Lamp unit and vehicle lamp apparatus including the same

A lamp unit which implements a source light source with a small number of light sources using a lens and a vehicle lamp apparatus including the same. The lamp unit includes an optical member, a base plate spaced from the optical member by a predetermined distance, and a spacer between the base plate and the optical member. The spacer supports an edge of the optical member, and a light source is disposed on the base plate. A lens is coupled to the base plate, and the lens covers the light source. The lens includes a connection portion contacting the base plate, and a reinforcement part contacting the spacer.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2012-0148014, filed in Korea on Dec. 18, 2012, which are hereby incorporated in its entirety by reference as if fully set forth herein.

BACKGROUND

Embodiments relate to a lamp unit including a surface light source and a vehicle lamp apparatus using the same.

In general, a lamp is a device which supplies or controls light for a certain purpose.

An incandescent lamp, a fluorescent lamp, a neon lamp or the like may be used as a lamp light source and a light emitting diode (LED) is recently used.

An LED is a device which converts an electrical signal into infrared or visible light using characteristics of compound semiconductors and causes almost no environmental pollution because it does not use a harmful substance such as mercury as compared to fluorescent lamps.

In addition, LEDs have longer lifespan than incandescent lamps, fluorescent lamps and neon lamps. In addition, LEDs have advantages of low power consumption, and superior visibility and less glare due to high color temperature, as compared to incandescent lamps, fluorescent lamps and neon lamps.

FIG. 1is a view illustrating a general lamp unit.

As shown inFIG. 1, the lamp unit includes a light source module1and a reflector2to determine an orientation angle of light emitted from the light source module1.

The light source module1may include at least one LED light source1aprovided on a printed circuit board (PCB)1b.

In addition, the reflector2collects light emitted from the LED light source1aand guides the light to emit through an opening at a predetermined orientation angle, and has a reflection surface on an inside surface thereof.

As described above, the lamp unit is a lamp which obtains light collected from a plurality of LED light sources1a. The lamp using LEDs may be used for backlights, display devices, lightings, vehicle pilot lamps, headlamps and the like according to application thereof.

In particular, it is considerably important for vehicle drivers to clearly distinguish luminous state of lamp units because the lamp units used for vehicles are closely related to safe driving of vehicles.

Accordingly, it may be necessary that lamp units used for vehicles secure light dose suitable for safe driving as well as appearance aesthetics of vehicles.

DETAILED DESCRIPTION

Hereinafter, embodiments will be described with reference to the annexed drawings.

It will be understood that when an element is referred to as being “on” or “under” another element, it can be directly on/under the element, and one or more intervening elements may also be present. When an element is referred to as being “on” or “under”, “under the element” as well as “on the element” may be included based on the element.

In the drawings, the thickness or size of each layer is exaggerated, omitted, or schematically illustrated for convenience of description and clarity. In addition, the size or area of each constituent element does not entirely reflect the actual size thereof.

FIG. 2is a sectional view illustrating a lamp unit according to an embodiment.

As shown inFIG. 2, the lamp unit may include a plurality of light sources100, a plurality of lenses200, a base plate400, a spacer700and an optical member600.

The light sources100are disposed on the base plate400and the base plate400may include an electrode pattern to electrically connect the light sources100.

Additionally, the base plate400may have a flexibility and may include a printed circuit board (PCB) substrate formed of a material selected from a group consisting of polyethylene terephthalate (PET), glass, polycarbonate (PC), silicon (Si), polyimide, epoxy and the like, or a film type substrate.

In addition, the base plate400may be selected from a group consisting of monolayer PCB, a multilayer PCB, a ceramic substrate, a metal core PCB and the like.

The entirety of the base plate400may be formed of one material and a part of the base plate400may be formed of a different material as necessary.

For example, the base plate400may include a support portion contacting the light source100and a connection portion not contacting the light source100. For example, the support portion and the connection portion of the base plate400may be formed of one material.

The support portion and the connection portion may include a base member and a circuit pattern disposed on at least a portion of a surface of the base member, and the base member may be formed of a flexible and insulating material such as polyimide or epoxy (for example, FR-4).

In some cases, the support portion and the connection portion of the base plate400may be formed of different materials.

For example, the support portion may be a conductive material and the connection portion may be a non-conductive material.

In addition, the support portion of the base plate400may be formed of a hard material not allowing bending so as to support the light source100and the connection portion of the base plate400may be formed of a ductile material allowing bending so that the base plate400is applied to an object having a curvature to be mounted.

In some cases, the base plate400may have a configuration in which a circuit pattern for electrical connection is disposed on the light source100and a flexible and insulating film is disposed in at least one of upper and lower parts of the circuit pattern.

For example, the film may be formed of a material selected from a group consisting of photosolder resist (PSR), polyimide, epoxy (for example, FR-4) and a combination thereof.

In addition, when the film is disposed in the upper or lower part of the circuit pattern, a film disposed in the upper part of the circuit pattern may be different from a film disposed in the lower part of the circuit pattern.

As such, the base plate400may be bent due to use of a ductile material and may be bent due to structural deformation.

Accordingly, the base plate400may include a curved surface having one or more curvatures.

Next, the base plate400may include a plurality of holes formed respectively in regions corresponding to the connection portions210of the lenses200.

Here, the lens200may be coupled to the base plate400through the hole of the base plate400.

Accordingly, the number of holes of the base plate400may be equivalent to or greater than the number of lenses200.

In addition, the base plate400may include a plurality of fixing parts which project in a downward direction opposite to the upper surface of the base plate400facing the light source100.

Here, the base plate400may be fixed to an object having a curvature to be mounted through the fixing part.

Accordingly, the number of the fixing part may one or more.

In addition, the base plate400may include either a reflective coating film or a reflective coating material layer to reflect light generated by the light source100toward the optical member600.

