Light source unit, method of manufacturing the same, and vehicle lamp

Patent metadata

Field	Value
Publication number	US-2016290621-A1
Application number	US-201615084591-A
Country	US
Kind code	A1
Filing date	Mar 30, 2016
Priority date	Mar 31, 2015
Publication date	Oct 6, 2016
Grant date	—

Abstract

In one embodiment of a light source unit, the heat-dissipation plate is provided with a first heat-dissipation portion in contact with the substrate, the resin molding part is provided with a plurality of heat-dissipation fins and an engaging portion to be engaged with a predetermined member, and the socket housing is formed by an integral molding of the heat-dissipation plate and the resin molding part.

First claim

1 . A light source unit comprising:
a socket housing that has a heat-dissipation plate formed of a metallic material and a resin molding part; a substrate mounted on the socket housing; and a light emitting element serving as a light source and mounted on the substrate, wherein the beat-dissipation plate is provided with a first beat-dissipation portion in contact with the substrate, the resin molding part is provided with a plurality of heat-dissipation fins and an engaging portion to be engaged with a predetermined member, and the socket housing is formed by an integral molding of the heat-dissipation plate and the resin molding part.

2 . The light source unit according to claim 1 , wherein
the heat-dissipation plate is provided with a second heat-dissipation portion perpendicular to the first heat-dissipation portion.

3 . The light source unit according to claim 2 , wherein
the second heat-dissipation portion is positioned at an inside of an outermost heat-dissipation fin out of the plurality of heat-dissipation fins.

4 . The light source unit according to claim 2 , wherein
the heat-dissipation plate is provided with a third heat-dissipation portion which is bent in a direction perpendicular to the first heat-dissipation portion and is continuous with the first heat-dissipation portion.

5 . The light source unit according to claim 4 , wherein
the heat-dissipation plate is provided with a fourth heat-dissipation portion which is bent in a direction perpendicular to both of the second beat-dissipation portion and the third heat-dissipation portion and is continuous with both of the second heat-dissipation portion and the third heat-dissipation portion.

6 . The light source unit according to claim 1 , wherein
the socket housing is formed with a placement recess in which the substrate is placed, the substrate is attached to the heat-dissipation plate by an adhesive, and a gap is formed between an inner peripheral surface of the placement recess and an outer peripheral surface of the substrate.

7 . The light source unit according to claim 1 , further comprising a wiring pattern formed on the substrate, wherein
the wiring pattern is respectively formed on a front surface and a rear surface of the substrate, a front-side control element is arranged on the wiring pattern formed on the front surface of the substrate, a rear-side control element is arranged on the wiring pattern formed on the rear surface of the substrate, and at least a portion of the front-side control element and at least a portion of the rear-side control element are arranged offset from each other.

8 . The light source unit according to claim 7 , wherein
a first light emitting element to emit light in a first lighting state and a second light emitting element to emit light in a second lighting state are provided as the light emitting element, a first front-side control element to generate heat in the first lighting state and a second front-side control element to generate heat in the second lighting state are provided as the front-side control element, a first rear-side control element to generate heat in the first lighting state and a second rear-side control element to generate heat in the second lighting state are provided as the rear-side control element, at least a portion of the first front-side control element and at least a portion of the first rear-side control element are arranged offset from each other, and at least a portion of the second front-side control element and at least a portion of the second rear-side control element are arranged offset from each other.

9 . The light source unit claim 7 , wherein
the substrate is bonded to the heat-dissipation plate by an adhesive, and the adhesive is applied on the rear-side control element.

10 . The light source unit according to claim 9 , wherein
the adhesive is a silicone resin containing filler.

11 . The light source unit according to claim 1 , further comprising a wiring pattern formed on the substrate, wherein
the substrate is attached to the heat-dissipation plate in the state where the rear side of the substrate faces the first heat-dissipation portion, and a convex portion having a heat-dissipation property is provided at the region of the rear surface of the substrate other than the region having the wiring pattern Ruined thereon.

12 . A method of manufacturing a light source unit, in which the light source unit includes a socket housing which has a heat-dissipation plate formed of a metallic material and a resin molding part formed by solidifying a thermal conductive molten resin, comprising:
a holding process of supporting a supported portion of the heat-dissipation plate in a cavity of a mold by a movable die and holding the heat-dissipation plate in the cavity; a first filling process of filling the molten resin into the cavity and covering a portion of the heat-dissipation plate excluding a part thereof by the molten resin; and a second filling process of moving the movable die relative to the mold to release a support state of the supported portion and covering the supported portion by the molten resin.

13 . The vehicle lamp comprising a light source unit according to claim 1 .

Assignees

• Koito Mfg Co Ltd

Inventors

• Ozawa Atsushi
• Serita Takuya
• Murata Yoshimasa
• Naito Ryota
• Kumeta Takahiro

Classifications

• F21S45/48

  with means for conducting heat from the inside to the outside of the lighting devices, e.g. with fins on the outer surface of the lighting device · CPC title

• F21S41/151

  arranged in one or more lines · CPC title

• F21S43/14 Primary

  Light emitting diodes [LED] · CPC title

• F21Y2115/10

  Light-emitting diodes [LED] · CPC title

• F21V29/74 Primary

  with fins or blades · CPC title