Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is based on and claims priority from Japanese Patent Application Nos. 2015-225451 and 2016-087618, filed on Nov. 18, 2015 and Apr. 26, 2016, respectively, with the Japan Patent Office, the disclosures of which are incorporated herein in their entireties by reference. 
       TECHNICAL FIELD 
       [0002]    The present disclosure relates to a lamp using a light emitting element such as, for example, a light emission diode (LED) or a laser diode (LD) as a light source. In particular, the present disclosure relates to a lamp in which the heat dissipating property of the light emitting element is improved, the number of components is reduced, and the assembly work is facilitated. 
       BACKGROUND 
       [0003]    Many lamps using the above-described type of a light emitting element as a light source adopt the configuration in which a light source unit is constituted by mounting one or more light emitting elements in a circuit board (e.g., a printed wiring board), and the light source unit is equipped in a lamp housing. For example, in a vehicle lamp for an automobile, the light source unit is equipped in the lamp housing in a state where the inside of the lamp housing is almost hermetic, in order to protect the light source unit from an external environment. 
         [0004]    In this lamp, when the light source unit emits light, the temperature inside the lamp housing may increase due to heat generated from the light emitting element as the light source, and the temperature of the light emitting element may also increase accordingly. Thus, due to the so-called thermal runaway, the thermal reliability of the light emitting element may be deteriorated. Hence, it is required to dissipate the heat of the light emitting element to the outside of the lamp housing. 
         [0005]    For example, Japanese Laid-Open Patent Publication No. 2014-146440 discloses a configuration in which a heat dissipating member is integrated with the rear side inner surface of a lamp housing opposite to the rear surface of a circuit board, and an opening is formed at the corresponding rear side inner surface to expose the heat dissipating member to the outside. According to this configuration, the heat generated from the light emitting element may be transferred to the heat dissipating member from the circuit board, and dissipated to the outside through the opening. In addition, Japanese Laid-Open Patent Publication No. 2011-192905 discloses a technique in which a conductive member also serving as a heat dissipating member is integrally embedded in a resin-made lamp housing. 
       SUMMARY 
       [0006]    The technique of Japanese Laid-Open Patent Publication No. 2014-146440 integrates the heat dissipating member, which is a separate member from the lamp housing, with the lamp housing through, for example, a bonding. Hence, the heat dissipating member is required separately from the circuit board, thereby increasing the number of components, and furthermore, increasing the number of assembly work processes. 
         [0007]    The technique of Japanese Laid-Open Patent Publication No. 2011-192905 is advantageous in reducing the number of components because the conductive member integrated with the lamp housing also serves as a heat dissipating member so that an independent circuit board and an independent conductive member are not required. However, in Japanese Laid-Open Patent Publication No. 2011-192905, since the conductive member is integrated with the box-shaped lamp housing, the work of mounting the light emitting element on the conductive member is complicated. That is, since the board surface on which the light emitting element is to be mounted is not flat, it is difficult to apply the technique of automatically mounting the light emitting element by a so-called reflow method, and the mounting by a manual operation is required. This makes the lamp assembly work complicated. 
         [0008]    An object of the present disclosure is to provide a lamp and a manufacturing method thereof in which the heat dissipating property of the light emitting element is improved, the number of components is reduced, and the assembly work is simplified by enabling the automatic mounting of the light emitting element. 
         [0009]    The lamp of the present disclosure includes a resin-made body in which a conductive lead frame is integrally molded, and a light emitting element mounted on the corresponding lead frame. A pad is installed in the lead frame and exposed within a concave portion formed on the surface of the body. The light emitting element is mounted on the pad within the corresponding concave portion. 
         [0010]    In the lamp of the present disclosure, the edges of the concave portion are formed as tapered surfaces in the thickness direction, and the outer edges of the light emitting element are in contact with the corresponding tapered surfaces. In addition, the body is formed as a lamp housing of which at least a part is bending-processed. In addition, the body includes a connector case formed by bending-processing at least a part of the body, and a connector terminal formed by bending-processing a part of the lead frame within the connector case. In this case, the body has the configuration in which a window is opened at a position adjacent to the connector case, and at least a part of the lead frame is exposed to the corresponding window. 
