JP5479994B2 - LED luminaire manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing a lighting fixture using LEDs.

  Conventionally, incandescent lamps, fluorescent lamps and the like have been generally used as lighting fixtures. Lighting fixtures using incandescent lamps and fluorescent lamps have a certain size of components, and also require space for heat dissipation, which increases the size of the lighting fixture itself, If it is desired to distribute light in different directions, it is necessary to install a similar instrument in that direction, which further increases the size.

  In recent years, instead of incandescent lamps and fluorescent lamps, LEDs are being replaced in various lighting fields due to their low power consumption and long life. The main body of the LED can be reduced in size, and from these aspects, the replacement of the conventional incandescent lamp and fluorescent lamp is rapidly progressing. Under such circumstances, various types of LED lighting fixtures have been proposed in which the fixture is miniaturized and features low power consumption and long life.

  For example, Patent Literature 1 discloses an LED lighting apparatus including a substrate on which surface-mounted LEDs are mounted in a straight tubular translucent tube. Patent Document 2 discloses an LED lighting apparatus in which an LED is disposed on a lid portion that is fitted in an opening of a long mounting base having a substantially U-shaped cross section disposed on a floor surface or the like. Has been.

  However, since the lighting fixtures of Patent Documents 1 and 2 have a linear glove, they only function as a linear light source, bend two-dimensionally or three-dimensionally, and do not function as a three-dimensional light source. Moreover, it cannot function as indirect illumination which emits soft light because of the shape of the globe. Further, since the LED light source has strong directivity, luminance unevenness occurs on the light transmission surface of the globe, resulting in a bright and dark eyeball-shaped lamp image, which is not suitable as a lighting fixture.

  As a method for removing the lamp image, Patent Documents 3 and 4 propose a light diffusing sheet in which various light diffusing materials are contained in a transparent synthetic resin sheet. However, Patent Documents 3 and 4 simply propose a sheet-like member and do not disclose any specific shape of the globe.

JP 2002-197901 A JP 2005-19299 A Japanese Patent No. 3663835 JP-A-10-3811

The present invention provides a method for manufacturing an LED lighting apparatus that has a pipe portion bent in two dimensions or three dimensions, functions as a three-dimensional light source, and has few lamp images derived from the directivity of the LED light source. Objective.

That is, the manufacturing method of the LED lighting apparatus of the present invention includes an LED light source disposed inside the pipe portion of a molded body having a pipe portion having a curved pipe portion and made of a light-transmitting resin, and an outer surface of the pipe portion. pipe portion cavity having an at least an inner surface of at least a portion of the inner surface, a method for manufacturing an LED luminaire having fine irregularities, the outlet at the other end has a pressure port having a floating core at one end After injecting the molten resin into the pipe cavity of the mold provided with the above, the pressurized fluid is press-fitted from the pressurized port to move the floating core to the discharge port side and from the discharge port Forming the molded body by extruding a molten resin, the floating core has fine irregularities on the surface, and the movement of the floating core causes a pie Wherein the allowed to produce fine irregularities on portion surface.

  ADVANTAGE OF THE INVENTION According to this invention, it has a pipe part bent in two dimensions or three dimensions, functions as a three-dimensional light source, and the LED lighting fixture with few lamp images derived from the directivity of an LED light source is obtained. In addition, since the number of lamp images is small, the number of LEDs can be reduced, which is useful for reducing energy consumption and cost. Furthermore, when it has a fin part and a flat plate part, it can function also as indirect illumination which emits soft light by transmitting light through the pipe part having the curved pipe part. Therefore, the LED lighting device of the present invention is suitable as a lighting device used for a footlight, a spotlight, etc. installed in an architect house, a vehicle or indoors or outdoors, or a lighting device used for an electric sign for an advertisement signboard. is there.

It is a figure which shows an example of the LED lighting fixture of this invention. It is a figure which shows an example of the LED mounting board used by this invention. It is a figure which shows the state which inserts an LED mounting substrate in a glove. It is a figure which shows an example of the LED lighting fixture of this invention. It is a figure which shows an example of the LED mounting board used by this invention. It is a figure which shows an example of the LED lighting fixture which has a fin part of this invention. It is a figure which shows an example of the LED lighting fixture which has a fin part of this invention. It is a figure which shows an example of the LED lighting fixture which has a flat plate part of this invention. It is a figure which shows an example of the metal mold | die used for manufacturing the glove of the LED lighting fixture of FIG. It is explanatory drawing of the manufacturing method of this invention, and is a figure which shows the state which filled the metal mold cavity with molten resin. It is explanatory drawing of the manufacturing method of this invention, and is a figure which shows the state with which resin was filled in the cavity which moves a floating core by press injection of a pressurized fluid, and accommodates excess resin. It is a figure which shows an example of the metal mold | die used for manufacturing the glove of the LED lighting fixture of FIG. It is explanatory drawing of the manufacturing method of this invention, and is a figure which shows the state which filled the metal mold cavity with molten resin. It is explanatory drawing of the manufacturing method of this invention, and is a figure which shows the state with which resin was filled in the cavity which moves a floating core by press injection of a pressurized fluid, and accommodates excess resin. It is sectional drawing which shows an example of the floating core used by this invention. It is a figure which shows an example of the geometric pattern formed in the pipe part cavity surface of a metal mold | die.

