JP7613835B2 - Light source unit and vehicle lamp - Google Patents

Description

This invention relates to a light source unit in which a light emitting element and a power supply attachment are supported by a metal plate, and to a vehicle lamp equipped with the light source unit.

Conventionally, light source units for vehicle lamps and the like have been known that include a light-emitting element and a power supply attachment for supplying power to the light-emitting element.

Generally, as described in, for example, "Patent Document 1," a power supply attachment is configured to include a power supply section that contacts the light-emitting element to supply power, a connector section that is electrically connected to an external power source, and an intermediate section located between the two.

Patent Document 1 describes a light source unit in which a light-emitting element and a power supply attachment are supported by a die-cast heat sink.

On the other hand, Patent Document 2 describes a light source unit in which a light-emitting element and a power supply attachment are supported on a metal plate. The power supply attachment described in Patent Document 2 is supported on the underside of the metal plate together with the light-emitting element, and the connector portion is formed to open in the space on the underside of the metal plate.

JP 2014-197550 A JP 2018-92847 A

When the light emission output of the light source unit is relatively small, as described in the above-mentioned "Patent Document 2," it is possible to ensure the heat dissipation function of the light source unit even by using a metal plate instead of a die-cast heat sink.

However, in the light source unit described in the above-mentioned "Patent Document 2," the connector part of the power supply attachment is formed so that it opens in the space on the underside of the metal plate (i.e., the same side as the light-emitting element), which causes the following problems:

In other words, in the vehicle lamp described in the above-mentioned "Patent Document 2," the light emitted from the light-emitting element of the light source unit is reflected toward the front of the lamp by a reflector arranged below the light source unit, but care must be taken to ensure that the reflector does not interfere with the connector part of the power supply attachment.

As a result, in such vehicle lamps, the degree of freedom in the shape of light control components such as reflectors that control the light from the light-emitting elements and the degree of freedom in the placement of the connector part are reduced.

The present invention was made in consideration of these circumstances, and aims to provide a light source unit in which a light emitting element and a power supply attachment are supported by a metal plate, which allows for greater freedom in the shape of the light control member and the arrangement of the connector, and to provide a vehicle lamp equipped with the light source unit.

The present invention aims to achieve the above objective by improving the configuration of the power supply attachment.

That is, the light source unit according to the present invention is
A light source unit including a light emitting element, a power supply attachment for supplying power to the light emitting element, and a metal plate for supporting the light emitting element and the power supply attachment,
the light emitting element is supported on a first plate surface of the metal plate,
the power supply attachment includes a power supply section that contacts the light emitting element to supply power, a connector section that is electrically connected to an external power source, and an intermediate section that is located between the power supply section and the connector section;
the power supply portion is supported on a first plate surface of the metal plate,
The connector portion is formed so as to open in the space on the second plate surface side of the metal plate.

The specific shape of the "metal plate" is not particularly limited, and may be, for example, simply formed into a flat plate, or may be bent or cut in areas other than the area where the light-emitting element and power supply attachment are supported.

The material of the above-mentioned "metal plate" is not particularly limited, and for example, an aluminum plate or a copper plate can be used.

The orientation of the metal plate is not particularly limited.

As long as the above-mentioned "connector portion" is formed so as to open in the space on the second plate side of the metal plate, there are no particular limitations on its specific configuration, such as its specific shape or the direction in which it opens.

On the other hand, a vehicle lamp according to the present invention is a vehicle lamp equipped with such a light source unit,
The light source unit includes a reflector that reflects light emitted from the light-emitting element toward the front of the lamp.
the reflector is disposed below the light source unit,
The light source unit is characterized in that the light source unit is supported by the reflector at the metal plate with the first plate surface of the metal plate facing downward.

The light source unit according to the present invention is a power supply attachment for supplying power to a light-emitting element, and is configured to include a power supply section that contacts the light-emitting element to supply power, a connector section that is electrically connected to an external power source, and an intermediate section located between the two. The power supply section of the power supply attachment is supported on the first plate surface of the metal plate together with the light-emitting element, and the connector section of the power supply attachment is formed so as to open in the space on the second plate surface side of the metal plate, so that the following effects can be obtained.

In other words, it is easily possible to arrange light control members such as reflectors in a free layout in the space on the first plate side of the metal plate. In addition, it is easily possible to arrange the connector portion of the power supply attachment in a state in which it opens in a free direction in the space on the second plate side of the metal plate. This increases the degree of freedom in the shape of the light control member and the degree of freedom in the arrangement of the connector portion.

In this way, the present invention allows for greater freedom in the shape of the light control member and the arrangement of the connector section in a light source unit in which a light-emitting element and a power supply attachment are supported by a metal plate.

In the above configuration, if an opening is formed in the metal plate and the power supply attachment is formed so that its middle portion extends through the opening, the power supply attachment can be made compact. Furthermore, by adopting such a configuration, the metal plate is arranged over a relatively wide area around the light-emitting element, thereby improving the heat dissipation function of the light source unit.

In the above configuration, if the light-emitting element is placed on the first surface of the metal plate via heat transfer grease, and protrusions for positioning the light-emitting element are formed at multiple locations surrounding the mounting area for mounting the light-emitting element on the first surface of the metal plate, and the light-emitting element is pressed against the metal plate by the power supply attachment while being positioned in the mounting area by the multiple protrusions, the following effects can be obtained.

In other words, the light-emitting element can be supported on the metal plate without using adhesive. This eliminates the need for a process for applying adhesive, and also eliminates the need for a process for hardening the adhesive while maintaining the light-emitting element in a positioned state, simplifying the work process.

When this type of configuration is adopted, if the tip of each protrusion is chamfered on the side of the mounting area, the light-emitting element can be smoothly placed in the mounting area.

In addition, when this type of configuration is adopted, if recesses are formed in the areas adjacent to each protrusion in the mounting area, the following effects can be obtained.

In other words, corners are inevitably formed at the connection portions between each protrusion and the first surface of the metal plate, so if the recesses were not formed, the light-emitting element would come into contact with the connection portion of the metal plate, and there is a risk that the light-emitting element would not be placed accurately in the placement area.

In response to this, by forming recesses in the mounting area adjacent to each protrusion, it is possible to prevent the light-emitting element from coming into contact with the connection portion of the metal plate, thereby enabling the light-emitting element to be accurately mounted in the mounting area.

In the above configuration, if the light-emitting element is placed on the first surface of the metal plate via heat transfer grease, and protrusions for positioning the light-emitting element in the required direction are formed in two locations surrounding the mounting area for mounting the light-emitting element on the first surface of the metal plate, the light-emitting element is pressed against the metal plate by the power supply attachment, and the power supply attachment is formed with a biasing piece that biases the light-emitting element in the required direction by contacting the light-emitting element, the following effects can be obtained.

In other words, the light-emitting element can be supported on the metal plate without using adhesive. This eliminates the need for a process for applying adhesive, and also eliminates the need for a process for hardening the adhesive while maintaining the light-emitting element in a positioned state, simplifying the work process. Furthermore, it becomes easy to position the light-emitting element in the mounting area.

In the above configuration, if the power supply attachment is supported on the metal plate by engaging the power supply attachment with the metal plate, the following effects can be obtained.

In other words, since there is no need to fasten the parts with screws, the number of parts can be reduced and the work process can be simplified. In addition, it is possible to prevent the light emitted from the light-emitting element from being blocked by the head of the screw protruding from the power supply attachment.

When this type of configuration is adopted, if the power supply attachment is formed with multiple engagement pieces and the metal plate is formed with multiple engagement holes, and each engagement piece is configured so that its tip engages with the metal plate when inserted into each engagement hole, the power supply attachment can be engaged with the metal plate with a simple configuration, and the power supply attachment can be easily positioned in the direction perpendicular to the surface of the metal plate.

In this case, if at least some of the multiple engagement pieces are configured to have abutment portions that come into contact with the inner wall surface of the engagement hole when inserted into the engagement hole, it becomes easy to position the power supply attachment in the direction along the surface of the metal plate when the power supply attachment is engaged with the metal plate.

In addition, if the power supply attachment is configured to engage with the metal plate by crimping the metal plate to the power supply attachment, it becomes easy to position the power supply attachment in the direction perpendicular to and along the surface of the metal plate.

In the above configuration, if a base portion is formed on the first plate surface of the metal plate, and a mounting area for mounting a light-emitting element on the first plate surface of the metal plate is located on the base portion, the following effects can be obtained.

In other words, even if the thickness of the power supply attachment is increased by the height of the base, the light emitted from the light-emitting element is not blocked by the power supply attachment, which makes it easy to manufacture the power supply attachment. Also, even if the power supply attachment is supported on the metal plate by tightening screws, the light emitted from the light-emitting element is less likely to be blocked by the screw heads protruding from the power supply attachment.