         [0011]    In addition, in the present disclosure, the body may include one or more heat dissipating pins which project from the rear surface of the body. In addition, at least a part of the lead frame is curved, and each heat dissipating pin is formed as a heat dissipating pin in which the curved part is embedded inside the body. Alternatively, the heat dissipating pin may have a configuration in which the curved part is exposed to the outside from the inside of the body. In addition, the concave portion may include a sealing portion that covers the pad and the light emitting element. 
         [0012]    The lamp manufacturing method of the present disclosure may include processing a conductive lead frame into a pattern shape having at least a pad and a connector terminal, forming a body by integrally molding the lead frame with a resin material, mounting a light emitting element on the pad exposed within a concave portion provided in the body, and forming a lamp housing by bending-processing a part of the body. This manufacturing method may further include bending-processing the connector terminal exposed to the body, and forming a connector case in a part of the body. 
         [0013]    According to the lamp of the present disclosure, since the lead frame is integrally molded with the body, and the pad of the lead frame is exposed in the concave portion provided in the body, the lamp may be formed by mounting a light emitting element in the body and mounting a front lens in the body. Accordingly, the lamp may be constituted with the minimum number of components. Further, the lamp housing or the connector may be configured by bending-processing the body and the lead frame, thereby facilitating the manufacturing. The heat dissipating effect of the light emitting element may be further improved by installing a heat dissipating pin in the body or including a bending-processed curved portion in the lead frame. In addition, by providing the sealing portion in the concave portion, the light emitting element and the pad may be protected from the external environment, and the relevant reliability may be improved. 
         [0014]    According to the manufacturing method of the present disclosure, the light emitting element may be surface-mounted on the body in which the lead frame is integrally molded, by an automatic machine. Further, the lamp housing and the connector may be formed by bending-processing the body and the lead frame. Accordingly, the lamp may be easily manufactured while reducing the number of lamp assembly processes. 
         [0015]    The above-described summary is illustration purposes only and does not intend to limit in any ways. In addition to the illustrative embodiment, examples, and features described above, additional embodiment, example, and features will become apparent by referring to the drawings and the following detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1A  is a partially cutaway appearance perspective view of an HMSL of Exemplary Embodiment 1 when viewed from the front side, and  FIG. 1B  is an appearance perspective view of the same when viewed from the rear side. 
           [0017]      FIG. 2A  is a front view of a body, and  FIG. 2B  is a cross-sectional view taken along the line B-B in  FIG. 2A . 
           [0018]      FIG. 3  is a perspective view of a lead frame. 
           [0019]      FIG. 4A  is an enlarged cross-sectional view taken along the line a-a in  FIG. 2A , and  FIG. 4B  is an enlarged cross-sectional view taken along the line b-b in  FIG. 2A . 
           [0020]      FIGS. 5A and 5B  are schematic perspective views for explaining a manufacturing process (part 1). 
           [0021]      FIG. 6  is a schematic perspective view for explaining a manufacturing process (part 2). 
           [0022]      FIGS. 7A and 7B  are schematic perspective views for explaining a manufacturing process (part 3). 
           [0023]      FIGS. 8A and 8B  are schematic perspective view for explaining a partially modified manufacturing process. 
           [0024]      FIG. 9A  is an appearance perspective view of an HMSL of Exemplary Embodiment 2 when viewed from the rear side, and  FIG. 9B  is an enlarged cross-sectional view taken along the line C-C in  FIG. 9A . 
           [0025]      FIG. 10A  is a perspective view of a lead frame, and  FIG. 10B  is a rear side perspective view of an insert-molded body. 
           [0026]      FIG. 11A  is a perspective view of an LED pad, and  FIG. 11B  is an enlarged cross-sectional view taken along the line D-D in  FIG. 11A . 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    In the following detailed description, reference is made to the accompanying drawing, which form a part hereof. The illustrative exemplary embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other exemplary embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. 