  Hereinafter, the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a diagram showing an example of an LED lighting apparatus according to the present invention.

The LED lighting apparatus shown in FIG. 1 includes an LED mounting substrate as an LED light source in a glove (molded body) made of a translucent resin pipe portion 1 having straight pipe portions 2 and curved pipe portions 3 alternately and continuously. 6 is disposed. One end of the LED mounting substrate 6 is connected to the control unit 7 and the power supply unit 8, and the other end is fixed to the attachment unit 9 by an appropriate means. As shown in FIG. 2, the LED mounting substrate 6 has the LED 5 surface-mounted on a flexible tape-like substrate 4 and can be easily inserted from the opening of the pipe portion 1 as shown in FIG.

  Fine irregularities are provided on the entire inner surface and outer surface of the pipe portion 1. For this reason, the light with strong directivity from an LED light source is scattered when it permeate | transmits a pipe part, and it can remove a lamp image.

  The shape, size, and depth of fine irregularities on the inner surface and outer surface of the pipe portion 1 are not particularly limited, but the depth is preferably 30 μm to 1000 μm. If it is 30 μm or more, a light scattering effect is recognized, which is effective in removing a lamp image. Moreover, if it is 1000 micrometers or less, it is effective for lamp image removal, and the problem of the external appearance of a glove | globe, the ease of stain | pollution | contamination, and an intensity | strength do not arise.

  Examples of a method for forming fine irregularities on the outer surface of the pipe part 1 include a method of transferring at the time of injection molding using a mold in which fine irregularities are formed on a cavity surface. In particular, when a so-called textured mold cavity is used, a ground glass-like pipe outer surface is obtained, which is preferable.

  As a method of forming fine irregularities on the inner surface of the pipe portion 1, for example, when forming by an injection molding method using a floating core described later, a floating core having fine irregularities on the surface is used. And a method of forming streaky or random fine irregularities.

  In the LED lighting apparatus shown in FIG. 1, fine irregularities are provided on the entire inner surface and outer surface of the pipe portion 1, but fine irregularities may be provided on only one of the inner surface and the outer surface, or the inner surface may be provided. Or you may provide a fine unevenness | corrugation only in a part of outer surface.

  Although the other example of the LED lighting fixture of this invention is shown below, in any example, the fine unevenness | corrugation is provided in the whole inner surface of the pipe part 1, and the outer surface. Of course, like the LED lighting apparatus shown in FIG. 1, fine irregularities may be provided only on one of the inner surface and the outer surface of the pipe portion 1, or fine irregularities may be provided only on a part of the inner surface or the outer surface.

  4 is the same as the LED lighting apparatus of FIG. 1 except that the LED double-sided mounting substrate 12 is used. The LED double-sided mounting board 12 uses two LED mounting boards 12 ′ in which a plurality of LED mounting board units 12 ″ in which the LEDs 5 are surface-mounted on the board 4 shown in FIG. The back side of the substrate 4 is joined by an appropriate means such as adhesion so as to be staggered.

  6 and 7 are views showing an example of an LED lighting apparatus having a fin portion in which a globe is injection-molded integrally with a pipe portion.

  The LED lighting apparatus shown in FIG. 6 is orthogonal to the axial direction of the translucent resin pipe parts 1 having the straight pipe parts 2 and the curved pipe parts 3 alternately and continuously, and the straight pipe part 2 of the pipe part 1. An LED double-sided mounting substrate 12 is disposed inside a pipe portion 1 of a globe composed of a disk-shaped light-transmitting resin fin portion 13. Since the globe is integrally formed by injection molding, there is no welded portion or joint between the pipe portion 1 and the fin portion 4. One end of the LED double-sided mounting substrate 12 is connected to a control unit and a power supply unit (not shown), and the other end is fixed to the attachment unit 9 by appropriate means. The LED double-sided mounting substrate 12 is obtained by using two flexible LED mounting substrates 6 shown in FIG. 2 and bonding the back side of the substrate 4 by an appropriate means such as bonding so that the LEDs 5 are alternated.

  On the other hand, the LED lighting apparatus shown in FIG. 7 (LED double-sided mounting board, control unit, power supply unit not shown) is a rectangular plate in which fin portions are provided in parallel to the axial direction of the straight pipe portion 2 of the pipe portion 1. Except for the fin portion 13 having the shape, it is the same as the LED lighting apparatus of FIG.

  In the LED lighting device having the fin portion, light from the LED light source transmits not only the pipe portion but also the fin portion, and the lighting device is suitable as a soft light source such as indirect lighting. Further, by forming fine irregularities similar to those formed on the outer surface of the pipe part on at least a part of the surface of the fin part, the light transmitted through the fin part is also scattered, and the lamp image is more effectively removed. be able to. Furthermore, the fin portion also has a function of radiating heat generated from the LED light source, which can contribute to durability and brightness improvement of the LED lighting apparatus.