On the other hand, the vehicle lamp according to the present invention is a vehicle lamp equipped with such a light source unit, and is configured with a reflector that reflects the light emitted from the light-emitting element of the light source unit toward the front of the lamp. In this case, the reflector is disposed below the light source unit, and the light source unit is supported by the reflector on the metal plate with the first plate surface of the metal plate facing downward, so that the following effects can be obtained.

In other words, the light source unit is positioned with the second surface of the metal plate facing upwards, making it easy to connect the connector on the external power source to the connector part of the power supply attachment.

In the above configuration, if multiple sets of light source units and reflectors are arranged side by side in the vehicle width direction, the required brightness for the light emitted from the vehicle lamp can be easily ensured even if the light output of each set of light source units is reduced, and the required heat dissipation function can be easily ensured.

In the above configuration, if the light source unit is configured so that the opening formed in the metal plate is located on the rear side of the light-emitting element and the connector portion opens toward the rear of the lamp, the task of connecting the connector portion to the connector on the external power source side can be performed even more easily.

FIG. 1 is a cross-sectional plan view showing a vehicle lamp including a light source unit according to an embodiment of the present invention; Cross-sectional view of line II-II in FIG. Detailed view of the main part of Figure 2 FIG. 4 is a view taken along the arrow IV in FIG. 3, showing the light source unit alone. FIG. 4 is a diagram similar to FIG. 3, illustrating the operation of the embodiment in comparison with a comparative example. FIG. 4 is a view similar to FIG. 3, showing a first modification of the embodiment; 4A and 4B are views similar to FIG. 3 showing second and third modified examples of the above embodiment; FIG. 4 is a view similar to FIG. 3, showing a fourth modification of the embodiment; IX direction of FIG. 8 . XX line cross-sectional view of FIG. Detailed view of the main part of FIG. Detailed view of the main part of FIG. FIG. 13 is a perspective view showing a state of assembly of the light source unit in the fourth modified example. FIG. 13 is a view similar to FIG. 12 showing a fifth modification of the above embodiment. 15A and 15B are diagrams for explaining the operation of the fifth modified example, where (a) is a diagram similar to FIG. 14, (b) is a cross-sectional view taken along line bb in (a), and (c) is a cross-sectional view taken along line cc in (a). FIG. 11 is a diagram showing a sixth modified example of the embodiment, which is turned upside down from the state shown in FIG. FIG. 16 is a diagram similar to FIG. 16, showing a seventh modification of the above embodiment; FIG. 16 is a diagram similar to FIG. 16, showing an eighth modification of the above embodiment. 10A to 11B are views similar to FIG. 10 showing ninth to eleventh modified examples of the above embodiment;

The following describes an embodiment of the present invention with reference to the drawings.

Figure 1 is a plan cross-sectional view showing a vehicle lamp 10 equipped with a light source unit 30 according to one embodiment of the present invention, and Figure 2 is a cross-sectional view taken along line II-II in Figure 1.

In Figures 1 and 2, the direction indicated by X is "in front of the lamp," the direction indicated by Y is the "left direction" (the "right direction" when viewed from the front of the lamp) perpendicular to the "front of the lamp," and the direction indicated by Z is the "upward direction." This is the same in other figures besides Figures 1 and 2.

As shown in Figures 1 and 2, the vehicle lamp 10 according to this embodiment is a headlamp installed at the right front end of the vehicle, and is configured such that three lamp units 20A, 20B, and 20C are assembled side-by-side in the vehicle width direction within a lamp chamber formed by a lamp body 12 and a plain translucent cover 14 attached to the front end opening of the lamp body 12.

Each of the lamp units 20A to 20C is configured with a light source unit 30 that uses a light emitting element 40 as a light source, and a reflector 70 arranged below the light source unit 30.

The light source unit 30 is arranged with the light-emitting surface 40a of the light-emitting element 40 facing downward.

The reflector 70 has a reflective surface 70a on which multiple reflective elements 70s are formed, and each reflective element 70s reflects the light emitted from the light-emitting element 40 toward the front of the lamp.

A light source support section 72 that supports the light source unit 30 is formed at the upper end of the reflector 70. A connector 80 on the external power source side is connected from the rear side of the lamp to the light source unit 30 supported by the light source support section 72, so that power is supplied to the light source unit 30.

The three lamp units 20A to 20C differ from each other in the surface shape of each reflective element 70s that constitutes the reflective surface 70a of the reflector 70, but otherwise have the same configuration. The reflectors 70 of the three lamp units 20A to 20C are made of resin materials and are formed integrally with each other.

The vehicle lamp 10 according to this embodiment is configured to form a required light distribution pattern (e.g., a low beam light distribution pattern) using the light emitted from the three lamp units 20A to 20C.

Figure 3 is a detailed view of the main parts of Figure 2. Figure 4 is a view taken in the direction of arrow IV in Figure 3, showing the light source unit 30 alone.

As shown in Figures 3 and 4, the light source unit 30 is configured such that a light emitting element 40 and a power supply attachment 50 for supplying power to the light emitting element 40 are supported by a metal plate 60.

The metal plate 60 is an aluminum plate of uniform thickness, and is arranged to extend along a horizontal plane. When viewed from above, the metal plate 60 has a rectangular outer shape that is long in the front-to-rear direction of the lamp.

The light-emitting element 40 is a white light-emitting diode, and its light-emitting surface 40a is formed in a horizontally elongated rectangular shape. This light-emitting element 40 is configured such that an element body 40A having the light-emitting surface 40a is supported by a body support part 40B, which supports the first plate surface 60a, which is the lower surface of a metal plate 60, on the body support part 40B. This support is achieved by fixing the body support part 40B to the first plate surface 60a using, for example, an adhesive or the like.

The body support 40B has a horizontally elongated rectangular shape in a plan view, and a pair of left and right terminals 40b are disposed on the underside of the body support 40B on both the left and right sides of the light emitting element 40. The left and right terminals 40b are electrically connected to the cathode and anode electrodes of the element body 40A, respectively.

An opening 60c is formed in the metal plate 60 at a position adjacent to the rear side of the lamp where the light emitting element 40 is supported. This opening 60c has a rectangular inner peripheral surface shape.

The power supply attachment 50 includes a power supply section 50A that contacts the light-emitting element 40 to supply power, a connector section 50B that is electrically connected to an external power source, and an intermediate section 50C that is located between the power supply section 50A and the connector section 50B.

In this case, the power supply unit 50A is supported on the first plate surface 60a of the metal plate 60. The middle portion 50C is formed to extend through the opening 60c of the metal plate 60. Furthermore, the connector portion 50B is formed to open in the space S2 on the second plate surface 60b side, which is the upper surface of the metal plate 60.

Next, the specific configuration of the power supply attachment 50 will be described.

The power supply attachment 50 is configured as an insert molded product in which a pair of left and right bus bar electrodes 54 for electrical conduction with the light emitting element 40 are embedded in an insulating member 52 formed to surround the light emitting element 40 with a portion of each exposed.

Insulating member 52 is formed in power supply component area 52A located in power supply unit 50A so as to extend flat along the horizontal plane, and has a horizontally elongated rectangular outer shape in plan view. A horizontally elongated rectangular opening 52a is formed in power supply component area 52A at its left-right center, and a pair of left and right flanges 52b protruding horizontally are formed on both left and right side surfaces.

A pair of left and right screw insertion holes 52f are formed in the pair of left and right flange portions 52b. Meanwhile, a pair of left and right screw holes 60f are formed in the metal plate 60 at positions corresponding to the pair of left and right screw insertion holes 52f. Then, with the power supply portion configuration area 52A of the insulating member 52 pressed against the first plate surface 60a of the metal plate 60 from below, the power supply attachment 50 is fixed to the metal plate 60 by tightening the screws 56 into the screw holes 60f through the screw insertion holes 52f.

A pair of left and right positioning pins 52c are formed on the upper surfaces of the pair of left and right flange portions 52b. Meanwhile, a pair of left and right engagement holes 60e are formed in the metal plate 60 at positions corresponding to the pair of left and right positioning pins 52c. At this time, one of the pair of left and right engagement holes 60e is formed in a circular shape, and the other is formed in a horizontally elongated rectangular shape. Then, when the power supply part forming area 52A of the insulating member 52 is pressed against the first plate surface 60a of the metal plate 60, each positioning pin 52c is inserted into each engagement hole 60e, so that the power supply attachment 50 is positioned in the horizontal direction relative to the metal plate 60.

