JP5864349B2 - LED bulb - Google Patents

Description

  The present invention relates to an LED bulb, and more particularly, to an LED bulb using an LED as a light source.

  Conventionally, an LED bulb having an LED as a light source has been disclosed, for example, having a structure as shown in FIG. That is, a plurality of leads 90, 91, 92 arranged in a straight line are integrated by a light transmissive first resin 93 to form an elongated rod-shaped package 94, and the package 94 includes a plurality of leads 90, A light emitting element 95 fixed to any one of 91 and 92 with an adhesive material, and a bonding wire 105 for electrically connecting the electrode of the light emitting element 95 to one of the plurality of leads 90, 91, and 92. The light emitting device 97 is formed by sealing all the light emitting elements 96 and all the bonding wires 105 with a light transmissive second resin 96.

  As shown in FIG. 13, the LED bulb 102 has a control board (not shown) built in a base 99 that hermetically seals the glass cover 98, and is used for control in the airtight inner space 100 of the glass cover 98. Six light emitting devices 97 are connected in series to a pair of power supply leads 103 extending from the substrate, and the filament portions 101 are formed in a zigzag manner so that adjacent light emitting devices 97 form a V shape. .

  In this case, the light-emitting device 97 functions as a light guide because both the first resin 93 and the second resin 96 have light transmissivity, and light extraction from the back surface is increased to achieve wide directivity. To do. As a result, the filament portion 101 exhibits a light emission form similar to that of a filament of a general incandescent bulb (see Patent Document 1).

  Further, as shown in FIG. 14, an LED chain 82 is formed by chaining a plurality of LED lamps 80 by a flexible member 81, and stems 84 constituting the light bulb body 83 are formed at both ends of the LED chain 82. Similarly, there is also disclosed an LED bulb connected to two internal lead-in wires 87 extending into a hollow body 86 of a glass bulb 85 constituting the bulb body 83 (see Patent Document 2).

JP 2009-170759 A Utility model registration No. 3075689

  By the way, in the LED bulb of Patent Document 1, heat generated when the light emitting element 95 is turned on is dissipated only through the pair of power supply leads 103. In the LED bulb of Patent Document 2, when the LED lamp 80 is turned on. Heat generation is dissipated only via the two internal lead wires 87.

  For this reason, none of the LED bulbs can obtain a sufficient heat dissipation effect against the heat generated when the light source is turned on, and a desired amount of irradiation light cannot be secured due to a decrease in the light emission efficiency of the light source due to a temperature rise. At the same time, the reliability is impaired by shortening the light source life due to the temperature rise.

  In order to solve this heat dissipation problem, it is conceivable to provide heat dissipation means such as a heat sink in the LED bulb, but in that case, by providing the heat dissipation means, the arrangement of the light sources is biased or the emitted light from the light sources is blocked. Therefore, it is difficult to obtain desired light distribution characteristics and to realize optical characteristics equivalent to those of conventional incandescent bulbs.

  Therefore, the present invention was devised in view of the above problems, and the object thereof is to have a sufficient heat dissipation effect against the heat generated when the light source is turned on and to have a light distribution characteristic equivalent to that of a conventional incandescent bulb. It is providing the LED light bulb which can obtain.

  In order to solve the above-mentioned problem, the invention described in claim 1 of the present invention is such that a glass bulb in which an LED module in which an LED element is mounted inside is hermetically sealed is mounted on a metal base. The LED module is supported and fixed to an introduction line that hermetically penetrates the glass bulb. At the same time, the LED module hermetically penetrates the glass bulb and has a tip abutting against the inner wall of the glass bulb and the glass bulb. The lead-out portion from the valve is also supported and fixed by a linear metal anchor wire joined to the metal base.

  The invention described in claim 2 of the present invention is characterized in that, in claim 1, a gas having high thermal conductivity is sealed in the glass bulb.

  The invention described in claim 3 of the present invention is characterized in that, in claim 2, the gas having high thermal conductivity is nitrogen or helium.

  The LED bulb of the present invention has a glass bulb in which an LED module in which an LED element is mounted in a hermetically sealed interior is mounted on a metal base, an introduction line that hermetically penetrates the LED bulb through the glass bulb, The glass bulb is hermetically penetrated, the tip is in contact with the inner wall of the glass bulb, and the lead-out portion from the glass bulb is supported and fixed by a linear metal anchor wire joined to a metal base.