  FIG. 8 is a view showing an example of an LED lighting apparatus having a flat plate portion in which a globe is integrally molded with a pipe portion, where (a) is a top view and (b) is a side view.

  The globe of the LED lighting apparatus shown in FIG. 8 has a straight pipe part 2 and a curved pipe part 3 continuously, and a pipe part 1 having an alphabet character shape of “RP” is arranged on a flat plate part 21. Has been. Further, the end portion of the pipe portion 1 is connected to one of the side plate portions 22 erected from the end portion of the flat plate portion 21. In the side plate portion 22 to which the end portion of the pipe portion 1 is connected, an access hole 23 equivalent to the inner diameter of the pipe portion 1 is formed. Since the globe is integrally formed by injection molding, there is no welded portion or joint between the pipe portion 1, the flat plate portion 21, and the side plate portion 22. Inside the pipe portion 1 of the globe, an LED double-sided mounting substrate 12 inserted from the access hole 23 is disposed. In order to make it easier to dispose a long LED mounting substrate such as the LED double-sided mounting substrate 12 in the pipe portion 1, it is desirable that the cross-sectional shape of the hollow portion of the pipe portion 1 is a smooth circle.

  In LED lighting fixtures with a flat plate part, light from the LED light source is transmitted not only through the pipe part but also through the flat plate part around the pipe part, making it suitable as an indirect lighting or electric sign such as one-stroke character shape as a surface emitting lighting fixture Lighting equipment. Further, by forming fine irregularities similar to those formed on the outer surface of the pipe part on at least part of the surface of the flat part, preferably at least part of the surface of the flat part around the pipe part, the flat part is transmitted. The scattered light is also scattered, and the lamp image can be removed more effectively. Furthermore, the flat plate portion also has a function of dissipating heat generated from the LEDs, which can contribute to the durability and brightness improvement of the LED lighting apparatus. Moreover, a flat plate part can also be made to act as a support body of a pipe part.

  Examples of the translucent resin used in the present invention include any thermoplastic resin and thermosetting resin that can be injection-molded. From the viewpoint of pipe moldability in injection molding, a thermoplastic resin is preferred. Specifically, PMMA, polycarbonate, polystyrene, transparent ABS, AS resin, MS resin, cyclic olefin resin, PVC, and transparent resins such as PSU, PES, PEI, polymethylpentene, and PAR as high heat resistant resins Can be mentioned. In the translucent resin, in order to reduce the directivity of the LED light source and more effectively remove the lamp image, inorganic light diffusing materials such as titanium oxide, silicon oxide, calcium carbonate, talc, or crosslinked polystyrene fine particles, It is preferable to add an organic light diffusing material such as crosslinked polymethyl methacrylate fine particles and silicon-based crosslinked fine particles. The content of the light diffusing material is preferably 0.5 wt% to 15 wt%, more preferably 1 wt% to 5 wt%. If the content of the light diffusing material is less than 0.5 wt%, a sufficient light diffusing effect may not be obtained, and if it exceeds 15 wt%, the light transmission is inhibited, and physical properties as a glove cannot be obtained. May cause problems. The translucent resin may be colored as long as the necessary translucency is satisfied.

  Although it does not specifically limit as an LED light source used by this invention, The LED mounting substrate with which several LED was surface-mounted by the LED single-piece | unit integrated with the board | substrate is used preferably. The LED mounting substrate preferably has flexibility so that it can be inserted along the bent portion of the pipe portion. Specifically, those using a flexible substrate such as a tape-like substrate, the substrate itself does not have flexibility, but a plurality of LED mounting substrate units are flexible wires, cables, electric wires What is connected by etc. is mentioned.

  Only one LED mounting board may be disposed inside the pipe part, or a plurality of LED mounting boards may be inserted as long as the space inside the pipe part permits. Further, when a plurality of sheets are inserted, they may be arranged so that the back surfaces of the substrates are joined to emit light toward both surfaces.

  Further, when the LED light source has a substrate on which LEDs are disposed, such as an LED mounting substrate, the light reflectance on the substrate surface is preferably 70% or more. When the light reflectance of the substrate is 70% or more, a part of the light from the LED light source reflected from the inner surface of the pipe portion is rereflected, the light diffusibility can be further improved, and the light intensity can be prevented from being attenuated. The substrate may be a white substrate or the like having a light reflectance of 70% or more. For example, a known reflector sheet such as a metallic aluminum glossy sheet or a fine foamed plastic sheet is bonded to the light reflectance. May be 70% or more.

  Next, a method for manufacturing the LED lighting apparatus of the present invention will be described.

  The LED lighting apparatus of the present invention can be manufactured by forming a globe and placing the LED, such as an LED mounting board, into the pipe portion of the obtained globe.

