Patent Application
20160195249
The invention relates to lighting modules which comprise solid state light emitters on a carrier held by a holder. The lighting modules are often provided with a cover and/or optical components and comprise means to connect the lighting modules to other components such that they can be easily integrated in, for example, luminaires.
The invention further relates to a lighting module and a method of manufacturing a holder for a lighting module.
A light emitter manufacturer may integrated manufactured solid state light emitters, such as Light Emitting Diodes (LEDs), in a semi-finished lighting module which is ready for integration in a luminaire. Different levels of integration are defined. A level 2 module at least comprises solid state light emitters on a printed circuit board (PCB) and comprises a driving circuit. The driving circuit may be provided on a separate PCB. The PCB with the solid state light emitters often acts as an interface to a heat sink. Level 2 plus lighting modules further comprise a holder for holding and/or enclosing the PCB with solid state light emitters and the holder comprises holes for mounting the level 2 plus module to other surfaces/modules (for example, to a heat sink of a luminaire). A user, or a luminaire manufacturer may use screws for mounting the level 2 plus lighting module. The holder protects the PCB with solid state light emitters such that a user, when the lighting module is assembled in a luminaire, cannot touch the PCB and/or the solid state light emitters. The holder may comprise additional optical elements through which, in use, light is emitted into the ambient of the level 2 plus module.
In general the manufacturer of the (level 2 plus) lighting module assembles the lighting module as far as possible such that the PCB with solid state light emitter is at least mounted to the holder to allow a customer to easily screw the assembled lighting module to an appropriate surface of a luminaire.
Published patent application EP2423570A2 discloses an embodiment of such a lighting module. The lighting module includes a light engine having a printed circuit board and an array of light emitting diodes coupled to the printed circuit board. The printed circuit board has a power connector interface defining a separable interface for coupling with a power connector of the light module. A base ring holds the light engine and has side walls defining a cavity. The side walls have a securing feature. The base ring also comprises holes for receiving screws for fastening the lighting module to another component. An optical component is received in the cavity and is positioned to receive light from the LEDs. The optical component has a predetermined lighting characteristic and emits the light generated by the LEDs in accordance with the predetermined lighting characteristic. A top cover is coupled to the base ring and has a securing feature engaging the securing feature of the base ring to couple the top cover to the base ring. A compression ring is positioned between the base ring and the optical component. The compression ring is compressed between the base ring and the optical component when the top cover is coupled to the base ring.
The lighting module of the above cited patent application has holes in the base ring for receiving screws to attach the module to a component (such as a heat sink of a luminaire). These holes are, when the lighting module is assembled, covered by at least the optical component. Thus, when the manufacturer of the lighting module delivers the assembled lighting module to a customer, the customer has to remove the top cover and the optical component to access the holes. Alternatively, the manufacturer may deliver half-assembled lighting modules and the customer has to assemble the lighting module himself. Both options are inconvenient for a customer.
It is an object of the invention to provide a holder for a printed circuit board (PCB) with solid state light emitters which reliable holds the PCB and which easily allows a user to fasten an assembled lighting module comprising the PCB and the holder.
A first aspect of the disclosure provides a holder for a lighting module. A second aspect provides a lighting module. A third aspect provides a luminaire. A fourth aspect provides a method of manufacturing a holder for a lighting module. Advantageous embodiments are defined in the dependent claims.
A holder in accordance with the first aspect of the invention comprises a light exit window, a fastening element, a contact surface and at least two hooks. The holder is suitable for holding a carrier which comprises solid state light emitters. The light exit window allows a transmission of light into an ambient of the holder wherein the light is emitted, in use, by the solid state light emitters of the carrier. The fastening element is for receiving a fastening means for fastening the holder to a surface of another object. The fastening element is accessible from the outside of the holder when the holder holds the carrier and when the holder with carrier is fastened to the mounting surface. The contact surface provides a stop position with which the carrier is in contact when the carrier is assembled in the holder and which holds the carrier between the contract surface and the surface of the another object when the holder is fastened to the surface of the another object. The at least two hooks are moveable between a clamping position and a sidewards position. When the holder is assembled to the carrier and when said hooks are in the clamping position, said hooks are arranged for clamping the carrier between the hooks and the contact surface. When the holder is assembled to the carrier and when the holder is fastened to the surface of the another objects, said hooks are arranged to be in the sidewards position, the sidewards positions is a position away from the carrier.