The pair of left and right busbar electrodes 54 have two pairs of left and right terminal pieces 54a that protrude into the opening 52a, and are electrically connected to the light-emitting element 40 by abutting against a pair of left and right terminal parts 40b of the light-emitting element 40.

The pair of left and right busbar electrodes 54 also have two pairs of front and rear pressing pieces 54b that protrude into the opening 52a, which abut against the underside of the main body support part 40B to position the light emitting element 40.

At this time, each terminal piece 54a and each pressing piece 54b is configured as an elastic piece that elastically presses the main body support part 40B from below.

The insulating member 52 is formed such that the intermediate portion forming region 52C located in the intermediate portion 50C extends vertically upward from the rear end of the power supply portion forming region 52A in a rectangular column shape. This intermediate portion forming region 52C is formed to be located in the center of the power supply portion forming region 52A in the left-right direction and has a narrower left-right width than the power supply portion forming region 52A. This intermediate portion forming region 52C is formed to vertically penetrate the opening 60c of the metal plate 60 at a position near the front end face.

The insulating member 52 is formed so that the connector portion forming region 52B located in the connector portion 50B extends horizontally from the upper end of the intermediate portion forming region 52C toward the rear of the lamp. This connector portion forming region 52B extends in a rectangular cylindrical shape with the same left-right width as the intermediate portion forming region 52C, and is formed so as to open toward the rear of the lamp.

A rectangular hole 52d extending in the front-to-rear direction of the lamp is formed in the upper wall of the connector portion configuration area 52B, and rectangular recesses 52e are formed in both the left and right side walls of this connector portion configuration area 52B.

In the internal space of the connector section configuration area 52B, the terminal pins 54c of the pair of left and right bus bar electrodes 54 are arranged in a state where they protrude toward the rear of the lamp. Each of the pair of left and right terminal pins 54c is formed to extend in a plate shape along a vertical plane. The connector 80 on the external power source side is inserted into the internal space of the connector section configuration area 52B and engages with the rectangular hole 52d and the pair of left and right recesses 52e, so that the power supply attachment 50 is electrically connected to the external power source.

The opening 60c of the metal plate 60 is formed so that its rear edge is positioned rearward of the lamp relative to the rear end face of the connector portion 50B so that the middle portion 50C and the connector portion 50B of the power supply attachment 50 do not interfere with the metal plate 60 when the power supply attachment 50 is attached to the first plate surface 60a of the metal plate 60.

As shown in Figures 1 and 2, the reflector 70 supports the light source unit 30 by crimping the light source support portion 72 at three points.

To achieve this, as shown by the two-dot chain line in FIG. 3, three locations on the light source support portion 72 of the reflector 70 are formed with rivet pins 72a extending upward, and three locations on the metal plate 60 of the light source unit 30 are formed with insertion holes 60d for inserting the rivet pins 72a. When the metal plate 60 of the light source unit 30 is placed on the upper surface of the light source support portion 72 of the reflector 70, the tip of each rivet pin 72a is thermally rivet with each rivet pin 72a inserted into each insertion hole 60d, thereby fixing the light source unit 30 to the reflector 70.

Next, we will explain the effects of this embodiment.

The vehicle lamp 10 according to this embodiment includes three lamp units 20A, 20B, and 20C. The light source unit 30 of each of the lamp units 20A to 20C includes a power supply attachment 50 for supplying power to the light-emitting element 40, which includes a power supply section 50A that contacts the light-emitting element 40 to supply power, a connector section 50B that is electrically connected to an external power source, and an intermediate section 50C located between the power supply section 50A and the connector section 50B that is electrically connected to an external power source, and the intermediate section 50C located between the power supply section 50A and the light-emitting element 40. The power supply section 50A of the power supply attachment 50 is supported on the first plate surface 60a of the metal plate 60 together with the light-emitting element 40, and the connector section 50B of the power supply attachment 50 is formed to open in the space S2 on the second plate surface 60b side of the metal plate 60, so that the following effects can be obtained.

That is, in this embodiment, the reflector 70 can be easily arranged in a free layout in the space S1 on the first plate surface 60a side of the metal plate 60. Also, the connector portion 50B of the power supply attachment 50 can be easily arranged in a state in which it opens in a free direction in the space S2 on the second plate surface 60b side of the metal plate 60. Therefore, the degree of freedom in the shape of the reflector 70 and the degree of freedom in the arrangement of the connector portion 50B can be increased.

This point will be explained in detail with reference to Figure 5.

Figure 5(a) is a diagram similar to Figure 3, showing the light source unit 30 according to this embodiment. Meanwhile, Figure 5(b) is a diagram similar to Figure 5(a), showing a light source unit 530 as a comparative example of this embodiment.

As shown in FIG. 5(b), the light source unit 530 according to the comparative example also has a configuration in which the power supply portion 550A of the power supply attachment 550 is supported on the first plate surface 560a of the metal plate 560 together with the light emitting element 40. However, the configuration differs from this embodiment in that the connector portion 550B of the power supply attachment 550 is formed to open in the space S1 on the first plate surface 560a side of the metal plate 560, rather than the space S2 on the second plate surface 560b side of the metal plate 560 as in this embodiment.

In this light source unit 530, the connector portion 550B of the power supply attachment 550 is formed to protrude downward from the lower surface of the power supply portion 550A in the space S1 on the first plate surface 560a side. Accordingly, the reflector 570 is configured with the upper region of the reflective surface 570a missing in order to prevent interference with the connector portion 550B of the power supply attachment 550. Therefore, it is not possible to make maximum effective use of the light emitted from the light emitting element 40 as reflected light by the reflector 570.

On the other hand, as shown in FIG. 5(a), in the light source unit 30 according to this embodiment, the connector portion 50B of the power supply attachment 50 is formed to open in the space S2 on the second plate surface 60b side of the metal plate 60, so that in the space S1 on the first plate surface 60a side, there is no portion that protrudes downward from the underside of the power supply portion 50A, and the upper region of the reflecting surface 70a of the reflector 70 is not missing. Therefore, the light emitted from the light-emitting element 40 can be utilized as reflected light by the reflector 70 to the maximum extent possible.

In this way, according to this embodiment, in a vehicle lamp 10 having a light source unit 30 in which a light emitting element 40 and a power supply attachment 50 are supported by a metal plate 60, the degree of freedom in the shape of the reflector 70 as a light control member and the degree of freedom in the arrangement of the connector portion 50B can be increased.

In addition, in the light source unit 30 according to this embodiment, the middle portion 50C of the power supply attachment 50 is formed so as to extend through the opening 60c formed in the metal plate 60, so that the power supply attachment 50 can be configured compactly. In addition, by adopting a configuration in which the opening 60 is formed in the metal plate 60 in this manner, the metal plate 60 is disposed over a wider area around the light emitting element 40 compared to, for example, a configuration in which a recess is formed in the rear end surface of the metal plate 60, so that the heat dissipation function of the light source unit 30 can be improved.

In addition, the vehicle lamp 10 according to this embodiment has three lamp units 20A-20C arranged side by side in the vehicle width direction, so even if the light output of the light source unit 30 of each lamp unit 20A-20C is reduced, the brightness required for the light emitted from the vehicle lamp 10 can be easily ensured. Therefore, the heat dissipation function required for each lamp unit 20A-20C can be easily ensured by the metal plate 60.

In addition, each of the lamp units 20A to 20C is configured such that the reflector 70 is disposed below the light source unit 30, and the light source unit 30 is supported by the reflector 70 on the metal plate 60 with the first plate surface 60a of the metal plate 60 facing downward, so that the following effects can be obtained.

In other words, the light source unit 30 is positioned with the second plate surface 60b of the metal plate 60 facing upward, making it easy to connect the connector 80 on the external power source side to the connector portion 50B of the power supply attachment 50.

In addition, the opening 60c formed in the metal plate 60 of the light source unit 30 is located on the rear side of the light emitting element 40, and the connector portion 50B opens toward the rear of the lamp, so that the connector 80 on the external power source side can be connected to the connector portion 50B more easily by sliding the connector 80 along the second plate surface 60b of the metal plate 60.

In the above embodiment, the middle part 50C of the power supply attachment 50 is described as being located in the opening 60c of the metal plate 60, but it is also possible to configure it to be located in a recess formed in the rear end surface of the metal plate 60, or to be located near the rear end surface or side end surface of the metal plate 60.

In the above embodiment, the power supply attachment 50 is described as being fixed to the metal plate 60 by screwing the pair of left and right flange portions 52b of the insulating member 52, but it is also possible to configure it to be fixed by clips or the like.