Here, the reflective coating film or the reflective coating material layer may include a metal or metal oxide having high reflectivity such as aluminum (Al), silver (Ag), gold (Au) or titanium dioxide (TiO2).

In some cases, the base plate400may be provided with a plurality of heat discharging pins to discharge heat generated by the light source100.

Next, the light source100may be a top view type light emitting diode. In some cases, the light source110of a light source module may be a side view type light emitting diode.

Here, the light source100may be a light emitting diode (LED) chip, and the light emitting diode chip may be formed as a red LED chip, a blue LED chip or an ultraviolet LED chip or as a package including a combination of at least one of a red LED chip, a green LED chip, a blue LED chip, a yellow green LED chip and a white LED chip.

In addition, the white LED may be implemented by using a yellow phosphor on a blue LED, or using both a red phosphor and a green phosphor on a blue LED, or all of a yellow phosphor, a red phosphor and a green phosphor on a blue LED.

For example, when the lamp unit is applied to a vehicle taillight, the light source100may be a vertical-type light emitting chip, for example, a red light emitting chip, but the embodiment is not limited thereto.

Next, the lens200may cover the light source100and be coupled to the base plate400.

Here, the lens200may include at least one of a connection portion210penetrating the base plate400and a reinforcement part220contacting the spacer700.

A plurality of connection portions210including the extension part may project from an edge of the lower surface of the lenses200toward the base plate400.

In some cases, the connection portion210may further include a stopper which is extended from an edge of the lower surface of the lens200to the center of the lower surface thereof.

In addition, the connection portion210may be disposed in an x-axis direction passing through the center of the lens200, but the disclosure is not limited thereto.

In some cases, the connection portion210may be disposed in an x-axis direction passing through the center of the lens200and in a y-axis direction vertical to the x-axis direction.

That is, two connection portions210including the connection portion210may be symmetrical to each other with respect to the x-axis direction and a total of four connection portions210may be symmetrical to one another with respect to both the x-axis direction and the y-axis direction.

In addition, the reinforcement part220may project outwardly from a side surface of the lens200and may be spaced from the base plate400by a predetermined distance.

Here, the reinforcement parts220may be disposed in the y-axis direction vertical to the x-axis direction, but the disclosure is not limited thereto.

That is, the reinforcement part220may be disposed between the adjacent connection portions210.

For example, one or more of the reinforcement part220may be disposed on the side surface of the lenses200.

When the two or more reinforcement parts are present, a distance between the reinforcement parts220may be identical or different.

In addition, in some cases, the reinforcement part220may be disposed so as to surround an entirety of the side surface of the lens200.

In addition, the reinforcement part220may have the lower surface facing the base plate400. The lower surface of the reinforcement part220may be flush with the lower surface of the lens200.

Additionally, the lens200may have a lower surface facing the base plate400and the lower surface of the lens200may be spaced from the base plate400by a predetermined distance.

Here, the lens200may have a lower surface facing the base plate400and an upper surface facing the optical member600. The lower surface of the lens200may be a planar surface and the upper surface of the lens200may be a curved surface.

The upper surface of the lens200may include a groove corresponding to a central region of a light emission surface of the light source100.

In some cases, the lower surface of the lens200facing the light source100may include a groove.

Here, a cross-section of the groove may have a trapezoidal shape wherein the top of the cross-section is wider than the bottom thereof. In addition, the groove may have a frustoconical shape.

As such, the formation of the groove in the lens200aims at increasing an orientation angle of light emitted from the light source100, and the embodiments are not limited thereto and a variety of shapes of lenses may be used.

Meanwhile, the light source100may be a light emitting diode (LED) chip and be a light emitting diode package including a light emitting diode chip disposed in a package body.

The lens200may be disposed to cover the light source100and a variety of structures of lenses200may be used according to type of the light source100.

For example, when the light source100is a type in which a light emitting diode (LED) chip is directly disposed on the base plate400, the lens200may be disposed on the base plate400so as to cover the light source100.

Here, the lens200may include a groove corresponding to a central region of a light emission surface of the light source100.

In addition, when the light source100is a type of a light emitting diode package including a light emitting diode chip disposed in a package body, the lens200may be disposed on the package body so as to cover the light emitting diode chip.

Next, when the light source100is a type of a light emitting diode package including a light emitting diode chip disposed in a package body, the lens200may be disposed on the base plate400so as to cover the entirety of the package body including the light emitting diode chip.

The lens200may cover a region of the light emitting diode package, excluding a predetermined portion of the package body.

In some cases, the lens200may have a hemi-spherical shape having no groove.

Next, the spacer700is disposed between the base plate400and the optical member600and supports an edge of the optical member600.

Here, the spacer700may include a bottom surface facing the base plate400and a side surface extending from an edge of the bottom surface toward the optical member600.

A groove corresponding to the reinforcement part220of the lens200may be formed on the bottom surface of the spacer700.

Here, a shape of the groove of the spacer700may have the same as or different from that of the reinforcement part220of the lens200.

In addition, holes exposing the upper surface of the lens200may be respectively disposed in regions corresponding to the lenses on the bottom surface of the spacer700.

The number of holes of the spacer700may be equivalent to or greater than the number of the lenses200, but the disclosure is not limited thereto.

In addition, the bottom surface of the spacer700may be spaced from the base plate400by a predetermined distance d1.

However, in some cases, the bottom surface of the spacer700may contact the base plate400.

Next, the bottom surface of the spacer700may be a curved surface having one or more curvatures.

In addition, the side surface of the spacer700may be inclined with respect to the bottom surface of the spacer700.

In addition, the spacer700may be formed as either a reflective coating film or a reflective coating material layer and reflect light generated by the light source100toward the optical member600.

Here, the reflective coating film or the reflective coating material layer may contain a metal or metal oxide having a high reflectivity, such as aluminum (Al), silver (Ag), gold (Au) or titanium dioxide (TiO2).

