Light source device with arrayed light emitting elements and manufacturing therefor

• US 5,032,960 A
• Filed: 02/14/1990
• Issued: 07/16/1991
• Est. Priority Date: 02/15/1989
• Status: Expired due to Term

• Current Assignee: Sharp Kabushiki Kaisha (Hon Hai Precision Industry Co., Ltd.)
• Original Assignee: Sharp Kabushiki Kaisha (Hon Hai Precision Industry Co., Ltd.)
• Inventors: Katoh, Masaaki
• Primary Examiner(s): Lazarus, Ira S.
• Assistant Examiner(s): Cole, Richard R.
• Application Number:
  US07/480,141
• Time in Patent Office: 517 Days
• Field of Search: 362/800, 362/240, 362/235, 362/245, 362/249, 362/252, 362/241, 362/244, 355/70, 355/228, 355/229, 357/72
• US Class Current: 362/240
• CPC Class Codes: F21S 4/28 rigid, e.g. LED bars
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 2924/1815 Shape
• CPC Class Codes: H01L 2924/3025 Electromagnetic shielding
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A light source device with arrayed light emitting elements includes a base board on which a plurality of the light emitting elements are arranged in an array, a convergent rod lens provided parallel to the array of the light emitting elements, and a reflection casing for holding the convergent lens. The convergent lens and the reflection casing are integrally connected with an air-gap formed parallel to the cnvergent lens. The base board is secured upon being inserted into the air-gap. The convergent lens and reflection casing in the light source device with arrayed light emitting elements can integrally and simultaneously be molded by continuous two-color extrusion molding. Therefore, it is possible to manufacture the light source device with arrayed light emitting elements at lower cost and which can easily be assembly with a reduced number of parts.

Claims

1. A light source device with arrayed light emitting elements, comprising:

a base board on which a plurality of said light emitting elements are arranged in an array;

a convergent lens in the form of a rod, provided parallel to the array of said light emitting elements; and

a reflection casing for holding said convergent lens,

said convergent lens and said reflection casing being connected with each other and forming an air-gap parallel to said convergent lens,

said base board being secured upon insertion into said air-gap.

2. The light source device with arrayed light emitting elements in accordance with claim 1, said convergent lens and said reflection casing are integrally molded by continuous two-color extrusion molding.

3. The light source device with arrayed light emitting elements in accordance with claim 1, said convergent lens is formed of a convex rod lens with a planar surface facing said light emitting elements and an external surface curved convexly.

4. The light source device with arrayed light emitting elements in accordance with claim 1, said convergent lens is formed of a convex rod lens with both a surface facing said light emitting elements and an external surface curved convexly.

5. The light source device with arrayed light emitting elements in accordance with claim 1, each of said light emitting elements is formed of a super-miniature LED lamp comprising an LED chip molded with light transmissive resin.

6. The light source device with arrayed light emitting elements in accordance with claim 5, each of said light emitting elements comprising a lens portion with a surface curved convexly and formed on an outer surface of a layer of said light transmissive resin.

7. The light source device with arrayed light emitting elements in accordance with claim 5, each of said super-miniature LED lamps is of a flat package type which is mounted on said base board without the necessity of through-holes formed therein.

8. The light source device with arrayed light emitting elements in accordance with claim 1, said base board is secured in said reflection casing so that left and right sides of said base board fit in grooves formed parallel to said convergent lens inside said reflection casing.

9. A method of manufacturing a light source device with arrayed light emitting elements, comprising the steps of:

integrally molding a convergent rod lens and a reflection casing in parallel with each other by continuous two-color extrusion, with an air-gap formed in the form of tunnel; and

inserting a base board on which a plurality of said light emitting elements are arranged in an array into said air-gap, and securing said base board in said reflection casing.

10. The method of manufacturing a light source device with arrayed light emitting elements in accordance with claim 9, said method further comprising forming grooves parallel to an elongated direction of said convergent rod lens along said air-gap inside said reflection casing when the continuous two-color extrusion is carried out and inserting said base board into said air-gap with side ends of said base board fit in said grooves.

11. The method of manufacturing a light source device with arrayed light emitting elements in accordance with claim 9, said continuous two-color extrusion comprises using transparent resin as a material of said convergent lens and reflective opaque resin as a material of said reflection casing.

12. The method of manufacturing a light source device with arrayed light emitting elements in accordance with claim 9, said continuous two-color extrusion comprises using transparent acrylic resin as a material of said convergent lens and white Noryl resin as a material of said reflection casing.

13. The method of manufacturing a light source device with arrayed light emitting elements in accordance with claim 9, said light emitting elements are of a flat package type and are mounted on said base board without the use of through-holes formed therein.