In the above embodiment, the power supply attachment 50 and the light-emitting element 40 are electrically connected by the two pairs of left and right terminal pieces 54a of the pair of left and right busbar electrodes 54 abutting against the pair of left and right terminal portions 40b of the light-emitting element 40, but this is not limited to the arrangement in the above embodiment, and if the pattern shape of the pair of left and right terminal portions 40b differs from the pattern shape in the above embodiment, the arrangement of the two pairs of left and right terminal pieces 54 can also differ accordingly from that in the above embodiment.

For example, when the pair of left and right terminal portions 40b of the light-emitting element 40 are formed so as to extend from both the left and right sides of the body support portion 40B of the light-emitting element 40 toward the front of the lamp, the pair of left and right busbar electrodes 54 can be configured so that two pairs of left and right terminal pieces 54a abut the pair of left and right terminal portions 40b of the light-emitting element 40 on the front side of the lamp from the body support portion 40B of the light-emitting element 40. Also, when one terminal portion 40b is formed so as to extend from both the left and right sides of the body support portion 40B of the light-emitting element 40 toward the front of the lamp and the other terminal portion 40b extends toward the rear of the lamp, the pair of left and right busbar electrodes 54 can be configured so that one terminal piece 54a abuts the terminal portion 40b of the light-emitting element 40 on the front side of the lamp from the body support portion 40B of the light-emitting element 40 and the other terminal piece 54a abuts the terminal portion 40b of the light-emitting element 40 on the rear side of the lamp from the body support portion 40B of the light-emitting element 40.

In addition, instead of two pairs of terminal pieces 54a on the left and right, it is also possible to configure the device with one pair of terminal pieces 54a on the left and right, or three or more pairs of terminal pieces 54a on the left and right.

In the above embodiment, the light source unit 30 is supported by the reflector 70 by crimping, but it is also possible to use screws or other fastening methods.

In the above embodiment, the vehicle lamp 10 has been described as having three lamp units 20A to 20C, but it is also possible to have a configuration with two or less or four or more lamp units.

Next, we will explain a variation of the above embodiment.

First, we will explain the first variation of the above embodiment.

Figure 6 is a diagram similar to Figure 3, showing the light source unit 130 according to this modified example.

As shown in FIG. 6, the basic configuration of this modified example is similar to that of the above embodiment, but the configuration of the metal plate 160 is partially different from that of the above embodiment.

That is, in the light source unit 130 according to this modified example, the power supply portion 50A of the power supply attachment 50 is supported together with the light emitting element 40 on the first plate surface 160a, which is the lower surface of the metal plate 160, and the connector portion 50B of the power supply attachment 50 is formed to open in the space S2 on the second plate surface 160b, which is the upper surface of the metal plate 160. However, the metal plate 160 of this modified example is different from the above embodiment in that a downward extension portion 160e is formed that extends vertically downward from the rear end portion 160d.

The downward extension 160e is formed by bending the metal plate 160, so that the rear end 160d of the metal plate 160 is configured as a cylindrical convex surface on the second plate surface 160b side that extends in the left-right direction.

In the light source unit 130 according to this modified example, the metal plate 160 has an opening 160c formed therein, similar to that in the above embodiment. The power supply attachment 50 has an intermediate portion 50C formed to extend through the opening 160c.

Even when the configuration of this modified example is adopted, the same effects as those of the above embodiment can be obtained.

Furthermore, by adopting the configuration of this modified example, the thermal capacity of the metal plate 160 can be increased, thereby further improving the heat dissipation function of the light source unit 30.

In addition, in this modified example, the surface of the second plate surface 160b side at the rear end 160d of the metal plate 160 is configured as a cylindrical convex curved surface extending in the left-right direction, so that when the connector 80 on the external power source side is connected to the connector portion 50B of the power supply attachment 50, the connector 80 can be smoothly slid along the second plate surface 160b of the metal plate 160.

Next, we will explain the second variation of the above embodiment.

Figure 7(a) is a diagram similar to Figure 3, showing the light source unit 230 according to this modified example.

As shown in FIG. 7(a), the basic configuration of this modified example is the same as that of the above embodiment, but the configuration of the power supply attachment 250 is partially different from that of the above embodiment.

That is, the power supply attachment 250 of this modified example also includes a power supply section 250A that contacts the light-emitting element 40 to supply power, a connector section 250B that is electrically connected to an external power source, and an intermediate section 250C located between them. The power supply section 250A of the power supply attachment 250 is supported on the first plate surface 60a of the metal plate 60 together with the light-emitting element 40, and the connector section 250B of the power supply attachment 250 is formed to open in the space S2 on the second plate surface 60b side of the metal plate 60. However, this connector section 250B opens diagonally upwards rather than horizontally toward the rear of the lamp, which is different from the above embodiment.

Even when the configuration of this modified example is adopted, the same effects as those of the above embodiment can be obtained.

In addition, by adopting the configuration of this modified example, the connector 80 on the external power source side can be easily connected to the connector portion 250B of the power supply attachment 250 from an obliquely upward direction behind the lamp.

Next, we will explain the third variation of the above embodiment.

Figure 7(b) is a diagram similar to Figure 3, showing the light source unit 330 according to this modified example.

As shown in FIG. 7(b), the basic configuration of this modified example is the same as that of the above embodiment, but the configuration of the power supply attachment 350 is partially different from that of the above embodiment, and therefore the configuration of the metal plate 360 is also partially different from that of the above embodiment.

That is, the power supply attachment 350 of this modified example also includes a power supply section 350A that contacts the light-emitting element 40 to supply power, a connector section 350B that is electrically connected to an external power source, and an intermediate section 350C located between them. The power supply section 350A of the power supply attachment 350 is supported on the first plate surface 360a of the metal plate 360 together with the light-emitting element 40, and the connector section 350B of the power supply attachment 350 is formed so as to open in the space S2 on the second plate surface 360b side of the metal plate 360, but differs from the above embodiment in that this connector section 350B opens vertically upward.

Even when the configuration of this modified example is adopted, the same effects as those of the above embodiment can be obtained.

In addition, by adopting the configuration of this modified example, the connector 80 on the external power source side can be connected to the connector portion 350B of the power supply attachment 350 from directly above. Therefore, depending on the configuration of the vehicle lamp 10, workability can be improved.

In addition, in the light source unit 330 according to this modified example, the middle portion 350C of the power supply attachment 350 is formed to extend through the opening 360c of the metal plate 360, but the power supply attachment 350 is formed with the same front-to-back width for the connector portion 350B and the middle portion 350C, so that the power supply attachment 350 can be configured even more compactly than in the above embodiment. This also allows the front-to-back width of the opening 360c to be narrower than in the above embodiment, so that the heat capacity of the metal plate 360 can be increased accordingly, thereby further improving the heat dissipation function of the light source unit 330.

Next, we will explain the fourth variation of the above embodiment.

Figure 8 is a view similar to Figure 3, showing a lamp unit 620A according to this modified example. Also, Figure 9 is a view taken along the line IX in Figure 8, and Figure 10 is a cross-sectional view taken along the line X-X in Figure 8. Furthermore, Figure 11 is a detailed view of the main parts of Figure 8, and Figure 12 is a detailed view of the main parts of Figure 9.

As shown in Figures 8 to 12, the basic configuration of this modified example is similar to that of the above embodiment, but the configuration of the light source unit 630 is partially different from that of the above embodiment, and therefore the configuration of the reflector 670 is also partially different from that of the above embodiment.

As in the above embodiment, the light source unit 630 is configured such that the light emitting element 640 and the power supply attachment 650 are supported by a metal plate 660. The light source unit 630 is supported by a reflector 670 at the metal plate 660 with the light emitting surface 640a of the light emitting element 640 facing downward.

The reflector 670 has a reflective surface 670a similar to that of the above embodiment, and a light source support part 672 is formed on its upper end. The reflector 670 is fixed to the metal plate 660 by crimping with crimp pins 672a formed at three locations on the light source support part 672 inserted into insertion holes 660j formed in the metal plate 660.

As in the above embodiment, the light source unit 630 has the power supply portion 650A of the power supply attachment 650 supported together with the light emitting element 640 on the first plate surface 660a, which is the lower surface of the metal plate 660, and the connector portion 650B of the power supply attachment 650 is formed so as to open in the space S2 on the second plate surface 660b, which is the upper surface of the metal plate 660.

In this modification, the metal plate 660 has an opening 660c formed on the rear side of the light emitting element 640, and the power supply attachment 650 is formed so that its middle portion 650C extends through the opening 660c. And, as in the first modification, the metal plate 660 has a downward extension portion 660e extending vertically downward from its rear end portion 660d.