  As a method for producing a glove, a gas assist injection molding method (for example, Japanese Patent Publication No. 57-14968), a water assist injection molding method (for example, plastic age (Sep. 2007, page 106)), a floating core is used. An injection molding method (for example, Japanese Patent Publication No. 7-20646) can be used. Among these, in order to keep the inner diameter of the pipe uniform over the entire area of the pipe, and in order to form fine irregularities on the inner surface of the pipe portion, an injection molding method using a floating core is preferable, more preferably one end. After injecting molten resin into the pipe part cavity of a mold having a pressure part port with a floating core and having a discharge port at the other end, a pressurized fluid is injected from the pressure port. In which the floating core is moved to the discharge port side and the molten resin is extruded from the discharge port.

  Hereinafter, a method for manufacturing the globe of the LED lighting apparatus of FIG. 6 by an injection molding method using a floating core will be described.

  FIG. 9 is a diagram showing a mold used in this example.

  As shown in FIG. 9, the mold is a glove having a shape along the outer shape of the glove, which is composed of a pipe portion cavity 1 ′ composed of a straight tube portion cavity 2 ′ and a curved tube portion cavity 3 ′, and a fin portion cavity 13 ′. It has a cavity 24. Further, in order to form fine irregularities on the outer surface of the pipe part, fine irregularities having a depth of about 30 μm to 1000 μm are formed on the mold surface of the pipe part cavity 1 ′. Specifically, the surface of the mold of the pipe cavity 1 ′ has, for example, a texture, a groove in any direction, a lattice pattern obtained by crossing the grooves, a disk shape, a pyramid shape, a lens shape, or the like. A pattern or the like is formed by embossing or machining. In the case where fine irregularities are not formed on the outer surface of the pipe part, the mold surface of the pipe part cavity 1 'may be a glossy surface. Further, in the case where fine irregularities are formed on the surface of the fin part, the same process as that of the mold surface of the pipe part cavity 1 ′ may be performed on the mold surface of the fin part cavity 13 ′.

  At one end 14 of the pipe portion cavity, a floating core 15 having a diameter corresponding to the inner diameter of the pipe portion 1 is provided, and a pressurized fluid that moves the floating core 15 toward the other end 17 side of the pipe portion cavity. A pressurizing port 16 is provided for press-fitting.

  The floating core 15 is provided in the pipe portion cavity 1 ′ with the pressurizing port 16 in the back so that it can be pressed by the pressurizing fluid that is press-fitted from the pressurizing port 16. For example, copper, iron, aluminum, In addition to metal such as stainless steel and steel, it can be made of resin. The shape of the floating core 15 may be, for example, a conical shape, a bullet shape, a hemispherical shape, or the like as long as the maximum diameter corresponds to the inner diameter of the pipe portion 1 in addition to the illustrated spherical shape. Further, in order to form fine irregularities on the inner surface of the pipe portion, fine irregularities having a depth of about 30 μm to 1000 μm are formed on the surface of the floating core 15. Specific examples include a floating core having a plurality of V-shaped grooves formed on the surface, a floating core having a satin-finished surface, and a floating core having a plurality of protrusions formed on the surface. FIG. 15 is a diagram showing a cross section of a spherical floating core having a plurality of circumferential V-shaped grooves formed on the surface as an example. If fine irregularities are not formed on the inner surface of the pipe portion, a floating core having a smooth surface may be used.

  The pressurized port 16 is connected to a pressurized fluid system (not shown) for pressurizing and discharging pressurized fluid. The pressurizing port 16 is for causing the pressurized fluid supplied from the pressurized fluid system to act on the back surface of the floating core 15 and pressing the floating core 15 toward the other end 17 side of the pipe portion cavity. The pressurization of the pressurized fluid from the pressurization port 16 is performed after the inside of the glove cavity 24 is filled with the resin, and the floating core 15 is moved to the pressurization port without floating the floating core 15 when the molten resin is injected. A resin gate is provided at a position slightly away from the floating core 15 so that the inside of the glove cavity 24 can be filled with the molten resin while being pressed against the resin.

  A communication port 18 is provided on the other end 17 side of the pipe portion cavity, and an excess resin storage cavity 19 is communicated with the pipe portion cavity 1 ′ through the communication port 18. The communication port 18 has a size that allows the floating core 15 to pass through, but it is preferable that the communication port 18 has a slightly constricted shape from the viewpoint of ease of a subsequent cutting step and the like. The surplus resin storage cavity 19 is filled with resin in the glove cavity 24 and pressurized with a fluid under pressure from the pressurization port 16, and when the floating core 15 is moved, surplus resin pushed out from the glove cavity 24 and the floating core 15 It has a volume that can be accommodated with a margin.

  The means for opening and closing the communication port 18 is not particularly limited, and examples include means for opening and closing the communication port 18 by means of advancement and retraction of the receiving shaft by means such as hydraulic pressure. Specifically, a receiving shaft that is inserted so as to be able to advance and retreat through almost the center of the surplus resin housing cavity 19 is pressed against the peripheral wall of the communication port 18 at the time of forward movement, so that the communication port is opened. In addition to closing, the communication port 18 is opened and closed during advancement and retreat. Alternatively, a method of opening / closing by a means such as hydraulic pressure using a bar or the like that simply opens and closes in a sliding manner can be applied.