       Exemplary Embodiment 1 
       [0028]    Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings.  FIGS. 1A and 1B  are appearance perspective views of Exemplary Embodiment 1 which applies the present disclosure to a high mount stop lamp (HMSL) as one of automobile lamps.  FIG. 1A  is a partially cutaway appearance perspective view of the HMSL when viewed in the front direction, and  FIG. 1B  is an appearance perspective view of the same when viewed in the rear direction. 
         [0029]    In the HMSL  1 , as illustrated in  FIG. 1A , a lamp housing  2  is constituted with a body  3  having a horizontally long container shape of which the front side is opened, and a front lens  4  mounted on the front opening of the body  3 . A plurality of light sources  5  are arranged and supported horizontally inside the lamp housing  2  (here, the body  3 ). The HMSL  1  is equipped in the rear side portion of an automobile body (not illustrated) in a state where the front lens  4  is directed toward the rear side of the automobile, and turned on, for example, at a time of operating the brake of the automobile. 
         [0030]    The body  3  is formed in a rectangular container shape including a rectangular bottom portion  31  and four side portions  32  to  35  surrounding the bottom portion  31 . The above-described plurality of light emitting elements as light sources (here, four (4) rectangular LED chips  5 ) are mounted on the inner bottom surface  31   a  of the bottom portion  31 . The four LED chips  5  are arranged in a row along the longitudinal direction of the body  3  at required intervals, and individually surface-mounted on the inner bottom surface  31   a  of the body  3 . 
         [0031]    As illustrated in  FIG. 1B , a connector  6  is integrally formed on the outer bottom surface  31   b  of the bottom portion  31  of the body  3 . The connector  6  is configured to make a power source connector  8  connected to an on-automobile body power source attachable/detachable, and to be fed with a power to cause the LED chips  5  to emit light. In addition, a plurality of windows  36   a  and  36   b  to be described later are opened in the outer bottom surface  31   b.    
         [0032]      FIG. 2A  is a front view of the HMSL  1 , and  FIG. 2B  is a cross-sectional view taken along the line B-B of  FIG. 2A . The body  3  is formed in a plate shape by molding a heat resistant resin such as, for example, a polyphenylene sulfide (PPS) resin, and then, formed in the above-described rectangular container shape by a subsequent processing. A lead frame  7  formed of a copper material is integrally embedded inside the body  3  through, for example, insert-molding. The lead frame  7  is embedded within the area of the bottom portion  31  of the body  3 , and is not embedded within the areas of the four side portions  32  to  35 . 
         [0033]    The lead frame  7  is formed by a patterning and a bending of a conductive metal plate such as, for example, copper.  FIG. 3  represents the state prior to the bending. The lead frame  7  includes four pairs of LED pads  71  on which the four LED chips  5  are to be mounted, respectively, a pair of connector terminals  72  constituting a terminal of the connector  6 , and a wiring portion  73  electrically connecting the LED pads  71  and the connector terminals  72  to each other. Further, here, the lead frame  7  also includes four heat dissipating portions  74  each having a rectangular plate shape with a required area. Further, if needed, the lead frame  7  includes a component pad that mounts thereon an electronic component constituting a light emission circuit to cause the light emission of the LED chips  5 . However, the present exemplary embodiment represents an example where no component pad is provided. 
         [0034]      FIG. 4A  is an enlarged cross-sectional view taken along the line a-a in  FIG. 2A . Rectangular concave portions  37  are formed at positions corresponding to the four pairs of LED pads  71  of the lead frame  7 , respectively, in the inner bottom surface  31   a  of the bottom portion  31  of the body  3 . The four pairs of LED pads  71  are exposed on the inner bottom surfaces of the four concave portions  37 , respectively. Each concave portion  37  is formed to have longitudinal and lateral dimensions corresponding to the external appearance of each LED chip  5  to be mounted, and the four edges of the concave portion  37  are formed as tapered surfaces  37   a  inclined outwardly in the plate thickness direction. 