  This anchor wire contributes to heat radiation of the heat generated when the LED element mounted on the LED module emits light (lights), and has a function of making the support and fixing of the LED module stronger than the case where the support and fixing of the LED module is supported and fixed only by the lead-in wire. .

  As a result, it has lower power consumption than conventional incandescent bulbs, optical characteristics such as light distribution characteristics of irradiated light are equivalent to those of conventional white bulbs, and suppresses temperature rise due to self-heating when LED elements emit light LED lamps with high mechanical reliability against vibrations and shocks can be achieved by shortening the light emission life and reducing the light emission efficiency due to temperature rise and ensuring high reliability and appropriate light intensity It became possible to do.

It is explanatory drawing of a LED element. It is upper surface explanatory drawing of a LED module. It is side surface explanatory drawing of a LED module. It is a perspective explanatory view of a lead terminal. It is explanatory drawing of a flare stem. It is explanatory drawing of integration of an LED module. It is joining explanatory drawing of a lead terminal and an introductory wire. It is accommodation explanatory drawing of the LED module in a glass bulb. It is explanatory drawing of a nozzle | cap | die. It is explanatory drawing of a LED bulb. It is use explanatory drawing of a glass bead. It is explanatory drawing of a prior art example. It is explanatory drawing of a prior art example. It is explanatory drawing of a prior art example.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to FIGS. 1 to 11 (the same parts are given the same reference numerals). The embodiments described below are preferable specific examples of the present invention, and thus various technically preferable limitations are given. However, the scope of the present invention particularly limits the present invention in the following description. Unless stated to the effect, the present invention is not limited to these embodiments.

  1-3 is explanatory drawing regarding the LED module which comprises the LED bulb of this invention. The LED module is a part corresponding to a filament that becomes a light emitting part in a conventional incandescent bulb.

  A plurality of LED elements (LED chips) 2 used as light emitting sources in the LED module are flip-chip (FC) mounting type elements, as shown in FIG. A pair of electrodes 3 (an anode electrode 3a and a cathode electrode 3b) for causing the LED element 2 to emit light are provided on the lower surface 6 side of the upper surface 5 and the lower surface 6 facing each other across the light emitting layer 4 of the LED element 2, From the upper surface 5 and the lower surface 6 of the element 2, the emitted light from the LED element 2 is divided into substantially equal light outputs and emitted to the outside.

  The plurality of LED elements 2 are formed of a transparent member such as glass as shown in FIG. 2 (top view of the LED module) and FIG. 3 (side view of the LED module). On the upper surface of the electrode pattern 8 transparent electrode substrate 8 (hereinafter referred to as “transparent substrate”) 7 in which the electrode pattern 8 is formed in a substantially linear shape, the electrode pattern 8 is placed on each of the adjacent electrode patterns 8. The LED element 2 is flip-chip mounted in a state where the pair of electrodes 3 3a and 3b (see FIG. 1) are positioned.

  At this time, the plurality of LED elements 2 mounted on the transparent substrate 7 are all electrically connected in series via a plurality of independent electrode patterns 8, and are connected between the lead terminal joining electrode patterns 8a and 8b. All LED elements 2 can emit light (light on) by applying a predetermined voltage.

  The electrode pattern 8 formed on the transparent substrate 7 includes a transparent electrode pattern made of a transparent metal material such as ITO or IZO, or a nickel underlayer and a gold plating layer, a gold vapor deposition layer, or a gold sputter layer formed on a metal film such as aluminum. It consists of an opaque conductor pattern made of fine metal wires. Even if the conductor pattern is opaque, it is a thin line, so the conductor pattern hardly affects the optical characteristics, and the reliability such as die shear strength with respect to the transparent substrate 7 is improved as compared with the transparent conductor pattern.

  Lead terminal bonding electrode patterns 8a and 8b are formed at both ends of the transparent substrate 7 on which the plurality of LED elements 2 are mounted. Each end of the transparent electrode 7 is connected to a clip-type lead terminal (hereinafter referred to as “lead”). Lead terminal bonding by joining the lead terminal bonding electrode patterns 8a and 8b and the clip portion 11 with a conductive bonding member such as solder or conductive paste in a state of being held by the clip portion 11 of 9). The electrode patterns 8a, 8b and the lead terminals 9 are electrically joined, and the transparent substrate 7 and the lead terminals 9 are mechanically joined.