  Next, a specific procedure of injection molding using the mold shown in FIG. 9 will be described.

  First, as shown in FIG. 10, the molten resin is injected with the communication port 18 closed. This injection can be performed using a known injection molding apparatus.

  Next, as shown in FIG. 11, the communication port 18 is opened and pressurized fluid is press-fitted from the pressurized port 16. As a result, the floating core 15 extrudes the molten resin in the central portion, which is delayed in solidification, through the communication port 18 to the surplus resin containing cavity 19 while leaving the resin in the outer peripheral portion of the pipe cavity 1 ′ that has been solidified by cooling or heating. Further, while forming the streaky or random fine unevenness on the resin surface (surface that becomes the inner surface of the pipe portion) of the remaining outer periphery of the pipe portion cavity 1 ′ by the fine unevenness provided on the surface of the floating core 15. It advances toward the surplus resin storage cavity 19. Finally, the floating core 15 enters the surplus resin housing cavity 19, and the surplus resin housing cavity 19 is filled with the resin extruded from the communication port 18. After the floating core 15 passes, a hollow portion 20 having a diameter substantially equal to the diameter of the floating core 15 is formed. Therefore, by selecting the diameter of the floating core 15, the diameter of the formed hollow portion 20 can be adjusted. And the resin of the location in which the hollow part 20 was formed is pressed against the surrounding wall surface of the pipe part cavity 1 'by the pressure of the pressurized fluid, and the shape is transferred to form fine irregularities.

As the pressurized fluid, a gas or liquid that does not react with or compatible with the resin used under the temperature and pressure of injection molding is used. Specifically, for example, nitrogen gas, carbon dioxide gas, air, water, glycerin, liquid paraffin and the like can be used, but inert gas including nitrogen gas is preferable. For example, when a gas such as nitrogen gas is used, the pressurized fluid is introduced into the pressurized port 16 through a pipe with the pressurized gas that has been previously pressurized and stored in the animal pressure tank (not shown) by a compressor. In addition, the pressure can be increased by feeding the pressurized gas directly into the pressure port 16 with a compressor. The pressure of the pressurized gas supplied to the pressurized port 16 is usually 4.90 to 29.42 MPa (50 to 300 kg / cm ² G), although it varies depending on the type of resin used and the size of the floating core 5. Degree.

  Next, the resin is preferably cooled while maintaining the internal pressure in the mold, and after the pressurized fluid in the hollow portion 20 is discharged, the molded product is taken out. When the gas is used as the pressurized fluid, the pressurized fluid can be discharged by opening the pressurized port 16 to the atmosphere. However, the pressurized fluid is recovered and recycled for use in a recovery tank (not shown). You can also.

  A glove can be obtained by separating a sub-molded product (not shown) molded in the surplus resin accommodating cavity 19 from the taken-out molded product. The sub-molded product can be easily separated by a method such as cutting in the vicinity of the communication port, but can be more easily separated and cut by previously forming the communication port 18 in a constricted shape.

  Next, a method for manufacturing the globe of the LED lighting apparatus of FIG. 8 by an injection molding method using a floating core will be described.

  FIG. 12 is a diagram showing a mold used in this example.

  As shown in FIG. 12, the mold has an outer shape of a globe including a pipe part cavity 1 ′ composed of a straight pipe part cavity 2 ′ and a curved pipe part cavity 3 ′, a flat plate part cavity 25, and a side plate part cavity 26. And a glove cavity 24 having a shape along the surface. Further, in order to form fine irregularities on the outer surface of the pipe part, fine irregularities having a depth of about 30 μm to 1000 μm are formed on the mold surface of the pipe part cavity 1 ′. Specifically, the surface of the mold of the pipe cavity 1 ′ has, for example, a texture, a groove in any direction, a lattice pattern obtained by crossing the grooves, a disk shape, a pyramid shape, a lens shape, or the like. A pattern or the like is formed by embossing or machining. In the case where fine irregularities are not formed on the outer surface of the pipe part, the mold surface of the pipe part cavity 1 'may be a glossy surface. Further, in the case where fine irregularities are formed on the surface of the flat plate portion or the side plate portion, the same processing as that of the mold surface of the pipe portion cavity 1 ′ is applied to the mold surface of the flat plate portion cavity 25 or the side plate portion cavity 26. That's fine.

  At one end 14 of the pipe portion cavity, a floating core 15 having a diameter corresponding to the inner diameter of the pipe portion 1 is provided, and a pressurized fluid that moves the floating core 15 toward the other end 17 side of the pipe portion cavity. A pressurizing port 16 is provided for press-fitting.