         [0035]    A light emitting surface portion  51  of each LED chip  5  is directed toward the front opening of the body  3 , and electrodes  52  including a pair of positive and negative electrodes are provided on the rear surface of the LED chip  5  opposite to the light emitting surface of the LED chip  5 , and soldered to the LED pad  71  via a reflow solder  9  so that the LED chip  5  is mounted on the LED pad  71 . In the mounted state, the four outer edges of the LED chip  5  at the rear side thereof are in a state of being in contact with the four tapered surfaces  37   a  of the concave portion  37 , respectively. 
         [0036]      FIG. 4B  is an enlarged cross-sectional view taken along the line b-b of  FIG. 2A . A rectangular cylinder-shaped connector case  61  is formed on a part of the outer bottom surface  31   b  of the body  3  integrally with the body  3  and constituted with piece portions  38  as a part of the body  3 , as described later. Inside the connector case  61 , the pair of connector terminals  72  of the lead frame  7  are arranged in a vertically bent state. The connector case  61  and the connector terminals  72  constitute the connector  6 . The power source connector  8  may be inserted into the connector case  61 , and when the power source connector  8  is inserted thereinto, the pair of connector terminals  72  are electrically connected to the corresponding power source connector  8 . 
         [0037]    In addition, as illustrated in  FIGS. 1B and 2B , rectangular windows  36   a  and  36   b  are opened in the outer bottom surface  31   b  of the body  3  at opposite sides of the connector case  61 , and at opposite sides of the outer sides from the opposite sides of the connector case  61 , respectively. The heat dissipating portions  74  of the lead frame  74  are partially exposed in the windows  36   a  and  36   b . Since the windows  36   a  and  36   b  are closed by the heat dissipating portions  74  or a part of the bottom portion  31 , the inner bottom surface  31   a  of the body  3  does not communicate with the outer bottom surface  31   b  side through the windows  36   a  and  36   b.    
         [0038]    The front lens  4  is made of a translucent resin and formed in a rectangular plate shape. The front lens  4  is mounted on the front opening of the body  3 . Here, the circumferential edge of the front lens  4  is welded or bonded to the opening edge of the body  3 . Instead of the welding or bonding, the front lens  4  may be mounted on the body  3  by, for example, integrally forming tongue-like engagement pieces at the longitudinal opposite ends of the front lens  4 , respectively, and engaging the engagement pieces with engagement holes formed to project from the longitudinal opposite side surfaces of the body  3 , though not illustrated. 
         [0039]    In addition, a lens step may be formed on the inner surface of the front lens  4  to cause the light emitted from the LED chips  5  to be refracted and emitted toward the front side of the HMSL with a required light distribution. The lens step may adopt, for example, a configuration in which the inner surface of the front lens  4  is divided into plural vertical and horizontal square blocks, and a fine spherical lens is integrally formed in each block. 
         [0040]    The HMSL  1  configured as described above is supplied with a required power, for example, currents, from the power source connector  8  inserted into the connector  6 . The currents are supplied to the wiring portion  73  from the connector terminals  72  and further supplied to the four LED pads  71 . The four LED chips  5  are supplied with the currents through the LED pads  71  on which the LED chips  5  are mounted, respectively, so as to emit light. The light emitted from each of the LED chips  5  penetrates through the front lens  4  and is refracted by the lens step of the front lens  4  to irradiate the front side of HMSL  1  with a required light distribution. In addition, the inner surface of the body  3  may be subject to a surface processing to serve as a light reflecting surface such that the reflected light of the light emitted from the LED chips  5  is emitted from the front lens  4 . 
         [0041]    When each LED chip  5  emits light, the LED chip  5  generates heat. The generated heat is transferred to the LED pads  71  of the lead frame  7 , and further transferred to the wiring portion  73  or the heat dissipating portions  74 . Then, the heat is directly dissipated to the outside from the heat dissipating portions  74  exposed to the windows  36  opened at the outer bottom surface  31   b  of the body  3 . In addition, the heat is transferred to the bottom portion  31  of the body  3  from the wiring portion  73  or the heat dissipating portions  74  and dissipated from the outer bottom surface. Accordingly, the temperature rise of the LED chips  5  and the thermal runaway resulting therefrom are suppressed so that the thermal reliability is improved. 
