined interval, and a normal line of the first mounting surface extending to the first substrate side intersects with a normal line of the second mounting surface extending to the second substrate side.
With this configuration, the distance between the light emitting element mounted on the first substrate and the light emitting element mounted on the second substrate can be shortened and the distance between the light emitting elements along the surface of the heat sink can be increased, as compared with the case where the first mounting surface and the second mounting surface are located on the same plane. Therefore, the heat generated in the light emitting elements can be more appropriately dispersed in the heat sink, and the region between the light emitting elements in the heat sink can be suppressed from being overheated. In addition, compared with the case where the first mounting surface and the second mounting surface are located on the same plane, the distance between the two light emitting elements can be shortened, and the size can be reduced. Therefore, the light source unit can be miniaturized while suppressing overheating of the heat sink.
In the light source unit according to the sixth aspect, it is preferable that the light source unit further includes a fan, and the heat sink includes: a first base plate having the first mounting surface formed on one surface thereof; and a second base plate having the second placement surface formed on one surface thereof, wherein a part of an outer edge of the first base plate and a part of an outer edge of the second base plate are connected to each other, and the fan is configured to circulate air between the other surface of the first base plate and the other surface of the second base plate.
With this configuration, the fan can suppress air from being trapped in the vicinity of the other surface of the first floor panel and the other surface of the second floor panel, and the first floor panel and the second floor panel can be cooled as compared with the case where the fan is not provided. The fan may send air toward the other surface of the first base plate and the other surface of the second base plate to circulate air on the surfaces, or may suck air in the vicinity of the other surfaces to circulate air on the surfaces. The first mounting surface is formed on one surface of the first base plate as the plate member, and the second mounting surface is formed on one surface of the second base plate as the plate member. Therefore, the other surface of the first base plate is inclined with respect to the other surface of the second base plate, and the angle formed between the other surface of the first base plate and the other surface of the second base plate is larger than 180 degrees. Therefore, the two other surfaces are less likely to cause resistance to air flow by the fan, compared to a case where the two other surfaces are both surfaces perpendicular to the direction of air flow between the surfaces and the fan, or a case where the angle formed by the two other surfaces is smaller than 180 degrees. Therefore, the flow velocity of the air in the vicinity of these surfaces can be suppressed from being lowered. Therefore, the first and second baseplates can be cooled more appropriately by the fan.
In the light source unit according to the sixth aspect, when the light source unit includes a fan, the heat sink preferably includes: a cylindrical peripheral wall part having at least a part of one end thereof fixed to the first base plate and the second base plate; a vent port that communicates an internal space and an external space of the peripheral wall portion; the fan forms air circulation through an opening at the other end of the peripheral wall portion, and at least a part of the air vent is disposed on a side opposite to the fan side with respect to a connecting portion between the first base plate and the second base plate in a cross section perpendicular to the other surface of the first base plate and the other surface of the second base plate.
The air flowing through the opening at the other end of the peripheral wall portion includes air flowing from the external space of the peripheral wall portion to the internal space through the opening and air flowing from the internal space of the peripheral wall portion to the external space through the opening. When the fan forms a circulation of air that circulates from the external space to the internal space of the peripheral wall portion through the opening of the peripheral wall portion, a part of the air that flows into the internal space of the peripheral wall portion from the opening passes through the internal space of the peripheral wall portion and faces the other surface of the first base plate and the other surface of the second base plate. Then, a part of the air passes through the ventilation opening and flows out to the outside space of the peripheral wall portion. In this way, the air directed toward the other surface of the first base plate and the other surface of the second base plate by the fan is prevented from diffusing by the peripheral wall portion, as compared with the case where the peripheral wall portion is not provided. Therefore, the amount of air directed to the other surface of the first base plate and the other surface of the second base plate can be increased, and the first base plate and the second base plate can be cooled more appropriately. As described above, at least a part of the ventilation opening is disposed on the side opposite to the fan side with respect to the connecting portion between the first floor panel and the second floor panel in the cross section perpendicular to the other surface of the first floor panel and the other surface of the second floor panel. Therefore, air can be prevented from being trapped in the vicinity of the other surface of the first base plate and the other surface of the second base plate, and the first base plate and the second base plate can be cooled more appropriately. On the other hand, when the fan forms air circulation that circulates from the internal space of the peripheral wall portion to the external space through the opening of the peripheral wall portion, air flows into the internal space of the peripheral wall portion from the ventilation opening. A part of the air flowing in from the ventilation opening passes through the internal space of the peripheral wall portion and flows out from the opening at the other end of the peripheral wall portion to the external space of the peripheral wall portion. Here, as described above, at least a part of the ventilation opening is disposed on the side opposite to the fan side with respect to the connecting portion between the first floor panel and the second floor panel in the cross section perpendicular to the other surface of the first floor panel and the other surface of the second floor panel. Therefore, a part of the air flowing in from the ventilation opening passes through the vicinity of the other surface of the first base plate and the other surface of the second base plate and is directed toward the opening at the other end of the peripheral wall portion. That is, air near these other faces is drawn by the fan. Therefore, the fan can suck the air near the other surface more than the case without the peripheral wall portion. Therefore, the air can be suppressed from being trapped in the vicinity of the other surfaces, and the first base plate and the second base plate can be cooled more appropriately. The fan may be configured to be capable of forming at least one of air flow that flows from the external space to the internal space of the peripheral wall portion through the opening of the peripheral wall portion and air flow that flows from the internal space to the external space of the peripheral wall portion through the opening. For example, the fan may be capable of switching the flow of the formed air.
In the light source unit according to the sixth aspect, when the heat sink has a peripheral wall portion, the peripheral wall portion preferably surrounds an outer periphery of the fan.
With this configuration, when the fan forms air flow that flows from the external space to the internal space of the peripheral wall portion through the opening of the peripheral wall portion, the amount of air flowing toward the other surface of the first base plate and the other surface of the second base plate can be increased as compared with a case where the peripheral wall portion does not surround the outer periphery of the fan. On the other hand, when the fan forms the circulation of the air circulating from the internal space of the peripheral wall portion to the external space through the opening of the peripheral wall portion, the fan can suck more air in the vicinity of the other surface of the first base plate and the other surface of the second base plate than in the case where the peripheral wall portion does not surround the outer periphery of the fan. Therefore, the first base plate and the second base plate can be cooled more appropriately.
In the light source unit according to the sixth aspect, when the heat sink has the peripheral wall portion, a part of at least one of the first substrate and the second substrate may overlap the vent in an opening direction of the vent.
With this configuration, when the fan forms air flow that flows from the external space of the peripheral wall portion to the internal space through the opening of the peripheral wall portion, a part of the air flowing out from the vent port to the external space of the peripheral wall portion can be directed toward at least one of the first substrate and the second substrate. Therefore, at least one of the first substrate and the second substrate may be cooled by the heat sink, and may be directly cooled by air flowing out of the vent. On the other hand, when the fan forms air flowing from the internal space of the peripheral wall portion to the external space through the opening of the peripheral wall portion, a part of the air that is intended to flow into the internal space of the peripheral wall portion from the vent can flow along at least one of the first substrate and the second substrate. Therefore, at least one of the first substrate and the second substrate can be cooled by the heat sink, and can also be directly cooled by air flowing into the internal space of the peripheral wall portion from the air vent. Therefore, the first substrate and the second substrate can be cooled more appropriately.
In the light source unit according to the sixth aspect, when the heat sink has a peripheral wall portion, the heat sink further preferably has at least one flow regulating plate extending from the one end side to the other end side of the peripheral wall portion at least in an internal space of the peripheral wall portion.
With this configuration, the turbulence of the air flow in the internal space of the peripheral wall portion is adjusted. Therefore, when the fan forms the circulation of the air that circulates from the external space to the internal space of the peripheral wall portion through the opening of the peripheral wall portion, the amount of the air that flows toward the other surface of the first base plate and the other surface of the second base plate can be increased as compared with the case where the heat sink does not have the rectifying plate. On the other hand, when the fan forms the circulation of the air circulating from the internal space of the peripheral wall portion to the external space through the opening of the peripheral wall portion, the fan can suck more air in the vicinity of the other surface of the first base plate and the other surface of the second base plate than the case where the radiator does not have the rectifying plate. Therefore, the first base plate and the second base plate can be cooled more appropriately.
In the light source unit according to the sixth aspect, when the heat sink includes a rectifying plate, the rectifying plate is preferably connected to the first base plate and the second base plate.
After a part of the heat of the first substrate and the second substrate is transferred to the first base plate and the second base plate, the heat is dispersed to a member connected to the first base plate and the second base plate, for example, a cylindrical wall portion. In this light source unit, since the rectifying plate is connected to the first base plate and the second base plate as described above, heat can be dispersed to the rectifying plate, and the first base plate and the second base plate can be cooled more appropriately.
In the light source unit according to the sixth aspect, when the heat sink includes the flow regulating plate, the flow regulating plate preferably crosses the ventilation opening when viewed from the opening direction of the ventilation opening.
As described above, the rectifying plate extends from one end side of the peripheral wall portion to the other end side in the internal space of the peripheral wall portion. Therefore, a space sandwiched between the peripheral wall portion and the rectifying plate can be formed in the inner space of the peripheral wall portion. In addition, when the heat sink has a plurality of flow straightening plates, a space sandwiched by the plurality of flow straightening plates can be formed. In this light source unit, since the rectifying plate crosses the ventilation opening when viewed from the opening direction of the ventilation opening as described above, the spaces that can be formed in the internal space of the peripheral wall portion all communicate with the ventilation opening. Therefore, air can be prevented from being accumulated in the internal space of the peripheral wall portion, and the first base plate and the second base plate can be cooled more appropriately.
In the light source unit according to the sixth aspect, it is preferable that, when the rectifying plate crosses the vent as viewed from the opening direction of the vent, a part of at least one of the first substrate and the second substrate overlaps the vent in the opening direction of the vent, and at least one of the rectifying plates has a protruding portion protruding from the vent to the outer space of the peripheral wall portion, and the protruding portion is in contact with the substrate overlapping the vent as viewed from the opening direction of the vent.
With this configuration, the protruding portion doubles as a part of the first mounting surface or the second mounting surface, and the area of the first mounting surface or the second mounting surface is increased as compared with a case where the protruding portion does not doubles as a part of the first mounting surface or the second mounting surface. Therefore, at least one of the first substrate and the second substrate can be mounted more stably. Further, since the rectifying plate extends in the internal space of the peripheral wall portion as described above, the air flowing in the internal space of the peripheral wall portion by the fan cools the air. The protrusion of the thus cooled rectifying plate is in contact with at least one of the first substrate and the second substrate, and therefore, the substrate in contact with which the rectifying plate is in contact can be cooled more appropriately. Further, since the protrusion of the rectifying plate protrudes from the vent hole to the space outside the peripheral wall portion, the turbulence of the air flow near the vent hole is adjusted by the protrusion, and the air can be more appropriately made to flow out from the vent hole to the space outside the peripheral wall portion or flow into the space inside the peripheral wall portion from the vent hole. Therefore, the first substrate and the second substrate can be cooled more appropriately.
In the light source unit according to the sixth aspect, when the heat sink has a peripheral wall portion, the air vent preferably includes, in a cross section perpendicular to the other surface of the first base plate and the other surface of the second base plate, a first air vent disposed closer to the first base plate than a connecting portion between the first base plate and the second base plate, and a second air vent disposed closer to the second base plate than the connecting portion between the first base plate and the second base plate.
With this configuration, when the fan forms a flow of air flowing from the external space to the internal space of the peripheral wall portion through the opening of the peripheral wall portion, a part of the air on the first substrate side in the air near the first substrate and the second substrate can be flowed out to the external space of the peripheral wall portion from the first vent hole disposed on the first substrate side. Further, a part of the air on the second substrate side can be made to flow out to the space outside the peripheral wall portion from the first ventilation opening disposed on the second substrate side. Therefore, the air can be more appropriately flowed out to the outside space of the peripheral wall portion, and the first base plate and the second base plate can be more appropriately cooled than a case where the ventilation opening is the first ventilation opening or the second ventilation opening. On the other hand, when the fan forms the circulation of the air circulating from the external space to the internal space of the peripheral wall portion through the opening of the peripheral wall portion, a part of the air flowing into the internal space of the peripheral wall portion from the first vent can be circulated along the other surface of the first base plate. In addition, a part of the air flowing into the internal space of the peripheral wall portion from the second ventilation opening can be made to flow along the other surface of the second base plate. Therefore, the air can be appropriately prevented from being retained in the vicinity of the other surface of the first floor panel and the other surface of the second floor panel, and the first floor panel and the second floor panel can be cooled more appropriately than in the case where the ventilation opening is the first ventilation opening or the second ventilation opening.
Drawings
Fig. 1 is a diagram illustrating a lamp including a light source unit according to the present embodiment.
Fig. 2 is a perspective view of the lamp unit and the support unit shown in fig. 1.
Fig. 3 is an exploded perspective view of the lamp unit shown in fig. 1 as viewed from the front side.
Fig. 4 is an exploded perspective view of the lamp unit shown in fig. 1 as viewed from the rear side.
Fig. 5 is a perspective view of the heat sink.
Fig. 6 is a schematic sectional view of the heat sink.
Fig. 7 is a front view of the first substrate, the second substrate, and the flexible printed circuit substrate.
Fig. 8 is a diagram showing a state where the first substrate is mounted on a heat sink.
Fig. 9 is a diagram showing a state in which the first substrate and the second substrate are mounted on the heat sink.
Fig. 10 is a view showing a state where the second substrate is mounted on the heat sink.
Fig. 11 is a schematic sectional view through the flexible printed circuit board of fig. 9.
Fig. 12 is a perspective view of the light source unit.
Fig. 13 is a front view of the light source unit.
Fig. 14 is a schematic sectional view of the light source unit.
Fig. 15 is a perspective view of the support plate viewed from the front side.
Fig. 16 is a perspective view of the support plate viewed from the rear side.
Fig. 17 is a view showing a state of the second substrate in plan view of fig. 9.
Fig. 18 is a view showing a state where the second substrate is fixed to the heat sink.
Fig. 19 is a schematic sectional view of the lamp unit.
Fig. 20 is a view showing a light distribution pattern.
Fig. 21 is a flowchart showing a method of manufacturing the heat sink shown in fig. 4 to 6.
Fig. 22 is a schematic cross-sectional view showing a part of the intermediate member.
Fig. 23 is a view showing a light source unit according to a second embodiment of the present invention, as in fig. 14.
Fig. 24 is a view similar to fig. 14 showing a light source unit according to a third embodiment of the present invention.
Fig. 25 is a view similar to fig. 14 showing a light source unit according to a fourth embodiment of the present invention.
Fig. 26 is a view showing a light source unit according to a fifth embodiment of the present invention, as in fig. 14.
Detailed Description
Hereinafter, embodiments of a light source unit for implementing the present invention are illustrated based on the drawings. The following exemplary embodiments are provided to facilitate understanding of the present invention, and are not intended to limit the present invention. The present invention can be modified and improved from the following embodiments without departing from the spirit thereof.
(first embodiment)
First, the configuration of the lamp of the present embodiment will be described.
Fig. 1 is a diagram illustrating a lamp including a light source unit according to the present embodiment. In the present embodiment, the lamp is a vehicle headlamp. In general, vehicle headlamps are provided in the left and right directions of the front of a vehicle, and the left and right headlamps are configured to be substantially symmetrical in the left and right directions. Therefore, in the present embodiment, one of the vehicle headlamps will be described.
As shown in fig. 1, a vehicle headlamp 1 according to the present embodiment includes a housing 2, a lamp unit 3, and a support unit 4 as main components. Fig. 1 is a side view of the vehicle headlamp 1, and fig. 1 shows the housing 2 in a sectional view for easy understanding.
Next, the housing 2 will be explained.
The housing 2 mainly includes a lamp housing 11, a front cover 12, and a rear cover 13. A front cover 12 having translucency is fixed to the lamp envelope 11 so as to close the front opening of the lamp envelope 11. An opening smaller than the front is formed in the rear of the lamp housing 11, and a rear cover 13 is fixed to the lamp housing 11 to close the opening.
A space formed by the lamp housing 11, the front cover 12 closing the front opening of the lamp housing 11, and the rear cover 13 closing the rear opening of the lamp housing 11 is a lamp chamber R. The lamp unit 3 and the support unit 4 are accommodated in the lamp chamber R.
Next, the support unit 4 will be explained.
Fig. 2 is a perspective view of the lamp unit and the support unit shown in fig. 1. As shown in fig. 1 and 2, the support unit 4 mainly includes a bracket 15, a first link arm 16a, and a second link arm 16b. The holder 15 is a frame-shaped body, and includes: a base portion 15a extending in the left-right direction, column portions 15b, 15c extending upward from both left and right end portions of the base portion 15a, respectively, and a support portion 15d extending in the left-right direction and connected to upper end portions of both the column portions 15b, 15 c. The lamp unit 3 is disposed between the base portion 15a and the support portion 15d. The upper portion of the lamp unit 3 and the support portion 15d of the bracket 15 are connected by the first connecting arm 16a, and the lamp unit 3 is suspended from the support portion 15d of the bracket 15. The lower portion of the lamp unit 3 and the base portion 15a of the bracket 15 are coupled by a second connecting arm 16b, and the base portion 15a side of the second connecting arm 16b is connected to a driving unit, not shown, attached to the base portion 15a via a gear, not shown, or the like. In this way, the lamp unit 3 is attached to the bracket 15 by the first connecting arm 16a and the second connecting arm 16b. The lamp unit 3 is rotatable in the left-right direction and tiltable in the front-rear direction with respect to the bracket 15 by a drive unit, not shown, attached to the base portion 15 a. The holder 15 is fixed to the housing 2 by a device not shown.
Next, the lamp unit 3 will be explained.
Fig. 3 is an exploded perspective view of the lamp unit shown in fig. 1 as viewed from the front side, and fig. 4 is an exploded perspective view of the lamp unit shown in fig. 1 as viewed from the rear side. Fig. 3 and 4 both show the first connecting arm 16a and the second connecting arm 16b of the support unit 4. As shown in fig. 3 and 4, the lamp unit 3 of the present embodiment includes, as main components, a projection lens 20, a lens holder 25, and a light source unit LU.
Next, the light source unit LU will be explained.
As shown in fig. 3 and 4, the light source unit LU according to the present embodiment mainly includes: the flexible printed circuit board includes a support plate 30 as a pressing member, a reflector unit 40, a first substrate 50, a second substrate 60, two flexible printed circuit boards 70, a heat sink 80 as a mounting member, and a fan 81.
Next, the heat sink 80 will be described.
Fig. 5 is a perspective view of the heat sink, and fig. 6 is a schematic sectional view of the heat sink. Fig. 6 also shows a fan 81. As shown in fig. 4 to 6, the heat sink 80 is made of, for example, metal, and mainly includes a first base plate 82, a second base plate 83, a peripheral wall portion 84, and a rectifying plate 85.
The first base plate 82 is a plate-like body extending diagonally upward and forward and rightward and leftward. In the present embodiment, the first mounting surface 86, the first rib 87, the boss 88, and the recess 89 are formed on the front surface 82f of the first base plate 82. The first mounting surface 86 is a surface on which at least a part of the first board 50 is mounted, and is an end surface of the base 90 that protrudes forward from the front surface 82f of the first base plate 82, and is substantially parallel to the front surface 82f of the first base plate 82. The term "substantially parallel" in the present specification includes a completely parallel state, and also includes a state in which one is inclined by about 1 ° from the completely parallel state with respect to the other. Of the outer edges of the first mounting surface 86, an outer edge 86e located at the lower end extends in the left-right direction.
As shown in fig. 5, a first rib 87 is formed in a region on the lower side of the front surface 82f of the first base plate 82, and the first rib 87 protrudes forward from the front surface 82 f. Therefore, the first rib 87 is inclined with respect to the normal line of the first mounting surface 86. The first rib 87 extends upward from below when the first mounting surface 86 is viewed in plan (in plan view), and is inclined upward with respect to the first mounting surface 86. In the present embodiment, the cross-sectional shape perpendicular to the longitudinal direction of the first rib 87 is circular.
Two bosses 88 are formed at positions above the first ribs 87 and project forward from the front surface 82f of the first base plate 82 similarly to the first ribs 87. Therefore, the bosses 88 are inclined with respect to the normal line of the first carriage surface 86, respectively. Each boss 88 extends upward from below in a plan view of the first mounting surface 86 and is inclined upward with respect to the first mounting surface 86. An abutment surface 88s substantially perpendicular to the first mounting surface 86 is formed on the outer peripheral surface of the boss 88 on the lower side. In the present specification, the term "substantially vertical" includes a state of being completely vertical, and also includes a state of being inclined by about 1 ° from the state of being completely vertical with respect to the other. In the present embodiment, the abutment surface 88s of each boss 88 is a flat surface extending in the left-right direction in a plan view of the first mounting surface 86, and is not parallel to the vertical direction which is the extending direction of the first rib 87 in a plan view of the first mounting surface 86.
Concave portions 89 are formed on the right and left sides of the first mounting surface 86. The recessed portion 89 is a portion of the front surface 82f of the first base plate 82 recessed toward the side opposite to the first mounting surface 86 side. In the present embodiment, as will be described later, the concave portion 89 is recessed in an arc shape in a vertical cross section.
The second base plate 83 is a plate-like body extending diagonally forward and downward and rightward and leftward. The outer edge of the second base plate 83 on the upper side is connected to the outer edge of the first base plate on the lower side. In the present embodiment, the second mounting surface 91, the second rib 92, the rib reinforcing portion 93, the projection 94, and the two bosses 100 are formed on the front surface 83f of the second base plate 83. The second mounting surface 91 is a surface on which at least a part of the second substrate 60 is mounted, and is an end surface of the pedestal 95 protruding forward from the front surface 83f of the second base plate 83, and is substantially parallel to the front surface 83f of the second base plate 83. Therefore, a normal line extending toward the second substrate 60 of the second mounting surface 91 intersects a normal line extending toward the first substrate 50 of the first mounting surface 86, and an angle formed by the first mounting surface 86 and the second mounting surface 91 is smaller than 180 degrees. Therefore, the first mounting surface 86 and the second mounting surface 91 are not parallel to each other, and the angle formed by the first substrate 50 and the second substrate 60 is smaller than 180 degrees. Further, since the first base plate 82 and the second base plate 83 are plate-like bodies, the rear surface 82b of the first base plate 82 is inclined with respect to the rear surface 83b of the second base plate 83, and the angle formed by the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83 is larger than 180 degrees. Specifically, the rear surface 82b of the first base plate 82 is inclined obliquely upward toward the front, and the rear surface 83b of the second base plate 83 is inclined obliquely downward toward the front. Fig. 6 is a cross-sectional view perpendicular to the front surface 82f of the first base plate 82 and the front surface 83f of the second base plate 83. Since the first base plate 82 and the second base plate 83 are each a plate-like body as described above, fig. 6 is also a cross-sectional view perpendicular to the rear surface 83b of the first base plate 82 and the rear surface 83b of the second base plate 83. Further, an outer edge 91e of the outer edge of the second mounting surface 91, which is positioned on the first mounting surface 86 side, i.e., the upper end, is substantially parallel to an outer edge 86e of the outer edge of the first mounting surface 86, which is positioned on the second mounting surface 91 side, i.e., the lower end.