  The lead terminal 9 is formed in advance as a lead frame 10 having a shape as shown in FIG. 4 (a perspective view of the lead terminal) by subjecting a rectangular flat spring material to sheet metal processing. As shown in FIG. 4, the lead frame 10 is formed with clip portions 11 at both ends, and the clip portions 11 are connected to each other by extension portions 12 extending from the respective clip portions 11. It has a shape in which a through hole 12a is provided.

  The clip portions 11 are substantially L toward the both end portions in the longitudinal direction of the rectangular flat spring material from the respective distal end portions inward along the longitudinal direction toward the lateral end portions in the short direction at a predetermined position. It has a sandwiching piece 11a in which a character-shaped cut is made and the cut portion is bent toward the tip.

  The lead terminal 9 joined to the transparent substrate 7 is used by cutting a lead frame 10 molded in advance at an appropriate position of the extended portion 12. The lead frame 10 is used not only as a lead terminal 9 but also for other uses such as connection between LED modules described later.

  As described above, the LED module having the above-described structure has a plurality of LED elements that emit substantially uniform light output from the upper surface and the lower surface mounted on the transparent conductive pattern formed on the transparent substrate or the thin-line opaque conductive pattern. . For this reason, the LED module emits light emitted from each LED element in all directions of the LED module, and can form a light distribution characteristic approximately similar to a filament of a conventional general incandescent bulb. it can.

  As a result, by using the LED module as a light source instead of the filament of the conventional incandescent bulb, the light distribution characteristics of the conventional incandescent bulb are secured, and the characteristics of the LED elements such as long life and low power consumption are utilized. An LED bulb can be realized.

  Therefore, a specific structural example of the LED bulb 50 using the LED module will be described based on the manufacturing process shown in FIGS.

  First, as shown in FIG. 5 (explanation of the flare stem), a flare stem 20 is prepared in which 21 pairs of lead-in wires 22a and 22b penetrate airtightly through the flare glass and the exhaust pipe 23 is fused.

  Next, two LED modules 1 are prepared as shown in FIG. 6 (description of integration of LED modules). In this case, one LED module (first LED module) 1a and one other LED module (second LED module) 1b are connected to the lead terminal bonding electrode patterns 8a and 8b having different polarities from each other in the lead frame 10 The lead terminal 9 is cut at an appropriate position of the extending portion 12 and joined, and the lead terminal joining electrode pattern 8b in which the lead terminals 9 of the first LED module 1a and the second LED module 1b are not joined. 8a, a lead frame 10 bent in a substantially inverted V shape is joined to achieve electrical conduction, and the first LED module 1a and the second LED module 1b are substantially inverted V via the lead frame 10. It is integrated into a letter shape.

  The substantially V shape formed by the first LED module 1a and the second LED module 1b corresponds to the C-2V filament shape in a conventional incandescent bulb.

  Thereafter, a linear metal anchor wire 24 is inserted into the through-hole 12 provided in the extended portion 12 of the lead frame 10, and the through-hole 12 is protruded from the through-hole 12 by a predetermined length. The extended portion 12 and the anchor line 24 are joined at the portion. This joining is performed by, for example, solder joining 13 or the like.

  Then, as shown in FIG. 7 (description of joining of lead terminal and lead-in wire), the anchor wire 24 is inserted into the exhaust pipe 23 and joined to the first LED module 1a and the second LED module 1b. The extended portion 12 of the lead terminal 9 is joined and fixed to the pair of lead wires 22a and 22b by spot welding 14 or the like.

  Next, as shown in FIG. 8 (Explanation for housing the LED module in the glass bulb), the flare glass 21 is inserted into the cylindrical portion 25b of the glass bulb 25 having the spherical portion 25a and the cylindrical portion 25b. The first LED module 1a and the second LED module 1b arranged in a substantially V shape are accommodated in the spherical portion 25a and the tip 24b of the anchor wire 24 is in contact with the inner wall 25c of the spherical portion 25a. Thus, the cylindrical portion 25b and the flare glass 21 are heat-sealed and hermetically sealed.