         [0042]    Further, since the HMSL 1  includes the three parts which include the four LED chips  5  as light sources, the body  3 , and the front lens  4 , the number of the components is small, and the assembly work may be simplified. Especially, since the lead frame  7  configured to supply a power to the LED chips  5  is integrally embedded in the body  3 , the work of assembling the lead frame  7  mounted with the LED chips  5  in the body  3  is unnecessary. 
         [0043]      FIG. 5A  to  FIG. 7B  are schematic perspective views for explaining a manufacturing method of the above-described HMSL. First, as illustrated in  FIG. 3 , a flat copper plate is subject to a patterning so as to form the lead frame  7  including the four pairs of LED pads  71 , the pair of connector terminals  72 , the wiring portion  73  electrically connecting the LED pads  71  and the connector terminals  72  to each other, and the rectangular heat dissipating portions  74  also serving as a part of the wiring portion  73 . In this state, the lead frame  7  is not yet subject to the bending. 
         [0044]    Here, in the actual lead frame  7 , since the electrically separated portions of the respective components  71  to  74  are kept in a state of being mechanically connected to each other, a dummy connecting portion is formed as needed. However, here, the dummy connecting portion is not illustrated. In addition, as represented by the alternate long and two dot line in  FIG. 3 , the resin-made body  3  in which the lead frame  7  is insert-molded is formed. 
         [0045]    The formed body  3  is molded in a flat plate shape in which the bottom portion  31  and the four side portions  31  to  35  are developed, as represented by the front side perspective view in  FIG. 5A  and the rear side perspective view in  FIG. 5B . In addition, concave grooves each having a reduced thickness are formed at the positions where the four side portions  32  to  35  of the body  3  are connected to the bottom portion  31 , along the boundaries between the side portions  32  to  35  and the bottom portion  31 , respectively. The concave grooves are formed as so-called integral hinges  30   a  enabling bending of the boundary portions between the bottom portion  31  and the respective side portions  32  to  35  in the thickness direction. The lead frame  7  is embedded only in the bottom portion  31  of the body  3 , and is not pushed out to the side portions  32  to  35  beyond the integral hinges  30   a.    
         [0046]    The concave portions  37  are formed on the inner bottom surface  31   a  of the molded body  3 , and the LED pads  71  of the lead frame  7  are exposed to the inner bottom surfaces of the concave portions  37 . Meanwhile, an opening  39  is provided at the portion of the outer bottom surface  31   b  of the body  3  where the connector terminals  72  of the lead frame  7  are formed, and the connector terminals  72  are exposed within the opening  39 . In addition, the rectangular windows  36   a  are opened at the areas corresponding to parts of the heat dissipating portions  74  of the lead frame  7 , and the parts of the heat dissipating portions  74  are exposed in the windows  36   a , respectively. 
         [0047]    In the outer bottom surface  31   b  of the body  3 , a pair of substantially U-shaped slits  38   a  are formed to face to each other at the opposite sides of the body  3  between which the opening  39  is interposed, here, the longitudinal opposite sides of the body  3 . The slits  38   a  are formed at the areas corresponding to the other parts of the heat dissipating portions  74  of the lead frame  7 , and substantially U-shaped integral hinges  30   b  are formed facing the slits  38   a  in the piece portions  38  surrounded by the slits  38   a , respectively. 
         [0048]    Then, as illustrated in  FIG. 6 , the body  3  is set in an automatic reflow mounting machine (not illustrated) to perform the mounting of the LED chips  5 . The body  3  is set in the automatic reflow mounting machine while the inner bottom surface  31   a  is directed upward. The LED chips  5  picked up by a tool T of the corresponding mounting machine are set within the concave portions  37  formed in the inner bottom surface  31   a . The LED chips  5  are placed on the LED pads  71  exposed within the concave portions  37 , and in that state, the reflow is performed so that the LED chips  5  are surface-mounted on the LED pads  71 , respectively. 