As shown in fig. 5, a second rib 92 is formed in a region on the lower side of the front surface 83f of the second base plate 83, and this second rib 92 projects forward from the front surface 83f of the second base plate 83. Therefore, the second rib 92 is inclined with respect to the normal line of the second mounting surface 91. The second rib 92 extends downward from above in a plan view of the second mounting surface 91 and is inclined downward with respect to the second mounting surface 91. In the present embodiment, the cross-sectional shape perpendicular to the longitudinal direction of the second rib 92 is circular. The second rib 92 is substantially parallel to the first rib 87. The second mounting surface 91 is visible from the front end side of the first rib 87 in the extending direction of the first rib 87. The first mounting surface 86 is visible from the front end side of the second rib 92, i.e., from the front in the extending direction of the second rib 92.
A rib reinforcing portion 93 is formed on the lower side of the outer peripheral surface of the second rib 92, and the rib reinforcing portion 93 is connected to the front surface 83f of the second base plate 83. The rib reinforcing portion 93 suppresses the second rib 92 from falling downward with respect to the second mounting surface 91. In addition, the strength of the second rib 92 is improved as compared with the case where the rib reinforcing portion 93 is not provided. In the present embodiment, the rib reinforcing portion 93 is not in contact with the second substrate 60.
Projections 94 are formed on both sides of the second base plate 83 in the left-right direction. Each of the projections 94 projects from the front surface 83f of the second base plate 83 in the direction normal to the second mounting surface 91. On the outer peripheral surfaces of the projections 94 on the upper side and the lower side, contact surfaces 94s substantially perpendicular to the second mounting surface 91 are formed, respectively. In the present embodiment, the contact surface 94s is a plane extending along the left and right in a plan view of the second mounting surface 91, and is not parallel to the vertical direction, which is the extending direction of the second rib 92 in a plan view of the second mounting surface 91. The second rib 92 projects more than the projection 94 in the normal direction of the second mounting surface 91.
Bosses 100 are formed on both sides of the second base plate 83 in the left-right direction, and the above-described projection 94 is located between these bosses 100. Each boss 100 protrudes forward from the front surface 83f of the second base plate 83 substantially in parallel with the second rib 92. The tip of each boss 100 is a plane substantially perpendicular to the protruding direction of the boss 100. The substantially vertical state in the present specification includes a true vertical state and also includes a state inclined by about 1 ° from the true vertical state. At the tip end of each boss 100, a female screw 100a is formed along the boss 100 from the end surface.
A flow member recess 96 is formed between the outer peripheral surface of the first base plate 82 on the lower side of the base 90 and the front surface 83f of the second base plate 83 on the upper side of the base 95. These two surfaces are arranged from the first mounting surface 86 side toward the second mounting surface 91 side, and the angle formed by these two surfaces is smaller than 180 degrees. The flow member recess 96 connects the two faces. In the present embodiment, as shown in fig. 6, the flow member recess 96 has a substantially V-shaped vertical cross section. The vertical cross-sectional shape of the flow member recess 96 is not particularly limited, and may be, for example, a U-shape.
As shown in fig. 5, a protrusion 97 protruding forward is formed on the surface defining the flow member recess 96. The projection 97 projects more than the first mounting surface 86 in the normal direction of the first mounting surface 86. An abutment surface 97s substantially perpendicular to the first mounting surface 86 is formed on the upper outer peripheral surface of the projection 97. The abutment surface 97s is located on the lower side than the abutment surface 88s of the boss 88 formed on the first base plate 82. In the present embodiment, the flow member recess 96 is connected to the outer peripheral surface of the lower side of the base 90 and the front surface 83f of the second base plate 83 on the upper side of the base 95. Therefore, the protrusion 97 extends across the flow member recess 96 in the vertical direction. In the present embodiment, two projections 97 are formed, and the contact surface 97s is a plane extending in the left-right direction in a plan view of the first mounting surface and is not parallel to the vertical direction which is the extending direction of the first rib 87 in a plan view of the first mounting surface 86.
The peripheral wall portion 84 is a cylindrical body extending in the front-rear direction. As shown in fig. 4, a part of the front end of the peripheral wall portion 84 is fixed to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83. The rear end of the peripheral wall portion 84 is an open end, and an opening 84H is formed. In the present embodiment, the peripheral wall portion 84 is composed of a pair of side walls 84a, an upper wall 84b, and a lower wall 84 c. The pair of side walls 84a, 84a are plate-like bodies extending in the front-rear direction and the up-down direction with a predetermined interval therebetween. The front outer edges of the pair of side walls 84a, 84a are connected to the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83 from the upper outer edge of the first base plate 82 to the lower outer edge of the second base plate 83. As shown in fig. 6, the upper wall 84b is a plate-like body that is positioned above the upper outer edge of the first base plate 82, connects the upper outer edges of the pair of side walls 84a, and extends in the front-rear direction and the left-right direction. The lower wall 84c is positioned below the outer edge of the lower side of the second base plate 83, and is a plate-like body that connects the lower outer edges of the pair of side walls 84a, 84a and extends in the front-rear direction and the left-right direction.
The first ventilation opening 98a defined by the inner surface of the upper wall 84b and the outer edge of the upper side of the first base plate 82 is formed in the heat sink 80. The first air vent 98a is disposed on the first floor panel 82 side of the connection portion 99 at a position forward of the connection portion 99 between the first floor panel 82 and the second floor panel 83. The heat sink 80 is provided with a second air vent 98b defined by an inner surface of the lower wall 84c and an outer edge of the lower side of the second base plate 83. The second ventilation opening 98b is located forward of the connection portion 99 between the first base plate 82 and the second base plate 83, and is located on the second base plate 83 side of the connection portion 99. The first air vent 98a and the second air vent 98b communicate the internal space and the external space of the peripheral wall portion 84.
The rectifying plate 85 is a plate-like body disposed in the internal space of the peripheral wall portion 84 and extending from the front end side to the rear end side of the peripheral wall portion 84. As shown in fig. 4, in the present embodiment, the flow regulating plate 85 extends in the front-rear direction and the up-down direction, the upper outer edge of the flow regulating plate 85 is connected to the inner peripheral surface of the upper wall 84b of the peripheral wall portion 84, and the lower outer edge of the flow regulating plate 85 is connected to the inner peripheral surface of the lower wall 84c of the peripheral wall portion 84. As shown in fig. 6, the outer edge 85f of the rectifying plate 85 on the front side is connected to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83. The rear outer edge 85b of the rectifying plate 85 is positioned forward of the opening 84H. In fig. 6, the front outer edge 85f and the rear outer edge 85b of the rectifying plate 85 are shown by broken lines. In the present embodiment, the heat sink 80 includes a plurality of flow rectification plates 85. The plurality of flow straightening plates 85 cross the first ventilation openings 98a when viewed from the front, which is the opening direction of the first ventilation openings 98a, and cross the second ventilation openings 98b when viewed from the front, which is the opening direction of the second ventilation openings 98b. In addition, some of the plurality of flow rectification plates 85 have a protruding portion 85a that extends forward from the second ventilation opening 98b and protrudes toward the space outside the peripheral wall portion 84.
Next, the fan 81 will be explained.
As shown in fig. 6, the fan 81 is disposed rearward of the rectifying plate 85 in the internal space of the peripheral wall portion 84, and the outer periphery of the fan 81 is surrounded by the peripheral wall portion 84. The fan 81 is fixed to the heat sink 80 by screws 81a shown in fig. 4. In the present embodiment, the fan 81 sends air to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83. That is, the air flow direction between the rear surfaces 82b and 83b and the fan 81 is a direction from the rear to the front. The fan 81 is configured to be capable of switching the air blowing direction to the reverse direction. That is, the fan 81 can send air not to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83 but to the opening 84H side by switching the blowing direction to the reverse direction. As described above, the first ventilation opening 98a and the second ventilation opening 98b are located forward of the connection portion 99 between the first floor panel 82 and the second floor panel 83. Therefore, the first air vent 98a and the second air vent 98b are disposed on the side opposite to the fan 81 side with respect to the connecting portion 99 between the first base plate 82 and the second base plate 83 in the cross section perpendicular to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83.
Next, the first substrate 50, the second substrate 60, and the flexible printed circuit board 70 will be described.
Fig. 7 is a front view of the first substrate, the second substrate, and the flexible printed circuit substrate. In fig. 3 and 4, the flexible printed circuit board 70 is shown in a bent state, but in fig. 7, the flexible printed circuit board 70 is shown in a non-bent state and shows a state in which the first substrate 50 and the second substrate 60 are spread on the same plane.
The first substrate 50 is a plate-like body, and is made of, for example, metal. The first substrate 50 is formed with a through hole 51 penetrating in the thickness direction. Two first contact surfaces 51s, which are flat surfaces facing each other from one surface to the other surface of the first substrate 50 and substantially parallel to each other, are formed on the inner peripheral surface of the first substrate 50 defining the through-hole 51. That is, the first contact surface 51s is a part of the inner peripheral surface of the first substrate 50 defining the through hole 51. The first contact surface 51s is substantially perpendicular to the front surface and the back surface of the first substrate 50. The through-hole 51 is formed at a position corresponding to the first rib 87 of the first base plate 82 of the heat sink 80, and the distance between the two first contact surfaces 51s is slightly larger than the outer diameter of the first rib 87. For example, the distance between the two first contact surfaces 51s may be about 0.05mm to 0.1mm larger than the outer diameter of the first rib 87.
A side surface on one side in a direction parallel to the first contact surface 51s in a plan view of the first substrate 50 is a second contact surface 52s substantially perpendicular to the first contact surface 51s. Further, a positioning concave portion 53 is formed on the outer edge of the first substrate 50 opposite to the second contact surface 52s side in plan view, the outer edge being recessed toward the second contact surface 52s side. A third contact surface 53s substantially perpendicular to the first contact surface 51s from one surface of the first substrate 50 to the other surface is formed on a side surface of the first substrate 50 defining the positioning recess 53. The positioning recess 53 is formed at a position corresponding to the boss 88 of the first base plate 82 of the heat sink 80, and two positioning recesses 53 are formed. The distance between the second contact surface 52s and the third contact surface 53s is slightly smaller than the distance between the contact surface 88s of the boss 88 of the heat sink 80 and the contact surface 97s of the protrusion 97. For example, the distance between the second contact surface 52s and the third contact surface 53s may be about 0.05mm to 0.1mm smaller than the distance between the contact surface 88s of the boss 88 and the contact surface 97s of the protrusion 97. Further, the first substrate 50 is formed with a notch 54 extending from the outer edge of the second contact surface 52s side to a predetermined position on the side opposite to the second contact surface 52s side. In the present embodiment, two notches 54 are formed.
A first light-emitting element 55 and a thermistor 56 are mounted on one surface of the first substrate 50. In a plan view of the first substrate 50, the first light-emitting element 55 is located on the second contact surface 52s side, and the thermistor 56 is located on the opposite side to the second contact surface 52s side. In the present embodiment, the center of gravity 50G of the first substrate 50 is located between the first light-emitting element 55 and the thermistor 56. The first light emitting element 55 emits the first light as a low beam. Examples of the first light emitting element 55 include an LED. In the present embodiment, the first light-emitting element 55 is an LED array including a plurality of LEDs connected in parallel in a direction substantially perpendicular to the first contact surface 51s in a plan view of the first substrate 50. The LED arrays are connected in series by a power supply circuit 57 formed on the first substrate 50. The thermistor 56 is connected to a thermistor circuit 58 formed on the first substrate 50. The first light-emitting element 55, the thermistor 56, the power supply circuit 57, and the thermistor circuit 58 are insulated from the first substrate 50 by an insulating layer, not shown, provided on the surface of the first substrate 50.
The second substrate 60 is a plate-like body, and is made of metal, for example. The second substrate 60 has a through hole 61 penetrating therethrough in the thickness direction. Two first contact surfaces 61s, which are flat surfaces facing each other from one surface of the second substrate 60 to the other surface and substantially parallel to each other, are formed on the inner peripheral surface of the second substrate 60 defining the through hole 61. That is, the first contact surface 61s is a part of the inner peripheral surface of the second substrate 60 defining the through hole 61. The first contact surface 61s is substantially perpendicular to the front surface and the back surface of the second substrate 60. The through-hole 61 is formed in the second base plate 83 of the heat sink 80 at a position corresponding to the second rib 92, and the distance between the two first contact surfaces 61s is slightly larger than the outer diameter of the second rib 92. For example, the distance between the two first contact surfaces 61s may be about 0.05mm to 0.1mm larger than the outer diameter of the second rib 92.
A positioning concave portion 62 is formed in which the outer edge of the second substrate 60 is depressed in a direction substantially perpendicular to the first contact surface 61s when the second substrate 60 is viewed in plan. Two second contact surfaces 62s facing each other from one surface to the other surface of the second substrate 60 and substantially perpendicular to the first contact surfaces 61s are formed on the side surface of the second substrate 60 defining the positioning recess 62. The positioning recesses 62 are formed at positions corresponding to the projections 94 of the second base plate 83 of the heat sink 80, and two positioning recesses 62 are formed in the second base plate 83. The distance between the two second abutment surfaces 62s of each positioning recess 62 is slightly larger than the distance between the two abutment surfaces 94s of the projection 94. For example, the distance between the two second contact surfaces 62s may be about 0.05mm to 0.1mm larger than the distance between the two contact surfaces 94s of the protrusion 94.
A second light-emitting element 63 and a connector 64 are mounted on one surface of the second substrate 60. When the second substrate 60 is viewed in plan, the second light-emitting element 63 is positioned on one side in a direction parallel to the first contact surface 61s, and the connector 64 is positioned on the other side. In the present embodiment, the center of gravity 60G of the second substrate 60 is located between the second light emitting element 63 and the connector 64. The second light emitting element 63 and the connector 64 are electrically connected by a power supply circuit 65 formed on the second substrate 60. The second light emitting element 63 emits the second light as the high beam. Examples of the second light emitting element 63 include an LED. In the present embodiment, the second light emitting element 63 is an LED array including a plurality of LEDs connected in parallel along a direction substantially perpendicular to the first contact surface 61s in a plan view of the second substrate 60. Two adjacent LEDs of the LED array are connected in parallel by the power supply circuit 65, and the two LEDs connected in parallel can be made to emit light alone or not.
The second substrate 60 is provided with a first power feeding wiring 66a, a second power feeding wiring 66b, a first thermistor wiring 67a, and a second thermistor wiring 67b, each of which has one end connected to the connector 64. In the present embodiment, the first thermistor wire 67a is located on one side of the power supply circuit 65 in a direction substantially perpendicular to the first contact surface 61s in a plan view of the second substrate 60. The first power feeding wiring 66a is located between the power feeding circuit 65 and the first thermistor wiring 67a in a direction substantially perpendicular to the first contact surface 61s in a plan view of the second substrate 60. The second thermistor wire 67b is located on the other side of the feeding circuit 65 in a direction substantially perpendicular to the first contact surface 61s in a plan view of the second substrate 60. The second power feeding wiring 66b is located between the power feeding circuit 65 and the second thermistor wiring 67b in a direction substantially perpendicular to the first contact surface 61s in a plan view of the second substrate 60. A not-shown wire harness is connected to the connector 64. The number of the connectors 64 is not particularly limited, and fig. 7 illustrates an example in which two connectors 64 are mounted in parallel in a direction substantially perpendicular to the first contact surface 61s. The second light-emitting element 63, the power supply circuit 65, the first power supply wiring 66a, the second power supply wiring 66b, the first thermistor wiring 67a, and the second thermistor wiring 67b are insulated from the second substrate 60 by an insulating layer, not shown, provided on the surface of the second substrate 60.
In the present embodiment, the two flexible printed circuit boards 70 have a substantially bilaterally symmetrical structure. Hereinafter, one flexible printed circuit board 70 will be described, and the description of the other flexible printed circuit board 70 will be omitted as appropriate. The flexible printed circuit board 70 has flexibility, and is composed of, for example, an insulating sheet and a metal film provided on one surface of the insulating sheet. The flexible printed circuit board 70 of the present embodiment includes: a substantially rectangular band portion 73, a first connection portion 71 connected to one end of the band portion 73 in the longitudinal direction, and a second connection portion 72 connected to the other end of the band portion 73 in the longitudinal direction. The width of the tape portion 73 in the direction perpendicular to the longitudinal direction is smaller than the width of the first connection portion 71 and the second connection portion 72 in the direction. In the present embodiment, the band portion 73 is formed with a slit 73s substantially parallel to the longitudinal direction of the band portion 73. The bending rigidity of the belt portion 73 is reduced by the slit 73s as compared with the case where the slit 73s is not formed. In particular, the rigidity of the belt portion 73 in the direction perpendicular to the longitudinal direction is reduced. The widths of the first connection portion 71, the second connection portion 72, and the belt portion 73 are not particularly limited. For example, the width of the belt portion 73 may be larger than the widths of the first connection portion 71 and the second connection portion 72. The width of the belt portion 73 may be changed in the longitudinal direction of the belt portion 73. The slit 73s may not be formed in the belt portion 73.
The first connection portion 71 is provided with a first power feeding terminal 74a and a first thermistor terminal 75a, and the second connection portion 72 is provided with a second power feeding terminal 74b and a second thermistor terminal 75b. Further, the flexible printed circuit board 70 is provided with a power feeding wiring 74c for electrically connecting the first power feeding terminal 74a and the second power feeding terminal 74b via the tape portion 73. Further, similarly to the power supply wiring 74c, a thermistor wiring 75c is formed to electrically connect the first thermistor terminal 75a and the second thermistor terminal 75b via the tape portion 73. The power feeding wire 74c passes through one side in a direction perpendicular to the longitudinal direction of the tape portion 73 with reference to the slit 73s of the tape portion 73. On the other hand, the thermistor wire 75c passes through the other side in the direction perpendicular to the longitudinal direction of the tape portion 73 with reference to the slit 73s of the tape portion 73. That is, the flexible printed circuit board 70 has two wires 74c, 75c extending from the first connection portion 71 to the second connection portion 72, and a slit 73s is formed between the two wires 74c, 75c.
Each of the flexible printed circuit boards 70 connects the first substrate 50 and the second substrate 60, and electrically connects the circuit formed on the first substrate 50 and the circuit formed on the second substrate 60. Specifically, the first connection portions 71 of the flexible printed circuit boards 70 are bonded to the mounting surface of the first substrate 50 on which the first light-emitting elements 55 are mounted, for example, by solder. The second connection portions 72 of the flexible printed circuit boards 70 are bonded to the mounting surface of the second substrate 60 on which the second light-emitting elements 63 are mounted, for example, with solder. In this way, the respective flexible printed circuit substrates 70 are connected to the first substrate 50 and the second substrate 60. The longitudinal directions of the tape portions 73 in the flexible printed circuit boards 70 are substantially parallel to each other. In the present embodiment, the first contact surface 51s of the first substrate 50 and the first contact surface 61s of the second substrate 60 are substantially parallel to each other in a state where the first substrate 50 and the second substrate 60 are disposed on the same plane. In addition, the first light-emitting element 55 side of the first substrate 50 is positioned on the second light-emitting element 63 side of the second substrate 60.
The first connection portions 71 of the respective flexible printed circuit boards 70 are located at substantially the same positions as each other in a direction parallel to the first contact surface 51s in a plan view of the first substrate 50. The second connection portions 72 of the flexible printed circuit boards 70 are located at substantially the same positions as each other in a direction parallel to the first contact surface 61s when the second substrate 60 is viewed in plan. The center of gravity 50G of the first substrate 50 and the first light emitting element 55 are located between the first connection portions 71 of the flexible printed circuit substrates 70. The first connection portion 71 of each flexible printed circuit board 70 is located on the opposite side of the first light-emitting element 55 side with respect to the center of gravity 50G of the first substrate 50. The center of gravity 60G of the second substrate 60 and the second light-emitting element 63 are located between the second connection portions 72 of the flexible printed circuit substrates 70. The center of gravity 50G of the first substrate 50 and the first light-emitting element 55 may not be located between the first connection portions 71. Further, the center of gravity 60G of the second substrate 60 and the second light emitting element 63 may not be located between the second connection portions 72. When viewed from the side of the flexible printed circuit board 70 opposite to the first substrate 50 side, a part of the tape portion 73 of each flexible printed circuit board 70 overlaps the notch 54 of the first substrate 50. The width of the slit 54 is larger than the width of the belt portion 73. The tape portion 73 of each flexible printed circuit board 70 does not overlap the first substrate 50 from the outer edge of the second substrate 60 intersected by the tape portion 73 to a predetermined position within the notch 54 when viewed from the same viewpoint. The tape portion 73 of the flexible printed circuit board 70 of the present embodiment does not overlap the first substrate 50 from the outer edge of the second substrate 60, which is intersected by the tape portion 73, to the outer edge on the side opposite to the second substrate 60, out of the outer edges defining the notch 54 of the first substrate 50. In addition, the first light-emitting element 55 of the first substrate 50 is disposed closer to the second substrate 60 than the edge of the notch 54 on the side opposite to the second substrate side in a plan view of the first substrate 50. The first light-emitting element 55 is overlapped with such a portion of the band part 73 that does not overlap with the first substrate 50 in a direction perpendicular to the longitudinal direction of the band part 73.
Further, a cathode-side end 57c of the feeding circuit 57 formed on the first substrate 50 is connected to the first feeding terminal 74a of the one flexible printed circuit board 70. The anode-side end 57a of the feeding circuit 57 of the first substrate 50 is connected to the first feeding terminal 74a of the other flexible printed circuit board 70. Further, a cathode-side end 58c of the thermistor circuit 58 formed on the first substrate 50 is connected to the first thermistor terminal 75a of the single flexible printed circuit board 70. The first thermistor terminal 75a of the other flexible printed circuit board 70 is connected to the anode-side end 58a of the thermistor circuit 58 formed on the first substrate 50.
The end of the first power feeding wiring 66a of the second substrate 60 on the side opposite to the connector 64 side is connected to the second power feeding terminal 74b of one flexible printed circuit board 70. The end of the second power feeding wiring 66b of the second substrate 60 on the side opposite to the connector 64 side is connected to the second power feeding terminal 74b of the other flexible printed circuit board 70. The end of the first thermistor wire 67a of the second substrate 60 opposite to the connector 64 side is connected to the second thermistor terminal 75b of the single flexible printed circuit board 70. The end of the second thermistor wire 67b of the second substrate 60 on the side opposite to the connector 64 side is connected to the second thermistor terminal 75b of the other flexible printed circuit board 70.
In this way, the two flexible printed circuit boards 70 are connected to the first board 50 and the second board 60, and the connector 64 of the second board 60 and the feeding circuit 65 of the first board 50 are electrically connected. Then, power is supplied to the first light emitting element 55 of the first substrate 50 via the connector 64. The connector 64 of the second substrate 60 is electrically connected to the thermistor circuit 58 of the first substrate 50, and applies a current to the thermistor 56 of the first substrate 50.
Next, mounting of the first substrate 50 on the heat sink 80 will be described.
