Optical apparatus, method for manufacturing optical apparatus, and headlight

A method for manufacturing an optical apparatus including a lens, a plurality of solid-state light sources, and a substrate on which the solid-state light sources are mounted, the method comprising:

• forming an insulating layer on a base material that is rigid, the insulating layer including a mount surface, which has a curved surface shape that substantially matches a focal plane shape of the lens, such that a line connecting centers of light-emitting surfaces of the plurality of solid-state light sources substantially coincides with a focal plane of the lens in a cross-sectional view, or the line is present at a position spaced apart from the focal plane in an optical axis direction of the lens, and forming a circuit pattern on the mount surface to manufacture the substrate;
• then, mounting the solid-state light sources on the mount surface of the substrate to be electrically connected with the circuit pattern;
• and
• then, positioning the substrate with respect to the lens such that a position of the focal plane of the lens substantially coincides with positions of emission surfaces of the solid-state light sources, wherein
• the base material is formed of metal, ceramic, or a highly heat-conductive resin, and includes a formation surface formed in a curved surface shape that substantially matches the focal plane shape of the lens, and
• an insulating layer is formed on the formation surface, the insulating layer having an electrical insulation property and including a surface to serve as the mount surface.

A method for manufacturing an optical apparatus including a lens, a plurality of solid-state light sources, and a substrate on which the solid-state light sources are mounted, the method comprising:

• forming an insulating layer on a base material that is rigid, the insulating layer including a mount surface, which has a curved surface shape that substantially matches a focal plane shape of the lens, such that a line connecting centers of light-emitting surfaces of the plurality of solid-state light sources substantially coincides with a focal plane of the lens in a cross-sectional view, or the line is present at a position spaced apart from the focal plane in an optical axis direction of the lens, and forming a circuit pattern on the mount surface;
• then, repeating a predetermined number of times a step of forming, on the mount surface, a next insulating layer including a mount surface, which has a curved surface shape that substantially matches the focal plane shape of the lens, such that a line connecting centers of light-emitting surfaces of the plurality of solid-state light sources substantially coincides with the focal plane of the lens in the cross-sectional view, or the line is present at a position spaced apart from the focal plane in the optical axis direction of the lens, and forming a circuit pattern on the mount surface to manufacture the substrate;
• then, mounting the solid-state light sources on the mount surface of the substrate to be electrically connected with the circuit pattern;
• and
• then, positioning the substrate with respect to the lens such that a position of the focal plane of the lens substantially coincides with positions of emission surfaces of the solid-state light sources, wherein
• the base material is formed of metal, ceramic, or a highly heat-conductive resin, and includes a formation surface formed in a curved surface shape that substantially matches the focal plane shape of the lens, and
• an insulating layer is formed on the formation surface, the insulating layer having an electrical insulation property and including a surface to serve as the mount surface.