Next, the optical member600may be spaced from the base plate400via a gap corresponding to a predetermined distance and a light mixing area750may be formed in the gap between the base plate400and the optical member600.

Here, the optical member600may be spaced from the base plate400by a predetermined distance d2 and the distance d2 may be about 10 mm or more.

When the distance d2 between the optical member600and the base plate400is about 10 mm or less, the lamp unit does not exhibit uniform luminance, and a hot spot phenomenon wherein intensive luminance is generated in a region in which the light source100is disposed, or a dark spot phenomenon wherein weaker luminance is generated in a region in which the light source100is disposed may occur.

In addition, the optical member600may include at least one sheet selected from a diffusion sheet, a prism sheet, a luminance-enhancing sheet and the like.

Here, the diffusion sheet diffuses light emitted from the light source100, the prism sheet guides diffused light to a light emitting area and the luminance diffusion sheet enhances luminance.

For example, the diffusion sheet is generally formed of an acrylic resin, but the disclosure is not limited thereto. Furthermore, the material for the diffusion sheet includes light-diffusing materials such as polystyrene (PS), poly(methyl methacrylate) (PMMA), cycloolefin copolymers (COCs), polyethylene terephthalate (PET), and highly permeable plastics such as resins.

In addition, the optical member600may have an irregular pattern on an upper surface thereof.

The optical member600functions to diffuse light from the light source100, and includes the irregular pattern on the upper surface thereof so as to improve diffusion effects.

That is, the optical member600may include a plurality of layers and the irregular pattern may be provided on a surface of the uppermost layer or any layer.

In addition, the irregular pattern may have a stripe shape disposed in one direction.

The irregular pattern has a projection portion disposed on the surface of the optical member600, the projection portion has a first surface and a second surface which face each other and an angle between the first surface and the second surface may be an obtuse angle or an acute angle.

In some cases, the optical member600may include at least two inclined surfaces having at least one inflection point.

In addition, the optical member600may include a curved surface having one or more curvatures.

Here, the optical member600may have a surface having at least one of a recessed curved surface, a protruded curved surface and a flat planar surface according to outer appearance (shape) of the cover member or the object to be mounted.

Then, a heat discharge member may be disposed under the base plate400.

Here, the heat discharge member functions to discharge heat generated by the light source100to the outside.

For example, the heat discharge member may be formed of a material having high thermal conductivity, for example, aluminum, an aluminum alloy, copper or a copper alloy.

Alternatively, a metal core printed circuit board (MCPCB) in which the base plate400integrates with the heat discharge member may be provided and a separate heat discharge member may be further disposed on the lower surface of the MCPCB.

When the separate heat discharge member is bonded to the lower surface of MCPCB, the bonding is carried out through an acrylic adhesive (not shown).

Next, the cover member may further be disposed on the optical member600.

The cover member protects the base plate400including the light source100from exterior shock and may be formed of a material (for example, acryl) allowing permeation of light emitted from the light source.

In addition, the cover member may be disposed such that it contacts the optical member600. Alternatively, one part of the cover member may contact the optical member600and the remaining part may be spaced therefrom by a predetermined distance.

In some cases, the entire surface of the cover member facing the optical member600may contact the optical member600.

In addition, the entire surface of the cover member facing the optical member600may be spaced from the optical member600by a predetermined distance.

The distance between the cover member and the optical member600may variably change according to design conditions of light source module required for an object mounted so as to provide overall uniform luminance.

As such, in accordance with the present embodiment, a surface light source is implemented using a small number of light sources by forming a light mixing area750between the lens200covering the light source100, the base plate400and the optical member600.

Here, the surface light source means a light source which includes a light emission area diffusing light in a planar form. The embodiment may provide a lamp unit which implements the surface light source with a small number of light sources.

In addition, the lamp unit according to the present embodiment may be applied to objects having a variety of shapes including a curved shape, because the bendable base plate400may be coupled to the lenses200covering the light sources100.

Accordingly, the present embodiment improves economic efficiency and freedom of product design of the lamp unit.

FIGS. 3A to 3Care views illustrating the lens shown inFIG. 2. More specifically,FIG. 3Ais a plan view of the lens ofFIG. 2,FIG. 3Bis a side view seen in a direction A ofFIG. 3AandFIG. 3Cis a side view seen in a direction B ofFIG. 3A.

As shown inFIGS. 3A to 3C, the lens200may include a connection portion210and a reinforcement part220.

Here, a plurality of connection portions210including the connection portion210may project from an edge of the lower surface201facing the base plate (represented by reference numeral “400” inFIG. 2).

In addition, a lower part of the connection portion210may have a hook shape.

Accordingly, the connection portion210may project from the edge of the lower surface201of the lens20toward the base plate (represented by reference numeral “400” inFIG. 2) and be coupled to the base plate (represented by reference numeral “400” inFIG. 2).

The connection portion210may be disposed in an x-axis direction passing through the center of the lens200.

For example, when the number of the connection portions210is two, the two connection portions210may be symmetrical to each other with respect to the x-axis direction.

In addition, the reinforcement part220may project outwardly from a side surface203of the lens200.

In addition, the reinforcement part220may have a lower surface222facing the base plate (represented by reference numeral “400” inFIG. 2). The lower surface222of the reinforcement part220may be flush with the lower surface201of the lens200.

In some cases, the lower surface222of the reinforcement part220may not be flush with the lower surface201of the lens200.

The reinforcement part220may be disposed in a y-axis direction vertical to the x-axis direction.

For example, when two connection portions210including the connection portion210are present, they may be symmetrical to each other with respect to the y-axis direction.

Meanwhile, the connection portion210may be disposed in the x-axis direction passing through the center of the lens200, but the disclosure is not limited thereto.

In some cases, the connection portion210may be disposed in an x-axis direction passing through the center of the lens200and in a y-axis direction vertical to the x-axis direction.