The light-emitting element 640 is configured such that an element body 640A having a light-emitting surface 640a formed in a horizontally elongated rectangular shape is supported by a body support part 640B, which is supported by a metal plate 660.

Specifically, the light-emitting element 640 is supported by the metal plate 660 by being pressed against the metal plate 660 by the power supply attachment 650 while being placed on the first plate surface 660a of the metal plate 660 via the thermal transfer grease 642.

The body support 640B has a horizontally elongated rectangular shape in a plan view, and a pair of terminals 640b are disposed on the underside of the light emitting element 640 on the left and right sides thereof, and are electrically connected to the cathode and anode electrodes of the element body 640A, respectively.

The power supply attachment 650 is configured as an insert molded product in which a pair of left and right bus bar electrodes 654 for electrical conduction with the light emitting element 640 are embedded in an insulating member 652 formed to surround the light emitting element 640 with a portion of each exposed.

Insulating member 652 is formed in power supply portion configuration area 652A located in power supply portion 650A so as to extend in a flat plate shape along a horizontal plane, and has a horizontally elongated rectangular outer shape in plan view. A horizontally elongated rectangular opening 652a is formed in power supply portion configuration area 652A at its left-right center.

The pair of left and right busbar electrodes 654 have a pair of left and right terminal pieces 654a that protrude from the rear inner circumferential surface of the power supply portion configuration area 652A toward the opening 652a, and are electrically connected to the light-emitting element 640 by abutting against a pair of left and right terminal parts 640b of the light-emitting element 640. Each terminal piece 654a is configured as an elastic piece that elastically presses the main body support part 640B from below in the opening 652a, thereby supporting the light-emitting element 640.

A pair of flanges 652b protruding horizontally are formed on both the left and right side surfaces of the power supply component area 652A of the insulating member 652.

The pair of left and right flanges 652b are formed in a state where they are offset upward from the power supply unit configuration area 652A. The pair of left and right flanges 652b are formed with a pair of left and right screw insertion holes 652f.

On the other hand, the metal plate 660 has an area located at the pair of left and right flange portions 652b offset upward, so that a pair of left and right substantially rectangular recesses 660m are formed on the first plate surface 660a. The depth of each recess 660m is set to be substantially the same value as the thickness of the flange portion 652b. Furthermore, a pair of left and right screw holes 660f are formed in the metal plate 660 at positions corresponding to the pair of left and right screw insertion holes 652f.

A pair of left and right positioning pins 652c that protrude upward are formed on both the left and right sides of the opening 652a in the power supply portion configuration area 652A. The base end of each positioning pin 652c is formed in a cylindrical shape and the tip end is formed in a conical shape.

On the other hand, a pair of left and right engagement holes 660k are formed in the metal plate 660 at positions corresponding to the pair of left and right positioning pins 652c. In this case, one of the pair of left and right engagement holes 660k is formed in a circular shape, and the other is formed in an oval shape that is long in the left-right direction.

Then, with the pair of left and right flange portions 652b of the insulating member 652 pressed against the pair of left and right recesses 660m of the first plate surface 660a of the metal plate 660 from below, the screws 656 are fastened to the screw holes 660f through the screw insertion holes 652f, thereby fixing the power supply attachment 650 to the metal plate 660. At this time, the positioning pins 652c are inserted into the engagement holes 660k, so that the power supply attachment 650 is positioned in the horizontal direction relative to the metal plate 660.

The insulating member 652 is formed such that the intermediate portion forming region 652C located in the intermediate portion 650C extends vertically upward from the rear end of the power supply portion forming region 652A in a rectangular column shape. This intermediate portion forming region 652C is formed to be located at the center of the power supply portion forming region 652A in the left-right direction and has a narrower left-right width than the power supply portion forming region 652A. This intermediate portion forming region 652C is formed to vertically penetrate the opening 660c of the metal plate 660 at a position near the front end face.

The insulating member 652 is formed so that the connector portion forming region 652B located in the connector portion 650B extends horizontally from the upper end of the intermediate portion forming region 652C toward the rear of the lamp. This connector portion forming region 652B extends in a rectangular cylindrical shape with the same left-right width as the intermediate portion forming region 652C, and is formed so as to open toward the rear of the lamp.

A rectangular hole 652d extending in the front-to-rear direction of the lamp is formed in the upper wall of the connector portion configuration area 652B, and rectangular recesses 652e are formed in both the left and right side walls of this connector portion configuration area 652B.

In the internal space of the connector section configuration area 652B, the terminal pins 654c of the pair of left and right bus bar electrodes 654 are arranged in a state where they protrude toward the rear of the lamp. Each of the pair of left and right terminal pins 654c is formed to extend in a plate shape along a vertical plane. The connector 80 on the external power source side is inserted into the internal space of the connector section configuration area 652B and engages with the rectangular hole 652d and the pair of left and right recesses 652e, so that the power supply attachment 650 is electrically connected to the external power source.

Figure 13 is a perspective view showing the state when the light-emitting element 640 is placed on the first plate surface 660a of the metal plate 660, as viewed from diagonally below. That is, in Figure 13, the metal plate 660 is shown in a state in which it is inverted upside down from the state shown in Figure 8.

As shown in FIG. 13, protrusions 660g for positioning the light-emitting element 640 are formed on the first plate surface 660a of the metal plate 660 at four locations surrounding the mounting area A for mounting the light-emitting element 640. The light-emitting element 640 is pressed against the metal plate 660 by the power supply attachment 650 in a state where it is positioned in the mounting area A by the four protrusions 660g.

Each protrusion 660g is formed in a substantially rectangular parallelepiped shape, and the tip of the protrusion 660g1 is chamfered on the side of the mounting area A. Each protrusion 660g is formed by plastically deforming a part of the metal plate 660 when the metal plate 660 is press-formed into an L-shape.

The first plate surface 660a of the metal plate 660 has recesses 660i formed in the portions adjacent to the protrusions 660g in the mounting area A. Each recess 660i has a long and narrow rectangular shape that surrounds the inner surface of each protrusion 660g (i.e., the surface on the mounting area A side). Each protrusion 660g is formed so that its inner surface extends to the bottom surface of the recess 660i. The depth of each recess 660i is set to a value equal to or slightly larger than the size of the corner R formed at the base end position of the inner surface of each protrusion 660g.

Then, after placing the metal plate 660 with its first plate surface 660a facing upward, heat transfer grease 642 is applied to the bottom surface of the body support portion 640B of the light emitting element 640 (or heat transfer grease 642 is applied to the mounting area A of the first plate surface 660a of the metal plate 660), the light emitting element 640 is inserted between the four protrusions 660g and pressed against the first plate surface 660a of the metal plate 660, so that the light emitting element 640 is placed on the first plate surface 660a of the metal plate 660 while being positioned in the mounting area A.

At this time, each protrusion 660g is chamfered 660g1, so that the light-emitting element 640 is smoothly guided to the mounting area A while being guided by the four protrusions 660g.

In addition, recesses 660i are formed on the first plate surface 660a of the metal plate 660 in the areas adjacent to the protrusions 660g in the mounting area A, so that the light-emitting element 640 can be accurately mounted in the mounting area A even if some corner R is formed at the base end position of the inner surface of each protrusion 660g.

As shown in Figures 10 and 11, a substantially rectangular parallelepiped recess 660h is formed on the second plate surface 660b of the metal plate 660 at a position substantially directly above each protrusion 660g, thereby improving the shape precision of each protrusion 660g formed by plastic deformation of the metal plate 660.

Even when the configuration of this modified example is adopted, the same effects as those of the above embodiment can be obtained.

In addition, in the light source unit 630 according to this modified example, the light emitting element 640 is placed on the first plate surface 660a of the metal plate 660 via the thermal transfer grease 642, and protrusions 660g for positioning the light emitting element 640 are formed at four locations on the first plate surface 660a of the metal plate 660 surrounding the mounting area A for mounting the light emitting element 640. In addition, the light emitting element 640 is pressed against the metal plate 660 by the power supply attachment 650 while being positioned in the mounting area A by the four protrusions 660g, so that the following effects can be obtained.

In other words, the light emitting element 640 can be supported on the metal plate 660 without using adhesive. This eliminates the need for a process for applying adhesive, and also eliminates the need for a process for hardening the adhesive while maintaining the light emitting element 640 in a positioned state, simplifying the work process.

Moreover, in this modified example, the tip of each protrusion 660g is chamfered 660g1 on the side of the mounting area A, so that the light-emitting element 640 can be smoothly placed in the mounting area A.