Then, after exhausting the air in the glass bulb 25 through the exhaust pipe 23, similarly, an inert gas or N ₂ gas or He gas having a good thermal conductivity is injected into the glass bulb 25 through the exhaust pipe 23. Later, the exhaust pipe 23 is heated and hermetically sealed. At this time, the anchor wire 24 is led out of the exhaust pipe 23 through the hermetic sealing portion of the exhaust pipe 23 in an airtight manner.

  Next, the flare glass 21 is attached to the metal base 30. As shown in FIG. 9 (description of the base), the base 30 has a cup shape having a bottom and an opening, and the bottom is a substantially flat plate made of, for example, a phenolic resin containing paper fibers or glass fibers. A pair of eyelet portions 32 a and 32 b each having a through hole are provided at the center of the insulator 31.

  Therefore, when the flare glass 21 is attached to the base 30, the flare glass is connected to the first LED module 1a and the second LED module 1b in the bulb 25 as shown in FIG. A pair of lead-in wires 22a and 22b penetrating airtightly 21 and led out of the valve 25 are inserted into through-holes of eyelet portions 32a and 32b provided in the insulator 31 located at the bottom of the base 30. While being joined to the lead frame 10 that mechanically and electrically connects the first LED module 1a and the second LED module 1b within the bulb 25, the tip 24a abuts against the inner wall 25c of the bulb 25. While the anchor wire 24 penetrating the exhaust pipe 23 in an airtight manner and leading out of the valve 25 is brought into contact with the base 30, the flare glass 21 is attached to the base 30. Inserting from the mouth to the mouth gold 30.

  Thereafter, the flare glass 21 is bonded and fixed to the base 30, and the lead wires 22a and 22b are joined to the eyelet portions 32a and 32b with a conductive joining member such as solder to form contact portions 33a and 33b. Further, the anchor wire 24 is joined (not shown) to the metal base 30 via a conductive joining member.

  Thereby, the LED bulb 50 is assembled.

  Therefore, although not shown, when power is supplied from the external power source in a state where the contact portions 33a and 33b of the LED bulb 50 are in contact with a pair of external electrodes connected to the external power source, the contact portions 33a and 33b of the LED bulb 50 are connected. A voltage is applied, and the voltage is applied to the first LED module 1a and the second LED module 1b via the pair of lead-in wires 22a and 22b, and all the LED elements 2 emit light (light on).

When the LED element 2 emits light, heat is also generated. The heat is transferred to an inert gas partially sealed in the glass bulb 25 or an enclosed gas such as N ₂ gas or He gas having a good thermal conductivity, and efficiently passed to the glass bulb 25 via the enclosed gas. The heat transferred and conducted through the glass bulb 25 is dissipated into the atmosphere that touches the glass bulb 25.

  At the same time, part of the heat generated from the LED element 2 moves to the pair of lead wires 22a and 22b through the transparent substrate 7 on which the LED element 2 is mounted, and the contact portion 33a to which the lead wires 22a and 22b are joined. It moves out of the LED bulb 50 through the external electrode in contact with 33b.

  Furthermore, in the LED light bulb of the present invention, the anchor wire 24 contributes to further improvement of heat dissipation in addition to the heat dissipation path of the heat generated from the LED element 2. Specifically, the heat generated from the LED element 2 and moved to the transparent substrate 7 on which the LED element 2 is mounted is conducted through the lead frame 10 connecting the first LED module 1a and the second LED module 1b. Then, the heat moves to the anchor wire 24, and part of the heat moved to the anchor wire 24 moves to the glass bulb 25 where the tip 24b of the anchor wire 24 abuts, and the heat conducted through the glass bulb 25 is the glass bulb. 25 is dissipated in the atmosphere.

  Part of the heat transferred to the anchor wire 24 is transferred to the metal base 30 to which the anchor wire 24 is joined through the anchor wire 24 and is dissipated into the atmosphere that touches the base 30.

  Thus, the LED bulb 50 of the present invention has the structure including the anchor wire 24, and the anchor wire 24 has a function that contributes to the improvement of the heat dissipation effect. As a result, the heat generated from the LED element 2 is efficiently radiated through a plurality of heat transfer paths, the temperature rise due to self-heating during the light emission of the LED element 2 is suppressed, and the light emission lifetime is shortened and the light emission efficiency due to the temperature rise. Is suppressed, and high reliability and an appropriate amount of irradiation light can be secured.

