JP5356009B2 - LED lighting and manufacturing method - Google Patents

Description

  The present invention relates to an LED lamp and a manufacturing method, and more particularly to an lamp using a light-emitting diode mounted on a flexible printed circuit board and a manufacturing method thereof.

Conventionally, as a substitute for a fluorescent tube, an illuminating lamp having a structure in which a substrate 41 mounted with a plurality of LEDs 42 as shown in FIG. 8 is inserted into a cylinder 40 made of transparent acrylic or the like is used. However, when such an illuminating lamp is used as a substitute for a fluorescent lamp luminaire, in the manufacturing method in which the LED element is mounted on one side of the plate-like substrate 41 and inserted into the tube 40, the light irradiation direction, angle (diffusion width) ) Is limited to the direction of the arrow. In addition, when the printed circuit board is fixed in a cylinder made of acrylic or the like, there is a problem that the redesign of the printed circuit board is required due to the change in the accuracy of the fixing position and the diameter of the cylinder, and the development cost increases.
Further, in Patent Document 1, mounting protrusions to be fitted in insertion holes of a socket of a fluorescent lamp lighting fixture are provided at both ends in the longitudinal direction of a rectangular support base, and the support base is provided between the both ends in the longitudinal direction. In a fluorescent lamp type LED lamp to which an illumination board on which a plurality of LEDs are arranged is attached, a fluorescent lamp type LED lamp in which the illumination board is rotatably attached to a support base is disclosed.
Patent Document 2 discloses that a fluorescent lamp type LED lamp to be used in place of the fluorescent lamp in a ready-made fluorescent lamp luminaire is to easily and accurately maintain the mounting posture of a plurality of light emitting diodes. There is disclosed an LED lamp capable of realizing the incorporation of electric power for turning on a light emitting diode, conversion and adjustment of the electric power with a simpler configuration, and the like.
JP 2007-122933 A JP 2004-303614 A

However, the prior art disclosed in Patent Document 1 changes the light distribution direction by changing the orientation of the LED attached to the substrate, and operates the LED substrate every time the light distribution direction is changed. There is a problem that it must be troublesome.
The prior art disclosed in Patent Document 2 is to mount each LED by inserting it into an exterior material that maintains the mounting posture, and it takes time and effort to attach a large number of LEDs to the exterior material. There is a problem that becomes high.
The present invention has been made in view of such a problem. Since the LED is mounted on a flexible printed board, the board is bent and inserted into a cylindrical case, the manufacturing method is easy. And it aims at providing the illuminating lamp which implement | achieved weight reduction.
Another object is to make it possible to divert existing fluorescent lamp fixtures with a wide light distribution angle.

In order to solve this problem, the present invention provides a flexible printed circuit board, a plurality of light emitting diodes mounted on the flexible printed circuit board, and a cylindrical case having a light transmitting part at least in part. The light emitting surface of the light emitting diode is formed by the repulsive force of the flexible printed circuit board by making the length of the two opposite sides of the flexible printed circuit board shorter than the circumferential length of the inner peripheral surface of the tubular case. It is fixed only by the force pressed on the inner surface of the case.
The most significant feature of the present invention is that a plurality of light-emitting diodes are mounted on a flexible printed circuit board, and the flexible printed circuit board is bent into a cylindrical shape by utilizing the characteristics of the flexible printed circuit board and has a translucent portion at least partially. Is to be inserted into the case. This not only simplifies the manufacturing process and reduces the manufacturing cost, but also has the advantage that it can be easily replaced when the light emitting diode fails.
The flexible printed circuit board to the General consists of a material such as polyimide. Polyimide is a material excellent in insulating properties and heat resistance, and depending on the thickness, a strong repulsive force is exerted to return to the original state when bent. Therefore, in the present invention, the lengths of the two opposing sides of the flexible printed circuit board are configured to be shorter than the peripheral length of the inner peripheral surface of the cylindrical case. Here, the reason why the two opposite sides of the flexible printed circuit board are shorter than the circumferential length of the inner peripheral surface of the cylindrical case is to allow the light emitting diode to efficiently press against the inner surface of the cylindrical case by the repulsive force. . As a result, the light emitting diode can be brought into close contact with and fixed to the inner surface of the case simply by bending the flexible printed board and inserting it into the cylindrical case.