In addition, in this modified example, recesses 660i are formed in the areas adjacent to the protrusions 660g in the mounting area A, which provides the following effects:

In other words, corners R are inevitably formed at the connection portions between each protrusion 660g and the first plate surface 660a of the metal plate 660. If the recessed portion 660i were not formed, the light-emitting element 640 would come into contact with the connection portion of the metal plate 660, and the light-emitting element 640 would not be accurately placed in the placement area A.

In contrast, in this modified example, recesses 660i are formed in the portions of the mounting area A adjacent to each protrusion 660g, so that the light-emitting element 640 does not come into contact with the connection portion of the metal plate 660, and this allows the light-emitting element 640 to be accurately mounted in the mounting area A.

Next, we will explain the fifth variation of the above embodiment.

Figure 14 is a diagram similar to Figure 12, showing the main parts of the light source unit according to this modified example.

As shown in FIG. 14, the basic configuration of this modified example is the same as that of the fourth modified example described above, but the configuration of the metal plate 760 and the power supply attachment 750 differs in part from that of the fourth modified example described above.

That is, of the four locations on the first plate surface 760a of the metal plate 760 that surround the mounting area for mounting the light-emitting element 640, two locations, one on the front side of the lamp and one on the left side, have protrusions 760g formed for positioning the light-emitting element 640, but two locations, one on the rear side of the lamp and one on the right side, do not have protrusions 760g formed.

In this modified example, recesses 760i are formed in the portions of the first plate surface 760a adjacent to the protrusions 760g in the mounting area. On the other hand, the portions of the tips of the protrusions 760g facing the mounting area are not chamfered.

The power supply attachment 750 is configured to include an insulating member 752 formed to surround the light-emitting element 640, and a pair of left and right bus bar electrodes 754 that protrude from the rear inner circumferential surface of the power supply portion configuration area 752A toward the opening 752a, but the configuration of the power supply portion configuration area 752A is partially different from that of the fourth modified example.

That is, the power supply portion configuration area 752A is formed with a rectangular biasing piece 752g that protrudes from the rear inner peripheral surface toward the opening 752a, and a rectangular biasing piece 752h that protrudes from the right inner peripheral surface toward the opening 752a.

The biasing piece 752g is formed to be wider than the protrusion 760g at the position facing the protrusion 760g on the front side of the lamp, and its tip surface is formed in a positional relationship symmetrical in the front-to-back direction with the tip surface of the protrusion 760g on the front side of the lamp with respect to the mounting area. The corner portion of the tip of this biasing piece 752g on the first plate surface 760a side of the metal plate 760 is chamfered, thereby forming an inclined surface 752g1.

The biasing piece 752h is formed to be wider than the protrusion 760g at the position facing the left protrusion 760g, and its tip surface is formed in a symmetrical positional relationship with the tip surface of the left protrusion 760g with respect to the mounting area. The corner portion of the tip of this biasing piece 752h on the first plate surface 760a side of the metal plate 760 is chamfered, thereby forming an inclined surface 752h1.

In this modified example, the light-emitting element 640 is positioned in its mounting area by protrusions 660g formed in two locations on the first plate surface 660a of the metal plate 660 and biasing pieces 752g, 752h formed in two locations on the insulating member 752 of the power supply attachment 750.

Figure 15 shows the state when the light-emitting element 640 is placed on the first plate surface 760a of the metal plate 760, where (a) is a view similar to FIG. 14, (b) is a cross-sectional view taken along line b-b in (a), and (c) is a cross-sectional view taken along line c-c in (a).

As shown in FIG. 15(a), the metal plate 760 is placed with its first plate surface 760a facing upward, and then, with heat transfer grease 642 applied to the bottom surface of the body support portion 640B of the light emitting element 640, the light emitting element 640 is placed on the first plate surface 760a at a position diagonally away from the two protrusions 760g toward the rear.

15(b), when the insulating member 752 of the power supply attachment 750 is brought closer to the metal plate 760 from above (see arrow D), the inclined surface 752g1 of the biasing piece 752g comes into contact with the rear corner of the element body 640A of the light-emitting element 640. This presses the light-emitting element 640 towards the front of the lamp (see arrow F). Since the light-emitting element 640 is placed on the first plate surface 760a of the metal plate 760 via the thermal grease 642, it slides towards the front of the lamp and comes into contact with the protrusion 760g on the front side of the lamp. Then, the rear end corner of the element body 640A comes off the inclined surface 752g1 of the biasing piece 752g, and the tip surface of the biasing piece 752g descends along the rear end surface of the element body 640A, so that the light emitting element 640 is clamped from both the front and rear sides by the protrusion 760g on the front side of the lamp and the biasing piece 752g.

As shown in FIG. 15(c), when the insulating member 752 of the power supply attachment 750 is brought close to the metal plate 760 from above, the inclined surface 752h1 of the biasing piece 752h comes into contact with the right corner (the left corner in FIG. 15(c)) of the main body support part 640B of the light-emitting element 640. This causes the light-emitting element 640 to be pressed leftward (see arrow L) and slide leftward to come into contact with the left-side protrusion 760g. Then, the right corner of the main body support part 640B comes off the inclined surface 752h1 of the biasing piece 752h, and the tip surface of the biasing piece 752h descends along the right end surface of the main body support part 640B, so that the light-emitting element 640 is sandwiched from both the left and right sides by the left-side protrusion 760g and the biasing piece 752h.

In this way, when the power supply attachment 750 is attached, the light-emitting element 640 slides diagonally forward and left on the first plate surface 760a of the metal plate 760 as shown by the arrow FL in FIG. 15(a), and then comes into contact with the two protrusions 760g to be positioned in the mounting area.

Even when the configuration of this modified example is adopted, the light-emitting element 640 can be supported on the metal plate 760 without using adhesive. This eliminates the need for a process of applying adhesive, and also eliminates the need for a process of hardening the adhesive while maintaining the light-emitting element 640 in a positioned state, simplifying the work process. Furthermore, it becomes easy to position the light-emitting element 640 in the mounting area.

In addition, in this modified example, protrusions 760g for positioning the light-emitting element 640 in front and to the left of the lamp are formed in two places surrounding the mounting area for mounting the light-emitting element 640 on the first plate surface 760a of the metal plate 760, and the power supply attachment 750 is formed with a biasing piece 752g that biases the light-emitting element 640 toward the front of the lamp by contacting the light-emitting element 640, and a biasing piece 752h that biases the light-emitting element 640 toward the left. Therefore, by pressing the light-emitting element 640 against the metal plate 760 with the power supply attachment 750, the light-emitting element 640 can be easily positioned in the mounting area.

In this modified example, it is preferable to set the inclination angle of the inclined surfaces 752g1, 752h1 formed on each of the biasing pieces 752g, 752h to a value of approximately 15 to 60°.

In this modified example, the inclined surfaces 752g1 and 752h1 are formed to extend in a flat plane, but they can also be formed to extend in a convex or concave curved shape.

Next, we will explain the sixth variation of the above embodiment.

Figure 16 is a diagram similar to Figure 10, showing the main parts of the light source unit according to this modified example. However, in Figure 16, the main parts of the light source unit are shown in a state in which they are inverted from the state shown in Figure 10.

As shown in FIG. 16, the basic configuration of this modified example is the same as that of the fourth modified example described above, but it differs from the fourth modified example in that the power supply attachment 850 is supported on the metal plate 860 by engaging the power supply attachment 850 with the metal plate 860.

That is, in this modified example, a pair of left and right engagement pieces 852j are formed on the insulating member 852 of the power supply attachment 850, and a pair of left and right engagement holes 860n are formed on the metal plate 860 at positions corresponding to the pair of left and right engagement pieces 852j. Each engagement piece 852j is adapted to engage with the metal plate 860 when inserted into each engagement hole 860n.

Each engagement piece 852j is composed of a shaft portion 852j1 that extends vertically at multiple locations (e.g., three locations) in the circumferential direction around a through hole 852i formed in the insulating member 852, and a folded portion 852j2 that folds back at an acute angle from the tip of the shaft portion 852j1 toward the base end portion toward the radial outer periphery.

When each engagement piece 852j is inserted into each engagement hole 860n from the first plate surface 860a side of the metal plate 860, its folded portion 852j2 abuts against the entrance portion of the inner wall surface of each engagement hole 860n, elastically deforms from the state shown in FIG. 16(a) toward the inner circumference, and passes through each engagement hole 860n in a shape as shown in FIG. 16(b). When the folded portion 852j2 exits on the opposite side of each engagement hole 860n, it is engaged with the metal plate 860 in a state in which it spreads out toward the outer circumference along the second plate surface 860b as shown in FIG. 16(c).

When the power supply attachment 850 is supported by the metal plate 860, the pair of left and right engagement pieces 852j engage with the pair of left and right engagement holes 860n to determine its vertical positioning, and the pair of left and right positioning pins 852c engage with the pair of left and right engagement holes 860k to determine its horizontal positioning.