The holder is configured for holding a carrier which comprises solid state light emitters. The carrier may be a printed circuit board, but may also be another type of carrier (such as a substrate of glass or a synthetic material) on which wires and solid state light emitters are provided. The carrier may be flat, but may also be slightly curved. The holder is in particular configured to hold the carrier when the holder is fastened to a mounting surface of another object. Such another object may be a component of a luminaire and the mounting surface of the another object may provide an interface to a heat sink. When the holder is assembled to the carrier, in other words, when the holder holds the carrier, and when the solid state light emitters of the carrier emit light, the emitted light is transmitted through the light exit window into the ambient of the holder.
When the holder is assembled to the carrier, thus, when the holder holds the carrier, the carrier is in contact with the contact surface of the holder. As will be discussed hereinafter, the carrier may be clamped in the holder and/or the carrier may be provided in between the contact surface and the mounting surface of the another object. When the carrier is clamped in or hold by the holder, the carrier may receive a force into the direction of the light exit window and the contact surface defines a position at which the carrier is stopped (a surface to which surface the carrier may be pressed) when the carrier receives such a force. More in particular, when the holder is fastened with fastening means to the mounting surface, a portion of the carrier is in between the contact surface and the surface of the another object.
The holder also comprises at least two hooks. The hooks have, in particular, an important role in the assembling of the holder to the carrier. When the holder is assembled to the carrier, the at least two hooks are in the clamping positions and in this position the at least two hooks are arranged for clamping the carrier between the hooks and the contact surface. It is to be noted that this configuration, wherein the at least two hooks clamp the carrier to the contact surface, relates to a configuration wherein the holder is not fastened to the mounting surface of the another object. When the holder, which holds the carrier, is fastened to the mounting surface of the another object, the hooks are in a sidewards position, which means that the hooks are arranged in a position that is away from the carrier. In other words, the hooks to not touch the carrier and are in a position where they cannot be in between the carrier and the mounting surface. The hooks are moveable between the clamping position and the sidewards positions.
The above discussed holder has hooks which clamp the carrier in a position against the contact surface such that the carrier with solid state light emitters is secured within the holder. It is very convenient for the manufacturer and the customer that the holder can be assembled to the carrier without the need to fasten the holder to the mounting surface. This implies that the manufacturer is able to sell the holder with carrier as a single component. Subsequently, when the customer fastens the holder with carrier to the mounting surface, the hooks are in the sidewards position and in the sidewards position the carrier is held in between the mounting surface and the contact surface and no parts of the hooks are in between the carrier and the mounting surface. Thus, the carrier can make good contact to the mounting surface, for example, for forming a good thermal coupling to the mounting surface.
It is not required for the customer to remove the hooks form the holder or it is not required for a customer to open the complete holder in order to remove the hooks or to provide fastening means. Thus, the fact that the hooks are, when the holder is fastened to the mounting surface, in the sidewards position is conveniently for the customer.
It is to be noted that at every location where the term “customer” is used, or where the term “user” is used, the term “manufacturer of a luminaire” may be read as well, because, in many practical situations the manufacturer of the luminaire buys the holder with the carrier and fastens the holder with carrier to the mounting surface of the another object.
The fastening element is provided at the outside of the holder when the holder holds the carrier and the holder is fastened to the mounting surface. This means that the user does not have to open the holder or remove elements from the holder in order to access the fastening element. In an example, the fastening opening is a recess in the outer surface of the holder and the recess for receiving a screw or a nail for fastening the holder to the mounting surface. In another example, the fastening opening is a protrusion which extends from the holder and which is in contact with the mounting surface of the another object when the holder is pressed against the mounting surface, the protrusion may provide an opening for receiving a screw or a nail for fastening the holder to the mounting surface.