         [0049]    In this case, since the edges of each concave portion  37  are formed as the tapered surfaces  37   a  as illustrated in  FIG. 4A , the outer edges of each LED chip  5 , especially, the lower edges thereof are in contact with the corresponding tapered surfaces  37   a  when the LED chip  5  is placed on each LED pad  71 , which enables self-alignment of the positioning of the LED chips  5  with respect to the concave portions  37 , i.e., the positioning of the LED chips  5  with respect to the LED pads  71 . 
         [0050]    Subsequently, as illustrated in  FIG. 7A , the body  3  in which the LED chips  5  have been completely mounted is set in an automatic bending/welding machine (not illustrated), and first processed to be bent along the integral hinges  30   a  provided in the body  3 . In the integral hinges  30   a  surrounding the bottom portion  31 , the four side portions  32  to  35  are processed to be bent vertically in the thickness direction of the inner bottom surface  31   a  so that the bottom portion  31  and the four side portions  32  to  35  are formed in a rectangular container shape. Then, the side portions of the side portions  32  to  35  where the side portions  32  are in contact with each other are heated for a welding processing so that the bottom portion  31  and the four side portions  32  to  35  are formed as a rectangular container-shaped body. 
         [0051]    Simultaneously, as illustrated in  FIG. 7B , the connector terminals  72  of the lead frame  7  which are exposed to the opening  39  of the outer bottom surface  31   b  of the bottom portion  31  are bent and erected vertically with respect to the outer bottom surface  31   b . In addition, the piece portions  38  surrounded by the slits  38   a  of the outer bottom surface  31   b  are processed to be bent by using the integral hinges  30   b . That is, first, the pair of piece portions  38  are bent and erected vertically in the outer surface direction along the integral hinges  30   b . Since the piece portions  38  exist in the areas of the heat dissipating portions  74  of the lead frame  7 , it is possible to bend and erect only the piece portions  38 . Subsequently, both the ends of each bent and erected piece portion  38  are processed to be bent vertically. By the bending and erecting and the bending, the windows  36   b  are opened at the portions where the piece portions  38  are bent and erected, and the heat dissipating portions  74  of the lead frame  74  are also exposed in the windows  36   b.    
         [0052]    Then, the side portions of the pair of bent piece portions  38  where the piece portions  38  are in contact with each other are subject to a welding processing so that the rectangular container-shaped connector case  61  is formed to surround the connector terminals  72  as illustrated in  FIG. 7B . That is, the connector  6  is formed by the connector terminals  72  and the connector case  61 . 
         [0053]    In addition, when the above-described dummy connecting portion (not illustrated) is provided in the lead frame  7 , a part of the inner bottom surface  31   a  of the body  3  may be processed to have a hole or a notch with a depth exceeding the leading frame  7  such that the corresponding dummy connecting portion is disconnected, and the respective components of the lead frame  7  are insulated and separated from each other. 
         [0054]    Then, as illustrated in  FIGS. 1A and 1B , the front lens  4  is mounted on the opening of the body  3  formed in the rectangular container shape. Here, the mounting is performed by bonding or welding as described above. The front lens  4  is integrated with the body  3  so that the HMSL 1  is completed. When the engagement pieces are formed in the front lens  4 , the front lens  4  may be mounted simply by being engaged with the body  3 . 
         [0055]    As described above, in this manufacturing method, the manufacture of the HMSL is completed by the process of processing the lead frame  7 , the process of insert-molding the processed lead frame  7  in a resin to form the body  3 , the process of mounting the LED chips  5  on the lead frame  7  integrated with the body  3  through, for example, the reflow, the process of the bending and the bonding for the body  3  and the lead frame  7 , and the process of mounting the front lens  4 . Accordingly, the HMSL may be manufactured with a small number of components, and furthermore, a small number of manufacturing processes. 