Fig. 8 is a diagram showing a state where the first substrate is mounted on a heat sink. As shown in fig. 8, the first substrate 50 is placed on the first placement surface 86 of the first base plate 82 of the heat sink 80 in a state where the first contact surface 51s is substantially parallel to the vertical direction and the first light-emitting element 55 side is located on the lower side. The outer edge of the first mounting surface 86 is surrounded by the outer edge of the first substrate 50 in a plan view of the first substrate. In the present embodiment, since the grease as a flow member to be described later is applied to the surface of the first substrate 50 opposite to the side on which the first light-emitting element 55 is mounted, the grease is interposed between the surface of the first substrate 50 opposite to the side on which the first light-emitting element 55 is mounted and the first mounting surface 86. The first ribs 87 of the first base plate 82 are inserted into the through holes 51 of the first substrate 50. As described above, since the first rib 87 is inclined upward with respect to the first mounting surface 86 and extends upward from below when the first mounting surface 86 is viewed in plan, the first rib 87 is inserted in a state inclined upward with respect to the opening direction of the through hole 51. As described above, the center of the first rib 87 inserted into the through hole 51 is positioned between the two first contact surfaces 51s when viewed from the front, which is the extending direction of the first rib 87. As described above, the distance between the two first contact surfaces 51s is slightly larger than the outer diameter of the first rib 87. Therefore, when the first substrate 50 moves relative to the heat sink 80 in the direction perpendicular to the first contact surfaces 51s along the first placement surface 86, the outer peripheral surface of the first rib 87 contacts one of the two first contact surfaces 51s. Here, when the first mounting surface 86 is viewed from above, the first rib 87 extends upward from below, and the first contact surface 51s is substantially parallel to the vertical direction. Therefore, it can be understood that: at least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the first rib 87 in the left-right direction, which is a direction perpendicular to the extending direction of the first rib 87 when the first mounting surface 86 is viewed in plan, abuts against the first abutment surface 51s. Therefore, the position of the first substrate 50 relative to the heat sink 80 in the direction parallel to the first placement surface 86 is limited so that the position in the direction perpendicular to the extending direction of the first ribs 87 in plan view of the first placement surface 86 falls within a predetermined range. At least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the first rib 87 in the direction perpendicular to the extending direction of the first rib 87 in a plan view of the first mounting surface 86 may always abut against the first abutment surface 51s. For example, the first rib 87 may be press-fitted into the through hole 51.
The two bosses 88 of the first base plate 82 enter the two positioning recesses 53 of the first base plate 50, respectively. As described above, the abutment surface 88s of the boss 88 is a flat surface extending in the left-right direction in a plan view of the first mounting surface 86, perpendicular to the first mounting surface 86. The third contact surface 53s defining the side surface of the first substrate 50 of the positioning recess 53 is substantially perpendicular to the first contact surface 51s substantially parallel to the vertical direction. Therefore, the contact surface 88s and the third contact surface 53s are opposed to each other in a substantially parallel state.
The second contact surface 52s of the first substrate 50 is located above the protrusion 97 of the heat sink 80. As described above, the contact surface 97s of the projection 97 is a flat surface extending substantially perpendicular to the first mounting surface 86 in the left-right direction when the first mounting surface 86 is viewed in plan. The second contact surface 52s of the first substrate 50 is substantially perpendicular to the first contact surface 51s substantially parallel to the vertical direction. Therefore, the contact surface 97s and the second contact surface 52s are opposed to each other in a substantially parallel state. As described above, the distance between the second contact surface 52s and the third contact surface 53s in the first substrate 50 is slightly smaller than the distance between the contact surface 88s of the boss 88 and the contact surface 97s of the protrusion 97 in the heat sink 80. Therefore, when the first substrate 50 moves along the first placement surface 86 in a direction parallel to the first contact surface 51s with respect to the heat sink 80, the second contact surface 52s of the first substrate 50 contacts the contact surface 97s of the protrusion 97. Further, the third abutment surface 53s of the first substrate 50 abuts against the abutment surface 88s of the boss 88. Here, as described above, the contact surface 88s is a flat surface extending in the left-right direction in a plan view of the first mounting surface 86, and the contact surface 88s and the third contact surface 53s face each other in a substantially parallel state. Therefore, when the first placement surface 86 is viewed in plan, a tangent line at which the contact surface 88s and the third contact surface 53s contact extends substantially in the left-right direction. Therefore, the tangent is substantially perpendicular to and non-parallel to the extending direction of the first rib 87. As described above, the contact surface 97s is a flat surface extending in the left-right direction in a plan view of the first placement surface 86, and the contact surface 97s and the second contact surface 52s are opposed to each other in a substantially parallel state. Therefore, a tangent line when the contact surface 97s contacts the second contact surface 52s extends substantially in the left-right direction when the first placement surface 86 is viewed in plan. Therefore, the tangent is substantially perpendicular to and non-parallel to the extending direction of the first rib 87. Therefore, the position of the first substrate 50 with respect to the heat sink 80 in the direction parallel to the first mounting surface 86 is limited so that the position in the vertical direction, which is the extending direction of the first rib 87 when the first mounting surface 86 is viewed in plan, falls within a predetermined range. In at least one of a state in which the contact surface 88s is in contact with the third contact surface 53s and a state in which the contact surface 97s is in contact with the second contact surface 52s, the first rib 87 does not contact the first substrate 50 in the extending direction of the first rib 87 when the first placement surface 86 is viewed in plan. The second contact surface 52s of the first substrate 50 and the contact surface 97s of the projection 97 may always be in contact with each other, and the third contact surface 53s of the first substrate 50 and the contact surface 88s of the boss 88 may always be in contact with each other.
Further, as described above, since the first base plate 82 extends diagonally upward and forward, the first mounting surface 86 also extends diagonally upward and forward, and the first substrate 50 mounted on the first mounting surface 86 also extends diagonally upward and forward. As shown in fig. 8, when viewed from the front, which is the opening direction of the first ventilation opening 98a, a part of the first substrate 50 overlaps the first ventilation opening 98 a. As described above, the first substrate 50 is placed on the first placement surface 86 of the heat sink 80 in a state where the first contact surface 51s is substantially parallel to the vertical direction. The first light emitting element 55 is an LED array including a plurality of LEDs connected in parallel in a direction substantially perpendicular to the first contact surface 51s. Therefore, the LED arrays as the first light emitting element 55 are connected in parallel in the left-right direction.
Next, mounting of the second substrate 60 on the heat sink 80 will be described.
Fig. 9 is a diagram showing a state in which the first substrate and the second substrate are mounted on the heat sink. As shown in fig. 9, the second substrate 60 is disposed on the second mounting surface 91 of the second base plate 83 of the heat sink 80 in a state where the first contact surface 61s is substantially parallel to the vertical direction and the second light-emitting element 63 side is positioned upward. When the second substrate 60 is viewed in plan, the outer edge of the second mounting surface 91 is surrounded by the outer edge of the second substrate 60. In fig. 9, the first substrate 50 side of the second substrate 60 and the second substrate 60 side of the first substrate 50 overlap each other, but the second substrate 60 and the first substrate 50 are separated from each other. That is, the first substrate 50 and the second substrate 60 are mounted on the heat sink 80 with a predetermined interval.
In the present embodiment, since the surface of the second substrate 60 opposite to the side on which the second light-emitting element 63 is mounted is coated with grease as a flow member to be described later, as in the case of the first substrate 50, the grease is interposed between the surface of the second substrate 60 opposite to the side on which the second light-emitting element 63 is mounted and the second mounting surface 91. The second ribs 92 of the second base plate 83 are inserted into the through holes 61 of the second substrate 60. As described above, since the second rib 92 extends downward from above when viewed from above with respect to the second mounting surface 91 while being inclined downward with respect to the second mounting surface 91, the second rib 92 is inserted in a state of being inclined downward with respect to the opening direction of the through hole 61. In this way, the center of the second rib 92 inserted into the through hole 61 is positioned between the two first abutment surfaces 61s when viewed from the front, which is the extending direction of the second rib 92. As described above, the distance between the two first contact surfaces 61s is slightly larger than the outer diameter of the second rib 92. Therefore, when the second substrate 60 moves in the direction perpendicular to the first contact surfaces 61s along the second placement surface 91 with respect to the heat sink 80, the outer peripheral surface of the second rib 92 contacts one of the two first contact surfaces 61s. Here, as described above, when the second mounting surface 91 is viewed in plan, the second rib 92 extends downward from above, and the first contact surface 61s is substantially parallel to the vertical direction. Therefore, it can be understood that: at least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the second rib 92 abuts against the first abutment surface 61s in the left-right direction which is a direction perpendicular to the extending direction of the second rib 92 when the second mounting surface 91 is viewed in plan. Therefore, the position of the second substrate 60 relative to the heat sink 80 in the direction parallel to the second mounting surface 91 is limited so that the position in the direction perpendicular to the extending direction of the second ribs 92 when the second mounting surface 91 is viewed in plan falls within a predetermined range. At least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the second rib 92 in the direction perpendicular to the extending direction of the second rib 92 in a plan view of the second mounting surface 91 may be constantly in contact with the first contact surface 61s. For example, the second rib 92 may be press-fitted into the through hole 61.
The two protrusions 94 of the second base plate 83 enter the two positioning recesses 62 of the second base plate 60, respectively. As described above, the abutment surfaces 94s formed on the outer peripheral surfaces of the upper and lower sides of the projection 94 are respectively formed as planes extending in the left and right directions in plan view of the second mounting surface 91 substantially perpendicular to the second mounting surface 91. Two second contact surfaces 62s facing each other on the side surfaces of the second substrate 60 defined by the positioning recess 62 are set to be substantially perpendicular to the first contact surface 61s substantially parallel to the vertical direction. Therefore, the contact surface 94s and the second contact surface 62s are opposed to each other in a substantially parallel state. As described above, the distance between the two second abutment surfaces 62s of each positioning recess 62 is slightly larger than the distance between the two abutment surfaces 94s of the projection 94. Therefore, when the second substrate 60 moves along the second placement surface 91 with respect to the heat sink 80 in a direction parallel to the first contact surface 61s, one of the contact surfaces 94s that faces the first contact surface 61s comes into contact with the first contact surface 61s. Here, as described above, the contact surface 94s is a flat surface extending in the left-right direction when the second placement surface 91 is viewed in plan, and the contact surface 94s and the second contact surface 62s face each other in a substantially parallel state. Therefore, when the second mounting surface 91 is viewed in plan, a tangent line at which the contact surface 94s and the second contact surface 62s contact extends substantially in the left-right direction. Therefore, the tangent is substantially perpendicular to and non-parallel to the extending direction of the second rib 92. Therefore, the position of the second substrate 60 in the direction parallel to the second mounting surface 91 with respect to the heat sink 80 is limited so that the position in the direction parallel to the first contact surface 61s falls within a predetermined range. In the state where the contact surface 94s is in contact with the second contact surface 62s, the second rib 92 is not in contact with the second substrate 60 in the extending direction of the second rib 92 when the second mounting surface 91 is viewed in plan.
Further, since the second base plate 83 extends diagonally forward and downward as described above, the second mounting surface 91 also extends diagonally forward and upward, and the second substrate 60 mounted on the second mounting surface 91 also extends diagonally forward and downward. As shown in fig. 9, the second substrate 60 overlaps the second ventilation opening 98b when viewed from the front, which is the opening direction of the second ventilation opening 98b. As described above, the second substrate 60 is placed on the second placement surface 91 of the heat sink 80 in a state where the first contact surface 61s is substantially parallel to the vertical direction. The second light emitting element 63 is an LED array connected in parallel in a direction substantially perpendicular to the first contact surface 61s. Therefore, the LED arrays as the second light emitting elements 63 are connected in parallel in the left-right direction. In addition, as described above, since the first light-emitting element 55 side of the first substrate 50 is positioned on the second light-emitting element 63 side of the second substrate 60, the second light-emitting element 63 is positioned on the first substrate 50 side of the second substrate 60 with respect to the second substrate 60 side. The first light-emitting element 55 is located on the second substrate 60 side of the first substrate 50 with respect to the first substrate 50 side.
When viewed from the side of the flexible printed circuit board 70 opposite to the heat sink 80, the band portions 73 of the two flexible printed circuit boards 70 do not overlap the first board 50 from the outer edge of the second board 60 intersected by the band portions 73 to a predetermined position within the notch 54. When viewed from the same viewpoint, the first light-emitting elements 55 of the first substrate 50 overlap such portions of the band portions 73 that do not overlap the first substrate 50 in a direction perpendicular to the longitudinal direction of the band portions 73. In addition, when viewed from the same viewpoint, the one concave portion 89 of the heat sink 80 crosses both edges of the one flexible printed circuit board 70 in a direction perpendicular to the longitudinal direction of the one flexible printed circuit board 70. The other concave portion 89 crosses edges on both sides of the flexible printed circuit board 70 in a direction perpendicular to the longitudinal direction of the other flexible printed circuit board 70.
Fig. 10 is a view showing a state where the second substrate is mounted on the heat sink, and is a partially enlarged view of the second substrate and the heat sink as viewed from a side. As described above, some of the plurality of flow rectification plates 85 have the protruding portion 85a that extends forward from the second ventilation opening 98b and protrudes toward the space outside the peripheral wall portion 84. As shown in fig. 10, the protruding portion 85a contacts the surface of the second substrate 60 opposite to the side on which the second light-emitting element 63 is mounted. That is, the second board 60 is mounted on the second mounting surface 91 of the second base plate 83 and also mounted on the protruding portion 85a.
Next, a state of the flexible printed circuit board 70 in a state where the first substrate 50 and the second substrate 60 are mounted on the heat sink 80 will be described.
In the present embodiment, the two flexible printed circuit boards 70 are in substantially the same state in a state where the first substrate 50 and the second substrate 60 are mounted on the heat sink 80. Therefore, one flexible printed circuit board 70 will be described below, and the description of the other flexible printed circuit board 70 will be omitted. Fig. 11 is a schematic cross-sectional view through the flexible printed circuit board of fig. 9, and is a schematic cross-sectional view parallel to the longitudinal direction of the tape portion 73 of the flexible printed circuit board 70. As described above, the first connection portion 71 is bonded to the mounting surface 50s of the first substrate 50 on which the first light-emitting element 55 is mounted, and the second connection portion 72 is bonded to the mounting surface 60s of the second substrate 60 on which the second light-emitting element 63 is mounted. Therefore, the first connection portion 71 is connected to the first substrate 50 on the side opposite to the first mounting surface 86 side, and the second connection portion 72 is connected to the second substrate 60 on the side opposite to the second mounting surface 91 side. As shown in fig. 11, the tape portion 73 of the flexible printed circuit board 70 is bent in a convex shape toward the heat sink 80 between the first substrate 50 and the second substrate 60 on the first substrate 50 side of the first connection portion 71. In the present embodiment, the tape portion 73 of the flexible printed circuit board 70 passes through the notch 54 of the first substrate 50 while passing through the region on the first mounting surface 86 side of the first connection portion 71. The concave portion 89 of the heat sink 80 is recessed in an arc shape in the vertical cross section and is recessed on the opposite side of the first mounting surface 86 from the flexible printed circuit board 70. The tape portion 73 of the flexible printed circuit board 70 also passes through the concave portion 89. The flexible printed circuit board 70 thus flexed is not in contact with the heat sink 80. Further, for example, due to dimensional errors of the first substrate 50, the second substrate 60, the heat sink 80, and the like, the first substrate 50 and the second substrate 60 may be displaced in the left-right direction, which is a direction perpendicular to the longitudinal direction of the belt portion 73, and a stress may be generated in the left-right direction in the belt portion 73. However, as described above, by forming the slit 73s in the belt portion 73, the rigidity in the direction perpendicular to the longitudinal direction of the belt portion 73 is particularly reduced as compared with the case where the slit 73s is not formed. Therefore, even if a stress in the left-right direction is generated in the belt portion 73, the stress acting on the first connection portion and the second connection portion can be reduced as compared with the case where the slit 73s is not formed, and the occurrence of a failure can be suppressed.
Next, the reflector unit 40 will be explained.
Fig. 12 is a perspective view of the light source unit, fig. 13 is a front view of the light source unit, and fig. 14 is a schematic sectional view of the light source unit. As shown in fig. 12 and 13, the reflector unit 40 mainly has: the reflector 41 for the first light-emitting element 55, the first side reflector 41a for the first light-emitting element 55, the second side reflector 41b for the first light-emitting element 55, the reflector 42 for the second light-emitting element 63, the first side reflector 42a for the second light-emitting element 63, the second side reflector 42b for the second light-emitting element 63, and the light shield 43.
The reflector unit 40 is disposed on the side opposite to the heat sink 80 side with respect to the first substrate 50. The reflector unit 40 is fixed to the heat sink 80 so that the first substrate 50 is sandwiched between the reflector unit 40 and the heat sink 80. In the present embodiment, two screws 46 are used for fixing the reflector unit 40 to the heat sink 80.
As shown in fig. 4, the reflector unit 40 also has ribs 44. The rib 44 extends toward the first substrate 50, and a part of an end of the rib 44 on the first substrate 50 side is in contact with a mounting surface 50s of the first substrate 50 on which the first light-emitting element 55 is mounted. Therefore, the first substrate 50 is pressed against the first mounting surface 86 of the heat sink 80 by the reflector unit 40 and fixed to the heat sink 80. In the present embodiment, the reflector unit 40 has a plurality of ribs 44, and the contact portions of the ribs 44 with the first substrate 50 overlap the first mounting surface 86 in a plan view of the first substrate 50. Therefore, the first substrate 50 can be more appropriately pressed against the first mounting surface 86, and the relative position of the first substrate 50 with respect to the heat sink 80 can be suppressed from changing due to vibration or the like.
In the present embodiment, since the grease as the flow member is applied to the surface of the first substrate 50 opposite to the side on which the first light-emitting element 55 is mounted as described above, the grease 24 is interposed between the first substrate 50 and the first mounting surface 86 as shown in fig. 14. Therefore, when the first board 50 is pressed against the first mounting surface 86, a part of the grease 24 may be pushed out from between the first board 50 and the first mounting surface 86. As described above, the first placement surface 86 is an end surface of the base 90 that protrudes forward from the front surface 82f of the first base plate 82, and the outer edge of the first placement surface 86 is surrounded by the outer edge of the first base plate 50. Therefore, the excess grease 24 pushed out from between the first base plate 50 and the first placement surface 86 is pushed out onto the front surface 82f of the first base plate 82 around the pedestal 90. Therefore, the adhesion of a part of the excess grease 24 to the mounting surface 50s of the first substrate 50 on which the first light-emitting element 55 is mounted is suppressed, and the adhesion of the excess grease 24 to the first light-emitting element 55 is suppressed.
As shown in fig. 14, the light shield 43 is disposed between the first light-emitting element 55 and the second light-emitting element 63, and shields a part of the first light emitted from the first light-emitting element 55. The light shield 43 has a first reflection surface 43a on the upper surface and a second reflection surface 43b on the lower surface. The first reflecting surface 43a is a concave reflecting surface that extends forward from the first light emitting element 55 side and reflects a part of the first light forward. The second reflecting surface 43b is a concave reflecting surface that extends forward from the second light emitting element 63 side and reflects a part of the second light emitted from the second light emitting element 63 forward. The front end 43c of the shade 43 has a shape corresponding to a cut line described later, and is gradually recessed rearward from the left and right ends toward the center.
The reflector 41 is disposed above the first light emitting element 55, and has a third reflecting surface 41r on the first light emitting element 55 side to cover the top of the light emitting element 55. The third reflecting surface 41r and the first reflecting surface 43a of the light shield 43 are a pair of reflectors extending in the left-right direction and arranged so as to sandwich the first light emitting element 55 from the upper and lower sides.
As shown in fig. 12 and 13, the first side reflector 41a is formed on one side of the first light-emitting element 55 in the left-right direction in the space sandwiched between the first reflection surface 43a of the light shield 43 and the third reflection surface 41r of the reflector 41. The second side reflector 41b is formed on the other side of the space than the first light-emitting element 55. The first side reflector 41a and the second side reflector 41b are formed so that the distance therebetween increases from the rear side toward the front side.
As shown in fig. 14, the reflector 42 is disposed below the second light emitting element 63, and has a fourth reflecting surface 42r that covers the lower side of the second light emitting element 63 on the second light emitting element 63 side. The fourth reflecting surface 42r and the second reflecting surface 43b of the light shield 43 are a pair of reflectors extending in the left-right direction and arranged so as to sandwich the second light emitting element 63 from the upper and lower sides.
As shown in fig. 12 and 13, the first side reflector 42a is formed on one side of the second light emitting element 63 in the left-right direction in the space sandwiched between the second reflecting surface 43b of the light shield 43 and the fourth reflecting surface 42r of the reflector 42. The second side reflector 42b is formed on the other side of the space with respect to the second light emitting element 63. The first side reflector 42a and the second side reflector 42b are formed so that the distance therebetween increases from the rear side toward the front side.
Next, the support plate 30 will be explained.
Fig. 15 is a perspective view of the support plate as viewed from the front side, and fig. 16 is a perspective view of the support plate as viewed from the rear side. The support plate 30 has elasticity, and as shown in fig. 15 and 16, includes a base portion 31, a pair of fixing portions 32, a pair of first light-shielding portions 33, a second light-shielding portion 34, and a third light-shielding portion 35. In the present embodiment, the base portion 31, the pair of fixing portions 32, the pair of first light shielding portions 33, the second light shielding portion 34, and the third light shielding portion 35 are integrally formed by bending a metal plate. As shown in fig. 12 and 13, the support plate 30 is fixed to the heat sink 80 so as to cover a part of the second substrate 60 from the mounting surface 60s side on which the second light-emitting element 63 is mounted.
The base portion 31 is disposed on the side opposite to the heat sink 80 side with respect to the second substrate 60, and extends along the second substrate 60 between the connector 64 and the second light-emitting element 63. The base portion 31 has a projection 31a projecting toward the second substrate 60 and contacting a surface of the second substrate 60 opposite to the second mounting surface 91. That is, the convex portion 31a contacts the mounting surface 60s of the second substrate 60 on which the second light-emitting element 63 is mounted. In the present embodiment, the base portion 31 has two convex portions 31a. Fig. 17 is a view showing a state of the second substrate in plan view of fig. 9, and is an enlarged view of the vicinity of the positioning concave portion 62. As shown in fig. 7, 9, and 17, the contact portions 31b of the mounting surface 60s of the second substrate 60 on which the second light-emitting element 63 is mounted, which contact the two convex portions 31a, are located on the opposite side of the positioning concave portion 62 of the second substrate 60 from the second light-emitting element 63. The number and position of the convex portions 31a of the support plate 30 are not particularly limited. In other words, the number and position of the contact portions 31b of the second substrate 60 that contact the convex portions 31a are not particularly limited.
As shown in fig. 15 and 16, one fixing portion 32 of the pair of fixing portions 32 is connected to one outer edge portion of the base portion 31 in the left-right direction. The other fixing portion 32 is connected to the outer edge portion of the other side of the base portion 31 in the left-right direction. As shown in fig. 12 and 13, the pair of fixing portions 32 are fixed to the two bosses 100 of the heat sink 80 by screws 101.
