Lighting device and method manufacturing holder of lighting device

Patent metadata

Field	Value
Publication number	US-9052104-B2
Application number	US-201213978770-A
Country	US
Kind code	B2
Filing date	Jan 20, 2012
Priority date	Jan 21, 2011
Publication date	Jun 9, 2015
Grant date	Jun 9, 2015

Abstract

A lighting device includes a light source that includes at least one LED element and a module including a substrate on which the light source is mounted, and a holder in which at least a part of the module is arranged and held. The holder includes a cylindrical portion that includes a stepped portion and a flange of a heat conductor extending from an outer peripheral edge of the stepped portion on which the substrate is arranged, and the holder includes an insulation layer that covers at least outer peripheral surface of the cylindrical portion.

First claim

The invention claimed is:

1. A lighting device, comprising:
a module comprising a substrate and a light source that comprises at least one light-emitting diode element and that is mounted on the substrate; and
a holder comprising a heat conductor that is thermally connected to the at least one light-emitting diode element of the light source, and comprising an insulation layer, wherein
the heat conductor comprises an annular and flat stepped portion to support the substrate of the module, and comprises a flange that extends toward a front of the lighting device from an outer peripheral edge of the annular and flat stepped portion,
the insulation layer covers an outer peripheral surface of the heat conductor, the insulation layer extending from the outer peripheral surface, passing over an upper portion of the flange toward the front of the lighting device, and extending to an inner peripheral surface of the flange, and
the insulating layer comprises a stepped portion at an upper end toward the front of the lighting device, the stepped portion for holding a lens that is arranged to cover the light source of the module.

2. The lighting device according to claim 1 , wherein
the insulation layer covers at least a part of the inner peripheral surface of the flange.

3. The lighting device according to claim 1 , wherein
the holder comprises a body portion having a space therein, the space being demarcated by the heat conductor that extends from an inner peripheral edge of the annular and flat stepped portion under the substrate of the module toward a rear of the lighting device, and
the module further comprises a drive circuit that is arranged in the space of the holder and that is configured to drive the at least one light-emitting diode element of the light source.

4. The lighting device according to claim 3 , further comprising:
a base portion comprising a pair of electrical contacts that are electrically connected to the drive circuit, and disposed at a lower end of the holder toward the rear of the lighting device.

5. The lighting device according to claim 3 , wherein
the flange has an annular shape,
the inner peripheral edge of the annular and flat stepped portion is annular,
the heat conductor further comprises a cylindrical portion that is positioned inside the body portion of the holder and extends from the annular inner peripheral edge of the annular and flat stepped portion toward a position under the substrate of the module toward the rear of the lighting device, and the insulation layer covers at least an outer peripheral surface of each of the annular and flat stepped portion, the annular flange and the cylindrical portion of the heat conductor.

6. The lighting device according to claim 1 , wherein
the insulation layer is integrated with the outer peripheral surface of the heat conductor.

7. The lighting device according to claim 1 , wherein
the insulation layer comprises multi-layers formed on the outer peripheral surface of the heat conductor.

8. The lighting device according to claim 1 , wherein
the heat conductor comprises at least one heat-releasing fin that extends from the outer peripheral surface of the heat conductor toward an outside of the heat conductor.

9. The lighting device according to claim 1 , further comprising:
a lens covering the light source that is mounted on the substrate.

10. The lighting device according to claim 1 , wherein
the heat conductor is made of a metal.

11. The lighting device according to claim 10 , wherein
the heat conductor comprises at least one metal among of aluminum, iron, and brass.

12. The lighting device according to claim 1 , wherein
the insulation layer is made of a resin.

13. The lighting device according to claim 11 , wherein
the insulation layer comprises at least one resin of polybutylene terephthalate resin and polycarbonate resin.

14. The lighting device according to claim 1 , further comprising:
a circular heat-conducting plate disposed between a lower surface of the substrate on which the light source is mounted and the annular and flat stepped portion of the heat conductor.

15. A lighting device, comprising:
a module comprising a substrate and a light source that comprises at least one light-emitting diode element and that is mounted on the substrate; and
a holder comprising a heat conductor that is thermally connected to the at least one light-emitting diode element of the light source and comprising an insulation layer,
the heat conductor comprising an annular stepped portion provided on an upper portion of the holder toward a front of the lighting device, an annular flange that extends toward the front of the lighting device from an annular outer peripheral edge of the annular stepped portion and a cylindrical portion that extends from an annular inner peripheral edge of the annular stepped portion under the substrate toward a rear of the lighting device,
the insulation layer covering an outer peripheral surface of the heat conductor, the insulation layer passing over an upper portion of the flange toward the front of the lighting device and extending to an inner peripheral surface of the flange,
the insulation layer comprises a stepped portion at an upper end toward the front of the lighting device, and
the substrate on which the light source of the module is mounted is supported on the annular stepped portion of the heat conductor.

16. The lighting device according to claim 15 , further comprising:
a drive circuit comprising a board, the drive circuit being configured to drive the at least one light-emitting diode element of the light source,
wherein the heat conductor includes a space in the cylindrical portion under the substrate on which the light source of the module is mounted, and at least the board of the drive circuit is contained in the space in the cylindrical portion of the heat conductor.

17. A method for manufacturing a holder of a lighting device, the method comprising:
disposing a heat conductor comprising a stepped portion and a flange that extends toward a front of the lighting device from a peripheral edge of the stepped portion in a die;
injecting a resin between an inner surface of the die and an outer peripheral surface of the heat conductor to form an insulation layer integrated on the outer peripheral surface of the heat conductor; and
pressing the stepped portion of the heat conductor against the die by an injection pressure to flow the resin to pass over a top portion of the flange of the heat conductor toward the front of the lighting device and to reach an inner peripheral surface of the flange when injecting the resin between the inner surface of the die and the outer peripheral surface of the heat conductor.

Assignees

• Watanabe Masashi
• Akiyama Takashi
• Tonosaki Atsushi
• Shimura Takashi
• Kobayashi Ken
• Citizen Electronics
• Citizen Holdings Co Ltd

Inventors

• Watanabe Masashi
• Akiyama Takashi
• Tonosaki Atsushi
• Shimura Takashi
• Kobayashi Ken

Classifications

• B29C45/14467 Primary

  Joining articles or parts of a single article (B29C45/14377, B29C45/14385, B29C45/14581, B29C45/14614 and B29C45/006 take precedence) · CPC title

• F21V29/89

  Metals · CPC title

• F21K9/1375

  Mechanical Engineering · mapped topic

• F21V29/2206 Primary

  Mechanical Engineering · mapped topic

• F21V29/74

  with fins or blades · CPC title