That is, two connection portions210including the connection portion210may be symmetrical to each other with respect to the x-axis direction and a total of four connection portions210may be symmetrical to one another with respect to both the x-axis direction and the y-axis direction.

However, the connection portion210may be disposed in a variety of directions, regardless of the x-axis and y-axis directions.

In addition, the reinforcement part220may be disposed in the y-axis direction vertical to the x-axis direction, but the disclosure is not limited thereto.

That is, the reinforcement part220may be disposed between the adjacent connection portions210.

For example, one or a plurality of reinforcement parts220including the reinforcement part220may be disposed on side surface of the lenses200.

When the plurality of reinforcement parts220are present, a distance between the reinforcement parts220may be identical or different.

In addition, in some cases, the reinforcement part220may be disposed such that it surrounds all side surfaces of the lens200.

In addition, the lens200may include a lower surface201facing the base plate201(represented by reference numeral “400” inFIG. 2) and an upper surface facing the optical member (represented by reference numeral “600” inFIG. 2). The lower surface of the lens200may be a flat planar surface and the upper surface of the lens200may be a curved surface.

The upper surface of the lens200may include a groove corresponding to a central region of a light emission surface of the light source (represented by reference numeral “100” inFIG. 2).

As such, the formation of the groove in the lens200aims at increasing an orientation angle of light emitted from the light source (represented by reference numeral “100” inFIG. 2).

The lens200may be disposed to cover the light source and a variety of structures of lenses200may be used according to type of the light source.

For example, when the light source is a type in which a light emitting diode (LED) chip is directly disposed on the base plate, the lens200may be disposed on the base plate so as to cover the light source.

Here, the lens200may include a groove corresponding to a central region of a light emission surface of the light source.

When the light source is a type of a light emitting diode package including a light emitting diode chip disposed in a package body, the lens200may be disposed on the package body so as to cover the light emitting diode chip.

When the light source is a type of a light emitting diode package including a light emitting diode chip disposed in a package body, the lens200may be disposed on the base plate400so as to cover the entirety of the package body including the light emitting diode chip.

The lens200may cover a region of the light emitting diode package, excluding a predetermined portion of the package body.

In some cases, the lens200may have a hemi-spherical shape having no groove.

FIG. 4Ais a sectional view taken along the line I-I ofFIG. 3AandFIG. 4Bis a sectional view taken along the line II-II ofFIG. 3A.

As shown inFIGS. 4A and 4B, the lens200may include the connection portion210and the reinforcement part220and the connection portion210may project from an edge of the lower surface201of the lens200.

In addition, the lower part of the connection portion210may have a hook shape.

Next, the reinforcement part220may project outwardly from a side surface203of the lens200and the lower surface222of the reinforcement part220may be flush with the lower surface201of the lens200.

In addition, the lower surface201of the lens200may be a flat planar surface and the upper surface205of the lens200may be a curved surface.

Here, a groove230may be formed in a central region of the upper surface205of the lens200.

An area of an upper part of the groove230of the lens200may be greater than that of a lower part thereof.

FIGS. 5A and 5Bare sectional views illustrating a lens coupled to a base plate,FIG. 5Ais a sectional view illustrating a base plate having a monolayer structure andFIG. 5Bis a sectional view illustrating a base plate having a multilayer structure.

As shown inFIGS. 5A and 5B, a light source100is disposed on an upper surface403of the base plate400and a hole401is disposed in the base plate400adjacent to the light source100.

In addition, the connection portion210of the lens200is inserted into the hole401of the base plate400and is thus coupled to the base plate400.

Here, the hook disposed in a lower part of the connection portion210of the lens200may contact a lower surface405of the base plate400.

Next, the lower surface201of the lens200faces the light source100and the base plate400.

Here, the lower surface201of the lens200may be a flat planar surface and the upper surface205of the lens200may be a curved surface.

Next, the reinforcement part220may project outwardly from a side surface203of the lens200.

Here, the lower surface of the reinforcement part220may be flush with the lower surface201of the lens200.

In addition, the base plate400may be a monolayer as shown inFIG. 5Aand may be a multilayer, as shown inFIG. 5B.

For example, the base plate400may include a substrate402having a circuit pattern and a support member404supporting the substrate402.

Here, a material for the support member404may be a flexible and insulating film containing, for example, polyimide or epoxy (for example, FR-4).

FIG. 6is a sectional view illustrating a lens including a stopper andFIG. 7is a sectional view illustrating the lens ofFIG. 6coupled to the base plate.

As shown inFIGS. 6 and 7, the lens200may include the connection portion210and the reinforcement part220, and the connection portion210may project from an edge of the lower surface201of the lens200.

In addition, a lower part of the connection portion210may have a hook shape.

Next, the reinforcement part220may project outwardly from the side surface203of the lens200and the lower surface222of the reinforcement part220may be flush with the lower surface201of the lens200.

Next, the connection portion210may include a stopper212which projects from an edge of the lower surface201of the lens200to a central region of the lower surface201of the lens200.

Here, the stopper212may contact the upper surface403of the base plate400when the lens200is coupled to the base plate400.

Accordingly, the stopper212maintains a predetermined distance between the lower surface201of the lens200, and the base plate400and the light source100so that the lower surface201of the lens200does not contact the base plate400and the light source100.

The stopper212prevents the lens200from contacting the light source100and thus prevents damage of the light source100from exterior shock.

FIG. 8is a sectional view illustrating the fixing part of the base plate.

As shown inFIG. 8, the base plate400includes a hole enabling bonding to the lens200and a fixing part420which projects in a downward direction opposite to the upper surface403facing the light source.

Here, the base plate400may be fixed on an object having a curvature to be mounted, through the fixing part420.

In addition, the connection portion210of the lens200may project from the lower surface of the lens200and may be inserted into the hole of the base plate400.