The pair of fixing portions 32 has a substantially bilaterally symmetrical configuration, and includes an inner wall portion 32a, an outer wall portion 32b, and a front wall portion 32c. The inner wall portion 32a extends in a direction substantially perpendicular to the base portion 31 on the side opposite to the second substrate 60 side with respect to the base portion 31, and is connected to the base portion 31. The front wall portion 32c is located forward of the inner wall portion 32a and on the opposite side of the inner wall portion 32a from the base portion 31. The front wall portion 32c is substantially orthogonal to the inner wall portion 32a, extends in a substantially vertical direction, and is connected to the inner wall portion 32a. The outer side wall 32b extends substantially parallel to the inner side wall 32a at a position rearward of the front wall 32c, and is connected to the front wall 32c. The front wall portion 32c is formed with a through hole extending in a substantially vertical direction and penetrating in a plate thickness direction of the front wall portion 32c. As described above, the second substrate 60 extends diagonally downward and forward, and therefore, also extends diagonally downward and forward along the base portion 31 of the second substrate 60. Therefore, the front wall portion 32c of the fixing portion 32 is not parallel to the base portion 31. In the space surrounded by the inner wall portion 32a, the outer wall portion 32b, and the front wall portion 32c of the fixing portion 32, the boss 100 of the heat sink 80 is disposed, and the fixing portion 32 is fixed to the heat sink 80 with screws 101.
The second light shielding portion 34 is connected to an outer edge portion of the base portion 31 on the connector 64 side. The second light shielding portion 34 has an upper wall portion 34a and a pair of connecting wall portions 34b. The upper wall portion 34a is disposed above the connector 64 and extends substantially parallel to the base portion 31. One connecting wall portion 34b is connected to one side in the left-right direction of the outer edge portion of the base portion 31 on the connector 64 side, and extends to the side opposite to the second substrate 60 side. The outer edge portion of the one connecting wall portion 34b on the side opposite to the base portion 31 side is connected to the outer edge portion of the upper wall portion 34a on the second light emitting element 63 side. The other connecting wall portion 34b is connected to the other side in the left-right direction in the outer edge portion of the base portion 31 on the connector 64 side, and extends to the side opposite to the second board 60 side. The outer edge portion of the other connecting wall portion 34b on the side opposite to the base portion 31 side is connected to the outer edge portion of the upper wall portion 34a on the second light emitting element 63 side. Such a second light shielding portion 34 covers a part of the connector 64 on the side opposite to the second substrate 60 side.
The third light shielding portion 35 is connected to the first side reflector 41a side for the first light emitting element 55 in the outer edge portion of the base portion 31 on the second light emitting element 63 side. The third light-shielding portion 35 has a rear side wall portion 35a, a folded portion 35b, a side wall portion 35c, and a front side wall portion 35d, and the front side wall portion 35d shields a part of the first light. The rear side wall portion 35a is disposed on the first side reflector 41a side of the first and second light-emitting elements 55 and 63 on the side opposite to the second substrate 60 side with respect to the base portion 31. The rear side wall portion 35a extends vertically and horizontally and is connected to the base portion 31. The folded-back portion 35b is disposed forward of the rear side wall portion 35a and on the opposite side of the first side reflector 41a from the first light-emitting element 55. The folded portion 35b extends substantially parallel to the rear side wall portion 35a, and is connected to the rear side wall portion 35a on the side opposite to the first side reflector 41a side. The side wall portion 35c is disposed forward of the folded portion 35b and on the opposite side of the first side reflector 41a from the first light-emitting element 55. The side wall portion 35c extends in a direction substantially parallel to the inner wall portion 32a of the fixed portion 32, and is connected to the first side reflector 41a side of the folded portion 35 b. The front side wall portion 35d is disposed forward of the first side reflector 41a and on the first side reflector 41a side of the first and second light-emitting elements 55 and 63. The front side wall 35d extends vertically and horizontally and is connected to the side wall 35c. Such a front side wall portion 35d blocks a part of the first light emitted from the first light emitting element.
Next, the fixing of the second substrate 60 to the heat sink 80 will be described in detail.
Fig. 18 is a view showing a state in which the second substrate is fixed to the heat sink, and is a cross-sectional view of the light source unit LU through the convex portion 31a of the base portion 31 of the support plate 30. In fig. 18, the vicinity of the convex portion 31a is shown, and the description of the connector 64 and the like is omitted. As described above, the pair of fixing portions 32 are fixed to the bosses 100 of the heat sink 80 by the screws 101, respectively, whereby the support plate 30 is fixed to the heat sink 80. Specifically, the front wall portion 32c of the fixing portion 32 is formed such that the end face of the boss 100 and the front wall portion 32c are substantially parallel to each other and slightly separated from each other in a state where the convex portion 31a of the base portion 31 is in contact with the second base plate 60 and the through hole of the front wall portion 32c and the female screw 100a are aligned with each other. The support plate 30 is fixed to the heat sink 80 by inserting screws 101 through the through holes of the front wall portion 32c and screwing the screws into the female screws 100a. At this time, the support plate 30 is pushed toward the heat sink 80 by the screw 101 so as to reduce the gap between the end face of the boss 100 and the front wall portion 32c. Here, since the front wall portion 32c substantially parallel to the end face of the boss 100 extends in a substantially vertical direction, the support plate 30 is pushed rearward by the screw 101. As described above, the convex portion 31a of the base portion 31 contacts the mounting surface 60s of the second substrate 60 on which the second light-emitting element 63 is mounted. Therefore, the support plate 30 is elastically deformed, and the elastic force of the support plate 30 acts on the contact portion 31b of the second substrate 60. Since the support plate 30 is pushed rearward, as shown in fig. 18, the elastic force F of the support plate 30 acting on the contact portion 31b is directed rearward. The second substrate 60 is fixed to the heat sink 80 by the elastic force F of the support plate 30. Here, as described above, since the second board 60 mounted on the second mounting surface 91 extends obliquely forward and downward, the direction in which the support plate 30 is pushed in and the mounting surface 60s of the second board 60 on which the second light-emitting element 63 is mounted are not perpendicular to and parallel to each other. Therefore, the elastic force F of the support plate 30 is directed in a direction not perpendicular and not parallel to the mounting surface 60s of the second substrate 60. Therefore, the elastic force F of the support plate 30 is composed of a force F1 in a direction perpendicular to the second mounting surface 91 and a force F2 along the second mounting surface 91. Since the second board 60 mounted on the second mounting surface 91 extends diagonally forward and downward, the force F2 along the second mounting surface 91 out of the elastic force F of the support plate 30 is directed upward.
The second board 60 is pressed against the second mounting surface 91 by a force F1 in a direction perpendicular to the second mounting surface 91 among the elastic forces F of the support plate 30. Further, the second board 60 is pressed upward along the second mounting surface 91 by the force F2 along the second mounting surface 91 out of the elastic force F of the support plate 30, and a part of the side surface of the second board 60 is pressed against the outer peripheral surface of the protrusion 94 of the heat sink 80. More specifically, as shown in fig. 17, the second contact surface 62s on the lower side of the positioning recess 62 of the second substrate 60 is pressed against the contact surface 94s on the lower side of the protrusion 94 of the heat sink 80. That is, the force F2 along the second mounting surface 91 of the elastic force F of the support plate 30 is a force pressing the second substrate 60 against the abutment surface 94s on the lower side of the projection 94. Thus, the second board 60 is pressed against the abutment surface 94s on the lower side of the projection 94, and the second board 60 is prevented from being displaced along the second mounting surface 91 toward the side opposite to the direction in which the abutment surface 94s is pressed.
In the present embodiment, as described above, the two contact portions 31b are located on the opposite side of the second substrate 60 from the positioning recess 62 to the second light-emitting element 63, and enter the protrusion 94 in the positioning recess 62. That is, when the second substrate 60 is viewed in plan, the contact surface 94s on the lower side of the protrusion 94 is positioned in the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s on the lower side of the protrusion 94, compared to the contact portion 31b. In the present embodiment, as shown in fig. 7, the two contact portions 31b overlap each other in a direction perpendicular to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s when the second substrate is viewed in plan. One of the contact portions 31b corresponds to one of the protrusions 94, and the other contact portion 31b corresponds to the other protrusion 94. More specifically, as shown in fig. 17, at least a part of the lower abutment surface 94s of one of the projections 94 is positioned between the straight line La and the straight line Lb when the second substrate 60 is viewed in plan. The straight line La is a straight line passing through one end of the one contact portion 31b in the direction perpendicular to the direction in which the support plate 30 presses the second substrate 60 against the contact surface 94s in parallel with the direction F2 when the second substrate 60 is viewed in plan. The straight line Lb is a straight line passing through the other end of the one contact portion 31b in parallel with the straight line La. As shown in fig. 7, at least a part of the lower abutment surface 94s of the other protrusion 94 is located between the straight line Lc and the straight line Ld when the second substrate 60 is viewed in plan. Here, the positional relationship between the two protrusions 94 and the second substrate 60 shown by the dotted lines in fig. 7 is a positional relationship in which the second substrate 60 is fixed to the heat sink 80 by the elastic force of the support plate 30. The straight line Lc is a straight line that passes through one end of the other contact portion 31b in the direction perpendicular to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s in a plan view of the second substrate 60. The straight line Ld is a straight line passing through the other end of the other contact portion 31b in parallel with the straight line Lc.
A straight line La passing through one of the contact portions 31b is located on the opposite side to the other contact portion 31b. The straight line Lc of the other contact portion 31b is located on the opposite side to the one contact portion 31b side. These straight lines La and Lc are parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s when the second substrate 60 is viewed in plan. Therefore, the straight line La is also a straight line passing through the end of the one contact portion 31b on the side opposite to the other contact portion 31b side in parallel with the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s in a plan view of the second substrate 60. The straight line Lc also passes through the end of the other contact portion 31b opposite to the one contact portion 31b side in parallel with the straight line La. At least a part of the lower abutment surface 94s of one protrusion 94 and at least a part of the lower abutment surface 94s of the other protrusion 94 are located between the straight line La and the straight line Lc.
A straight line Lb passing through one of the contact portions 31b is positioned on the other contact portion 31b side, and a straight line Ld passing through the other contact portion 31b is positioned on the one contact portion 31b side. The straight line Lb and the straight line Ld are parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s when the second substrate 60 is viewed in plan. Therefore, the straight line Lb is also a straight line passing through the end of the one contact portion 31b on the other contact portion 31b side in parallel with the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s in a plan view of the second substrate 60. The straight line Ld is also a straight line passing through the end of the other contact portion 31b on the side of the one contact portion 31b in parallel with the straight line Lb. The center of gravity 60G of the second substrate 60 is located between the straight line Lb and the straight line Ld. Therefore, the center of gravity 60G of the second substrate 60 is also located between the straight line La and the straight line Lc.
In the present embodiment, since the grease 24 as a flow member is applied to the surface of the second substrate 60 opposite to the side on which the second light-emitting element 63 is mounted, as described above, the grease 24 is interposed between the second substrate 60 and the second mounting surface 91 as shown in fig. 14 and 18. Therefore, when the second board 60 is pressed against the second mounting surface 91, a part of the grease 24 may be pushed out from between the second board 60 and the second mounting surface 91. As described above, the second mounting surface 91 is an end surface of the base 95 protruding forward from the front surface 83f of the second base plate 83, and the outer edge of the second mounting surface 91 is surrounded by the outer edge of the second base plate 60. Therefore, the excess grease 24 pushed out from between the second substrate 60 and the second mounting surface 91 is pushed out onto the front surface 83f of the second base plate 83 around the pedestal 95. Therefore, the adhesion of a part of the excess grease 24 to the mounting surface 60s of the second light-emitting element 63 on which the second substrate 60 is mounted is suppressed, and the adhesion of the excess grease 24 to the second light-emitting element 63 is suppressed. The flow member is not limited to grease. The flow member is not limited to a member having fluidity at any time, as long as it has fluidity at least when the first substrate 50 is placed on the first placement surface 86 and when the second substrate 60 is placed on the second placement surface 91. Therefore, the flow member includes an uncured flow member in which the first substrate 50 and the second substrate 60 such as grease or an adhesive are not cured even after being placed on the placement surfaces 86 and 91, and a cured flow member in which the first substrate 50 and the second substrate 60 such as an adhesive made of a thermosetting resin are cured after being placed on the placement surfaces. The flow member interposed between the first substrate 50 and the first mounting surface 86 and the flow member interposed between the second substrate 60 and the second mounting surface 91 may be the same or different.
As described above, the flow member recess 96 is formed between the outer peripheral surface of the heat sink 80 on the lower side of the base 90 and the front surface 83f of the second base plate 83 on the upper side of the base 95. An outer edge 86e of the outer edge of the first mounting surface 86 on the second mounting surface 91 side is substantially parallel to an outer edge 91e of the outer edge of the second mounting surface 91 on the first mounting surface 86 side, and extends in the left-right direction. The outer edge of the first mounting surface 86 is surrounded by the outer edge of the first substrate 50, and the outer edge of the second mounting surface 91 is surrounded by the outer edge of the second substrate 60. Therefore, an outer edge 86e of the outer edge of the first mounting surface 86 on the second mounting surface 91 side is an edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50. An outer edge 91e of the outer edge of the second mounting surface 91 on the first mounting surface 86 side is an edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60. That is, the flow member recess 96 is formed between the edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60. Therefore, a part of the grease 24 toward the second substrate 60 out of the excess grease 24 pushed out from between the first substrate 50 and the first mounting surface 86 can be accommodated in the flow member recess 96. Further, a part of the grease 24 facing the first substrate 50 out of the excess grease 24 pushed out from between the second substrate 60 and the second placement surface 91 can be accommodated in the flow member recess 96. That is, a part of the excess grease 24 accumulated between the first base plate 50 and the second base plate 60 can be accommodated in the flow member recess 96.
As described above, the outer edge 86e of the outer edge of the first mounting surface 86, which is located on the second mounting surface 91 side, at the lower end is substantially parallel to the outer edge 91e of the outer edge of the second mounting surface 91, which is located on the first mounting surface 86 side, at the upper end, and extends in the left-right direction. Therefore, the region sandwiched between the outer edge 86e and the outer edge 91e is a region in which the distance between the edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60 is the smallest. At least a part of the flow member recess 96 is located in this region.
As shown in fig. 8, at least a part of the flow member recess 96 is located between a first straight line Lf passing through one end of the first light-emitting element 55 of the first substrate 50 in the direction perpendicular to the direction from the first substrate 50 side toward the second substrate 60 side and parallel to the direction from the first substrate 50 side toward the second substrate 60 side, and a second straight line Ls passing through the other end of the first light-emitting element 55 of the first substrate 50 and parallel to the first straight line Lf. That is, at least a part of the flow member recess 96 is positioned between a first straight line Lf passing through one end in the left-right direction of the first light emitting element 55 and parallel to the up-down direction, and a second straight line Ls passing through the other end in the left-right direction of the first light emitting element 55 and parallel to the first straight line Lf. Although the description of the drawing is omitted, at least a part of the flow member recess 96 is located between a straight line passing through one end of the second light-emitting element 63 of the second substrate 60 in the direction perpendicular to the direction from the first substrate 50 side toward the second substrate 60 side and parallel to the direction from the first substrate 50 side toward the second substrate 60 side, and another straight line passing through the other end of the second light-emitting element 63 of the second substrate 60 and parallel to the straight line. That is, at least a part of the flow member recess 96 is located between a straight line passing through one end in the left-right direction of the second light emitting element 63 and parallel to the up-down direction and another straight line passing through the other end in the left-right direction of the second light emitting element 63 and parallel to the straight line.
Next, the projection lens 20 will be described.
The projection lens 20 shown in fig. 1 to 4 is a plano-convex lens and is disposed in front of the light source unit LU. The first light and the second light emitted from the light source unit LU enter the projection lens 20 from a flat entrance surface on the rear surface side of the projection lens 20 and pass through the projection lens 20. The projection lens 20 has a flange 21 on the outer periphery. Examples of the material for forming the projection lens 20 include resin and glass.
Next, the lens holder 25 will be explained.
The lens holder 25 shown in fig. 1 to 4 is disposed between the heat sink 80 and the projection lens 20. The projection lens 20 is fixed to the lens holder 25. By fixing the lens holder 25 to the heat sink, the relative positions of the projection lens 20, the lens holder 25, and the heat sink 80 are fixed. As described above, the reflector unit 40, the support plate 30, the first substrate 50, and the second substrate 60 are fixed to the heat sink 80. Therefore, relative positions of the reflector unit 40, the support plate 30, the first substrate 50, the second substrate 60, the projection lens 20, and the lens holder 25 are also fixed.
The lens holder 25 has a cylindrical holding portion 26 and a leg portion 27. The lens holder 25 is formed of, for example, resin, and the holding portion 26 and the leg portion 27 are integrally formed. The holding portion 26 extends from the projection lens 20 side to the heat sink 80 side. A flange 21 of the projection lens 20 is fixed to an end of the holding portion 26 on the projection lens 20 side. The leg portion 27 extends from the end of the holding portion 26 on the heat sink 80 side toward the heat sink 80 side. In the present embodiment, the lens holder 25 has three leg portions 27. The two leg portions 27 are arranged in parallel in the left-right direction, and the other leg portion 27 is arranged above the two parallel leg portions 27. Flange portions 28 are formed at respective ends of the three leg portions 27 on the radiator 80 side, and the flange portions 28 are fixed to the radiator 80 by screws 29.
Of the three legs 27 fixed to the heat sink 80 in this way, the two legs 27 arranged in parallel sandwich the pair of first light-shielding portions 33 of the support plate 30. Further, as described above, since the pair of first light-shielding portions 33 are connected to the fixing portions 32 connected to the ends of the base portion 31 of the support plate 30 in the left-right direction, the pair of first light-shielding portions 33 are arranged in parallel in the left-right direction. Therefore, one first light-shielding portion 33 is positioned between one leg portion 27 of the two juxtaposed leg portions 27 and the projection lens 20, and the other first light-shielding portion 33 is positioned between the other leg portion 27 and the projection lens 20. By providing such a first light shielding portion 33, at least a part of the sunlight that has been transmitted through the projection lens 20 and entered is irradiated on the first light shielding portion 33 without being irradiated on the leg portion 27 of the lens holder 25. Therefore, damage to the lens holder 25 due to sunlight is suppressed.
As described above, the upper wall portion 34a of the second light shielding portion 34 of the support plate 30 is disposed above the connector 64 and extends substantially parallel to the base portion 31. Therefore, the upper wall portion 34a of the second light shielding portion 34 is located between the connector 64 and the projection lens 20. By providing such a second light shielding portion 34, at least a part of the sunlight transmitted through the projection lens 20 and incident thereon is irradiated on the upper wall portion 34a of the second light shielding portion 34 without being irradiated on the connector 64. Therefore, damage of the connector 64 due to sunlight is suppressed. In addition, the connector 64 is less visible through the projection lens 20, and the appearance design of the lamp unit can be improved.
Next, the emission of light from the vehicle headlamp 1 of the present embodiment will be described.
Fig. 19 is a schematic cross-sectional view of the lamp unit, schematically showing an example of an optical path of light emitted from the first light-emitting element and the second light-emitting element. In fig. 19, the radiator 80, the fan 81, and the like are not illustrated. In addition, the angle of each reflecting surface, the reflection angle of light, the refraction angle, and the like may be incorrect. As described above, the vehicle headlamps are symmetrically disposed on the left and right sides of the vehicle. In the following description of the light distribution, the light distribution in the case where the vehicle headlamps provided on the left and right are turned on or off in the same manner will be described.
As shown in fig. 19, a part of the first light L1 emitted from the first light-emitting element 55 is directly incident on the projection lens 20, and the other part of the first light L1 is reflected by one of the first reflection surface 43a of the light shield 43 and the third reflection surface 41r of the reflector 41 and is incident on the projection lens 20. Although the illustration is omitted, a part of the first light L1 emitted from the first light-emitting element 55 and diffused in the left-right direction is reflected by the first side reflector 41a and the second side reflector 41b and enters the projection lens 20. Further, a part of the first light L1 irradiated rearward of the front end 43c of the shade 43 is shielded by the shade 43. In addition, a part of the first light L1 irradiated to the front side wall portion 35d of the third light shielding portion 35 of the support plate 30 is shielded by the front side wall portion 35 d. As described above, the low beam light distribution shown in fig. 20 (a) is formed by the first light L1 emitted from the first light-emitting element 55, incident on the projection lens 20, transmitted therethrough, and emitted through the front cover 12. In fig. 20 (a), S represents a horizontal line.
Further, a part of the second light L2 emitted from the second light emitting element 63 is directly incident on the projection lens 20, and the other part of the second light L2 is reflected by either the second reflecting surface 43b of the light shield 43 or the fourth reflecting surface 42r of the reflector 42 and is incident on the projection lens 20. Although not illustrated, a part of the second light L2 emitted from the second light-emitting element 63 that is diffused in the left-right direction is reflected by the first side reflector 42a and the second side reflector 42b and enters the projection lens 20. In addition, part of the second light L2 that strikes the front side wall portion 35d of the third light-shielding portion 35 of the support plate 30 is shielded by the front side wall portion 35 d. In this way, the light distribution of the second light L2 emitted from the second light emitting element 63, incident on and transmitted through the projection lens 20, and emitted through the front cover 12 is combined with the light distribution of the low beam, thereby forming the light distribution of the high beam shown in fig. 20 (B). In fig. 20 (B), S represents a horizontal line.
Next, cooling of the light source unit LU will be described.
As described above, part of the heat generated when the first light-emitting element 55 emits light is transmitted from the first substrate 50 to the first base plate 82 of the heat sink 80 via the grease 24. Part of the heat generated when the second light-emitting element 63 emits light is transmitted from the second substrate 60 to the second base plate 83 of the heat sink 80 via the grease 24. The grease 24 suppresses formation of air layers between the first substrate 50 and the heat sink 80 and between the second substrate 60 and the heat sink 80, and the thermal conductivity between the two is improved as compared with the case where the grease 24 is not used. Even when an adhesive or bonding agent other than the grease 24 is used as the flow member, the formation of air layers between the first substrate 50 and the heat sink 80 and between the second substrate 60 and the heat sink 80 is suppressed, and the thermal conductivity between the substrates is improved. In this way, air is sent from the fan 81 to the rear surfaces 82b, 83b of the first base plate 82 and the second base plate 83, to which heat is transferred from the first light-emitting element 55 and the second light-emitting element 63. Specifically, as shown in fig. 14, the fan 81 sucks air into the internal space of the peripheral wall portion 84 from the opening 84H of the peripheral wall portion 84, and sends out the sucked air to the front end side of the peripheral wall portion 84. That is, the fan 81 forms an air flow passing through the opening 84H of the peripheral wall portion 84 and flowing from the external space to the internal space of the peripheral wall portion 84. Since the front ends of the peripheral wall portions 84 are partially fixed to the back surfaces 82b, 83b of the first and second base plates 82, 83, the air flows toward the back surfaces 82b, 83b of the first and second base plates 82, 83, and flows through the back surfaces 82b, 83b. Therefore, air is suppressed from being trapped near the rear surfaces 82b and 83b, the first base plate 82 and the second base plate 83 are cooled, and the first light-emitting element 55 and the second light-emitting element 63 are cooled. The air sent by the fan 81 is discharged from at least one of the first air vent 98a and the second air vent 98b.