According to a second aspect of the present invention, at least a part of the cylindrical case is made of a light-transmitting material, and the cylindrical case includes a plurality of heat radiation openings.
The light emitting diode mounted on the flexible printed board is mounted so as to have a light emitting surface on the surface of the board. Therefore, light from the light emitting diode is emitted from the inner surface of the case. Therefore, in the present invention, at least a part of the cylindrical case is made of a light-transmitting material. Thereby, the light emitted from the light emitting diode can be efficiently emitted to the outside.
According to a third aspect of the present invention, a connector is provided on both short sides of the LED board on which the plurality of light emitting diodes are mounted on the flexible printed circuit board, and by connecting to the connector of another LED board, an integral multiple of the length is obtained. An LED lamp is realized .

A fourth aspect of the present invention includes a fan for ventilating the inside of the cylindrical case.
Since the illuminating lamp of the present invention has a cylindrical shape, the center portion has a structure in which air flows. Accordingly, heat generated from the light emitting diode is dissipated through the flexible printed circuit board. The heat heats the air in the case and convection naturally occurs to the outside. However, the heat becomes slow at the central portion in the axial direction and the temperature rises. Therefore, the present invention includes a fan that forcibly ventilates the air in the case. Thereby, the heat in a case can be cooled and the temperature rise of a light emitting diode can be suppressed.
According to a fifth aspect of the present invention, the light emitting color of the light emitting diode is white, red, green, and / or blue.
When using a light emitting diode for illumination, white is effective. However, depending on the application, it may be necessary to illuminate with color. Therefore, in the present invention, the light emission color of the light emitting diode is white, red, green, and / or blue. Thereby, an arbitrary color can be created by combining each color.

According to a sixth aspect of the present invention, a control unit that selectively causes each of the light emitting diodes to emit light is provided.
In order to switch the light emitting diodes of the respective colors to emit light, a driver for lighting and driving the light emitting diodes of each color is necessary. Further, in order to fix the color and light up, a circuit may be configured in hardware. However, in order to continuously change each color, a control unit that is programmed and controlled in software is necessary. Thereby, the combination of each color can be arbitrarily changed as appropriate.
According to a seventh aspect of the present invention, a reflective plate that reflects light emitted from the cylindrical case is provided.
The flexible printed circuit board housed in the cylindrical case can have a light emitting diode disposed on the inner periphery of the case. At that time, light pointing downward can be used effectively, but light pointing sideways or upward cannot be used effectively. Therefore, in the present invention, for example, when a light reflecting plate that reflects light emitted from the cylindrical case is desired to be used downward, a light reflecting plate is disposed on the cylindrical case to reflect the upward light. And change direction downward. Thereby, the light emitted from the cylindrical case can be used effectively.

According to an eighth aspect of the present invention, there is provided a step of preparing a cylindrical case having a translucent part at least in part, a step of preparing a flexible printed circuit board, a step of mounting a plurality of light emitting diodes on the flexible printed circuit board, and the light emission At least a step of bending a flexible printed circuit board mounted with a diode so that a light emitting surface of the light emitting diode faces the inner surface of the cylindrical case, and fixing only with a force pressed against the inner surface of the cylindrical case. It is characterized by that.
In the process of manufacturing the illuminating lamp of the present invention, a cylindrical case having a translucent part at least partially and a flexible printed board are prepared. Then, for example, a chip-like light emitting diode is soldered and mounted on a portion where the light emitting diode formed on the flexible printed board is mounted. Next, the flexible printed circuit board on which all the light emitting diodes have been mounted is bent and stored in the cylindrical case so that the light emitting surface of the light emitting diode faces the inner surface of the cylindrical case. Since the flexible printed circuit board is elastic, the light emitting surface of the light emitting diode is fixed in close contact with the inner surface of the cylindrical case. Thereby, a manufacturing process becomes simple and manufacturing cost can be reduced.

According to the present invention, a plurality of light emitting diodes are mounted on a flexible printed circuit board, and the manufacturing process is performed by bending the flexible printed circuit board into a tubular shape and inserting it into a tubular case, taking advantage of the characteristics of the flexible printed circuit board. Not only can the manufacturing cost be simplified, but there is also an advantage that replacement is easy when the light emitting diode fails.
In addition, since it is composed of a rectangular substrate with two opposing sides shorter than the inner circumference of the cylindrical case, the LED is attached to the inner surface of the case simply by bending the flexible printed board and inserting it into the cylindrical case. And can be fixed.
In addition, since the cylindrical case is made of a light-transmitting material, the light emitted from the light emitting diode can be efficiently emitted to the outside.
Moreover, since the cylindrical case is provided with a plurality of openings for heat dissipation, the heat accumulated between the case and the light emitting diode can be dissipated.
Moreover, since the fan which forcibly ventilates the air in a case is provided, the heat in a case can be cooled and the temperature rise of a light emitting diode can be reduced.