Next, the reinforcement part220may project outwardly from the side surface203of the lens200and the lower surface of the reinforcement part220may be flush with the lower surface201of the lens200.

Next, the connection portion210may include a stopper212which projects from an edge of the lower surface201of the lens200to a central region of the lower surface201of the lens200.

Here, the stopper212may contact the upper surface403of the base plate400when the lens200is coupled to the base plate400.

Accordingly, the stopper212maintains a predetermined distance between the lower surface201of the lens200, and the base plate400and the light source100so that the lower surface201of the lens200does not contact the base plate400and the light source100.

FIG. 9Ais a perspective view illustrating a spacer andFIG. 9Bis a sectional view taken along the line III-Ill ofFIG. 9A.

As shown inFIGS. 9A and 9B, the spacer700may be disposed between the base plate (represented by reference numeral “400” inFIG. 2) and the optical member (represented by reference numeral “600” inFIG. 2) and support the optical member (represented by reference numeral “600” inFIG. 2).

Here, the spacer700may include a bottom surface702and a side surface704extending from an edge of the bottom surface702upwardly.

A groove720corresponding to the reinforcement part of the lens (represented by reference numeral “200” inFIG. 2) may be disposed on a lower surface702bof the bottom surface702of the spacer700.

In addition, a hole710exposing the upper surface of the lens (represented by reference numeral “200” inFIG. 2) may be disposed in a region corresponding to the lens (represented by reference numeral “200” inFIG. 2) on the bottom surface702of the spacer700.

Here, the hole710may correspond to the groove720of the spacer700.

In addition, the bottom surface702of the spacer700may be spaced from the base plate (represented by reference numeral “400” inFIG. 2) by a predetermined distance d1.

However, in some cases, the bottom surface702of the spacer700may contact the base plate (represented by reference numeral “400” inFIG. 2).

Next, the bottom surface702of the spacer700may be a curved surface having one or more curvatures.

In addition, the side surface704of the spacer700may be inclined with respect to the bottom surface702of the spacer700.

In addition, the spacer700may be formed as either a reflective coating film or a reflective coating material layer and reflect light generated by the light source (represented by reference numeral “100” inFIG. 2) toward the optical member (represented by reference numeral “600” inFIG. 2).

FIG. 10Ais a plan view seen from above inFIG. 9BandFIG. 10Bis a plan view seen from beneath inFIG. 9B.

As shown inFIGS. 10A and 10B, the spacer700may include the bottom surface702and the side surface704extending upwardly from an edge of the bottom surface702. The hole710exposing the lens (represented by reference numeral “200” inFIG. 2) may be disposed on an upper surface702aof the bottom surface702of the spacer700.

In addition, the hole710allowing insertion of the lens (represented by reference numeral “200” inFIG. 2) may be disposed on the lower surface702bof the bottom surface702of the spacer700and the groove720may be disposed adjacent to the hole710.

Here, the reinforcement part of the lens (represented by reference numeral “200” inFIG. 2) may be disposed in the groove720.

Here, a depth of the groove720may be equivalent to or greater than that of the reinforcement part of the lens (represented by reference numeral “200” inFIG. 2).

In addition, a plurality of grooves including the groove720may be present and the grooves720may be disposed symmetrical to one another near the hole710.

Here, the number of the grooves720may be equivalent to that of the reinforcement parts of the lenses (represented by reference numeral “200” inFIG. 2).

FIG. 11is a sectional view illustrating a spacer bonded to a lens.

As shown inFIG. 11, the spacer700may include a bottom surface702facing the base plate400, the groove may be disposed on the lower surface702bof the bottom surface702of the spacer700and the reinforcement part220of the lens200may be inserted into the groove.

In addition, the upper surface of the lens200may be exposed to the upper surface702aof the bottom surface702of the spacer700through the hole disposed in the bottom surface702of the spacer700.

Next, the connection portion210of the lens200may be inserted into the hole of the base plate400and may thus be coupled to the base plate400.

Here, the lower surface702bof the bottom surface702of the spacer700may be spaced from the base plate400by a predetermined distance d1.

However, in some cases, the lower surface702bof the bottom surface702of the spacer700may contact the base plate400.

Accordingly, the connection portion210of the lens200may be a projection enabling coupling to the base plate400and the reinforcement part220of the lens200may be a projection fixed through the groove of the bottom surface702of the spacer700.

FIG. 12is a sectional view illustrating the light source ofFIG. 2in detail.

As shown inFIG. 12, the light source100may be a vertical light emitting chip having a wavelength range of about 390 to 490 nm.

The light source100may include a second electrode layer1010, a reflective layer1020, a light emitting structure1040, a passivation layer1060and a first electrode layer1080.

Here, the second electrode layer1010and the first electrode layer1080may supply power to the light emitting structure1040.

In addition, the second electrode layer1010may include an electrode material layer1002for current injection, a support layer1004disposed on the electrode material layer1002and a bonding layer1006disposed on the support layer1004.

Here, the electrode material layer1002may be formed of Ti/Au and the support layer1004may be formed of a metal or a semiconductor material.

In addition, the support layer1004may be formed of a material having high electrical conductivity and thermal conductivity. For example, the support layer1004may be formed of a metal material including at least one of copper (Cu), a copper alloy (Cu alloy), gold (Au), nickel (Ni), molybdenum (Mo) and copper-tungsten (Cu—W) or a semiconductor including at least one of Si, Ge, GaAs, ZnO and SiC.

Next, the bonding layer1006may be disposed between the support layer1004and the reflective layer1020and function to bond the support layer1004to the reflective layer1020.

Here, the bonding layer1006may include a bonding metal material, for example, at least one of In, Sn, Ag, Nb, Pd, Ni, Au and Cu.

The bonding layer1006is formed to bond the support layer1004by a bonding method and may be omitted when the support layer1004is formed by plating or deposition.