  The anchor wire 24 supports and fixes the first LED module 1a and the second LED module 1b together with the lead-in wires 22a and 22b. By providing the anchor wire 24, the machine of the LED bulb 50 against vibration and impact is provided. It is possible to increase the reliability of the machine.

  The anchor line 24 is located in an inner region surrounded by the first LED module 1a and the second LED module 1b, which are light sources. Therefore, the light emitted from the LED element 2 is outside the glass bulb 25. It does not block the light path until it is emitted, and does not adversely affect the light distribution characteristics of the light emitted from the LED bulb 50.

  In the present embodiment, the first LED module 1a and the second LED module 1b, which are light sources, are arranged in a substantially inverted V shape, but are not necessarily limited to a substantially inverted V shape. The optimum shape and dimensions are appropriately set in consideration of the relationship with the length of the module, the brightness required for the LED bulb, the light distribution characteristics, the power consumption, and the like.

  By the way, it is also possible to make arrangements corresponding to the filament shapes of conventional incandescent bulbs, such as C-6, C-8, and C-2F.

  Further, in the present embodiment, the tip 24b of the anchor wire 24 is in direct contact with the inner wall 25c of the glass bulb 25. However, a glass bead 35 is attached to the tip 24a of the anchor wire 24 and the glass bead 35 and the glass bulb 25 are attached. It is also possible to fuse (see FIG. 11 (Explanation for joining glass bulb and anchor wire using glass beads)).

  As described above, the LED bulb of the present invention has a structure in which an LED module using an LED element as a light source is configured so that light emitted from the LED element is irradiated in all directions of the LED module. The LED module is used as a light source in place of the filament, and an anchor wire joined to the LED module is provided, and the anchor wire contributes to heat radiation when the LED element mounted on the LED module emits light (lights), and the LED The module has a function of strengthening the support and fixing of the module.

  As a result, it consumes less power than conventional incandescent bulbs, and the optical characteristics such as the light distribution characteristics of the irradiated light have the same performance as conventional white bulbs, and the temperature rise due to self-heating during LED light emission is suppressed. LED lamps with high mechanical reliability against vibrations and shocks can be achieved by shortening the light emission life and reducing the light emission efficiency due to temperature rise and ensuring high reliability and appropriate light intensity It becomes possible to do.

DESCRIPTION OF SYMBOLS 1 ... LED module 1a ... 1st LED module 1b ... 2nd LED module 2 ... LED element (LED chip)
DESCRIPTION OF SYMBOLS 3 ... Electrode 3a ... Anode electrode 3b ... Cathode electrode 4 ... Light emitting layer 5 ... Upper surface 6 ... Lower surface 7 ... Transparent substrate (transparent substrate) for LED element mounting
DESCRIPTION OF SYMBOLS 8 ... Electrode pattern 8a ... Electrode pattern for lead terminal joining 8b ... Electrode pattern for lead terminal joining 9 ... Lead terminal 10 ... Lead frame 11 ... Clip part 11a ... Nipping piece 12 ... Extension part 12a ... Through-hole 13 ... Solder joint 14 ... spot welding 20 ... flare stem 21 ... flare glass 22 ... lead wire 22a ... lead wire 22b ... lead wire 23 ... exhaust pipe 24 ... anchor wire 24a ... tip portion 24b ... tip 25 ... glass bulb 25a ... spherical portion 25b ... cylindrical shape Part 25c ... Inner wall 30 ... Base 31 ... Insulator 32 ... Eyelet part 32a ... Eyelet part 32b ... Eyelet part 33 ... Contact part 33a ... Contact part 33b ... Contact part 35 ... Glass bead 50 ... LED bulb

Claims (3)

An LED bulb in which a glass bulb containing an LED module in which an LED element is mounted inside an airtight seal is mounted on a metal base,
The LED module is supported and fixed to an introduction line that hermetically penetrates the glass bulb, and at the same time, hermetically penetrates the glass bulb, the tip portion abuts against the inner wall of the glass bulb, and the lead-out portion from the glass bulb is the An LED bulb characterized by being supported and fixed by a linear metal anchor wire joined to a metal base.   The LED bulb according to claim 1, wherein a gas having high thermal conductivity is sealed in the glass bulb.   The LED bulb according to claim 2, wherein the gas having high thermal conductivity is nitrogen or helium.

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