In addition, since the light emitting diodes use white, red, green, and / or blue, any color can be created by combining each color.
In addition, since a control unit that is programmed and controlled by software is provided to continuously change each color, the combination of each color can be arbitrarily changed as appropriate.
Further, since the reflecting plate is disposed on the cylindrical case, the light directed upward is reflected and the direction is changed downward, the light emitted from the cylindrical case can be used effectively.
In addition, a cylindrical case with translucency and a flexible printed circuit board on which a circuit pattern is formed are prepared, and the light emitting diode is soldered and mounted on the portion of the flexible printed circuit board on which the light emitting diode is mounted. The flexible printed circuit board on which all the light emitting diodes have been mounted is stored in the cylindrical case so that the light emitting surface of the light emitting diode faces the inner surface of the cylindrical case so that the light emitting surface of the light emitting diode is cylindrical. It is fixed in close contact with the inner surface of the case, the manufacturing process is simplified, and the manufacturing cost can be reduced.

Hereinafter, the present invention will be described in detail with reference to embodiments shown in the drawings. However, the components, types, combinations, shapes, relative arrangements, and the like described in this embodiment are merely illustrative examples and not intended to limit the scope of the present invention only unless otherwise specified. .
FIG. 1 is a view showing an example of a flexible printed circuit board used in the LED illumination lamp of the present invention. The flexible printed circuit board 1 generally uses polyimide as a material. A plurality of patterns 3 for mounting light emitting diodes (hereinafter referred to as LEDs) are formed on the surface, and each pattern 3 is connected by a circuit pattern 2. In this example, the pattern is formed so that all the LEDs are driven in parallel. However, the present invention is not limited to this, and a group in which several LEDs are connected in series may be connected in parallel. A pattern 17 for attaching a connector for connecting to an external control unit (not shown) is also provided. Further, in order to provide compatibility with existing fluorescent lamp fixtures, the base portion may have the same shape as an existing fluorescent tube, and the LED may be driven by AC power (AC 100 V). Further, when the dimension in the width direction of the flexible printed circuit board 1 is W and the dimension in the length direction is L, the dimension W in the width direction is W < It is configured to be P. Thereby, the error of the internal diameter of an illumination tube can be absorbed and the flexible printed circuit board 1 can be easily inserted in an illumination tube.

FIG. 2A is a diagram showing a state in which LEDs are mounted on a flexible printed circuit board. Here, a substrate in which the LED 4 is mounted on the flexible printed circuit board 1 is referred to as an LED substrate 10. The LED board 10 mounts the LEDs 4 in the same direction on the pattern 3 formed on the flexible printed board 1. Actually, it is automatically mounted by a mounting machine and soldered by reflow. Thereafter, the connector 6 is connected to the pattern 17 via the cable 5. Therefore, all the LEDs mounted on the flexible printed circuit board 1 can be turned on simultaneously by connecting the connector 6 to the power source. Further, the arrangement direction of the LEDs may be linear as shown in FIG. 2 or may be arranged in a staggered manner.
FIG. 2B is a diagram for realizing a long LED lamp by connecting the LED substrates 10 in cascade. By preparing the connectors 21 and 22 on the short sides on both sides of the LED substrate 10 and connecting them to each other, an LED lamp having an integral multiple length can be realized. Here, the connectors 21 and 22 are a male type and a female type, respectively.
FIG. 3 is a diagram illustrating a state in which the LED substrate is bent and stored in a cylindrical case. FIG. 3A is a diagram showing a state in which the LED substrate is bent, FIG. 3B is a diagram showing a state in which the LED substrate is completely inserted into the cylindrical case, and FIG. 3C is a diagram showing FIG. 3B. It is the figure seen from the cross section.
The most significant feature of the present invention is that a plurality of LEDs 4 are mounted on the flexible printed circuit board 1, and the flexible printed circuit board 1 is bent into a cylindrical shape by utilizing the characteristics of the flexible printed circuit board 1 (FIG. 3A). It is to insert into the cylindrical case 7 having the property (transparent or translucent). Thereby, not only can the manufacturing process be simplified and the manufacturing cost can be reduced, but also there is an advantage that replacement is easy when the LED 4 fails.