In addition, the reflective layer1020is disposed on the bonding layer1006and the reflective layer1020reflects light emitted from the light emitting structure1040and thereby improves light extraction efficiency.

Here, the reflective layer1020may be formed of a metal or alloy including, as a reflecting metal material, for example, at least one of Ag, Ni, Al, Rh, Pd, Ir, Ru, Mg, Zn, Pt, Au and Hf.

In addition, the reflective layer1020may be formed to have a monolayer or multilayer structure using a conductive oxide layer, for example, indium zinc oxide (IZO), Indium zinc tin oxide (IZTO), indium aluminum zinc oxide (IAZO), indium gallium zinc oxide (IGZO), indium gallium tin oxide (IGTO), aluminum zinc oxide (AZO), antimony tin oxide (ATO) or the like.

In some cases, the reflective layer1020may be formed to have a multilayer structure using a combination of a metal and conductive oxide such as IZO/Ni, AZO/Ag, IZO/Ag/Ni, or AZO/Ag/Ni.

Next, an ohmic region1030may be disposed between the reflective layer1020and the light emitting structure1040.

Here, the ohmic region1030is an area which ohmic-contacts the light emitting structure1040and functions to facilitate supply of power to the light emitting structure1040.

For example, the ohmic region1030may include AuBe and may have a dot shape.

Next, the light emitting structure1040may include a window layer1042, a second semiconductor layer1044, an active layer1046and a first semiconductor layer1048.

Here, the window layer1042is a semiconductor layer disposed on the reflective layer1020and contains GaP.

In some cases, the window layer1042may be omitted.

Next, the second semiconductor layer1044is disposed on the window layer1042and the second semiconductor layer1044may be implemented with a compound semiconductor such as Group III-V or Group II-VI compound semiconductor and be doped with a second conductive-type dopant.

In addition, the active layer1046may be disposed between the second semiconductor layer1044and the first semiconductor layer1048and may emit light by energy generated during recombination between electrons and holes supplied from the second semiconductor layer1044and the first semiconductor layer1048.

Here, the active layer1046may be a Group III-V or Group III-VI compound semiconductor and may have a single well structure, a multiple well structure, a quantum-wire structure, a quantum dot structure or the like.

For example, the active layer1046may have a single or multiple quantum well structure including a well layer and a barrier layer.

The well layer may be formed of a material having an energy band gap lower than that of the barrier layer and the active layer1046may be for example AlGaInP or GaInP.

Next, the first semiconductor layer1048may be formed of a semiconductor compound and the first semiconductor layer1048may be implemented with a Group III-V or Group II-VI compound semiconductor or the like and may be doped with a first conductive-type dopant.

In addition, the light emitting structure1040may emit blue light having a wavelength range of about 390 to 490 nm and the first semiconductor layer1048, the active layer1046and the second semiconductor layer1044may contain a material emitting blue light.

In addition, so as to improve light extraction efficiency, the first semiconductor layer1048may have a roughness1070on an upper surface thereof.

Next, the passivation layer1060is disposed on a side surface of the light emitting structure1040and the passivation layer1060electrically protects the light emitting structure1040.

In some cases, the passivation layer1060may be disposed only in at least part of the upper surface of the first semiconductor layer1048.

In addition, the first electrode layer1080may be disposed on the first semiconductor layer1048and may have a predetermined pattern.

Here, the first electrode layer1080may have a monolayer or multilayer structure and for example, the first electrode layer1080may include a first layer1082, a second layer1084and a third layer1086laminated in this order.

The first layer1082ohmic-contacts the first semiconductor layer1048and contains GaAs.

In addition, the second layer1084may be formed of an AuGe/Ni/Au alloy and the third layer1086may be formed of a Ti/Au alloy.

A phosphor layer including one or more of phosphors having a wavelength range of about 550 to 700 nm is disposed on the light source having the structure described above to emit light having a color of a square area determined by color coordinates (0.54, 0.37), (0.54, 0.45), (0.61, 0.45) and (0.61, 0.37) in a CIE chromaticity diagram.

Accordingly, the first electrode layer1080of the light source may be closer to the phosphor layer than the second electrode layer1010.

FIGS. 13A to 13Dare sectional views illustrating an irregular pattern of the optical member.

As shown inFIGS. 13A to 13D, the optical member600diffuses light emitted from the light source and may have an irregular pattern610on an upper surface thereof to improve diffusion effects.

Here, the irregular pattern610may have a strip shape disposed in one direction.

In addition, as shown inFIG. 13A, the irregular pattern610of the optical member600may be disposed on the upper surface600aof the optical member600and the upper surface600aof the optical member600may face a cover member (not shown).

When the optical member600has a multilayer structure, the irregular pattern610may be disposed on the surface of the uppermost layer.

Next, as shown inFIG. 13B, the irregular pattern610of the optical member600may be disposed on a lower surface600bof the optical member600and the lower surface600bof the optical member600may face a light module (not shown).

When the optical member600has a multilayer structure, the irregular pattern610may be disposed on the surface of the lowermost layer.

As shown inFIG. 13C, the irregular pattern610of the optical member600may be disposed on the upper surface600aof the optical member600and on the lower surface600bof the optical member600. When the optical member600has a multilayer structure, the irregular pattern610may be disposed both on the surface of the uppermost layer of the optical member600and on the surface of the lowermost layer thereof.

In addition, as shown inFIG. 13D, the irregular pattern610of the optical member600may be disposed in a portion of the upper surface600aof the optical member600or a portion of the lower surface600bof the optical member600.

The irregular pattern has a projection which bulges from the surface of the optical member600, the projection has a first surface and a second surface which face each other and an angle between the first surface and the second surface may be an obtuse angle or an acute angle.

In some cases, the irregular pattern may a recessed groove in the surface of the optical member600, the groove has a third surface and a fourth surface which face each other and an angle between the third surface and the fourth surface may be an obtuse angle or an acute angle.