  The floating core 15 is provided in the pipe portion cavity 1 ′ with the pressurizing port 16 in the back so that it can be pressed by the pressurizing fluid that is press-fitted from the pressurizing port 16. For example, copper, iron, aluminum, In addition to metal such as stainless steel and steel, it can be made of resin. The shape of the floating core 15 may be, for example, a conical shape, a bullet shape, a hemispherical shape, or the like as long as the maximum diameter corresponds to the inner diameter of the pipe portion 1 in addition to the illustrated spherical shape. Further, in order to form fine irregularities on the inner surface of the pipe portion, fine irregularities having a depth of about 30 μm to 1000 μm are formed on the surface of the floating core 15. Specific examples include a floating core having a plurality of V-shaped grooves formed on the surface, a floating core having a satin-finished surface, and a floating core having a plurality of protrusions formed on the surface. FIG. 15 is a diagram showing a cross section of a spherical floating core having a plurality of circumferential V-shaped grooves formed on the surface as an example. If fine irregularities are not formed on the inner surface of the pipe portion, a floating core having a smooth surface may be used.

  The pressurized port 16 is connected to a pressurized fluid system (not shown) for pressurizing and discharging pressurized fluid. The pressurizing port 16 is for causing the pressurized fluid supplied from the pressurized fluid system to act on the back surface of the floating core 15 and pressing the floating core 15 toward the other end 17 side of the pipe portion cavity. The pressurization of the pressurized fluid from the pressurization port 16 is performed after the inside of the glove cavity 24 is filled with the resin, and the floating core 15 is moved to the pressurization port without floating the floating core 15 when the molten resin is injected. A resin gate 27 is provided at a position away from the floating core 15 so that the inside of the globe cavity 24 can be filled with the molten resin while being pressed against the resin.

  A communication port 18 is provided on the other end 17 side of the pipe portion cavity, and an excess resin storage cavity 19 is communicated with the pipe portion cavity 1 ′ through the communication port 18. The communication port 18 has a size that allows the floating core 15 to pass through, but it is preferable that the communication port 18 has a slightly constricted shape from the viewpoint of ease of a subsequent cutting step and the like. The surplus resin storage cavity 19 is filled with resin in the glove cavity 24 and pressurized with a fluid under pressure from the pressurization port 16, and when the floating core 15 is moved, surplus resin pushed out from the glove cavity 24 and the floating core 15 It has a volume that can be accommodated with a margin.

  The means for opening and closing the communication port 18 is not particularly limited, and examples include means for opening and closing the communication port 18 by means of advancement and retraction of the receiving shaft by means such as hydraulic pressure. Specifically, a receiving shaft that is inserted so as to be able to advance and retreat through almost the center of the surplus resin housing cavity 19 is pressed against the peripheral wall of the communication port 18 at the time of forward movement, so that the communication port is opened. In addition to closing, the communication port 18 is opened and closed during advancement and retreat. Alternatively, a method of opening / closing by a means such as hydraulic pressure using a bar or the like that simply opens and closes in a sliding manner can be applied.

  Next, a specific procedure of injection molding using the mold shown in FIG. 12 will be described.

  First, as shown in FIG. 13, the molten resin is injected in a state where the communication port 18 is closed. This injection can be performed using a known injection molding apparatus.

  Next, as shown in FIG. 14, the communication port 18 is opened and pressurized fluid is press-fitted from the pressurized port 16. As a result, the floating core 15 extrudes the molten resin in the central portion, which is delayed in solidification, through the communication port 18 to the surplus resin containing cavity 19 while leaving the resin in the outer peripheral portion of the pipe cavity 1 ′ that has been solidified by cooling or heating. Further, while forming the streaky or random fine unevenness on the resin surface (surface that becomes the inner surface of the pipe portion) of the remaining outer periphery of the pipe portion cavity 1 ′ by the fine unevenness provided on the surface of the floating core 15. It advances toward the surplus resin storage cavity 19. Finally, the floating core 15 enters the surplus resin housing cavity 19, and the surplus resin housing cavity 19 is filled with the resin extruded from the communication port 18. After the floating core 15 passes, a hollow portion 20 having a diameter substantially equal to the diameter of the floating core 15 is formed. Therefore, by selecting the diameter of the floating core 15, the diameter of the formed hollow portion 20 can be adjusted. And the resin of the location in which the hollow part 20 was formed is pressed against the surrounding wall surface of the pipe part cavity 1 'by the pressure of the pressurized fluid, and the shape is transferred to form fine irregularities.

As the pressurized fluid, a gas or liquid that does not react with or compatible with the resin used under the temperature and pressure of injection molding is used. Specifically, for example, nitrogen gas, carbon dioxide gas, air, water, glycerin, liquid paraffin and the like can be used, but inert gas including nitrogen gas is preferable. For example, when a gas such as nitrogen gas is used, the pressurized fluid is introduced into the pressurized port 16 through a pipe with the pressurized gas that has been previously pressurized and stored in the animal pressure tank (not shown) by a compressor. In addition, the pressure can be increased by feeding the pressurized gas directly into the pressure port 16 with a compressor. The pressure of the pressurized gas supplied to the pressurizing port 16 is usually 4.90 to 29.42 MPa (50 to 300 kg / cm ² G), although it varies depending on the type of resin used and the size of the floating core 15. Degree.