In general, the flexible printed circuit board 1 is made of a material such as polyimide. Polyimide is a material excellent in insulation and heat resistance, and depending on the thickness, a strong repulsive force is exerted to return to the original when bent (direction of arrow in FIG. 3C). Therefore, in the present invention, the rectangular substrate 1 is formed with two sides (W) shorter than the circumferential length of the inner peripheral surface of the cylindrical case 7 facing each other. Here, the reason why the two opposite sides of the flexible printed circuit board 1 are made shorter than the circumferential length of the inner peripheral surface of the cylindrical case 7 is to allow the LED 4 to efficiently press against the inner surface of the cylindrical case 7 by the repulsive force. It is. In addition, the flexible printed circuit board 1 can be bent and easily inserted into the cylindrical case 7. Thus, the LED 4 can be brought into close contact with and fixed to the inner surface of the case simply by bending the flexible printed board 1 and inserting it into the cylindrical case 7.
Moreover, LED4 mounted in the flexible printed circuit board 1 is mounted so that it may have a light emission surface on the surface of a board | substrate. Therefore, the light from the LED 4 is emitted from the inner surface of the cylindrical case 7 to the outside. Therefore, in the present invention, the cylindrical case 7 is made of a translucent material. Thereby, the light emitted from the LED 4 can be efficiently emitted outside. Moreover, by making it translucent, the light of LED can be diffused and a soft light-emitting source can be made.

  Moreover, the process which manufactures the illuminating lamp of this invention prepares the cylindrical case 7 which has translucency, and the flexible printed circuit board 1 in which the circuit pattern was formed (FIG. 1). Then, for example, a chip-like LED 4 is soldered and mounted on a portion where the LED 4 formed on the flexible printed board 1 is mounted (FIG. 2). Next, the LED substrate 10 on which all the LEDs 4 have been mounted is curved so that the light emitting surface of the LED 4 faces the inner surface of the cylindrical case 7 (FIG. 3A), and is stored in the cylindrical case 7 ( FIG. 3 (b)). Since the flexible printed circuit board 1 is elastic, the light emitting surface of the LED 4 is fixed in close contact with the inner surface of the cylindrical case 7 (FIG. 3C). Thereby, a manufacturing process becomes simple and manufacturing cost can be reduced.

FIG. 4 is a view showing another embodiment of a cylindrical case according to the LED illumination lamp of the present invention. The cylindrical case 8 of the present invention is provided with a plurality of openings 9 for heat dissipation. That is, the luminous efficiency of the LED 4 has a value comparable to the highest luminous efficiency of the fluorescent lamp. However, thermal energy is also released from the surface. Therefore, if a large number of LEDs 4 are turned on at the same time, heat is accumulated between the cylindrical case 8 and the LEDs, and the LED 4 is adversely affected. Therefore, in the present invention, the cylindrical case 8 is provided with a plurality of openings 9 for heat dissipation. Thereby, the heat accumulated between the cylindrical case 8 and the LED 4 can be dissipated. The shape of the opening 9 may be any shape.
FIG. 5 is a view showing another embodiment of the cylindrical case according to the LED illumination lamp of the present invention. The cylindrical cases 7 and 8 of the present invention are provided with a fan 11 for ventilating the inside of the cylindrical cases 7 and 8. The fan 11 is provided at the tip of the cylindrical cases 7 and 8, and determines the rotation direction of the motor 12 so as to intake or exhaust air in the cylindrical cases 7 and 8. That is, since the LED lighting lamp 20 of the present invention has a cylindrical shape, the center portion has a structure in which air flows. Therefore, the heat generated from the LEDs 4 is radiated through the surfaces of the flexible printed circuit board 1 and the cylindrical cases 7 and 8. The heat heats the air in the cylindrical cases 7 and 8 to cause convection naturally with the outside, but becomes slow at the central portion in the axial direction and the temperature rises. Therefore, the present invention includes a fan 11 that forcibly ventilates the air in the cylindrical cases 7 and 8. Thereby, the heat | fever in the cylindrical cases 7 and 8 can be cooled, and the temperature rise of LED4 can be suppressed.
Moreover, the heat dissipation effect can be enhanced by bringing the LED elements of the flexible printed circuit board 1 into close contact with the cylindrical cases 7 and 8. Further, by roughening the outer sides of the cylindrical cases 7 and 8, the surface area can be increased and the heat dissipation effect can be enhanced.