As described above, the fan 81 is configured to be able to switch the blowing direction to the reverse direction. When the blowing direction of the fan 81 is switched, the fan 81 sucks air on the first base plate 82 and the second base plate 83 side of the fan 81 in the internal space of the peripheral wall portion 84, sends the sucked air to the opening 84H side of the peripheral wall portion 84, and flows out from the opening 84H to the external space of the peripheral wall portion 84. That is, the fan 81 forms air flow that passes through the opening 84H of the peripheral wall portion 84 and flows from the internal space of the peripheral wall portion 84 to the external space. The first air vent 98a and the second air vent 98b are disposed closer to the first base plate 82 and the second base plate 83 than the fan 81. Therefore, air flows into the inner space of the peripheral wall portion 84 from the first ventilation opening 98a and the second ventilation opening 98b, and the air flows toward the fan 81. That is, the air flow direction between the rear surfaces 82b and 83b and the fan 81 is from the front to the rear. The first air vent 98a and the second air vent 98b are disposed on the opposite side of the fan 81 side from the connection portion 99 between the first base plate 82 and the second base plate 83 in the cross section perpendicular to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83. Therefore, the air near the rear surfaces 82b, 83b is sucked by the fan 81, and the air flows through the rear surfaces 82b, 83b. Therefore, air is suppressed from being trapped near the rear surfaces 82b and 83b, the first base plate 82 and the second base plate 83 are cooled, and the first light-emitting element 55 and the second light-emitting element 63 are cooled.
Next, a method for manufacturing the heat sink 80 will be described.
Fig. 21 is a flowchart showing a method of manufacturing the heat sink shown in fig. 4 to 6. Fig. 22 is a schematic cross-sectional view showing a part of the intermediate member, specifically, fig. 22 (a) is a schematic cross-sectional view showing the vicinity of the boss, and fig. 22 (B) is a cross-sectional view showing the vicinity of the protrusion formed on the second base plate. As shown in fig. 21, the method for manufacturing the heat sink 80 of the present embodiment includes a die forming step P1 and a cutting step P2 as main steps.
The mold forming step P1 is a step of forming the intermediate member 80i to be the heat sink 80 by mold forming. As shown in fig. 22, the intermediate member 80i of the present embodiment includes: the first temporary placement surface 86p, the second temporary placement surface 91p, the first temporary contact surface 88sp, and the second temporary contact surface 94sp are different from the heat sink 80 in structure. The first temporary placement surface 86p covers the first placement surface 86, and the second temporary placement surface 91p covers the second placement surface 91. The first temporary abutment surface 88sp covers an abutment surface 88s formed on the boss 88, and the second temporary abutment surface 94sp covers an abutment surface 94s formed on the outer peripheral surface on the upper side of the projection 94.
In the mold forming step P1, the material for forming the heat spreader 80 is melted, and the melted material is pressed into a cavity formed in the mold. The chamber is provided as a space corresponding to the intermediate member 80 i. In the present embodiment, the mold opening direction of the mold is set to a direction substantially parallel to the extending direction of the first rib 87. Since the extending directions of the first rib 87 and the second rib 92 are substantially parallel to each other, the opening direction is substantially parallel to the extending direction of the second rib 92. Next, the molten material filled in the cavity is cooled, and the cooled and solidified intermediate member 80i is taken out from the mold. Examples of the material forming the heat sink 80 include aluminum alloy and the like. In the die forming step P1, there is no particular limitation as long as the intermediate member 80i can be formed by die forming.
The cutting step P2 is a step of cutting a part of the intermediate member 80i formed in the die forming step P1. Specifically, the first temporary mounting surface 86p is cut to form the first mounting surface 86, and the first temporary contact surface 88sp is cut to form the contact surface 88s. Here, a part of the first mounting surface 86 and a part of the contact surface 88s are formed at the same time. Next, the second temporary mounting surface 91p is cut to form the second mounting surface 91, and the second temporary contact surface 94sp is cut to form the contact surface 94s. Here, a part of the second mounting surface 91 and the contact surface 94s are formed at the same time. In this way, the intermediate member 80i is formed with the first placement surface 86, the contact surface 88s, the second placement surface 91, and the contact surface 94s, and the intermediate member 80i serves as the heat sink 80. In the cutting step P2, the second mounting surface 91 and the contact surface 94s may be formed, and then the first mounting surface 86 and the contact surface 88s may be formed.
Further, when a substrate is mounted on a heat sink as in the light source unit of patent document 1, grease may be interposed between the substrate and the heat sink in order to improve the thermal conductivity between the substrate and the heat sink. When the substrate mounted on the heat sink via the grease is fixed to the heat sink in this manner, a part of the grease interposed between the substrate and the heat sink may be pushed out from between the substrate and the heat sink. In this case, when a plurality of substrates are mounted in parallel on one heat sink as in the light source unit described above, excess grease tends to accumulate between adjacent substrates. Therefore, excess grease is likely to adhere to the surface of the substrate opposite to the heat sink side. Since a light-emitting element is mounted on the surface of the substrate opposite to the heat sink side or a circuit is formed, excess grease may adhere to the light-emitting element or the circuit. When excess grease adheres to the light emitting element or the circuit, the optical path of light emitted from the light emitting element changes, and there is a concern that a desired light distribution may not be obtained or a short circuit may occur in the circuit.
Therefore, the light source unit LU according to the present embodiment as the first aspect includes the first substrate 50, the second substrate 60, the heat sink 80, and the grease 24 as the flow member. The first light-emitting element 55 is mounted on the first substrate 50, and the second light-emitting element 63 is mounted on the second substrate 60. The heat sink 80 has a first mounting surface 86 on which at least a part of the first substrate 50 is mounted and a second mounting surface 91 on which at least a part of the second substrate 60 is mounted. The grease 24 is interposed between the first substrate 50 and the first mounting surface 86 and between the second substrate 60 and the second mounting surface 91. The first substrate 50 and the second substrate 60 are mounted on the heat sink 80 with a predetermined gap therebetween. The heat sink 80 has a flow member recess 96 capable of accommodating a part of the grease 24 as a flow member between the edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60.
In the present embodiment as the first aspect, as described above, the heat sink 80 has the flow member recess 96 capable of accommodating a part of the grease 24 between the edge of the first placement surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second placement surface 91 on the first substrate 50 side in the region overlapping the second substrate 60. Therefore, a part of the grease 24 toward the second substrate 60 out of the excess grease 24 pushed out from between the first substrate 50 and the first mounting surface 86 can be accommodated in the flow member recess 96. Further, a part of the grease 24 facing the first substrate 50 out of the excess grease 24 pushed out from between the second substrate 60 and the second mounting surface 91 can be accommodated in the flow member recess 96. Therefore, a part of the excess grease 24 accumulated between the first substrate 50 and the second substrate 60 can be prevented from adhering to the surface of the first substrate 50 opposite to the first mounting surface 86 side and the surface of the second substrate 60 opposite to the second mounting surface 91 side. Therefore, the adhesion of the excess grease 24 to the first light-emitting element 55 mounted on the first substrate 50 and the second light-emitting element 63 mounted on the second substrate 60 can be suppressed. Therefore, the light source unit capable of suppressing the malfunction can be provided.
In the present embodiment as the first aspect, at least a part of the flow member recess 96 is located in a region where the distance between the edge of the first placement surface 86 on the second substrate 60 side in the region overlapping with the first substrate 50 and the edge of the second placement surface 91 on the first substrate 50 side in the region overlapping with the second substrate 60 is the smallest.
The excess grease 24 tends to gradually accumulate from a region where the distance between the edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60 is the smallest. In the light source unit LU, the flow member recess 96 is located in such a region, and therefore, it is possible to appropriately suppress adhesion of a part of the excess grease 24 to the surface of the first substrate 50 opposite to the first mounting surface 86 side and the surface of the second substrate 60 opposite to the second mounting surface 91 side. Therefore, it is possible to appropriately suppress adhesion of a part of the excess grease 24 to the first light-emitting element 55 mounted on the first substrate 50 and the light-emitting element 63 mounted on the second substrate 60.
In the present embodiment as the first aspect, at least a part of the flow member recess 96 is located between a first straight line Lf passing through one end of the first light-emitting element 55 of the first substrate 50 in the direction perpendicular to the direction from the first substrate 50 side toward the second substrate 60 side and parallel to the direction from the first substrate 50 side toward the second substrate 60 side, and a second straight line Ls passing through the other end and parallel to the first straight line Lf.
With this configuration, it is possible to prevent a portion of the excess grease 24 from adhering to the surface of the first substrate 50 opposite to the first mounting surface 86 side, from a portion closer to the first light-emitting element 55 mounted on the first substrate 50, out of the edge of the second substrate 60 side when the first substrate 50 is viewed in plan. Therefore, it is possible to appropriately suppress adhesion of a part of the excess grease 24 to the first light-emitting element 55 mounted on the first substrate 50.
In the present embodiment as the first aspect, at least a part of the flow member recess 96 is located between a straight line passing through one end of the second light-emitting element 63 of the second substrate 60 in the direction perpendicular to the direction from the first substrate 50 side toward the second substrate 60 side and parallel to the direction from the first substrate 50 side toward the second substrate 60 side, and another straight line passing through the other end and parallel to the straight line.
With this configuration, it is possible to prevent a portion of the excess grease 24 from adhering to the surface of the second substrate 60 opposite to the second mounting surface 91 side, from a portion closer to the second light-emitting element 63 mounted on the second substrate 60 among the edges of the first substrate 50 side in a plan view of the second substrate 60. Therefore, it is possible to appropriately suppress adhesion of a part of the excess grease 24 to the second light-emitting element 63 mounted on the second substrate 60.
In the present embodiment as the first aspect, the heat sink 80 includes the outer peripheral surface of the first base plate 82 on the lower side of the base 90 and the front surface 83f of the second base plate 83 on the upper side of the base 95. The two surfaces are located between the edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60. The two surfaces are arranged from the first mounting surface 86 side to the second mounting surface 91 side, and the angle formed by the two surfaces is smaller than 180 degrees. The flow member recess 96 is formed between and connected to the two faces.
In the light source unit LU as the first aspect, as described above, the heat sink 80 has two surfaces arranged from the first mounting surface 86 side toward the second mounting surface 91 side between the edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60. Therefore, a part of the excess grease 24 extending from the first substrate 50 side toward the second substrate 60 side can be pushed out onto the outer peripheral surface on the first mounting surface 86 side, that is, the lower side of the base 90, of the two surfaces. On the other hand, a part of the excess grease 24 extending from the second board 60 side toward the first board 50 side can be pushed out onto the front surface 83f of the second base plate 83 on the second mounting surface 91 side, that is, on the upper side of the base 95, of the two surfaces. In a state where the flow member is positioned on both surfaces having an angle smaller than 180 degrees and the both surfaces are visible from the upper side, the flow member on at least one surface tends to face between the both surfaces, and the flow member is likely to be accumulated between the both surfaces. As a state where both surfaces can be seen from above, for example, a state where both surfaces intersect in a substantially V-shape is given, and fig. 14 shows a state where the heat sink 80 is rotated so that the fan 81 is positioned below the first substrate 50 and the second substrate 60. In the light source unit LU, as described above, the angle formed by the outer peripheral surface of the lower side of the base 90 and the front surface 83f of the second base plate 83 on the upper side of the base 95 is smaller than 180 degrees, and the flow member recess 96 is formed between and connected to both surfaces. Therefore, at least one of the excess grease 24 pushed out to the surface on the first mounting surface 86 side and the excess grease 24 pushed out to the surface on the second mounting surface side is easily directed toward the flow member recess 96. Therefore, the flow member recess 96 can appropriately receive a part of at least one grease 24 of the excess grease 24 from the first substrate 50 side toward the second substrate 60 side and the excess grease 24 from the second substrate 60 side toward the first substrate 50 side. Therefore, the excess grease 24 can be appropriately prevented from adhering to at least one of the first light-emitting element 55 mounted on the first substrate 50 and the second light-emitting element 63 mounted on the second substrate 60.
In addition, in the light source unit including a plurality of substrates as in patent document 2, there is a demand for connecting the substrates to each other by using a flexible printed circuit board having flexibility in place of the lead wires. The flexible printed circuit board may be connected to a surface of the substrate opposite to the mounting member side by solder. Therefore, as in patent document 2, when the flexible printed circuit board is connected between two substrates forming an angle smaller than 180 degrees, a force directed to the opposite side of the substrate tends to act on the connection portion of the flexible printed circuit board with the substrate. In other words, a force for peeling the connection portion from the substrate is easily applied to the connection portion. Therefore, there is a fear that the connection portion between the flexible printed circuit board and the substrate is separated from the substrate, and a connection failure between the substrates occurs.
Therefore, the light source unit LU according to the present embodiment as the second aspect includes: a first substrate 50, a second substrate 60, a heat sink 80, and a flexible printed circuit substrate 70. The first light-emitting element 55 is mounted on the first substrate 50, and the second light-emitting element 63 is mounted on the second substrate 60. The heat sink 80 has a first mounting surface 86 on which at least a part of the first substrate 50 is mounted and a second mounting surface 91 on which at least a part of the second substrate 60 is mounted. The flexible printed circuit board 70 includes a first connection portion 71 connected to a mounting surface 50s of the first substrate 50 on which the first light-emitting element is mounted, and a second connection portion 72 connected to a mounting surface 60s of the second substrate 60 on which the light-emitting element is mounted. The first substrate 50 and the second substrate 60 are mounted on the heat sink 80 with a predetermined gap therebetween, and a normal line of the first mounting surface 86 extending toward the first substrate 50 intersects with a normal line of the second mounting surface 91 extending toward the second substrate 60. The tape portion 73 of the flexible printed circuit board 70 is bent in a convex shape toward the heat sink 80 side between the first substrate 50 and the second substrate 60, and passes through a region on the first mounting surface 86 side of the first connection portion 71.
In the present embodiment as the second aspect, as described above, the normal line extending toward the first substrate 50 of the first mounting surface 86 intersects the normal line extending toward the second substrate 60 of the second mounting surface 91, and therefore the angle formed by the first substrate 50 and the second substrate 60 is smaller than 180 degrees. The flexible printed circuit board 70 is bent in a convex shape toward the heat sink 80 between the first substrate 50 and the second substrate 60, and passes through a region closer to the first mounting surface 86 than the first connection portion 71. Therefore, a force pressing the first substrate 50 side can act on the first connection portion 71. Therefore, the first connection portion 71 can be prevented from being peeled off from the first substrate 50, and the occurrence of a connection failure between the first substrate 50 and the second substrate 60 can be prevented. Therefore, a light source unit in which defects can be suppressed can be obtained.
In the present embodiment as the second aspect, the first substrate 50 is formed with the notch 54 extending from the outer edge of the second substrate 60 side to a predetermined position in a plan view of the first substrate 50, and the tape portion 73 of the flexible printed circuit board 70 passes through the notch 54.
In order to flex the flexible printed circuit board 70, the tape portion 73 of the flexible printed circuit board 70 needs to have a certain length, and thus the first substrate 50 is separated from the second substrate 60 to a certain extent. In the light source unit LU, as described above, the notch 54 extending from the outer edge of the second substrate 60 side to a predetermined position in a plan view of the first substrate 50 is formed in the first substrate 50, and the tape portion 73 of the flexible printed circuit board 70 passes through the notch 54. Therefore, even if the distance between the first substrate 50 and the second substrate 60 is not increased, the belt portion 73 of the flexible printed circuit board 70 can be bent between the first substrate 50 and the second substrate 60. Therefore, as compared with the case where the notch 54 is not formed in the first substrate 50, the distance between the first substrate 50 and the second substrate 60 can be shortened, and the light source unit LU can be downsized.
In the present embodiment as a second aspect, the light-emitting element 55 mounted on the first substrate 50 is disposed closer to the second substrate 60 than the edge of the cutout 54 on the side opposite to the second substrate 60 in a plan view of the first substrate 50.
As described above, when the notch 54 is not formed in the first substrate 50, the first substrate 50 and the second substrate 60 need to be separated from each other to some extent in order to bend the tape portion 73 of the flexible printed circuit board 70. Therefore, the first light-emitting element 55 mounted on the first substrate 50 and the second light-emitting element 63 mounted on the second substrate 60 are also separated to some extent. However, in the light source unit LU, as described above, the first light emitting element 55 mounted on the first substrate 50 is disposed on the second substrate 60 side with respect to the edge of the cutout 54 on the side opposite to the second substrate 60 side in a plan view of the first substrate 50. Therefore, as described above, the distance between the first substrate 50 and the second substrate 60 can be shortened, and the distance between the first light-emitting element 55 and the second light-emitting element 63 can also be shortened, as compared with the case where the notch 54 is not formed in the first substrate 50. Therefore, optical components such as reflectors that reflect light emitted from the two light emitting elements 55 and 63 can be reduced in size.
In the present embodiment as the second aspect, the heat sink 80 has a concave portion 89 that is recessed on the opposite side of the first mounting surface 86 from the flexible printed circuit board 70 between the first substrate 50 and the second substrate 60, and the flexible printed circuit board 70 passes through the concave portion 89.
With this configuration, the amount of flexure of the band portion 73 of the flexible printed circuit board 70 can be increased as compared with the case where the heat sink 80 does not have the concave portion 89. Therefore, the first connection portion 71 can be more appropriately pressed against the first substrate 50 side. Therefore, the first connection portion 71 can be further suppressed from being peeled off from the first substrate 50.
In the present embodiment as the second aspect, the flexible printed circuit board 70 is not in contact with the heat sink 80.
In the present embodiment as the second aspect, the light source unit LU is used for the vehicle headlamp 1, and therefore, the light source unit LU vibrates due to vibration of the vehicle. When the light source unit LU vibrates and the flexible printed circuit board 70 and the heat sink 80 come into contact with each other, the flexible printed circuit board 70 and the heat sink 80 tend to rub against each other. The flexible printed circuit board 70 and the heat sink 80 rub against each other, and thus, there may be a problem that the power supply wiring 74c or the thermistor wiring 75c formed on the flexible printed circuit board 70 is disconnected. In the light source unit LU, since the flexible printed circuit board 70 and the heat sink 80 are not in contact with each other as described above, friction between the flexible printed circuit board 70 and the heat sink 80 due to vibration of the light source unit LU and the like can be suppressed. Therefore, it is possible to suppress a failure such as disconnection of the power supply wiring 74c or the thermistor wiring 75c formed on the flexible printed circuit board 70.
The flexible printed circuit board 70 may be in contact with the heat sink 80. However, from the viewpoint of suppressing the above-described problems, it is preferable that the flexible printed circuit board 70 and the heat sink 80 do not come into contact with each other.
In the present embodiment as the second aspect, the flexible printed circuit board 70 includes the power feeding wiring 74c and the thermistor wiring 75c extending from the first connection portion 71 to the second connection portion 72, and a slit 73s is formed between the power feeding wiring 74c and the thermistor wiring 75c. Therefore, at least a part of the space between the power supply wiring 74c and the thermistor wiring 75c can be spatially separated by the slit 73s. Therefore, even if the wires 74c and 75c move, the occurrence of defects due to short circuits can be reduced, as compared with the case where the slit 73s is not formed between the wires 74c and 75c.
In the present embodiment as the second aspect, two flexible printed circuit boards 70 are provided, and the center of gravity 50G of the first substrate 50 is located between the first connection portions 71 of the two flexible printed circuit boards 70 connected to the first substrate 50. In addition, the center of gravity 60G of the second substrate 60 is located between the second connection portions 72 of the two flexible printed circuit substrates 70 connected to the second substrate 60. Therefore, in a state where the first substrate 50 and the second substrate 60 are connected by the two flexible printed circuit boards 70 and the substrates 50 and 60 are mounted on the heat sink 80, stress generated in the first connection portion 71 and the second connection portion 72 of the two flexible printed circuit boards 70 can be suppressed. Specifically, for example, when the first substrate 50 is suspended from the second substrate 60, the flexible printed circuit board 70 can be prevented from being distorted. Therefore, stress generated in the first connection portion 71 and the second connection portion 72 of the two flexible printed circuit boards 70 can be suppressed. Therefore, in a state before the first substrate 50 and the second substrate 60 are mounted on the heat sink 80, the first connection portion 71 can be prevented from peeling off from the first substrate 50 and the second connection portion 72 can be prevented from peeling off from the second substrate 60. Therefore, as compared with the case where the centers of gravity 50G and 60G of the first substrate 50 and the second substrate 60 are not located between the connection portions 71 and 72 of the two flexible printed circuit boards 70 connected to the substrates 50 and 60, handling of the substrates 50 and 60 is facilitated, and productivity of the light source unit LU is improved. At least one of the first substrate 50 and the second substrate 60 may have a center of gravity 50G, 60G located between the connection portions 71 of the two flexible printed circuit boards 70 connected to the one substrate 50, 60. With such a configuration, in a state before the first substrate 50 and the second substrate 60 are mounted on the heat sink 80, at least one of the first connection portion 71 and the second connection portion 72 can be prevented from being peeled off from the substrates 50 and 60 to which the connection portions 71 and 72 are connected.
In addition, from the viewpoint of productivity of the mounting member, a rib inclined with respect to a normal line of a mounting surface on which the substrate is mounted may be formed in the mounting member. As with the substrate of patent document 3, there is a demand for limiting the position of the substrate with respect to the mounting member using such ribs. When the rib is inserted into the through hole and the substrate is placed on the placement surface, the rib is obliquely inserted into the through hole of the substrate. Therefore, when the position of the substrate relative to the mounting member in the direction in which the rib extends in plan view of the mounting surface is regulated, the outer peripheral surface of the rib on the side inclined relative to the mounting surface abuts against the vicinity of the edge on the side opposite to the mounting surface side of the inner peripheral surface of the substrate defining the through hole 87. On the other hand, the outer peripheral surface of the rib on the side opposite to the side inclined with respect to the mounting surface abuts on the vicinity of the edge of the mounting surface side of the inner peripheral surface of the substrate defining the through hole.
In addition, when the substrate is formed of a metal, a through hole of the substrate may be formed by punching from the viewpoint of productivity or the like. In this case, the inner peripheral surface of the substrate defining the through-hole tends to have irregularities due to burrs in the vicinity of the edge on the mounting surface side or in the vicinity of the edge on the opposite side to the mounting surface side. Therefore, as described above, the rib inserted obliquely into the through hole abuts both the vicinity of the edge on the mounting surface side and the vicinity of the edge on the opposite side to the mounting surface side in the inner peripheral surface of the substrate defining the through hole, and therefore, it may be difficult to limit the position of the substrate with respect to the mounting member within a predetermined range due to the influence of the burr. When the position of the substrate with respect to the mounting member is different from the design value, the position of the light emitting element with respect to an optical member such as a reflector that reflects light emitted from the light emitting element is also different from the design value, and therefore, there is a fear that it is difficult to obtain a desired light distribution.