As such, the irregular pattern610of the optical member600may variably change according to design conditions of light source module required for an object mounted so as to provide overall uniform luminance.

FIGS. 14A to 14Care exploded views illustrating a vehicle lamp unit according to an embodiment.

As shown inFIGS. 14A to 14C, the vehicle lamp unit may include a base plate400having a plurality of lenses200covering a plurality of light sources, a spacer700and an optical member600.

Here, the light sources may be disposed on the base plate400and the base plate400may include an electrode pattern to electrically connect the light sources.

Additionally, the base plate400may have a flexibility and may be a printed circuit board (PCB) substrate formed of a material selected from polyethylene terephthalate (PET), glass, polycarbonate (PC), silicon (Si), polyimide, epoxy and the like, or a film type substrate.

In addition, the base plate400may be selected from a monolayer PCB, a multilayer PCB, a ceramic substrate, a metal core PCB and the like.

As such, the base plate400may be bent due to use of a ductile material and may be bent due to structural deformation.

Accordingly, the base plate400may include a curved surface having one or more curvatures.

Next, the base plate400may include a plurality of holes formed respectively in regions corresponding to the connection portions210of respective lenses200.

Here, the lens200may be coupled to the base plate400through the hole of the base plate400.

In addition, the base plate400may include a plurality of fixing parts420which project in a downward direction opposite to the upper surface of the base plate400facing the light source100.

Here, the base plate400may be fixed on an object having a curvature to be mounted through the fixing part.

In addition, the base plate400may include either a reflective coating film or a reflective coating material layer to reflect light generated by the light source100toward the optical member600.

Here, the reflective coating film or the reflective coating material layer may include a metal or metal oxide having high reflectivity such as aluminum (Al), silver (Ag), gold (Au) or titanium dioxide (TiO2).

In some cases, the base plate400may be provided with a plurality of heat discharging pins to discharge heat generated by the light source100.

Here, the light source100may be a light emitting diode (LED) chip, and the light emitting diode chip may be formed as a red LED chip, a blue LED chip or an ultraviolet LED chip or as a package including a combination of at least one of a red LED chip, a green LED chip, a blue LED chip, a yellow green LED chip and a white LED chip.

For example, when the lamp unit is applied to a vehicle taillight, the light source100may be a vertical-type light emitting chip, for example, a red light emitting chip, but the embodiment is not limited thereto.

Next, the lens200may cover the light source100and be coupled to the base plate400.

Here, the lens200may include a connection portion contacting the base plate400and a reinforcement part contacting the spacer700.

The connection portion210may project from an edge of the lower surface of the lenses200toward the base plate400.

In some cases, the connection portion may further include a stopper which projects from the edge of the lower surface of the lens200toward the center of the lower surface thereof.

In addition, the connection portion may be disposed in an x-axis direction passing through the center of the lens200.

In addition, the reinforcement part may project outwardly from a side surface of the lens200and may be spaced from the base plate400by a predetermined distance.

Here, the reinforcement part may be disposed in the y-axis direction vertical to the x-axis direction.

Additionally, the lens200may have a lower surface facing the base plate400and the lower surface of the lens200may be spaced from the base plate400by a predetermined distance.

Next, the spacer700may be disposed between the base plate400and the optical member600and support an edge of the optical member600.

Here, the spacer700may include a bottom surface facing the base plate400and a side surface extending from an edge of the bottom surface toward the optical member600.

A groove corresponding to the reinforcement part220of the lens200may be disposed on the bottom surface of the spacer700.

In addition, a hole exposing the upper surface of the lens200in a region corresponding to the lens may be disposed on the bottom surface of the spacer700.

In addition, the bottom surface of the spacer700may be spaced from the base plate400by a predetermined distance d1. However, in some cases, the bottom surface of the spacer700may contact the base plate400.

Next, the bottom surface of the spacer700may be a curved surface having one or more curvatures.

In addition, the side surface of the spacer700may be inclined with respect to the bottom surface of the spacer700.

In addition, the spacer700may include a reflective coating film or a reflective coating material layer to reflect light generated by the light source100toward the optical member600.

Here, the reflective coating film or the reflective coating material layer may contain a metal or metal oxide having a high reflectivity, such as aluminum (Al), silver (Ag), gold (Au) or titanium dioxide (TiO2).

Next, the optical member600may be spaced from the base plate400via a gap corresponding to a predetermined distance and a light mixing area750may be formed in the gap between the base plate400and the optical member600.

Here, the optical member600may be spaced from the base plate400by a predetermined distance d2 and the distance d2 may be about 10 mm or more.

When the distance d2 between the optical member600and the base plate400is about 10 mm or less, the lamp unit does not exhibit uniform luminance, and a hot spot phenomenon wherein intensive luminance is generated in a region in which the light source100is disposed, or a dark spot phenomenon wherein weaker luminance is generated in a region in which the light source100is disposed may occur.

In addition, the optical member600may include at least one selected from a diffusion sheet, a prism sheet, a luminance-enhancing sheet and the like.

Here, the diffusion sheet diffuses light emitted from the light source100, the prism sheet guides diffused light to a light emitting area and the luminance diffusion sheet enhances luminance.

For example, the diffusion sheet is generally formed of an acrylic resin, but the disclosure is not limited thereto. Furthermore, the material for the diffusion sheet includes light-diffusing materials such as polystyrene (PS), poly(methyl methacrylate) (PMMA), cycloolefin copolymers (COCs), polyethylene terephthalate (PET), and highly-permeable plastics such as resins.

Here, the optical member600may have a surface having at least one of a recessed curved surface, a protruded curved surface and a flat planar surface according to outer appearance (shape) of the cover member or the object to be mounted.

As such, in accordance with the embodiment, a surface light source is implemented using a small number of light sources by forming a light mixing area750between the lens200covering the light source100, the base plate400and the optical member600.