Even when the configuration of this modified example is adopted, the same effect as that of the fourth modified example can be obtained.

In addition, as in this modified example, the power supply attachment 850 is supported on the metal plate 860 by engaging the power supply attachment 850 with the metal plate 860, which eliminates the need for fastening with screws, thereby reducing the number of parts and simplifying the work process. In addition, it is possible to eliminate the risk of the light emitted from the light-emitting element 640 being blocked by the head of the screw protruding from the power supply attachment 850.

In addition, in this modified example, a pair of left and right engagement pieces 852j are formed on the power supply attachment 850, and a pair of left and right engagement holes 860n are formed on the metal plate 860. When each engagement piece 852j is inserted into each engagement hole 860n, its tip 852j engages with the metal plate 860. This allows the power supply attachment 850 and the metal plate 860 to be engaged with each other using a simple configuration.

Next, we will explain the seventh variation of the above embodiment.

Figure 17 is a diagram similar to Figure 16, showing the main parts of the light source unit according to this modified example.

As shown in FIG. 17, in this modification, the power supply attachment 950 is supported on the metal plate 960 by engaging the power supply attachment 950 with the metal plate 960, but the detailed structure is different from that of the sixth modification.

That is, in this modified example, a pair of left and right engagement pieces 952j are formed on the insulating member 952 of the power supply attachment 950, and a pair of left and right engagement holes 960n are formed on the metal plate 960. Each engagement piece 952j is adapted to engage with the metal plate 960 when inserted into each engagement hole 960n.

In this modified example, each engagement piece 952j is composed of a single shaft portion 952j1 that extends in the vertical direction and a pair of foldback portions 952j2 that fold back at an acute angle from the tip of the shaft portion 952j1 toward the base end portion on both the left and right sides.

In addition, in this modified example, an abutment portion 952j3 is formed at the base end of the shaft portion 952j1 of one of the pair of left and right engagement pieces 952j, protruding toward the other engagement piece 952j.

Furthermore, in this modified example, the distance between the pair of left and right engagement pieces 952j is set to a value slightly smaller than the distance between the pair of left and right engagement holes 960n.

When each engagement piece 952j is inserted into each engagement hole 960n from the first plate surface 960a side of the metal plate 960, its folded portion 952j2 abuts against the entrance portion of the inner wall surface of each engagement hole 960n, and passes through each engagement hole 960n in a state in which it elastically deforms from the state shown in FIG. 17(a) toward the shaft portion 952j1 and assumes the shape shown in FIG. 17(b). When the folded portion 952j2 exits the opposite side of each engagement hole 960n, it is engaged with the metal plate 960 in a state in which it spreads outward along the second plate surface 960b as shown in FIG. 17(c).

In this modified example, just before the folded portion 952j2 of one engagement piece 952j comes out to the opposite side of the engagement hole 960n, the abutment portion 952j3 formed on the base end of the shaft portion 952j1 comes into contact with the entrance portion of the inner wall surface of the engagement hole 960n, and when the folded portion 952j2 comes out to the opposite side of the engagement hole 960n, the abutment portion 952j3 comes into contact with the inner wall surface of the engagement hole 960n. At this time, the shaft portion 952j1 of the other engagement piece 952j also comes into contact with the inner wall surface of the engagement hole 960n.

When the power supply attachment 950 is supported by the metal plate 960, the pair of left and right engagement pieces 952j engage with the pair of left and right engagement holes 960n to determine its vertical positioning, and the pair of left and right positioning pins 952c engage with the pair of left and right engagement holes 960k to determine its horizontal positioning. At this time, the pair of left and right engagement pieces 952j abut against the inner wall surfaces of the pair of left and right engagement holes 960n, thereby improving the positioning accuracy in the left and right direction.

Even when the configuration of this modified example is adopted, the same effect as that of the sixth modified example can be obtained.

In addition, in this modified example, the abutment portion 952j3 formed at the base end of the shaft portion 952j1 of one of the pair of left and right engagement pieces 952j abuts against the inner wall surface of one of the engagement holes 960n, and the shaft portion 952j1 of the other engagement piece 952j abuts against the inner wall surface of the other engagement hole 960n, thereby improving the positioning accuracy in the left and right direction when the power supply attachment 950 and the metal plate 960 are engaged.

Next, we will explain the eighth variant of the above embodiment.

Figure 18 is a diagram similar to Figure 16, showing the main parts of the light source unit according to this modified example.

As shown in FIG. 18, in this modification, the power supply attachment 1050 is supported on the metal plate 1060 by engaging the power supply attachment 1050 with the metal plate 1060, but this modification differs from the sixth modification in that the engagement is achieved by crimping.

That is, in this modified example, burring is performed on two locations of the metal plate 1060, so that a pair of cylindrical burring portions 1060p on the left and right sides are formed on the metal plate 1060, protruding toward the first plate surface 1060a.

In this modified example, a pair of left and right engagement holes 1052k are formed at positions corresponding to the pair of left and right burring portions 1060p in the insulating member 1052 of the power supply attachment 1050. Each engagement hole 1052k is formed with an inner diameter slightly larger than the outer diameter of each burring portion 1060p, and a chamfer 1052k1 is applied to the end of the metal plate 1060 on the second plate surface 1060b side.

Each burring portion 1060p is formed to be slightly longer than the length of each engagement hole 1052k.

The power supply attachment 1050 is placed on the first plate surface 1060a of the metal plate 1060 as shown in Fig. 18(b) by inserting the pair of left and right burring portions 1060p into the pair of left and right engagement holes 1052k from the first plate surface 1060a side of the metal plate 1060 as shown in Fig. 18(a). At this time, the tip portions 1060p1 of the pair of left and right burring portions 1060p are in a state where they protrude from the pair of left and right engagement holes 1052k. Then, as shown in FIG. 18(c), the tip portions of a pair of left and right crimping jigs 1000 formed in a truncated cone shape are brought into contact with the tip portions 1060p1 of the pair of left and right burring portions 1060p, so that the tip portions 1060p1 of the burring portions 1060p are plastically deformed so as to expand toward the outer periphery along the surface of the insulating member 1052 and are engaged with the insulating member 1052.

Even when the configuration of this modified example is adopted, the same effect as that of the sixth modified example can be obtained.

In addition, in this modified example, the power supply attachment 1050 and the metal plate 1060 are engaged by crimping the metal plate 1060 to the power supply attachment 1050, which makes it easy to position the power supply attachment 1050 in the direction perpendicular to and along the surface of the metal plate 1060.

Therefore, in this modified example, the pair of left and right engagement holes 760k formed in the power supply attachment 750 of the fifth modified example and the pair of left and right positioning pins 752c formed in the metal plate 760 are no longer necessary.

Next, we will explain the ninth variation of the above embodiment.

Figure 19(a) is a diagram similar to Figure 10, showing the main parts of the light source unit according to this modified example.

As shown in FIG. 19(a), the basic configuration of this modified example is the same as that of the fourth modified example described above, but the configuration of the metal plate 1160 is partially different from that of the fourth modified example described above.

That is, in this modified example, the light-emitting element 640 and the power supply attachment 650 are supported by the metal plate 1160, but a base portion 1160q is formed on the first plate surface 1160a of the metal plate 1160. The mounting area on the first plate surface 1160a of the metal plate 1160 for mounting the light-emitting element 40 is located on the base portion 1160q.

The base portion 1160q is formed with approximately the same thickness as its surrounding area by plastically deforming the metal plate 1160, and a recess 1160r is formed on its back side (i.e., the second plate surface 1160b side).

The light emitting element 640 is supported on the metal plate 1160 by fixing the body support portion 640B of the light emitting element 640 to the base portion 1160q using, for example, an adhesive.

By adopting the configuration of this modified example, it is possible to prevent the light emitted from the light-emitting element 640 from being blocked by the power supply attachment 650. Therefore, the thickness of the insulating member 652 of the power supply attachment 650 can be provided with a margin equivalent to the height of the base portion 1160q, which makes it easy to manufacture the power supply attachment 650.

In addition, even though the power supply attachment 650 is supported on the metal plate 1160 by screwing as in this modified example, the light emitted from the light emitting element 640 is less likely to be blocked by the head of the screw protruding from the power supply attachment 650.

Next, we will explain the tenth variation of the above embodiment.

Figure 19(b) is a diagram similar to Figure 19(a) showing the main parts of the light source unit according to this modified example.

As shown in FIG. 19(b), the basic configuration of this modified example is the same as that of the ninth modified example described above, but differs from the ninth modified example in that multiple heat dissipation fins 1262 are additionally arranged on the second plate surface 1260b of the metal plate 1260.