FIG. 6 is a diagram showing a light path when the LED illumination lamp of the present invention is provided with a reflecting plate. In the present invention, the reflector 13 that reflects the light emitted from the cylindrical case 7 or 8 is provided. That is, the flexible printed circuit board 1 accommodated in the cylindrical case 7 or 8 can arrange the LEDs 4 on the circumference of the cylindrical case 7 or 8. At that time, the light 16 pointing downward can be used effectively, but the light pointing sideways or upward cannot be used effectively. Therefore, in the present invention, for example, when it is desired to use the reflection plate 13 that reflects light emitted from the cylindrical case 7 or 8 downward, the reflection plate 13 is disposed on the cylindrical case 7 or 8, The light 14 and 15 pointing upward is reflected to change the direction downward. Thereby, the light emitted from the cylindrical case 7 or 8 can be used effectively.
FIG. 7 is a diagram showing a control circuit when the LED illumination lamp of the present invention is colored. When the LED is used for illumination, white is effective. However, depending on the application, it may be necessary to illuminate with color. Therefore, in the present invention, white, red, green, and / or blue are used as the emission colors of the LEDs. Thereby, an arbitrary color can be created by combining each color. And the control part 30 which selectively light-emits white, red, green, and / or blue LED was provided. In the configuration of the present invention, a control unit 30 and a driver for driving the LED, a switching unit 31 for selectively switching the driver from the control unit 30, and B1 in which the LEDs of each color of R, G, B are made into one block. To Bn. That is, in order to switch the LEDs of each color to emit light, a driver that drives each LED of each color to light is required. Further, in order to fix the color and illuminate, a circuit may be configured in hardware. However, in order to continuously change each color, a control unit 30 that is programmed and controlled by software is necessary. Thereby, the combination of each color can be arbitrarily changed as appropriate.

It is a figure which shows an example of the flexible printed circuit board used for the LED illumination light of this invention. (A) is a figure which shows a mode that LED was mounted in the flexible printed circuit board, (b) is a figure which shows a mode that the flexible printed circuit board was connected in cascade. (A) is a figure which shows a mode that the LED board was curved, (b) is a figure which shows a mode that insertion of the LED board was completed to a cylindrical case, (c) is the figure which looked at (b) from the cross section. It is a figure which shows other embodiment of the cylindrical case which concerns on the LED lighting lamp of this invention. It is a figure which shows other embodiment of the cylindrical case which concerns on the LED lighting lamp of this invention. It is a figure which shows the path | route of light at the time of providing the reflecting plate in the LED lighting lamp of this invention. It is a figure which shows the control circuit at the time of making the LED illumination light of this invention into a color. It is a figure which shows the cross-sectional structure of the conventional LED illuminating lamp.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Flexible printed circuit board, 2 Circuit pattern, 3 pattern, 4 LED, 5 Cable, 6 Connector, 7, 8 Cylindrical case, 9 Opening part, 10 LED board, 11 Fan, 12 Motor, 13 Reflector, 20 LED lighting , 30 control unit, 31 switching unit

Claims (8)

A flexible printed circuit board, a plurality of light emitting diodes mounted on the flexible printed circuit board, and a cylindrical case having a translucent part at least in part,
By making the length of the two opposite sides of the flexible printed circuit board shorter than the peripheral length of the inner peripheral surface of the cylindrical case, the light emitting surface of the light emitting diode is made to be in the cylindrical case by the repulsive force of the flexible printed circuit board. An LED illumination lamp characterized by being fixed only by a force pressed against the inner surface.   2. The LED according to claim 1, wherein at least a part of the cylindrical case is made of a translucent material, and the cylindrical case includes a plurality of heat radiation openings. Lighting light. An LED lamp having an integral multiple is realized by providing connectors on the short sides on both sides of the LED board on which the plurality of light emitting diodes are mounted on the flexible printed board, and connecting to the connectors on the other LED boards. The LED illumination lamp according to claim 1 or 2 , wherein The LED illumination lamp according to any one of claims 1 to 3 , further comprising a fan for ventilating the inside of the cylindrical case. The emission color of the light-emitting diodes, white, red, green, or / and, LED lighting according to any one of claims 1 to 4, characterized in that it is blue. The LED illumination lamp according to any one of claims 1 to 5 , further comprising a control unit that selectively causes each of the light emitting diodes to emit light. The LED illumination lamp according to any one of claims 1 to 6 , further comprising a reflector that reflects light emitted from the cylindrical case. A step of preparing a cylindrical case having a light-transmitting part at least in part, a step of preparing a flexible printed circuit board, a step of mounting a plurality of light emitting diodes on the flexible printed circuit board, and a flexible structure mounting the light emitting diodes A step of bending the printed circuit board so that a light emitting surface of the light emitting diode faces the inner surface of the cylindrical case and fixing only with a force pressed against the inner surface of the cylindrical case. Manufacturing method of LED lighting.

Images