As such, in accordance with the present embodiment, a surface light source is implemented using a small number of light sources by forming a lens200covering the light source100and forming a light mixing area750between the base plate400and the optical member600.

Here, the surface light source means a light source which includes a light emission area diffusing light in a planar form. The present embodiment may provide a lamp unit which implements a surface light source with a small number of light sources.

In addition, the lamp unit according to the present embodiment may be applied to objects having a variety of shapes including a curved shape, because the bendable base plate400may be coupled to the lens200covering the light source100.

Accordingly, the present embodiment improves economic efficiency and freedom of product design of the lamp unit.

FIG. 15is a view illustrating a vehicle taillight according to an embodiment.

As shown inFIG. 15, the vehicle taillight800may include a first lamp unit812, a second lamp unit814, a third lamp unit816and a housing810.

Here, the first lamp unit812may be a light source serving as a turn signal lamp, the second lamp unit814may be a light source serving as a side marker light, and the third lamp unit816may be a light source serving as a stop light, but the embodiment is not limited thereto and the functions thereof may be interchanged.

In addition, the housing810may accommodate the first to third lamp units812,814and816, and may be formed of a light-transmitting material.

In this case, the housing810may have a curvature suited for the design of the vehicle body and the first to third lamp units812,814and816may implement a bendable surface light source according to shape of the housing810.

FIG. 16is a plan view illustrating a vehicle including a lamp unit according to an embodiment.

As shown inFIG. 16, when the lamp unit is applied to taillight of a vehicle900, regarding a safety standard of the lamp unit applied to the vehicle taillight, a projection area when seen at a horizontal angle of 45 degrees in an outer axis of the vehicle based on a central point of a light should be about 12.5 sq centimeters or more, for example, luminous intensity of a stop light should be about 4 to 420 candela (cd).

Accordingly, the vehicle taillight should provide a dose of light not lower than a predetermined value, when measured in a light dose measurement direction.

The lamp unit according to the present embodiment improves economical efficiency and freedom of product design of the lamp unit by implementing a surface light source which provides a dose of light not lower than a predetermined value in a predetermined light dose measurement direction even with a small number of light sources.

That is, in accordance with the present embodiment, first, a surface light source is implemented even with a small number of light sources by covering the light sources with lenses.

Second, a lamp unit having low weight may be manufactured at a low cost by forming a light mixing area in a gap between the light source and the optical member without forming a light guide plate.

Third, the lamp unit may be applied to an object having a curvature by disposing a plurality of light sources on a bendable base plate.

Accordingly, economic efficiency and product design freedom of the lamp unit may be improved.

Embodiments provide a lamp unit which implements a source light source with a small number of light sources using a lens and a vehicle lamp apparatus using the same.

Embodiments provide a lamp unit which includes a plurality of light sources disposed on a flexible base plate and is thus applicable to a curved object mounted thereon and a vehicle lamp apparatus using the same.

In one embodiment, a lamp unit includes an optical member, a base plate spaced from the optical member by a predetermined distance, a spacer between the base plate and the optical member, the spacer supporting an edge of the optical member, a light source disposed on the base plate, and a lens coupled to the base plate, the lens covering the light source, wherein the lens comprises a connection portion contacting the base plate and a reinforcement part contacting the spacer.

The connection portion may project from an edge of a lower surface of the lens toward the base plate.

The connection portion may include a stopper which projects from the edge of the lower surface of the lens toward a center of the lower surface of the lens.

The connection portion may be disposed in an x-axis direction passing through the center of the lens and the reinforcement part may be disposed in a y-axis direction vertical to the x-axis direction.

The reinforcement part may project outwardly from a side surface of the lens and be spaced from the base plate by a predetermined distance.

The reinforcement part may include a lower surface facing the base plate and the lower surface of the reinforcement part may be flush with the lower surface of the lens.

The lens may include a lower surface facing the base plate, wherein the lower surface of the lens is spaced from the base plate by a predetermined distance.

The lens may include the lower surface facing the base plate and an upper surface facing the optical member, wherein the lower surface of the lens is a planar surface and the upper surface of the lens is a curved surface.

The upper surface of the lens may include a groove corresponding to a central region of a light emission surface of the light source.

The base plate may include a hole disposed in a region corresponding to the connection portion of the lens and the base plate may include a curved surface having one or more curvatures.

The base plate may include a fixing part projecting in a, downward direction opposite to the upper surface of the base plate facing the light source.

The spacer may include a bottom surface facing the base plate and a side surface extending from an edge of the bottom surface toward the optical member.

The bottom surface of the spacer may include a groove corresponding to the reinforcement part of the lens and the bottom surface of the spacer may include a hole to expose the upper surface of the lens in a region corresponding to the lens.

The bottom surface of the spacer may include a curved surface having one or more curvatures and the bottom surface of the spacer may be spaced from the base plate by a predetermined distance.

A side surface of the spacer may be inclined with respect to the bottom surface of the spacer.

The optical member may include a curved surface having one or more curvatures and the optical member may be spaced from the base plate by a distance of 10 mm or more.

The connection portion may be disposed in a direction parallel to the base plate.

The connection portion may be disposed in a direction vertical to the reinforce projection.

A side surface of the spacer may be disposed at an obtuse angle with respect to the bottom surface of the spacer.

In another embodiment, a lamp unit includes an optical member, a base plate spaced from the optical member by a predetermined distance, a spacer between the base plate and the optical member, the spacer supporting an edge of the optical member, a light source disposed on the base plate, and a lens coupled to the base plate, the lens covering the light source, wherein the spacer includes a bottom surface contacting the base plate and a side surface extending from an edge of the bottom surface toward the optical member, wherein the bottom surface of the spacer comprises a hole to expose the upper surface of the lens in a region corresponding to the lens, the side surface of the spacer is inclined with respect to the bottom surface of the spacer and the distance between the optical member and the base plate is maintained at 10 mm or more.