         [0056]    Here, as illustrated in  FIG. 8A , when the lead frame  7  is formed, the connector terminals  72  may be bent and erected vertically toward the rear side, i.e., the outer bottom surface  31   b  side of the bottom portion  31 , and in this state, the lead frame  3  may be insert-molded in the body  3 . In the insert-molding of the body  3 , the rectangular frame-shaped connector case  61  of the connector  6  is integrally molded at a part  38  of the rear surface of the body  3  as illustrated in  FIG. 8B . Accordingly, the connector  6  may be formed simultaneously with the insert-molding of the body  3  so that the process of bending the connecter case  61  thereafter is unnecessary. Further, the strength of the connector case  61  also increases. In addition, even when the connector  6  is formed in advance on the rear side of the body  3 , the automatic mounting of the LED chips  5  as illustrated in  FIG. 6  may be implemented. 
       Exemplary Embodiment 2 
       [0057]      FIG. 9A  is a perspective view of an HMSL  1  of Exemplary Embodiment 2 when viewed from the rear side. In Exemplary Embodiment 2, the lead frame  7  and the body  3  are insert-molded in the same manner as those represented in  FIGS. 8A and 8B . In this insert-molding, the degree of freedom of the shape of the body  3  increases. Hence, in order to improve the heat dissipating property in the body  3  by using the increased degree of freedom of the shape, a plurality of vertical wall-shaped heat dissipating pins  9  are formed to integrally project from the rear surface of the body  3 . In addition, the windows  36   a  and  36   b  of Exemplary Embodiment 1 are not provided. The height dimension of each projecting heat dissipating pin  9  or the width dimension of the HMSL  1  along the vertical direction thereof is formed as large as possible without unnecessarily increasing the external size of the HMSL  1 . 
         [0058]    The heat dissipating pins  9  are arranged at the positions corresponding to the LED pads  71  provided in the lead frame  7  or the positions corresponding to the heat dissipating portions  74  of the lead frame  7 . Here, the heat dissipating pins  9  are arranged at the positions corresponding to the heat dissipating portions  74 . Then, as illustrated in  FIG. 9B  representing the enlarged cross-sectional view of the line C-C of  FIG. 9A , a part  74   a  of each heat dissipating portion  74  of the lead frame  7  is curved to be erected almost vertically toward the rear surface, and the curved part  74   a  is coated with a part of the body  3  to serve as the core so that each heat dissipating portion  74  is formed. 
         [0059]    As illustrated in the perspective view of the lead frame  7  in  FIG. 10A , U-shaped slits  74   b  are provided in each heat dissipating portion  74 , and the part  74   a  of the heat dissipating portion  74  surrounded by the slits  74   b  is bent and erected vertically toward the rear side (the outer bottom surface  31   b  side of the bottom portion  31 ) so that the part  74   a  is curved against the plane surface direction of the lead frame  7 . Then, by insert-molding the lead frame  7  in the body  3 , the curved part  74   a  is installed as the core in a state of being integrally embedded inside the heat dissipating pin  9 , as illustrated by the perspective view of  FIG. 10B . 
         [0060]    In this configuration of the body  3 , the heat generated in the LED chips  5  is transferred from the LED pads  71  to the heat dissipating portions  74 . Then, the heat is transferred from the heat dissipating portions  74  to the body  3  and dissipated to the outside from the rear surface of the body  3 . In this case, in each heat dissipating portion  74 , the part  74   a  projects toward the rear surface direction of the body  3 , and the heat is dissipated from each heat dissipating pin  9  formed by covering the projecting opposite surfaces with the resin. By the heat dissipating pins  9 , the heat dissipating area at the rear side of the body  3  is extended, and the heat transferred to the heat dissipating portions  74  may be dissipated with a high efficiency. 
         [0061]    In addition, when the size of the lead frame  7  is enough, a part of an area different from the heat dissipating portions  74  may be curved and erected, and the curved part may be covered with the body  3  to serve as a part of the heat dissipating pins  9 . For example, a part close to the LED pads  71  may be curved, and the curved part may be coated with a resin to form a heat dissipating pin  9 . By forming the heat dissipating pin  9  at a position as close as possible to the LED pads  71 , the heat dissipating effect may be further improved. 