Therefore, the light source unit LU according to the present embodiment as the third aspect includes: a first substrate 50 on which the first light emitting element 55 is mounted, a second substrate 60 on which the second light emitting element 63 is mounted, and a heat sink 80. A through hole 51 penetrating in the plate thickness direction is formed in the first substrate 50, and a through hole 61 penetrating in the plate thickness direction is formed in the second substrate 60. The heat sink 80 includes: the first mounting surface 86, the second mounting surface 91, the first rib 87, the second rib 92, the contact surfaces 88s, 97s, and the contact surface 94s. At least a part of the first substrate 50 is placed on the first placing surface 86, and at least a part of the second substrate 60 is placed on the second placing surface 91. The first ribs 87 are inserted into the through holes 51 of the first substrate 50 obliquely to the normal line of the first mounting surface 86, and the second ribs 92 are inserted into the through holes 61 of the second substrate 60 obliquely to the normal line of the second mounting surface 91. The contact surface 88s contacts the second contact surface 52s, which is a part of the side surface of the first substrate 50, and the contact surface 97s contacts the third contact surface 53s, which is a part of the side surface of the first substrate 50. The contact surface 94s contacts the second contact surface 62s that is a part of the side surface of the second substrate 60. At least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the first rib 87 in the direction perpendicular to the extending direction of the first rib 87 in a plan view of the first mounting surface 86 abuts against a first abutment surface 51s which is a part of the inner peripheral surface of the first substrate 50 defining the through hole 51. At least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the second rib 92 in a direction perpendicular to the extending direction of the second rib 92 in a plan view of the second mounting surface 91 abuts against the first abutment surface 61s which is a part of the inner peripheral surface of the second substrate 60 defining the through hole 61. A tangent to the third contact surface 53s and the contact surface 88s, which are a part of the side surface of the first substrate 50 in a plan view of the first mounting surface 86, is substantially perpendicular to and non-parallel to the extending direction of the first rib 87. Further, a tangent to the second contact surface 52s and the contact surface 97s of a part of the side surface of the first substrate 50 is substantially perpendicular to and non-parallel to the extending direction of the first rib 87. A tangent to the second contact surface 62s and the contact surface 94s, which are portions of the side surface of the second substrate 60 when the second mounting surface 91 is viewed in plan, is substantially perpendicular to and non-parallel to the extending direction of the second rib 92.
In the present embodiment as the third aspect, as described above, at least one of the outer peripheral surface on one side and the outer peripheral surface on the other side of the first rib 87 in the direction perpendicular to the extending direction of the first rib 87 in a plan view of the first mounting surface 86 abuts against the first abutment surface 51s which is a part of the inner peripheral surface of the first substrate 50 defining the through hole 51. Therefore, the position of the first substrate 50 relative to the heat sink 80 in the direction perpendicular to the direction in which the first ribs 87 extend when the first mounting surface 86 is viewed in plan can be limited to a predetermined range. As described above, the tangent to the third contact surface 53s and the contact surface 88s that contacts the third contact surface 53s when the first placement surface 86 is viewed in plan is not parallel to the extending direction of the first rib 87. Further, a tangent line of the second contact surface 52s and the contact surface 97s that contacts the second contact surface 52s when the first placement surface 86 is viewed in plan is not parallel to the extending direction of the first rib 87. Therefore, the position of the first substrate 50 with respect to the heat sink 80 in the extending direction of the first ribs 87 in a plan view of the first mounting surface 86 can be limited to a predetermined range. Therefore, the position of the first substrate 50 with respect to the heat sink 80 can be restricted within a predetermined range, and the outer peripheral surface of the first rib 87 can be prevented from coming into contact with at least one of the vicinity of the edge on the first mounting surface 86 side and the vicinity of the edge on the opposite side to the first mounting surface 86 side in the inner peripheral surface of the first substrate 50 defining the through hole 51. Therefore, the influence of the irregularities formed in the vicinity of the edge on the first mounting surface 86 side or the vicinity of the edge on the opposite side to the first mounting surface 86 side on the inner peripheral surface of the first substrate 50 defining the through hole 51 can be suppressed. Therefore, the position of the first light-emitting element 55 with respect to the optical component such as the reflector unit 40 that reflects the first light L1 emitted from the first light-emitting element 55 can be limited within a predetermined range. Therefore, a light source unit capable of forming a desired light distribution can be obtained.
As described above, in the direction perpendicular to the extending direction of the second rib 92 when the second mounting surface 91 is viewed in plan, at least one of the outer peripheral surface on one side and the outer peripheral surface on the other side of the second rib 92 abuts against the first abutment surface 61s, which is a part of the inner peripheral surface of the second substrate 60 defining the through hole 61. Therefore, the position of the second substrate 60 relative to the heat sink 80 in the direction perpendicular to the direction in which the second ribs 92 extend when the second mounting surface 91 is viewed in plan can be limited to a predetermined range. As described above, the tangent to the second contact surface 62s and the contact surface 94s that contacts the second contact surface 62s when the second placement surface 91 is viewed in plan is not parallel to the extending direction of the second rib 92. Therefore, the position of the second substrate 60 relative to the heat sink 80 in the extending direction of the second ribs 92 in a plan view of the second mounting surface 91 can be limited to a predetermined range. Therefore, the position of the second substrate 60 with respect to the heat sink 80 can be restricted within a predetermined range, and the outer peripheral surface of the second rib 92 can be prevented from coming into contact with at least one of the vicinity of the edge on the second placement surface 91 side and the vicinity of the edge on the opposite side from the second placement surface 91 side in the inner peripheral surface of the second substrate 60 defining the through hole 61. Therefore, the influence of the irregularities formed in the vicinity of the edge on the second mounting surface 91 side or the vicinity of the edge on the opposite side to the second mounting surface 91 side on the inner peripheral surface of the second substrate 60 defining the through hole 61 can be suppressed. Therefore, the position of the second light emitting element 63 with respect to the optical member such as the reflector unit 40 that reflects the second light L2 emitted from the second light emitting element 63 can be limited to a predetermined range. Therefore, a light source unit capable of forming a desired light distribution can be obtained.
In the present embodiment as the third aspect, the heat sink 80 further has a rib reinforcing portion 93. The rib reinforcing portion 93 is connected to the front surface 83f of the second base plate 83 on which the second ribs 92 are formed and the outer peripheral surface of the second rib 92 on the side inclined with respect to the second mounting surface 91, that is, on the lower side. Therefore, the strength of the second rib 92 is improved as compared with the case without the rib reinforcing portion 93, and breakage and the like of the second rib 92 can be suppressed. Therefore, the second substrate 60 can be prevented from being positionally displaced with respect to the heat sink 80, and the light distribution can be prevented from changing. The rib reinforcement portion 93 is preferably not in contact with the second substrate 60. In this way, the rib reinforcing portion 93 can be prevented from affecting the position regulation of the second substrate 60 with respect to the heat sink 80 by the second rib 92.
In the present embodiment as the third aspect, the heat sink 80 has the projection 94 formed with the abutment surface 94s, and the second rib 92 projects more than the projection 94 in the normal direction of the second placement surface 91. Therefore, the second ribs 92 can be inserted into the through holes 61 of the second substrate 60 before the second substrate 60 abuts on the protrusions 94. Therefore, the position of the second substrate 60 relative to the heat sink 80 can be restricted to some extent by the second ribs 92 inserted into the through holes 61, and the second substrate 60 can be placed on the second placement surface 91 in such a restricted state. Therefore, the second substrate 60 can be easily placed on the second placement surface 91.
In the present embodiment as the third aspect, as described above, the heat sink 80 includes the first mounting surface 86 on which at least a part of the first substrate 50 is mounted and the second mounting surface 91 on which at least a part of the second substrate 60 is mounted, and the first mounting surface 86 and the second mounting surface 91 are not parallel to each other. The second mounting surface 91 is visible from the front end side of the first rib 87 in the extending direction of the first rib 87.
When a heat sink having two mounting surfaces that are not parallel to each other is formed by die molding, the normal line of at least one of the mounting surfaces is not parallel to the die opening direction. Therefore, when the rib is formed on the mounting surface such that the normal line is not parallel to the mold opening direction, the projection tends to be a rib extending in the mold opening direction and inclined with respect to the normal line of the mounting surface from the viewpoint of productivity. Since the second mounting surface can be seen when viewed from the extending direction of the rib, the mounting member can be molded by molding a mold in which the mold opening direction is substantially parallel to the extending direction of the rib. In the present embodiment, as described above, the second mounting surface 91 is visible when viewed from the front end side of the first rib 87 in the extending direction of the first rib 87, that is, from the front, and therefore, the molding can be performed by die molding in which the mold opening direction is set to be substantially parallel to the extending direction of the first rib 87. Therefore, even if the heat sink 80 has the first mounting surface 86 and the second mounting surface 91 which are not parallel to each other, the position of the first substrate 50 with respect to the heat sink 80 can be restricted within a predetermined range by using the first ribs 87 as described above while suppressing a decrease in productivity of the heat sink 80.
The method of manufacturing the heat sink 80 used in the light source unit LU according to the fourth embodiment is a method of manufacturing the heat sink 80 having the first substrate 50 and the second substrate 60 mounted thereon. As described above, the heat sink 80 includes: the first mounting surface 86, the second mounting surface 91, the first rib 87, the second rib 92, the contact surface 88s, and the contact surface 94s. The contact surface 88s is in contact with a part of the side surface of the first substrate 50, and is not parallel to the extending direction of the first rib 87 in a plan view of the first mounting surface 86. The contact surface 94s is in contact with a part of the side surface of the second substrate 60, and is not parallel to the extending direction of the second rib 92 when the second mounting surface 91 is viewed in plan. The present embodiment includes a die forming step P1 and a cutting step P2. The mold forming step P1 is a step of forming the intermediate member 80i by mold forming. The intermediate member 80i has: a first temporary mounting surface 86p covering the first mounting surface 86, a second temporary mounting surface 91p covering the second mounting surface 91, a first temporary contact surface 88sp covering the contact surface 88s, a second temporary contact surface 94sp covering the contact surface 94s formed on the outer peripheral surface on the upper side of the projection 94, the first rib 87, and the second rib 92. In the cutting step P2, the first temporary placement surface 86P is cut to form the first placement surface 86, and the first temporary abutment surface 88sp is cut to form the abutment surface 88s. At this time, a part of the first mounting surface 86 and a part of the contact surface 88s are formed at the same time. Further, the second temporary mounting surface 91p is cut to form the second mounting surface 91, and the second temporary contact surface 94sp is cut to form the contact surface 94s. At this time, a part of the second mounting surface 91 and the contact surface 94s are formed at the same time.
In the present embodiment as the fourth aspect, since the part of the first placement surface 86 and the part of the contact surface 88s are formed simultaneously in the cutting step P2 as described above, productivity of the heat sink 80 can be improved as compared with a case where these surfaces are formed separately. In addition, since the contact surface 94s and a part of the second mounting surface 91 are formed at the same time in the cutting step P2, productivity of the heat sink 80 can be improved as compared with a case where these surfaces are formed separately.
Further, in the case where the light source unit is used in, for example, a vehicle lamp, the light source unit vibrates due to vibration of the vehicle. In the case where the substrate is pressed against the mounting member by a force substantially perpendicular to the mounting surface as in the light source unit of patent document 4, if the light source unit vibrates, the substrate may be displaced along the mounting surface. If the substrate is misaligned with respect to the mounting member, the light emitting element is misaligned with respect to an optical member such as a reflector, and therefore, it may be difficult to obtain a desired light distribution.
Therefore, the light source unit LU according to the fifth embodiment includes: a second substrate 60, a heat sink 80 as a mounting member, and a support plate 30 as a pressing member. The second light-emitting element 63 is mounted on the second substrate 60. The heat sink 80 has a second mounting surface 91 on which at least a part of the second substrate 60 is mounted, and a contact surface 94s that contacts a part of the side surface of the second substrate 60. The support plate 30 contacts the contact portion 31b on the mounting surface 60s of the second board 60 on which the second light-emitting element 63 is mounted, and presses the second board 60 against the second mounting surface 91 and the contact surface 94s.
Therefore, the second substrate 60 is pressed against the second mounting surface 91 and the contact surface 94s by the support plate 30. Therefore, even when the light source unit LU vibrates, the second substrate 60 can be prevented from floating from the second mounting surface 91 or from being displaced along the second mounting surface 91 to the opposite side of the pressing direction with respect to the contact surface 94s. Therefore, the second light emitting element 63 can be prevented from being displaced from the optical member such as the reflector unit 40 that reflects the light emitted from the second light emitting element 63. Therefore, a light source unit capable of forming a desired light distribution can be obtained.
In the present embodiment as the fifth aspect, at least a part of the contact surface 94s of the one protrusion 94 is located between a straight line La parallel to the direction of the force F2 of the support plate 30 pressing the second substrate 60 against the contact surface 94s and passing through one end of the contact portion 31b in the direction perpendicular to the direction and another straight line Lb parallel to the straight line La and passing through the other end of the contact portion 31b when the second substrate 60 is viewed from above. At least a part of the contact surface 94s of the other protrusion 94 is located between a straight line Lc that is parallel to the direction of the force F2 with which the support plate 30 presses the second substrate 60 against the contact surface 94s and passes through one end of the contact portion 31b in the direction perpendicular to the direction, and another straight line Ld that is parallel to the straight line Lc and passes through the other end of the contact portion 31b, in a plan view of the second substrate 60. Therefore, the force F2 with which the support plate 30 presses the second substrate 60 against the contact surfaces 94s becomes two contact surfaces 94s corresponding to the two contact portions 31b of the second substrate 60 that are in contact with the support plate 30, toward the two contact portions 31b. Therefore, the support plate 30 can appropriately press the second board 60 against the two abutment surfaces 94s, and even when the light source unit LU vibrates, the second board 60 can be appropriately prevented from being displaced along the second mounting surface 91 to the side opposite to the pressing direction against the abutment surfaces 94s.
In the present embodiment as the fifth aspect, the second substrate 60 has two contact portions 31b. The center of gravity 60G of the second board 60 is located between a straight line La parallel to the direction of the force F2 with which the support plate 30 presses the second board 60 against the contact surface 94s in a plan view of the second board 60 and passing through the end of the one contact portion 31b on the side opposite to the other contact portion 31b, and another straight line Lc parallel to the straight line La and passing through the end of the other contact portion 31b on the side opposite to the one contact portion 31b. Therefore, the support plate 30 can press the second board 60 against the second mounting surface 91 appropriately, as compared with a case where the center of gravity 60G of the second board 60 is not located between the straight line La and the straight line Lc. Therefore, even when the light source unit LU vibrates, the second substrate 60 can be prevented from floating from the second mounting surface 91. Therefore, the positional deviation of the second substrate 60 with respect to the heat sink 80 can be suppressed.
In the present embodiment as the fifth aspect, the second substrate 60 has two contact portions 31b. At least a part of the contact surface 94s is located between a straight line La parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s when the second substrate 60 is viewed in plan and passing through the end of the one contact portion 31b opposite to the other contact portion 31b side, and another straight line Lc parallel to the straight line La and passing through the end of the other contact portion 31b opposite to the one contact portion 31b side. Therefore, the support plate 30 can appropriately press the second substrate 60 against the abutment surface 94s, compared to the case where the abutment surface 94s is located on the opposite side of the straight line Lc with respect to the straight line La or on the opposite side of the straight line La with respect to the straight line Lc in a plan view of the second substrate. Therefore, even when the light source unit LU vibrates, the second substrate 60 can be appropriately prevented from being displaced along the second mounting surface 91 in the direction opposite to the pressing direction with respect to the contact surface 94s.
In the present embodiment as the fifth aspect, the support plate 30 has elasticity, and the second substrate 60 is pressed against the second mounting surface 91 and the contact surface 94s by the elastic force F of the support plate 30. Therefore, even if the contact surface 94s is separated from a part of the side surface of the second substrate 60 by vibration of the light source unit LU or the like, the contact surface 94s can be brought into contact with a part of the side surface of the second substrate 60 by the elastic force F of the support plate 30. That is, even if the second substrate 60 is displaced along the second mounting surface 91 to the opposite side of the pressing direction with respect to the contact surface 94s due to vibration of the light source unit LU or the like, the second substrate 60 can be moved to substantially the same position as before the displacement.
In addition, in some vehicle headlamps represented by automotive headlamps, a light source unit for illuminating a low beam in front of the headlamps at night and a light source unit for illuminating a high beam farther than the low beam are mounted. In the lamp having two light source units as described above, there is a demand for integrating the two light source units in an aligned state from the viewpoint of reduction in the number of components, downsizing, and the like. In response to this demand, for example, it is conceivable that two substrates on which light-emitting elements are respectively mounted are placed on the same placement surface of one heat sink, and that the two substrates and the light-emitting elements respectively mounted on the two substrates are cooled by the one heat sink.
However, when such a heat sink is mounted on two substrates, heat tends to accumulate in a region between the two substrates of the heat sink. Therefore, heat transferred from the two substrates to the heat sink is difficult to disperse to the entire heat sink, and the heat sink is locally overheated, and thus the two substrates and the light emitting elements mounted on the two substrates cannot be efficiently cooled. As a measure for suppressing such overheating of the heat sink, it is conceivable to mount the two substrates separately from each other on the heat sink. However, in this case, the heat sink may become large, and the light source unit and the lamp provided with the light source unit may become large.
Therefore, the light source unit LU according to the sixth embodiment includes: a first substrate 50 on which the first light emitting element 55 is mounted, a second substrate 60 on which the second light emitting element 63 is mounted, and a heat sink 80 having a first mounting surface 86 on which at least a part of the first substrate 50 is mounted and a second mounting surface 91 on which at least a part of the second substrate 60 is mounted. The first substrate 50 and the second substrate 60 are mounted on the heat sink 80 with a predetermined gap therebetween, and a normal line of the first mounting surface 86 extending toward the first substrate 50 intersects with a normal line of the second mounting surface 91 extending toward the second substrate 60.
Therefore, the distance between the first light-emitting element 55 mounted on the first substrate 50 and the second light-emitting element 63 mounted on the second substrate 60 can be shortened as compared with the case where the first mounting surface 86 and the second mounting surface 91 are located on the same plane. In addition, the distance between the first light emitting element 55 and the second light emitting element 63 along the surface of the heat sink 80 can be made longer. Therefore, the heat generated in the first light-emitting element 55 and the second light-emitting element 63 can be more appropriately dispersed in the heat sink 80. Therefore, overheating of the region between the first light emitting element 55 and the second light emitting element 63 of the heat sink 80 can be suppressed. In addition, compared to the case where the first mounting surface 86 and the second mounting surface 91 are located on the same plane, the distance between the first light emitting element 55 and the second light emitting element 63 can be shortened, and the size can be reduced. Therefore, the light source unit can be miniaturized while suppressing overheating of the heat sink 80.
In the present embodiment as the sixth aspect, the light source unit LU includes the fan 81. The heat sink 80 includes: a first base plate 82 having a first mounting surface 86 formed on a front surface 82 f; the second base plate 83 has a second mounting surface 91 formed on the front surface 83f. The outer edge of the lower side of the first base plate 82 and the outer edge of the upper side of the second base plate 83 are connected to each other. The fan 81 forms air circulation at the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83.
Therefore, the fan 81 can suppress air from being trapped near the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83, and the first base plate 82 and the second base plate 83 can be cooled compared to the case where the fan 81 is not provided. The first mounting surface 86 is formed on the front surface 82f of the first base plate 82 as a plate member, and the second mounting surface 91 is formed on the front surface 83f of the second base plate 83 as a plate member. Therefore, the back surface 82b of the first base plate 82 is inclined with respect to the back surface 83b of the second base plate 83, and the angle formed by the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83 is larger than 180 degrees. Therefore, the two back surfaces 82b, 83b are less likely to become resistance to air flow than when the two back surfaces 82b, 83b are both surfaces perpendicular to the direction of air flow between the back surfaces 82b, 83b and the fan 81, or when the angle formed by the two back surfaces 82b, 83b is smaller than 180. Therefore, the air flow velocity near the two back surfaces 82b, 83b can be suppressed from slowing down. Therefore, the first floor 82 and the second floor 83 can be cooled more appropriately by the fan 81.
In the present embodiment as a sixth aspect, the heat sink 80 includes: the tubular peripheral wall portion 84 of which the distal ends are partially fixed to the first base plate 82 and the second base plate 83, and the first ventilation opening 98a and the second ventilation opening 98b that communicate the internal space and the external space of the peripheral wall portion 84. The fan 81 forms air circulation through an opening 84H at the rear end of the peripheral wall portion 84. The first air vent 98a and the second air vent 98b are disposed on the side opposite to the fan 81 side with respect to the connecting portion 99 between the first base plate 82 and the second base plate 83, in a cross section perpendicular to the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83.
Here, the air flow passing through the opening 84H of the peripheral wall portion 84 includes: the air flowing from the external space of the peripheral wall 84 to the internal space through the opening 84H flows, and the air flowing from the internal space of the peripheral wall to the external space through the opening 84H flows. When the fan 81 forms air flowing from the external space to the internal space of the peripheral wall portion 84 through the opening 84H of the peripheral wall portion 84, a part of the air flowing into the internal space of the peripheral wall portion 84 from the opening 84H passes through the internal space of the peripheral wall portion 84 and faces the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83. Then, a part of the air flows out to the outside space of the peripheral wall portion 84 through the first ventilation opening 98a and the second ventilation opening 98b. The peripheral wall portion 84 suppresses the diffusion of air toward the rear surfaces 82b, 83b of the first and second base plates 82, 83 by the fan 81, as compared with the case where the peripheral wall portion 84 is not provided. Therefore, the amount of air flowing toward the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83 can be increased, and the first base plate 82 and the second base plate 83 can be cooled more appropriately. As described above, the first air vent 98a and the second air vent 98b are disposed on the side opposite to the fan 81 side with respect to the connecting portion 99 between the first base plate 82 and the second base plate 83 in the cross section perpendicular to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83. Therefore, air can be suppressed from being trapped near the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83, and the first base plate 82 and the second base plate 83 can be cooled more appropriately.
On the other hand, when the fan 81 forms air flow that flows from the internal space of the peripheral wall portion 84 to the external space through the opening 84H of the peripheral wall portion 84, air flows into the internal space of the peripheral wall portion 84 from the first ventilation opening 98a and the second ventilation opening 98b. A part of the air flowing in from the first ventilation opening 98a and the second ventilation opening 98b passes through the internal space of the peripheral wall portion 84 and flows out from the opening 84H of the peripheral wall portion 84 to the external space of the peripheral wall portion 84. As described above, the first air vent 98a and the second air vent 98b are disposed on the side opposite to the fan 81 side with respect to the connecting portion 99 between the first base plate 82 and the second base plate 83 in the cross section perpendicular to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83. Therefore, a part of the air flowing in from the first ventilation opening 98a and the second ventilation opening 98b passes through the vicinity of the back surfaces 82b, 83b of the first base plate 82 and the second base plate 83 toward the opening 84H of the peripheral wall portion 84. That is, the air near these back surfaces 82b, 83b is sucked by the fan 81. Therefore, the fan 81 can suck the air near the back surfaces 82b, 83b more than in the case where the peripheral wall portion 84 is not provided. Therefore, air can be suppressed from being trapped near the rear surfaces 82b and 83b, and the first base plate 82 and the second base plate 83 can be cooled more appropriately.
In the present embodiment as the sixth aspect, the peripheral wall portion 84 surrounds the outer periphery of the fan 81. Therefore, when the fan 81 forms air flow that flows from the space outside the peripheral wall portion 84 to the space inside the peripheral wall portion 84 through the opening 84H of the peripheral wall portion 84, the amount of air flowing toward the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83 can be increased as compared with the case where the peripheral wall portion 84 does not surround the outer periphery of the fan 81. On the other hand, when the fan 81 forms air flowing from the internal space of the peripheral wall portion 84 to the external space through the opening 84H of the peripheral wall portion 84, the fan 81 can suck a large amount of air near the rear surfaces 82b, 83b of the first base plate 82 and the second base plate 83, as compared with a case where the peripheral wall portion 84 does not surround the outer periphery of the fan 81. Therefore, the first base plate 82 and the second base plate 83 can be cooled more appropriately.