  Next, the resin is preferably cooled while maintaining the internal pressure in the mold, and after the pressurized fluid in the hollow portion 20 is discharged, the molded product is taken out. When the gas is used as the pressurized fluid, the pressurized fluid can be discharged by opening the pressurized port 16 to the atmosphere. However, the pressurized fluid is recovered and recycled for use in a recovery tank (not shown). You can also.

  A sub-molded product (not shown) molded in the surplus resin-accommodating cavity 19 is separated from the taken-out molded product, and the resin molded product of the present invention can be obtained. The sub-molded product can be easily separated by a method such as cutting in the vicinity of the communication port, but can be more easily separated and cut by previously forming the communication port 18 in a constricted shape.

<Example 1>
Using the mold as shown in FIG. 9, the globe of the following size shown in FIG. 6 was integrally formed using an injection machine (“TP-180H” manufactured by Toyo Machine Metal Co., Ltd.). A groove having an average depth of 100 μm and an average width of 500 μm is carved on the surface of the pipe part cavity of the mold in a direction orthogonal to the length direction of the straight pipe part cavity.

[Pipe part]
Outer diameter 30mm, inner diameter 25mm, wall thickness 2.5mm, straight pipe part length 150mm, 80mm, curved pipe part R50mm

[Fin part]
35mmφ disk, average thickness 1mm, 30 sheets

  As the floating core, as shown in FIG. 15, a steel ball (diameter 25 mm) having a plurality of circumferential V-shaped grooves (width 100 μm, depth 150 μm) on the surface was used. A gas generator for gas hollow injection molding ("Air Mold" manufactured by Asahi Engineer Link Co., Ltd.) was used to supply the pressurized fluid. Nitrogen gas was used as the pressurized fluid. As the translucent resin, a polycarbonate resin containing 3 wt% of spherical silica as an inorganic light diffusing material was used.

First, as shown in FIG. 10, the resin was injected at a resin temperature of 280 ° C. and an injection pressure of 14.71 MPa (150 kg / cm ² ). One second after the injection was completed, nitrogen at a pressure of 22.56 MPa (230 kg / cm ² ) Gas was injected and the floating core was moved in the mold as shown in FIG. 11 and cooled for 30 seconds, and then the glove shown in FIG. 6 was taken out.

  The LED double-sided mounting substrate 12 was inserted from one opening of the obtained pipe portion 1 of the globe, and was fixed by the attachment portion 9 to obtain the LED lighting apparatus shown in FIG. In addition, the LED double-sided mounting board 12 uses two LED mounting boards 12 ′ shown in FIG. 5 and is bonded to the back side of the white board 4 (light reflectance 75%) so that the LEDs 5 are staggered. .

  When energized through a control unit and a power supply unit (not shown), the light from the LED light source is useful as a luminaire that emits soft light by being diffused through the pipe part and through the fin part. It was. Table 1 shows the result of visual determination of the LED lamp image. In Table 1, the lamp image is indicated as ◎, invisible, ◯, almost invisible, △, but acceptable, Δ, slightly visible, x, clearly visible, xx.

<Example 2>
An LED lighting apparatus was produced in the same manner as in Example 1 except that a mold having a texture pattern with a depth of about 100 μm was used on the surface of the pipe cavity.

  Similar to the LED lighting fixture of Example 1, this LED lighting fixture was useful as a lighting fixture that emits soft light. Table 1 shows the result of visual determination of the lamp image.

<Example 3>
There is no fin cavity, and a pyramid shape having a depth of about 200 μm shown in FIG. 16 ((a) is a plan view and (b) is an AA ′ sectional view of (a)) is formed on the surface of the pipe cavity. A glove shown in FIG. 4 was formed in the same manner as in Example 1 except that a mold with a concave pattern was used, and an LED lighting apparatus was created.

  When this LED lighting device was energized, the light from the LED light source was diffused through the pipe portion and was useful as a lighting device that emits soft light. Table 1 shows the result of visual determination of the lamp image.

<Example 4>
An LED lighting apparatus was produced in the same manner as in Example 3 except that a mold having a glossy surface on the pipe cavity was used.

  Similar to the LED lighting fixture of Example 3, this LED lighting fixture was useful as a lighting fixture that emits soft light. Table 1 shows the result of visual determination of the lamp image.

<Example 5 (reference example) >
An LED lighting device was prepared in the same manner as in Example 3 except that a floating core having no fine unevenness on the surface was used and a black substrate (light reflectance 30%) was used as the substrate of the LED double-sided mounting substrate 12. .

  Similar to the LED lighting fixture of Example 3, this LED lighting fixture was useful as a lighting fixture that emits soft light. Table 1 shows the result of visual determination of the lamp image.

<Example 6>
An LED lighting fixture was prepared in the same manner as in Example 1 except that the light transmissive resin did not contain a diffusing material.