The multiple heat dissipation fins 1262 are fixed to the recess 1260r on the rear side of the base 1260q and multiple locations in the surrounding area by adhesive, welding, etc.

By adopting the configuration of this modified example, the heat generated by the light emitting element 640 can be efficiently dissipated by the multiple heat dissipation fins 1262. As a result, even though the base portion 1260q is formed on the first plate surface 1260a of the metal plate 1260 and the recess portion 1260r is formed on the back side of the base portion 1260q, the heat dissipation function of the metal plate 1260 can be sufficiently ensured.

In this modified example, the multiple heat dissipation fins 1262 are described as being separate from the metal plate 1260, but it is also possible to adopt a configuration in which they are formed integrally with the metal plate 1260.

Next, we will explain the eleventh variant of the above embodiment.

Figure 19(c) is a diagram similar to Figure 19(a) showing the main parts of the light source unit according to this modified example.

As shown in FIG. 19(c), the basic configuration of this modification is the same as that of the ninth modification, but the configuration of the metal plate 1360 is partially different from that of the ninth modification.

That is, in this modification, a pedestal portion 1360q similar to that in the ninth modification is formed on the first plate surface 1360a of the metal plate 1360, but the back side (i.e., the second plate surface 1360b side) does not have a recess 1160r like that in the ninth modification, and is formed as a flat portion 1360s that is flush with the surrounding area.

The flat portion 1360s is formed by forming the base portion 1360q by press molding, and then further plastically deforming a portion of the metal plate 1360.

By adopting the configuration of this modified example, the thickness of the portion of the metal plate 1360 where the base portion 1360q is located can be increased, thereby improving the heat dissipation function of the metal plate 1360.

Note that the numerical values shown as the specifications in the above embodiment and its modified examples are merely examples, and it goes without saying that these may be set to different values as appropriate.

Furthermore, the present invention is not limited to the configurations described in the above embodiment and its modified examples, and various other modified configurations can be adopted.

REFERENCE SIGNS LIST 10 Vehicle lamp 12 Lamp body 14 Translucent cover 20A, 20B, 20C Lamp unit 30, 130, 230, 330 Light source unit 40 Light emitting element 40A Element body 40B Body support portion 40a Light emitting surface 40b Terminal portion 50, 250, 350 Power supply attachment 50A, 250A, 350A Power supply portion 50B, 250B, 350B Connector portion 50C, 250C, 350C Intermediate portion 52 Insulating member 52A Power supply portion forming region 52B Connector portion forming region 52C Intermediate portion forming region 52a Opening 52b Flange portion 52c Positioning pin 52d Rectangular hole 52e Recess 52f Screw insertion hole 54 Bus bar electrode 54a Terminal piece 54b Pressing piece 54c Terminal pin 56 Screw 60, 160, 360 Metal plate 60a, 160a, 360a First plate surface 60b, 160b, 360b Second plate surface 60c, 360c Opening 60d Insertion hole 60e Engagement hole 60f Screw hole 70 Reflector 70a Reflecting surface 70s Reflecting element 72 Light source support portion 72a Crimping pin 80 Connector on external power supply side 160d Rear end portion 160e Downward extension portion S1 Space on first plate surface side S2 Space on second plate surface side 620A Lamp unit 630 Light source unit 640 Light emitting element 640A Element body 640B Body support portion 640a Light emitting surface 640b Terminal portion 642 Thermal transfer grease 650, 750, 850, 950, 1050 Power supply attachment 650A Power supply part 650B Connector part 650C Intermediate part 652, 752, 852, 952, 1052 Insulating member 652A, 752A Power supply part forming area 652B Connector part forming area 652C Intermediate part forming area 652a, 752a Opening 652b Flange part 652c, 852c, 952c Positioning pin 652d Rectangular hole 652e Recess 652f Screw insertion hole 654 Bus bar electrode 654a Terminal piece 654c Terminal pin 656 Screw 660, 760, 860, 960, 1060, 1160, 1260, 1360 Metal plate 660a, 760a, 860a, 960a, 1060a, 1160a, 1260a, 1360a First plate surface 660b, 860b, 960b, 1060b, 1160b, 1260b, 1360b Second plate surface 660c Opening 660d Rear end 660e Lower extension 660f Screw hole 660g, 760g Protrusion 660g1 Chamfer 660h Recess 660i, 760i Recess 660j Insertion hole 660k, 860k, 960k, 1052k Engagement hole 660m Recess 670 Reflector 670a Reflective surface 672 Light source support part 672a Caulking pin 752g, 752h Urging piece 752g1, 752h1 Inclined surface 754 Bus bar electrode 852i Through hole 852j, 952j Engagement piece 852j1, 952j1 Shaft portion 852j2, 952j2 Folded portion 860n, 960n Engagement hole 952j3 Contact portion 1000 Crimping jig 1052k1 Chamfer 1060p Burring portion 1060p1 Tip portion 1160q, 1360q Pedestal portion 1160r Recess 1262 Heat dissipation fin 1360s Flat portion A Mounting area

Claims (14)

A light source unit including a light emitting element, a power supply attachment for supplying power to the light emitting element, and a metal plate for supporting the light emitting element and the power supply attachment,
the light emitting element is supported on a first plate surface of the metal plate,
the power supply attachment is configured as an insert molding in which a bus bar electrode for establishing electrical conduction with the light-emitting element is embedded in an insulating member formed to surround the light-emitting element with a part of the bus bar electrode exposed,
the power supply attachment includes a power supply section that contacts the light emitting element to supply power, a connector section that is electrically connected to an external power source, and an intermediate section that is located between the power supply section and the connector section;
the power supply portion is supported on a first plate surface of the metal plate,
the connector portion is formed to open in a space on a second plate surface side of the metal plate,
An opening is formed in the metal plate,
The light source unit is characterized in that the power supply attachment is formed so that the intermediate portion extends through the opening . the light emitting element is mounted on the first plate surface of the metal plate via thermal conductive grease;
a first plate surface of the metal plate has a plurality of projections for positioning the light emitting element at a plurality of positions surrounding a mounting region for mounting the light emitting element;
2. The light source unit according to claim 1, wherein the light emitting element is pressed against the metal plate by the power supply attachment in a state where the light emitting element is positioned in the mounting area by the plurality of protrusions. The light source unit according to claim 2, characterized in that the tip of each of the protrusions is chamfered on the side of the mounting area. The light source unit according to claim 2 or 3, characterized in that a recess is formed in a portion of the mounting area adjacent to each of the protrusions. the light emitting element is mounted on the first plate surface of the metal plate via thermal conductive grease;
a projection portion for positioning the light-emitting element in a required direction is formed at two locations surrounding a mounting region for mounting the light-emitting element on the first plate surface of the metal plate,
the light emitting element is pressed against the metal plate by the power supply attachment,
2. The light source unit according to claim 1, wherein the power supply attachment is formed with a biasing piece for biasing the light emitting element in the required direction by contacting the light emitting element.
A light source unit according to any one of claims 1 to 5, characterized in that the power supply attachment is supported on the metal plate by engaging the power supply attachment with the metal plate. A plurality of engagement pieces are formed on the power supply attachment,
A plurality of engagement holes are formed in the metal plate,
7. The light source unit according to claim 6, wherein each of the engagement pieces is configured so that a tip portion of each of the engagement pieces engages with the metal plate when the engagement piece is inserted into the corresponding engagement hole. The light source unit according to claim 7, characterized in that at least some of the engagement pieces have abutment portions formed thereon that abut against the inner wall surface of the engagement hole when inserted into the engagement hole. The light source unit according to claim 6, characterized in that the power supply attachment and the metal plate are engaged by crimping the metal plate to the power supply attachment. A base portion is formed on a first plate surface of the metal plate,
10. The light source unit according to claim 1, wherein a mounting area for mounting the light emitting element is located on the first plate surface of the metal plate, the mounting area being located on the base portion. A vehicle lamp including the light source unit according to any one of claims 1 to 10,
The light source unit includes a reflector that reflects light emitted from the light-emitting element toward the front of the lamp.
the reflector is disposed below the light source unit,
The light source unit is supported by the reflector via the metal plate with a first plate surface of the metal plate facing downward. The vehicle lamp according to claim 11, characterized in that a plurality of pairs of the light source units and the reflectors are arranged side by side in the vehicle width direction. The opening is located on the rear side of the light emitting element,
13. The vehicular lamp according to claim 11, wherein the connector portion opens toward the rear of the lamp. 14. The vehicular lamp according to claim 11, wherein the opening is located on a front side of the reflector .

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