In the present embodiment as the sixth aspect, a part of the first substrate 50 overlaps the first ventilation opening 98a in the opening direction of the first ventilation opening 98 a. In addition, a part of the second substrate 60 overlaps the second ventilation opening 98b in the opening direction of the second ventilation opening 98b. Therefore, when the fan 81 forms air flowing from the external space to the internal space of the peripheral wall portion 84 through the opening 84H of the peripheral wall portion 84, a part of the air flowing out of the first air vent 98a can be directed to the first substrate 50, and a part of the air flowing out of the second air vent 98b can be directed to the second substrate 60. Therefore, the first substrate 50 and the second substrate 60 can be cooled by the heat sink 80 and also directly cooled by the air flowing out from the first air vent 98a and the second air vent 98b. On the other hand, when the fan 81 forms air flowing from the internal space of the peripheral wall portion 84 to the external space through the opening 84H of the peripheral wall portion 84, a part of the air flowing from the first vent hole 98a into the internal space of the peripheral wall portion 84 can be made to flow along the first substrate 50. In addition, a part of the air flowing into the internal space of the peripheral wall portion 84 from the second ventilation port 98b can be made to flow along the second substrate 60. Therefore, the first substrate 50 and the second substrate 60 can be cooled by the heat sink 80 and also directly cooled by the air flowing into the inner space of the peripheral wall portion 84 through the first air vent 98a and the second air vent 98b. Therefore, the first substrate 50 and the second substrate 60 can be cooled more appropriately.
In the present embodiment as the sixth aspect, the heat sink 80 includes a plurality of flow rectification plates 85 extending from the front end side toward the rear end side of the peripheral wall portion 84 in the internal space of the peripheral wall portion 84. Therefore, the turbulence of the air flow in the internal space of the peripheral wall portion 84 is adjusted. Therefore, when the fan 81 forms air flow that flows from the outside space to the inside space of the peripheral wall portion 84 through the opening 84H of the peripheral wall portion 84, the amount of air flowing toward the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83 can be increased as compared with the case where the heat sink 80 does not have the flow rectification plate 85. On the other hand, when the fan 81 forms air flow from the internal space of the peripheral wall portion 84 to the external space through the opening 84H of the peripheral wall portion 84, the fan 81 can suck a larger amount of air in the vicinity of the rear surfaces 82b, 83b of the first base plate 82 and the second base plate 83, as compared with the case where the radiator 80 does not have the flow rectification plate 85. Therefore, the first base plate 82 and the second base plate 83 can be cooled more appropriately by the air sent from the fan 81.
In the present embodiment as the sixth aspect, the rectifying plate 85 is connected to the first base plate 82 and the second base plate 83. After a part of the heat of the first substrate 50 and the second substrate 60 is transferred to the first base plate 82 and the second base plate 83, the heat is dispersed to a member connected to the first base plate 82 and the second base plate 83, for example, a peripheral wall portion 84. In the present embodiment, as described above, since the rectifying plate 85 is connected to the first base plate 82 and the second base plate 83, heat can be dispersed to the rectifying plate 85, and the first base plate 82 and the second base plate 83 can be cooled more appropriately.
As described above, the rectifying plate 85 extends from the front end side to the rear end side of the peripheral wall portion 84 in the internal space of the peripheral wall portion 84. Therefore, a space sandwiched between the peripheral wall portion 84 and the current plate 85 can be formed in the inner space of the peripheral wall portion 84. Further, since the heat sink 80 includes the plurality of flow rectification plates 85, a space sandwiched by the plurality of flow rectification plates 85 can be formed. In the present embodiment, as described above, the flow rectification plate 85 crosses the first vent 98a when viewed from the opening direction of the first vent 98a, and crosses the second vent 98b when viewed from the opening direction of the second vent 98b. Therefore, the spaces that can be formed in the inner space of the peripheral wall portion 84 are all communicated with the first ventilation opening 98a and the second ventilation opening 98b. Therefore, air can be prevented from being accumulated in the internal space of the peripheral wall portion 84, and the first base plate 82 and the second base plate 83 can be cooled more appropriately.
In the present embodiment as the sixth aspect, at least one of the flow rectification plates 85 has a protruding portion 85a protruding from the second ventilation opening 98b to the outside space of the peripheral wall portion 84. The protruding portion 85a contacts the second substrate 60 overlapping the second ventilation opening 98b when viewed from the opening direction of the second ventilation opening 98b. Therefore, the protruding portion 85a doubles as a part of the second mounting surface 91, and the area of the second mounting surface 91 is increased as compared with a case where it does not doubles as a part of the second mounting surface 91. Therefore, the second substrate 60 can be mounted more stably. Further, as described above, since the flow regulating plate 85 extends in the internal space of the peripheral wall portion 84, the flow regulating plate 85 is cooled by the air flowing through the internal space of the peripheral wall portion 84 by the fan 81. Since the protruding portion 85a of the current plate 85 cooled in this way is in contact with the second substrate 60, the second substrate 60 in contact with the current plate 85 can be cooled more appropriately. Further, since the protrusion 85a of the rectifying plate 85 protrudes from the second ventilation opening 98b to the outside space of the peripheral wall portion 84, the turbulence of the air flow near the second ventilation opening 98b is adjusted by the protrusion 85a. Therefore, the air can be made to flow out more appropriately from the second ventilation opening 98b to the outside space of the peripheral wall portion 84, or to flow into the inside space of the peripheral wall portion 84 from the second ventilation opening 98b. Therefore, the second substrate 60 can be cooled more appropriately.
In the present embodiment as the sixth aspect, the first ventilation opening 98a and the second ventilation opening 98b are formed, and in the cross section perpendicular to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83, the first ventilation opening 98a is disposed closer to the first base plate 82 than the connecting portion 99 of the first base plate 82 and the second base plate 83, and the second ventilation opening 98b is disposed closer to the second base plate 83 than the connecting portion 99 of the first base plate 82 and the second base plate 83. Therefore, when the fan 81 forms the air flow that flows from the external space of the peripheral wall portion 84 to the internal space through the opening 84H of the peripheral wall portion 84, a part of the air on the first base plate 82 side among the air in the vicinity of the first base plate 82 and the second base plate 83 can be made to flow out to the external space of the peripheral wall portion 84 from the first ventilation opening 98a disposed on the first base plate 82 side. Further, a part of the air on the second base plate 83 side can be made to flow out to the outside space of the peripheral wall portion 84 from the second ventilation opening 98b disposed on the second base plate 83 side. Therefore, the air can be more appropriately discharged to the space outside the peripheral wall portion 84, and the first base plate 82 and the second base plate 83 can be more appropriately cooled than in the case where the air vents are provided as the first air vents 98a or the second air vents 98b. On the other hand, when the fan 81 forms air flowing from the internal space of the peripheral wall portion 84 to the external space through the opening 84H of the peripheral wall portion 84, a part of the air flowing from the first ventilation opening 98a into the internal space of the peripheral wall portion 84 can be made to flow along the back surface 82b of the first base plate 82. Further, a part of the air flowing into the internal space of the peripheral wall portion 84 from the second ventilation opening 98b can be made to flow along the back surface 83b of the second base plate 83. Therefore, the air can be appropriately prevented from being trapped near the rear surfaces 82b, 83b of the first and second base plates 82, 83, and the first and second base plates 82, 83 can be cooled more appropriately than in the case where the air vents are provided as the first air vents 98a or the second air vents 98b.
(second embodiment)
Next, a second embodiment of the first aspect of the present invention will be described in detail with reference to fig. 23. The same or equivalent components as those in the first embodiment among the components of the lamp of the present embodiment are denoted by the same reference numerals and redundant description thereof is omitted except for the case of special description.
Fig. 23 is a view showing a light source unit according to a second embodiment of the present invention, as in fig. 14. As shown in fig. 23, the light source unit LU of the present embodiment is different from the light source unit LU of the first embodiment in that the heat sink 80 does not include the first base plate 82, the second base plate 83, the peripheral wall portion 84, the flow regulating plate 85, and the solid point, and does not include the fan 81. The light source unit LU of the present embodiment is also different from the light source unit LU of the first embodiment in that the first mounting surface 86 and the second mounting surface 91 are substantially parallel to each other, and the flow member concave portion 96 includes a first flow member concave portion 96a and a second flow member concave portion 96b. In fig. 23, the support plate 30, the reflector unit 40, the connector 64, and the like are not illustrated.
The heat sink 80 of the present embodiment is formed by filling the internal space of the peripheral wall portion 84 of the first embodiment with the material forming the heat sink 80. The front surface of the heat sink 80 includes a first face 80sa, a second face 80sb, and a third face 80sc. The first surface 80sa is a substantially vertical surface, and the second surface 80sb is a substantially vertical surface and is located below the first surface 80sa and in front of the first placement surface 86. The first surface 80sa and the second surface 80sb are substantially parallel to each other. The third surface 80sc is a substantially horizontal surface and is located between the first surface 80sa and the second surface 80sb. The lower end of the first surface 80sa and the upper end of the second surface 80sb are connected to the third surface 80sc. That is, the first and second faces 80sa and 80sb are connected to each other by the third face 80sc. The first surface 80sa may be inclined with respect to the second surface 80sb. The third surface 80sc is not particularly limited as long as the first surface 80sa and the second surface 80sb are connected.
The first surface 80sa is formed with a base 90 protruding forward. An end surface of the base 90 is substantially parallel to the first surface 80sa, and the end surface is a first mounting surface 86. A base 95 protruding forward is formed on the second surface 80sb. The end surface of the base 95 is substantially parallel to the second surface 80sb, and the end surface is the second mounting surface 91. Therefore, the first mounting surface 86 and the second mounting surface 91 are substantially vertical surfaces, and the first mounting surface 86 and the second mounting surface 91 are substantially parallel to each other. The first mounting surface 86 may be inclined with respect to the second mounting surface 91.
In the present embodiment, as in the first embodiment, the first substrate 50 is placed on the first placement surface 86, and the second substrate 60 is placed on the second placement surface 91. Grease 24 as a flow member is interposed between the first substrate 50 and the first mounting surface 86 and between the second substrate 60 and the second mounting surface 91. The outer edge of the first mounting surface 86 is surrounded by the outer edge of the first substrate 50 when the first mounting surface 86 is viewed in plan. The outer edge of the second mounting surface 91 is surrounded by the outer edge of the second substrate 60 when the second mounting surface 91 is viewed in plan. Therefore, an outer edge 86e of the outer edge of the first mounting surface 86 on the second mounting surface 91 side is an edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50. An outer edge 91e of the outer edge of the second mounting surface 91 on the first mounting surface 86 side is an edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60.
A flow member recess 96 is formed between the edge of the first placement surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second placement surface 91 on the first substrate 50 side in the region overlapping the second substrate 60. The flow member recess 96 includes a first flow member recess 96a and a second flow member recess 96b. The first flow member recess 96a is formed in the first surface 80sa and is recessed on the side opposite to the first substrate 50 side with respect to the first placement surface 86. The second flow member recess 96b is formed in the second surface 80sb, and is recessed on the side opposite to the second substrate 60 side with respect to the second mounting surface 91. Therefore, the first flow member recess 96a is located closer to the first substrate 50 than the second flow member recess 96b, and the second flow member recess 96b is located closer to the second substrate 60 than the first flow member recess 96a. The first flow member recess 96a extends substantially parallel to the outer edge 86e of the first mounting surface 86 on the second mounting surface 91 side by a predetermined length. The second flow member recess 96b extends by a predetermined length in parallel with an outer edge 91e of the outer edge of the second mounting surface 91 on the first mounting surface 86 side. The first flow member recess 96a and the second flow member recess 96b each have a substantially rectangular vertical cross-sectional shape. The vertical cross-sectional shapes of the first flow member concave portion 96a and the second flow member concave portion 96b are not particularly limited.
As described above, in the present embodiment as the first aspect, the heat sink 80 has the first flow member recess 96a and the second flow member recess 96b between the edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60. The first flow member recess 96a is located closer to the first substrate 50 than the second flow member recess 96b, and the second flow member recess 96b is located closer to the second substrate 60 than the first flow member recess 96a. Therefore, a part of the grease 24 toward the second substrate 60 out of the excess grease 24 pushed out from between the first substrate 50 and the first mounting surface 86 can be accommodated in the first flow member recess 96a. Further, a part of the grease 24 facing the first substrate 50 out of the excess grease 24 pushed out from between the second substrate 60 and the second placement surface 91 can be accommodated in the second flow member recess 96b. Further, a part of the excess grease 24 that has passed over the second flow member recess 96b and is directed toward the first substrate 50 side can be accommodated in the first flow member recess 96a. Therefore, it is possible to suppress a part of the excess grease 24 accumulated between the first substrate 50 and the second substrate 60 from adhering to the surface of the first substrate 50 opposite to the first mounting surface 86 side and the surface of the second substrate 60 opposite to the second mounting surface 91 side. Therefore, the excess grease 24 can be prevented from adhering to the light-emitting elements 55 mounted on the first substrate 50 and the light-emitting elements 63 mounted on the second substrate 60.
In addition, in the light source unit LU according to the present embodiment as the first aspect, compared to the case where the flow member recess 96 is formed by one recess, it is possible to suppress the adhesion of a part of the excess grease 24 accumulated between the first board 50 and the second board 60 to the surface of the first board 50 opposite to the first placement surface 86 side or the surface of the second board 60 opposite to the second placement surface 91 side.
The base 95 having the end face as the second mounting surface 91 is formed on the second surface 80sb, the second surface 80sb is positioned below the first surface 80sa and in front of the first mounting surface 86, and the third surface 80sc is positioned between the first surface 80sa and the second surface 80sb. Therefore, the excess grease 24 that has passed over the first flow member recess 96a and is directed toward the second substrate 60 can be prevented from being directed toward the second surface 80sb by the third surface 80sc. Therefore, a part of the excess grease 24 that has passed over the first flow member recess 96a and is directed toward the second substrate 60 can be prevented from adhering to the light-emitting element 63 mounted on the second substrate 60. The second surface 80sb is located forward of the first substrate 50, and a second flow member recess 96b is formed in the second surface 80sb. Therefore, the excess grease 24 can be prevented from flying off from the second surface 80sb and adhering to the surface of the first substrate 50 opposite to the first mounting surface 86 side.
(third embodiment)
Next, a third embodiment as a sixth aspect of the present invention will be described in detail with reference to fig. 24. The same or equivalent components as those in the first embodiment among the components of the lamp of the present embodiment are denoted by the same reference numerals and redundant description thereof is omitted except for the case of special description.
Fig. 24 is a view showing a light source unit according to a third embodiment of the present invention, as in fig. 14. As shown in fig. 24, the light source unit LU of the present embodiment is different from the light source unit LU of the first embodiment in that the first air vent 98a and the second air vent 98b are formed in the peripheral wall portion 84 of the heat sink 80.
The front end of the peripheral wall 84 of the heat sink 80 of the present embodiment is fixed to the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83 over the entire periphery. Specifically, the front outer edge of the upper wall 84b of the peripheral wall 84 is connected to the back surface 82b of the first base plate 82, and the front outer edge of the lower wall 84c is connected to the back surface 83b of the second base plate 83. The first ventilation opening 98a is a through hole penetrating the upper wall 84b in the plate thickness direction, and the second ventilation opening 98b is a through hole penetrating the lower wall 84c in the plate thickness direction. Therefore, the first air vent 98a is disposed closer to the first floor panel 82 than the connection portion 99 between the first floor panel 82 and the second floor panel 83, and the second air vent 98b is disposed closer to the second floor panel 83 than the connection portion 99. Further, a part of the first air vent 98a and a part of the first air vent 98a are located on the opposite side of the fan 81 from the connection portion 99.
In the present embodiment as the sixth aspect, the front end of the peripheral wall portion 84 of the heat sink 80 is fixed to the first base plate 82 and the second base plate 83. However, at least a part of the first air vent 98a and the second air vent 98b is disposed on the side opposite to the fan 81 side with respect to the connecting portion 99 between the first base plate 82 and the second base plate 83 in the cross section perpendicular to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83. Therefore, air can be suppressed from being trapped near the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83, and the first base plate 82 and the second base plate 83 can be cooled more appropriately. The first air vent 98a and the second air vent 98b may be formed in plural numbers, respectively, or may be formed in the side wall 84a. When formed in the side wall 84a, at least a part of the first air vent 98a and the second air vent 98b is preferably disposed on the side opposite to the fan 81 side with respect to the portion of the connecting portion 99 connected to the side wall 84a. With this configuration, air can be prevented from being trapped near the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83.
(fourth embodiment)
Next, a fourth embodiment as a sixth aspect of the present invention will be described in detail with reference to fig. 25. The same or equivalent components as those in the first embodiment among the components of the lamp of the present embodiment are denoted by the same reference numerals and redundant description thereof is omitted except for the case of special description.
Fig. 25 is a view similar to fig. 14 showing a light source unit according to a fourth embodiment of the present invention. As shown in fig. 25, the light source unit LU of the present embodiment is different from the light source unit LU of the first embodiment in that the first base plate 82 is a plate-like body extending obliquely upward and rearward and rightward and leftward. In fig. 25, the rectifying plate 85, the support plate 30, the reflector unit 40, the connector 64, and the like are not described.
The first base plate 82 of the present embodiment is a plate-like body extending obliquely upward and rearward and rightward and leftward. However, as in the first and third embodiments, the normal line of the first mounting surface 86 extending toward the first substrate 50 intersects the normal line of the second mounting surface 91 extending toward the second substrate 60. Therefore, the back surface 82b of the first base plate 82 is inclined with respect to the back surface 83b of the second base plate 83, and the angle formed by the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83 is larger than 180 degrees. Therefore, the rear surfaces 82b and 83b are less likely to cause resistance to the air flow than in the case where the rear surfaces 82b and 83b are both perpendicular to the direction of air flow between the rear surfaces 82b and 83b and the fan 81, or the angle formed by the rear surfaces 82b and 83b is smaller than 180 degrees. Therefore, the air in the vicinity of the back surfaces 82b and 83b can be prevented from slowing down. Therefore, the first floor 82 and the second floor 83 can be cooled more appropriately by the fan 81.
(fifth embodiment)
Next, a fifth embodiment as a sixth aspect of the present invention will be described in detail with reference to fig. 26. The same or equivalent components as those in the first embodiment among the components of the lamp of the present embodiment are denoted by the same reference numerals and redundant description thereof is omitted except for the case of special description.
Fig. 26 is a view similar to fig. 14 showing a light source unit according to a fifth embodiment of the present invention. As shown in fig. 26, the light source unit LU of the present embodiment is different from the light source unit LU of the first embodiment in that the heat sink 80 does not include the first base plate 82, the second base plate 83, the peripheral wall portion 84, the rectifying plate 85, and the solid point, and does not include the fan 81. In fig. 26, the support plate 30, the reflector unit 40, the connector 64, and the like are not illustrated.
The heat sink 80 of the present embodiment is formed by filling the internal space of the peripheral wall portion 84 of the first embodiment with the material forming the heat sink 80. However, a normal line of the first mounting surface 86 of the heat sink 80 extending toward the first substrate intersects with a normal line of the second mounting surface 91 extending toward the second substrate 60. Therefore, as in the first embodiment, the distance between the first light-emitting element 55 mounted on the first substrate 50 and the second light-emitting element 63 mounted on the second substrate 60 can be shortened as compared with the case where the first mounting surface 86 and the second mounting surface 91 are located on the same plane. In addition, the distance between the first light emitting element 55 and the second light emitting element 63 along the surface of the heat sink 80 can be made longer. Therefore, the heat generated in the first light-emitting element 55 and the second light-emitting element 63 can be more appropriately dispersed into the heat sink 80. Therefore, the region between the first light emitting element 55 and the second light emitting element 63 of the heat sink 80 can be suppressed from being overheated. In addition, compared to the case where the first mounting surface 86 and the second mounting surface 91 are located on the same plane, the distance between the first light emitting element 55 and the second light emitting element 63 can be shortened, and the size can be reduced.
Although the first to sixth aspects of the present invention have been described above by taking the embodiments as examples, the first to sixth aspects of the present invention are not limited to these.
For example, in the first embodiment, the first substrate 50 fixed to the heat sink 80 by being pressed against the first mounting surface 86 of the heat sink 80 by the reflector unit 40 has been described as an example. However, the first substrate 50 may be fixed to the heat sink 80, and for example, the first substrate 50 may be fixed to the heat sink 80 by screws or the like.
In the first embodiment, the second substrate 60 fixed to the heat sink 80 by the support plate 30 being pressed against the second mounting surface 91 of the heat sink 80 has been described as an example. However, the second substrate 60 may be fixed to the heat sink 80, and for example, the second substrate 60 may be fixed to the heat sink 80 with screws or the like, in addition to the case of the light source unit according to the fifth aspect.
In the first embodiment, the position of the first substrate 50 with respect to the heat sink 80 is limited to be within a predetermined range by using the through hole 51 and the side surface of the first substrate 50, and the first rib 87, the two bosses 88, and the two protrusions 97 of the heat sink 80. However, the position of the first substrate 50 with respect to the heat sink 80 is not particularly limited. In the first embodiment, the position of the second substrate 60 with respect to the heat sink 80 is restricted to fall within a predetermined range by using the through hole 61 and the side surface of the second substrate 60, and the second rib 92 and the two protrusions 94 of the heat sink 80. However, the position of the second substrate 60 with respect to the heat sink 80 is not particularly limited.
In the first embodiment, the first substrate 50 on which the plurality of first light-emitting elements 55 and the thermistor 56 are mounted and the second substrate 60 on which the plurality of second light-emitting elements 63 and the connector 64 are mounted have been described as an example. However, the first substrate 50 and the second substrate 60 may be provided with at least one light emitting element. In the first embodiment, the first substrate 50 and the second substrate 60 are connected by the flexible printed circuit board 70. However, in addition to the case of the light source unit according to the second aspect, the first substrate 50 and the second substrate 60 may not be connected by the flexible printed circuit board 70. In this case, for example, a connector may be mounted on the first substrate 50, and power may be supplied to the first light-emitting element 55 through the connector.
In the first embodiment, the first light-emitting element 55 is located on the second substrate 60 side of the first substrate 50 with respect to the first substrate 50 side. The second light-emitting element 63 is positioned on the second substrate 60 side closer to the first substrate 50 than the second substrate 60 side. However, the position of the first light-emitting element 55 with respect to the first substrate 50 and the position of the second light-emitting element 63 with respect to the second substrate 60 are not particularly limited. In addition, as in the first embodiment, when the first light-emitting element 55 is positioned on the second substrate 60 side of the first substrate 50 with respect to the first substrate 50 side, a part of the excess grease 24 accumulated between the first substrate 50 and the second substrate 60 is likely to adhere to the first light-emitting element 55. When the second light-emitting element 63 is positioned on the second substrate 60 side of the first substrate 50 with respect to the second substrate 60 side, a part of the excess grease 24 accumulated between the first substrate 50 and the second substrate 60 is likely to adhere to the first light-emitting element 55. Therefore, the first and second embodiments are useful when the light-emitting element of at least one of the first substrate 50 and the second substrate 60 is located on the other substrate side of the one substrate on which the light-emitting element is mounted.