  Similar to the LED lighting fixture of Example 1, this LED lighting fixture was useful as a lighting fixture that emits soft light. Table 1 shows the result of visual determination of the lamp image.

<Example 7>
Using a mold as shown in FIG. 12, the following glove size shown in FIG. 8 was integrally formed using an injection machine (“TP-180H” manufactured by Toyo Machine Metal Co., Ltd.). In addition, the surface of the pipe part cavity of a metal mold | die and the flat part part cavity was given the embossed pattern of 30 micrometers in depth.

[Pipe part]
10mm outer diameter, 7mm inner diameter, 1.5mm wall thickness, 250mm length,

[Plate part]
200mmx150mm, wall thickness 1.5mm

  As the floating core, as shown in FIG. 15, a steel ball (diameter 7 mm) having a plurality of circumferential V-shaped grooves (width 80 μm, depth 80 μm) on the surface was used. A gas generator for gas hollow injection molding ("Air Mold" manufactured by Asahi Engineer Link Co., Ltd.) was used to supply the pressurized fluid. Nitrogen gas was used as the pressurized fluid. As the translucent resin, a resin containing 2% of an organic diffusion material (crosslinked polystyrene) in PMMA resin was used.

First, as shown in FIG. 13, the resin was injected at a resin temperature of 230 ° C. and an injection pressure of 11.77 MPa (120 kg / cm ² ). One second after the completion of injection, nitrogen at a pressure of 22.56 MPa (230 kg / cm ² ) Gas was injected and the floating core was moved in the mold as shown in FIG. 14 and cooled for 30 seconds, and then the PMMA resin molded body shown in FIG. 8 was taken out. The inner diameter was a uniform circle of approximately 7 mm.

  The LED double-sided mounting substrate 12 was inserted from the entrance / exit hole 23 of the obtained pipe part 1 of the globe, and the LED lighting apparatus shown in FIG. 8 was obtained. In addition, the LED double-sided mounting board 12 uses two LED mounting boards 12 ′ shown in FIG. 5 and is bonded to the back side of the white board 4 (light reflectance 85%) so that the LEDs 5 are staggered. .

  When energized through a control unit (not shown) and a power supply unit, the light from the LED light source is diffused through the pipe part and the flat plate part around the pipe part, and is useful as an illumination and electrical sign as a surface light emitter. It was a thing. Table 1 shows the result of visual determination of the lamp image.

<Comparative Examples 1 and 2>
LED lighting fixtures were produced in the same manner as in Examples 1 and 3, except that a mold having a glossy surface on the pipe cavity was used and a floating core having no fine irregularities on the surface was used. Table 1 shows the result of visual determination of the LED lamp image.

<Comparative Example 3>
An LED lighting device was prepared in the same manner as in Example 7 except that a mold having a glossy surface on the surface of the pipe portion cavity and the flat plate portion cavity was used, and a floating core having no fine irregularities on the surface was used. Table 1 shows the result of visual determination of the LED lamp image.

DESCRIPTION OF SYMBOLS 1 Pipe part 1 'Pipe part cavity 2 Straight pipe part 2' Straight pipe part cavity 3 Curved pipe part 3 'Curved pipe part cavity 4 Board | substrate 5 LED
6 LED mounting substrate 7 Control unit 8 Power supply unit 9 Mounting unit 10 LED mounting substrate unit 11 Flexible connection unit 12 Double-sided mounting substrate 12 'LED mounting substrate 12 "LED mounting substrate unit 13 Fin portion 13' Fin portion cavity 14 Pipe portion One end of the cavity 15 Floating core 16 Pressurization port 17 The other end 18 of the pipe part cavity 18 Communication port 19 Excess resin housing cavity 20 Hollow part 21 Flat part 22 Side plate part 23 Entrance / exit hole 24 Globe cavity 25 Flat part part cavity 26 Side plate part cavity 27 Resin Gate

Claims (4)

An LED light source is arranged inside the pipe part of the molded body made of a light-transmitting resin having a pipe part having a curved pipe part, and at least a part of at least a part of the inner surface of the outer surface and the inner surface of the pipe part is fine. A method of manufacturing an LED lighting apparatus having unevenness,
After injecting molten resin into the pipe part cavity of a mold having a pressure part port with a floating core at one end and a discharge part outlet at the other end, pressurization from the pressure port Pressing the fluid, moving the floating core to the discharge port side and extruding the molten resin from the discharge port;
The floating core, the surface has fine irregularities, by the movement of the floating core, a manufacturing method of L ED luminaire you characterized in that allowed to produce fine irregularities on the pipe inner surface. 2. The method for manufacturing an LED lighting device according to claim 1 , wherein the pipe portion cavity has fine unevenness on a surface, and the fine unevenness is transferred to generate fine unevenness on an outer surface of the pipe portion. . The method for manufacturing an LED lighting apparatus according to claim 1, wherein the molded body has a fin portion that is injection-molded integrally with the pipe portion. The method for manufacturing an LED lighting apparatus according to claim 1, wherein the molded body has a flat plate portion formed by injection molding integrally with the pipe portion.

Images