         [0062]    In addition, each heat dissipating pin  9  of Exemplary Embodiment 2 may not be configured as a heat dissipating pin having a part of the lead frame  7  as the core. For example, only by forming a part of the rear surface of the body  3  as a vertical wall projecting from the rear surface and configuring the vertical wall as a heat dissipating pin, the area of the rear surface of the body  3 , i.e., the heat dissipation area may increase, thereby improving the heat dissipating effect. 
         [0063]    In addition, the curved part  74   a  of each heat dissipating portion  74  or the other curved part of the lead frame  7  may not be coated with the resin of the body  3 , and may be configured to project in a state of being exposed from the rear surface of the body  3 . As long as any problem is not caused in the appearance or the external and internal environments of the HMSL  1 , the heat dissipating pins may be configured by exposing the part  74   a  and others so that the heat dissipating effect may be further improved. 
         [0064]    In Exemplary Embodiment 2 as well, when the lead frame  7  is formed, the connector terminals  72  may be bent and erected vertically toward the rear side, and in this state, the lead frame  7  may be insert-molded in the body  3 , as in Exemplary Embodiment 1. In this insert-molding, when the rectangular frame-shaped connector case  61  of the connector  6  is integrally molded in the part  38  of the rear surface of the body  3 , the connector  6  may be configured simultaneously with the insert-molding of the body  3 , and the process of bending-processing the connector case  61  is unnecessary later. Furthermore, the strength of the connector case  61  also increases. 
         [0065]    The present disclosure may adopt the configuration of sealing each LED chip  5  with a translucent material in either Exemplary Embodiment 1 or 2.  FIGS. 11A and 11B  represent a perspective view of a part of the LED pads  71  and an enlarged cross-sectional view along the line D-D of  FIG. 11A . A translucent member  53  is provided in each concave portion  37  of the body  3  in which the LED pads  71  of the lead frame  7  are exposed, and an LED chip  5  is mounted. The LED chip  5  and the LED pads  71  are sealed by the translucent member  53 . 
         [0066]    Here, the translucent member  53  is formed by dropping and curing a molten translucent resin in the concave portion  37  through, for example, potting. The surface of the resin is formed in a spherical shape by the surface tension of the resin. Alternatively, a resin which was formed in advance in a predetermined shape or a translucent member such as, for example, glass may be attached. When the sealing is implemented by the translucent member  53 , the LED chip  5  and the LED pads  71  are not exposed to the external environment so that the relevant reliability may be improved. In addition, as described above, the surface of the translucent member  53  is formed in a spherical shape or a predetermined curved shape so that the light emitted from the LED chip  5  may be refracted and controlled to form a desired light distribution. 
         [0067]    In the exemplary embodiments, an example of the HMSL constituted with four LED chips as light sources has been described. However, the HMSL may be constituted with a different number of light sources. In addition, the light source is not limited to an LED chip, and may be an LD or other light sources as long as the light sources may be mounted by the automatic machine. 
         [0068]    In the exemplary embodiments, the lead frame is embedded in only the bottom portion in order to facilitate the formation of the lamp housing by the bending of the molded body. However, the lead frame may be embedded over the side portions from the bottom portion as long as the bending of the body in which the lead frame is embedded may be implemented. 
         [0069]    In the exemplary embodiments, an example where the present disclosure is applied to the HMSL has been described. However, the present disclosure may be identically applied to any lamp that has the configuration of mounting the light sources in the body. Especially, the present disclosure may be effectively applied to a lamp having the configuration in which light emitting sources may be mounted by the automatic machine such as, for example, reflow, when the light emitting elements are mounted on the lead frame integrally molded with the body. 
         [0070]    From the foregoing, it will be appreciated that various embodiments of the present disclosure have been described herein for purposes of illustration, and that various modifications may be made without departing from the scope and spirit of the present disclosure. Accordingly, the various embodiments disclosed herein are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Technology Category: 5