In the first embodiment, the angle formed by the first mounting surface 86 and the second mounting surface 91 is smaller than 180 degrees, and in the second embodiment, the first mounting surface 86 and the second mounting surface 91 are substantially parallel to each other. However, the angle formed by the first mounting surface 86 and the second mounting surface 91 may be larger than 180 degrees. When the angle formed by the first mounting surface 86 and the second mounting surface 91 is smaller than 180 degrees as described above in the first embodiment, excess grease 24 is likely to accumulate between the first mounting surface 86 and the second mounting surface 91, that is, between the first substrate 50 and the second substrate 60. Therefore, the first and second embodiments are useful when the angle formed by the first mounting surface 86 and the second mounting surface 91 is smaller than 180 degrees.
In the present embodiment, a part of the flow member recess 96 is located between a first straight line Lf passing through one end of the first light-emitting element 55 of the first substrate 50 in the direction perpendicular to the direction from the first substrate 50 side toward the second substrate 60 side and parallel to the direction from the first substrate 50 side toward the second substrate 60 side, and a second straight line Ls passing through the other end of the first light-emitting element 55 of the first substrate 50 and parallel to the first straight line Lf. Further, a part of the flow member recess 96 is positioned between a straight line passing through one end of the second light emitting element 63 of the second substrate 60 in the direction perpendicular to the direction from the first substrate 50 side toward the second substrate 60 side and parallel to the direction from the first substrate 50 side toward the second substrate 60 side, and another straight line passing through the other end of the second light emitting element 63 of the second substrate 60 and parallel to the straight line. However, the flow member recess 96 is not particularly limited as long as it is positioned between the edge of the first placement surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second placement surface 91 on the first substrate 50 side in the region overlapping the second substrate 60. In view of suppressing the adhesion of the remaining flow member to the light emitting element, it is preferable that a part of the flow member recess 96 is located between a first straight line passing through one end of the light emitting elements 55 and 63 of at least one of the first substrate 50 and the second substrate 60 in a direction perpendicular to a direction from the first substrate 50 side toward the second substrate 60 side and parallel to a direction from the first substrate 50 side toward the second substrate 60 side, and a second straight line passing through the other end and parallel to the first straight line.
In the above embodiment, a part of the first substrate 50 is placed on the first placing surface 86, and a part of the second substrate 60 is placed on the second placing surface 91. However, the heat sink 80 is not particularly limited as long as it has a first mounting surface on which at least a part of the first substrate 50 is mounted and a second mounting surface on which at least a part of the second substrate 60 is mounted, except for the light source unit according to the third aspect, the method for manufacturing the mounting member according to the fourth aspect, and the light source unit according to the fifth aspect. For example, the entire first substrate 50 may be mounted on the first mounting surface. The heat sink 80 may further include a substrate different from the first substrate 50 and the second substrate 60. The heat sink 80 is not particularly limited as long as it can mount a substrate. For example, the heat sink 80 may be a member having no function of cooling the mounted substrate, for example, a plate member made of only resin.
In the first embodiment, the flexible printed circuit board 70 is described as an example, which passes through the area on the first mounting surface 86 side of the first connection portion 71 between the first substrate 50 and the second substrate 60. However, the flexible printed circuit board 70 may pass through at least one of the region on the first mounting surface 86 side with respect to the first connection portion 71 and the region on the second mounting surface 91 side with respect to the second connection portion 72. For example, the flexible printed circuit board 70 may pass through a region on the first mounting surface 86 side of the first connection portion 71 and a region on the second mounting surface 91 side of the second connection portion 72.
In the first embodiment, the first substrate 50 is provided with the notch 54 extending from the outer edge of the second substrate 60 side to a predetermined position in a plan view of the first substrate 50. However, a notch extending from the outer edge of the other substrate side to a predetermined position in a plan view of the one substrate may be formed in at least one of the first substrate 50 and the second substrate 60, and the flexible printed circuit board 70 may pass through the notch. For example, such a notch may be formed in the second substrate 60.
In the first embodiment, the heat sink 80 has the concave portion 89 between the first substrate 50 and the second substrate 60, which is recessed toward the opposite side of the first mounting surface 86 from the flexible printed circuit board 70. However, the heat sink 80 may have a recess between the first substrate 50 and the second substrate 60, the recess being recessed on the opposite side of the flexible printed circuit board 70 side with respect to at least one of the first mounting surface 86 and the second mounting surface 91. For example, the heat sink 80 may have a concave portion between the first substrate 50 and the second substrate 60, the concave portion being recessed toward the side opposite to the flexible printed circuit board 70 side with respect to the second mounting surface 91.
In the first embodiment, the light source unit LU provided with two flexible printed circuit boards 70 is described as an example. However, the number of the flexible printed circuit boards 70 included in the light source unit LU is not particularly limited.
In the first embodiment, the flexible printed circuit board 70 includes the power supply wiring 74c and the thermistor wiring 75c extending from the first connection portion 71 to the second connection portion 72. However, the wirings of the flexible printed circuit board 70 are not limited to the power supply wiring 74c and the thermistor wiring 75c. For example, the flexible printed circuit board 70 may have another wiring extending from the first connection portion 71 to the second connection portion 72. In the case where the flexible printed circuit board 70 has a plurality of wires extending from the first connection portion 71 to the second connection portion 72, it is preferable to form a slit between the wires adjacent to each other. With this configuration, even if the wiring is moved, it is possible to reduce the occurrence of a defect due to a short circuit, as compared with the case where no slit is formed between the wirings.
In the first embodiment, the angle formed by the first mounting surface 86 and the second mounting surface 91 is smaller than 180 degrees. However, in the case of the light source unit according to the third aspect, the first mounting surface 86 and the second mounting surface 91 may not be parallel to each other, and for example, an angle formed by the first mounting surface 86 and the second mounting surface 91 may be larger than 180 degrees.
In the first embodiment, the first contact surface 51s of the first substrate 50 is a flat surface substantially parallel to the extending direction of the first rib 87 when the first mounting surface 86 is viewed from above. However, the first contact surface 51s may be configured to contact the outer peripheral surface of the first rib 87, and may be curved in a convex shape toward the first rib 87, for example. The first contact surface 61s of the second substrate 60 is a flat surface substantially parallel to the extending direction of the second rib 92 when the second mounting surface 91 is viewed in plan. However, the first contact surface 61s may be capable of contacting the outer peripheral surface of the second rib 92, and may be curved in a convex shape toward the second rib 92, for example.
In the first embodiment, the cross-sectional shape perpendicular to the longitudinal direction of the first rib 87 is circular, and the cross-sectional shape perpendicular to the longitudinal direction of the second rib 92 is circular. However, the cross-sectional shape perpendicular to the longitudinal direction of each of the first rib 87 and the second rib 92 is not particularly limited, and may be, for example, an oval shape.
In the first embodiment, the heat sink 80 having the two contact surfaces 88s, the two contact surfaces 94s, and the two contact surfaces 97s is described as an example. However, the number of these contact surfaces is not particularly limited.
In the first embodiment, the second contact surface 52s of the first substrate 50 and the contact surface 97s of the heat sink 80 face each other in a substantially parallel state. However, a tangent to the second contact surface 52s and the contact surface 97s when the first placement surface 86 is viewed in plan may not be parallel to the extending direction of the first rib 87. For example, the second contact surface 52s may be curved in a convex shape toward the contact surface 97s, and the contact surface 97s may be curved in a convex shape toward the second contact surface 52s.
In the first embodiment, the third contact surface 53s of the first substrate 50 and the contact surface 88s of the heat sink 80 face each other in a substantially parallel state. However, a tangent to the third contact surface 53s and the contact surface 88s when the first placement surface 86 is viewed in plan may not be parallel to the extending direction of the first rib 87. For example, the third contact surface 53s may be curved in a convex shape toward the contact surface 88s, and the contact surface 88s may be curved in a convex shape toward the third contact surface 53s.
In the first embodiment, the second contact surface 62s of the second substrate 60 and the contact surface 94s of the heat sink 80 face each other in a substantially parallel state. However, a tangent line of the second contact surface 62s and the contact surface 94s when the second placement surface 91 is viewed in plan may not be parallel to the extending direction of the second rib 92. For example, the second contact surface 62s may be curved in a convex shape toward the contact surface 94s, and the contact surface 94s may be curved in a convex shape toward the second contact surface 62s.
In the above embodiment, the heat sink 80 on which the first substrate 50 and the second substrate 60 are mounted is described as an example. However, the heat sink 80 may be any heat sink on which at least one substrate is mounted, except for the light source unit of the first aspect, the light source unit of the second aspect, and the light source unit of the sixth aspect. For example, the second substrate 60 may not be mounted on the heat sink 80. The heat sink 80 is not particularly limited as long as it can mount a substrate. For example, the heat sink 80 may be a member having no function of cooling the mounted substrate, for example, a plate member made of only resin.
In the first embodiment of the method for manufacturing a heat sink, the intermediate member 80i has a different configuration from the heat sink 80 at the point having the first temporary placement surface 86p, the second temporary placement surface 91p, the first temporary contact surface 88sp, and the second temporary contact surface 94 sp. However, the intermediate member 80i may further have another temporary contact surface that covers the contact surface 97s of the projection 97. In the case of such a configuration, for example, in the cutting step P2, the other temporary contact surface is also cut to form the contact surface 97s. At this time, a part of the first mounting surface 86 and a part of the contact surface 97s may be formed at the same time.
In the first embodiment, the support plate 30 having the base portion 31, the pair of fixing portions 32, the pair of first light-shielding portions 33, the second light-shielding portion 34, and the third light-shielding portion 35 has been described as an example. However, the support plate 30 is not particularly limited as long as it is in contact with at least the contact portion 31b on the mounting surface 60s of the second substrate 60 on which the second light-emitting element 63 is mounted and presses the second substrate 60 against the second mounting surface 91 and the contact surface 94s. For example, the support plate 30 may not have at least one of the pair of first light-shielding portions 33, the second light-shielding portion 34, and the third light-shielding portion 35. The support plate 30 may be configured such that the second board 60 is pressed against the second mounting surface 91 and the projection 94 from the side opposite to the second mounting surface 91 of the second board 60 by the elastic force of an elastic body such as a spring.
In the first embodiment, the grease 24 as the flow member is interposed between the second substrate 60 and the second mounting surface 91. However, in addition to the case of the light source unit according to the first aspect, no flow member may be interposed between the second substrate 60 and the second mounting surface 91.
In the first embodiment, the two abutting surfaces 94s formed below the two projections 94 are described as an example. However, the contact surface 94s is not particularly limited as long as a part of the side surface of the second substrate 60 is pressed by the support plate 30. For example, the contact surface 94s on which a part of the side surface of the second substrate 60 is pressed by the support plate 30 may be one, three or more, or may not be a plane.
In the first embodiment, the contact surface 94s is located in a direction in which the support plate 30 presses the second substrate 60 against the contact surface 94s, in a plan view of the second substrate 60, in comparison with the contact portion 31b of the second substrate 60. However, the contact surface 94s may be located in a direction opposite to a direction in which the support plate 30 presses the second substrate 60 against the contact surface 94s, compared to the contact portion 31b in a plan view of the second substrate 60.
In the first embodiment, at least a part of the contact surface 94s of the one protrusion 94 is located between the straight line La that is parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s and passes through one end of the contact portion 31b in the direction perpendicular to the direction, and the other straight line Lb that is parallel to the straight line La and passes through the other end of the contact portion 31b, when the second substrate 60 is viewed in plan. At least a part of the contact surface 94s of the other protrusion 94 is located between a straight line Lc that is parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s and passes through one end of the contact portion 31b in the direction perpendicular to the direction, and another straight line Ld that is parallel to the straight line La and passes through the other end of the contact portion 31b, in a plan view of the second substrate 60. However, the abutment surfaces 94s may not be located between the straight lines La and Lc and the straight lines Lb and Ld. For example, as in the first embodiment, when the second substrate 60 has two contact portions 31b, at least a part of the contact surface 94s may be positioned between a straight line Lb parallel to the direction of the force F2 with which the support plate 30 presses the second substrate 60 against the contact surface 94s and passing through the end of one contact portion 31b on the other contact portion 31b side and another straight line Ld parallel to the straight line Lb and passing through the end of the other contact portion 31b on the one contact portion 31b side in a plan view of the second substrate 60. With such a configuration, even if at least a part of the abutment surface 94s is not located between the straight lines La, lc and the straight lines Lb, ld, the support plate 30 can appropriately press the second substrate 60 against the abutment surface 94s.
In the first embodiment, the second substrate 60 has two contact portions 31b, and the center of gravity 60G of the second substrate 60 is located between a straight line La that is parallel to the direction of the force F2 with which the support plate 30 presses the second substrate 60 against the contact surface 94s and passes through the end of the one contact portion 31b on the side opposite to the other contact portion 31b side and another straight line Lc that is parallel to the straight line La and passes through the end of the other contact portion 31b on the side opposite to the one contact portion 31b side in a plan view of the second substrate 60. However, the center of gravity 60G of the second substrate 60 may not be located between the straight line La and the straight line Lc. In the first embodiment, the center of gravity 60G of the second substrate 60 is also located between a straight line Lb that is parallel to the direction of the force F2 with which the support plate 30 presses the second substrate 60 against the contact surface 94s and passes through the end on the other contact portion 31b side of the one contact portion 31b and another straight line Ld that is parallel to the straight line Lb and passes through the end on the one contact portion 31b side of the other contact portion 31b in a plan view of the second substrate 60. Therefore, even when the light source unit LU vibrates, the second substrate 60 can be more appropriately prevented from floating from the second mounting surface 91.
In the first embodiment, the second substrate 60 having the two contact portions 31b is described as an example. However, the number of the contact portions 31b is not particularly limited, and one contact portion 31b may be provided, or three or more contact portions may be provided. When the second board 60 has one contact portion 31b and the heat sink 80 has two contact surfaces 94s, it is preferable that a straight line passing through the contact portion 31b in parallel with the direction of the force F2 in which the support plate 30 presses the second board 60 against the contact surfaces 94s and passing between the two contact surfaces 94s when the second board 60 is viewed in plan. With this configuration, even if at least a part of the contact surface 94s is not located between the straight line La and the straight line Lb, the support plate 30 can appropriately press the second substrate 60 against the contact surface 94s.
In the first embodiment, the peripheral wall portion 84 surrounding the outer periphery of the fan 81 is described as an example. However, the peripheral wall portion 84 may not surround the outer periphery of the fan 81. In this case, for example, the fan 81 is disposed behind the opening 84H at the rear end of the peripheral wall portion 84, and flows air into the internal space of the peripheral wall portion 84 from the opening 84H or flows air out of the external space of the peripheral wall portion 84 from the opening 84H.
In the first embodiment, the rectifying plate 85 having the outer edge on the front side connected to the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83 has been described as an example. However, the rectifying plate 85 may extend from one end side of the peripheral wall portion 84 to the other end side in the inner space of the peripheral wall portion 84. For example, the outer edge of the rectifying plate 85 on the front side may not be connected to the back surface 82b of the first base plate 82 and the back surface 83b of the second base plate 83. The rectifying plate 85 may not have the protrusion 85a protruding from the second ventilation opening 98b to the outside space of the peripheral wall portion 84. The rectifying plate 85 may have another protrusion protruding from the first vent 98a to the space outside the peripheral wall 84 and contacting the first substrate 50. The flow regulating plate 85 may not cross the first ventilation opening 98a when viewed from the opening direction and front of the first ventilation opening 98a, or may not cross the second ventilation opening 98b when viewed from the opening direction and front of the second ventilation opening 98b. The radiator 80 may not have the current plate 85, or may not have the peripheral wall portion 84.
In the first embodiment, the first substrate 50, a part of which overlaps the first ventilation opening 98a in the opening direction of the first ventilation opening 98a, and the second substrate 60, a part of which overlaps the second ventilation opening 98b in the opening direction of the second ventilation opening 98b, have been described as an example. However, the first substrate 50 may not overlap the first ventilation openings 98a in the opening direction of the first ventilation openings 98a, and the second substrate 60 may not overlap the second ventilation openings 98b in the opening direction of the second ventilation openings 98b.
In the first, third, and fourth embodiments, the heat sink 80 has the first air vent 98a and the second air vent 98b. However, in the case where the heat sink 80 has the peripheral wall portion 84, the heat sink 80 may have a vent hole that communicates the internal space and the external space of the peripheral wall portion 84 and is disposed on the side opposite to the fan 81 side with respect to the connecting portion 99 between the first base plate 82 and the second base plate 83. For example, in the fourth embodiment, the heat sink 80 may not have the first air vents 98a, and even with this configuration, air can be suppressed from being trapped near the rear surface 82b of the first base plate 82 and the rear surface 83b of the second base plate 83.
In the first embodiment, the fan 81 can form air flow that flows from the space outside the peripheral wall portion 84 to the internal space through the opening 84H of the peripheral wall portion 84, or air flow that flows from the space inside the peripheral wall portion 84 to the external space through the opening 84H of the peripheral wall portion 84. The fan 81 can switch the flow of the formed air. However, the fan 81 may be configured to be capable of forming at least one of the circulation of air that passes through the opening 84H of the peripheral wall portion 84 and circulates from the external space to the internal space of the peripheral wall portion 84 and the circulation of air that passes through the opening 84H of the peripheral wall portion 84 and circulates from the internal space to the external space of the peripheral wall portion 84.
In the first, third, and fourth embodiments, the light source unit LU includes the fan 81, and the heat sink 80 includes the peripheral wall portion 84. However, the fan 81 may be formed so as to allow air to flow through the rear surfaces 82b, 83b of the first base plate 82 and the second base plate 83, and the heat sink 80 may not have the peripheral wall portion 84.
In addition to the case of the light source unit according to the fifth aspect, the second contact surface 62s of the second substrate 60 and the contact surface 94s of the projection 94 may be in contact with each other at all times. For example, the protrusion 94 may be pressed into the positioning recess 62.
As described above, according to the first and second aspects of the present invention, a light source unit capable of suppressing a failure is provided, according to the third to fifth aspects of the present invention, a light source unit capable of forming a desired light distribution and a method for manufacturing a mounting member for the light source unit are provided, and according to the sixth aspect of the present invention, a light source unit capable of suppressing overheating of a heat sink and being miniaturized is provided, and is applicable to the field of illumination and the like.
Description of the reference numerals
1 … head lamp for vehicle
3 … lamp unit
20 … projection lens
24 … grease (flow component)
25 … lens holder
30 … supporting plate (pressing part)
31 … base
31a … projection
31b … contact part
40 … reflector unit
50 … first substrate
Center of gravity of 50G … first substrate
50s … mounting surface
51 … through hole
51s … first abutting surface
52s … second abutment surface
53s … third abutting surface
54 … slit
55 … first light emitting element (light emitting element)
60 … second substrate
Center of gravity of 60G … second substrate
60s … carrying surface
61 … through hole
61s … first abutment surface
62 … positioning recess
62s … second abutment surface
63 … second light emitting element (light emitting element)
70 … flexible printed circuit board
71 … first connection portion
72 … second connector portion
73 … Belt
74c … power supply wiring (wiring)
75c … thermistor wire (wire)
80 … radiator (carrying parts)
80i … intermediate member
81 … fan
82 … first basesheet
82f … front surface of first basesheet
82b … the back of the first base plate
83 … second baseplate
83f … front surface of second baseplate
83b … the back of the second base plate
84 … peripheral wall portion
84H … opening
85 … rectifying plate
85a … projection
86 … first carrying surface
86p … first temporary mounting surface
87 … first Rib (Rib)
88 … boss
88s … abutting surface
88sp … first temporary abutment surface
89 … recess
91 … second carrying plane
91p … second temporary mounting surface
92 … second Rib
93 … Rib Reinforcement
94 … projection
94s … abutting surface
94sp … second temporary abutment surface
Recess (recess) for 96 … flow member
96a … recess for first flow member (first recess)
96b … recess for second flow member (second recess)
97 … projection
97s … abutting surface
98a … first vent (vent)
98b … second vent (vent)
La, lb, lc, ld … straight line
Lf … first straight line
Ls … second straight line
LU … light source unit

Claims (10)

1. A light source unit is characterized by comprising:
a first substrate and a second substrate on which light emitting elements are mounted, respectively;
a heat sink having a first mounting surface on which at least a part of the first substrate is mounted and a second mounting surface on which at least a part of the second substrate is mounted;
a flexible printed circuit board having a first connection portion connected to a mounting surface of the first substrate on which the light-emitting element is mounted, and a second connection portion connected to a mounting surface of the second substrate on which the light-emitting element is mounted;
the first substrate and the second substrate are mounted on the heat sink with a predetermined interval therebetween,
an angle formed by the first substrate side in an angle formed by the first mounting surface and the second mounting surface is smaller than 180 degrees,
a normal line of the first mounting surface extending toward the first substrate intersects a normal line of the second mounting surface extending toward the second substrate,
the flexible printed circuit board is bent in a convex shape toward the mounting member side between the first substrate and the second substrate and passes through at least one of a region on the first mounting surface side with respect to the first connection portion and a region on the second mounting surface side with respect to the second connection portion.
2. The light source unit according to claim 1,
the utility model is also provided with a fan,
the heat sink has: a first base plate having the first mounting surface formed on one surface thereof; a second base plate having the second mounting surface formed on one surface thereof,
a part of the outer edge of the first base plate and a part of the outer edge of the second base plate are connected to each other,
the fan forms circulation of air on the other surface of the first base plate and the other surface of the second base plate.
3. The light source unit according to claim 2,
the heat sink has: a cylindrical peripheral wall part having at least a part of one end thereof fixed to the first base plate and the second base plate; a vent port that communicates an internal space and an external space of the peripheral wall portion;
the fan forms circulation of air through the opening at the other end of the peripheral wall portion,
at least a part of the ventilation opening is disposed on a side opposite to the fan side with respect to a connecting portion between the first floor panel and the second floor panel in a cross section perpendicular to the other surface of the first floor panel and the other surface of the second floor panel.
4. The light source unit according to claim 3,
the peripheral wall portion surrounds an outer periphery of the fan.
5. The light source unit according to claim 3 or 4,
in the opening direction of the vent, a part of at least one of the first substrate and the second substrate overlaps with the vent.
6. The light source unit according to claim 3 or 4,
the radiator further has at least one flow rectification plate extending from the one end side to the other end side of the peripheral wall portion at least in the inner space of the peripheral wall portion.
7. The light source unit according to claim 6,
the rectifying plate is connected with the first base plate and the second base plate.
8. The light source unit according to claim 6,
the rectifying plate transverses the vent when being observed from the opening direction of the vent.
9. The light source unit according to claim 8,
a part of at least one of the first substrate and the second substrate overlaps the vent in an opening direction of the vent,
at least one of the flow rectification plates has a protruding portion protruding from the vent hole to an outer space of the peripheral wall portion,
the protruding portion is in contact with a substrate that overlaps the vent when viewed from the opening direction of the vent.
10. The light source unit according to claim 3 or 4,
the ventilation openings include a first ventilation opening and a second ventilation opening, and the first ventilation opening is disposed closer to the first base plate side than a connection portion between the first base plate and the second base plate, and the second ventilation opening is disposed closer to the second base plate side than the connection portion between the first base plate and the second base plate, in a cross section perpendicular to the other surface of the first base plate and the other surface of the second base plate.
CN201980017947.4A 2018-03-15 2019-03-11 Light source unit and method for manufacturing mounting member for the same Active CN111819392B (en)

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JP2018-048615 2018-03-15
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JP2018048614 2018-03-15
JP2018-048612 2018-03-15
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