The above described holder (and carrier) are not limited to any particular type of solid state light emitter. In a specific embodiment, the solid state light emitters are laser diodes, or Light Emitting Diodes (LEDs), or Organic Light Emitting Diodes (OLEDs). The solid state emitters may also comprise combinations of the different types of solid state light emitters.
As discussed above, the mounting surface of the another object may provide an interface to an heat sink or may be a surface of a heat sink. For example, when the mounting surface is a metal surface, it is well capable of receiving heat and transporting it away from the holder with the carrier comprising the solid state light emitters. In many practical embodiments of carriers comprising solid state light emitters, at a first side of the carrier are provided the solid state light emitters, and measures are taken to transport the heat of the slid state light emitters towards a second side of the carrier (which is opposite the first side of the carrier). Therefore, in many practical embodiments of a holder with a carrier, the first side of the carrier faces the light exit window such that the light emitted by the solid state light emitter can be transmitted through the light exit window into the ambient of the holder, and the second side of the carrier is present at a side of the holder which is opposite the light exit window and which is in contact with the mounting surface when the holder with carrier is fastened to the mounting surface. Thus, in many practical embodiments, the first side of the carrier is partially in contact with the contact surface. In many practical embodiments, a back side of the holder, which is opposite a front side of the holder (which is the side which comprises the light exit window), is parallel to the second surface of the carrier when the holder holds the carrier.
The carrier comprises the solid state light emitters. More in particular, the carrier carries the solid state light emitters. A specific embodiment of the carrier comprising the solid state light emitters is a printed circuit board. Other embodiments are possible as well, such as, for example, a carrier of glass on which metal tracks and solid state light emitters are provided.
In the sidewards position, the hooks are in a position away from the carrier, which means that they are not any more in contact with the carrier and there is at least a small distance between the carrier and the hooks. In an embodiment, the hook are sidewards of the carrier when they are in the sidewards position. Sidewards of the carrier means that, seen in a lateral direction (which is a direction parallel to the carrier) the sidewards position is a position away from the carrier, which means, a position further away from the center of the carrier in comparison to the clamping position.
Optionally, the position of the contact surface and said hooks in the sidewards position are arranged for allowing a contact between the carrier and the mounting surface of the another object. A good contact between the carrier and the mounting surface creates a relatively good thermal interface such that heat generated in the solid state light emitters may easily flow towards a heat sink that is thermally coupled to the mounting surface. In an embodiment, when the carrier has a first surface carrying the solid state light emitters and has a second surface opposite the first surface, the whole second surface is configured to be brought in contact with the mounting surface. In specific other embodiment, the second surface of the carrier may have protruding element which are thermal conductive and the protruding elements are brought in contact with the mounting surface.
Optionally, the holder has a front panel which is a panel of the holder which comprises the light exit window. Said hooks comprise an arm which protrudes away from the front panel. Said arms have a base end at a position where the arms are coupled to the front panel, and said arms have a free end which is opposite the base end. Said hooks comprise a clip for engaging with a side of the carrier in the clamping position of said hooks. Said clips are for clamping the carrier between said clips and the contact surface and they are arranged at the free end of said arms and extend from the free end substantially into a direction of a central point of the carrier when the holder holds the carrier.
Manufacturing arms with clips is relatively easy and, thus, may result in a relatively low price for the holders. Furthermore, the clips on the arms may allow clicking the carriers into the holder which is a relatively easy step to perform thereby creating an efficient, and thus relatively cheap, assembling step.
It is to be noted that the arms have not necessary a bar shape, or a rod shape. The term “arm” is used because in a cross-sectional shape the arms have a rod-like or bar-like shape. Thus, the arms also have the shape of a wall and the walls may have the shape of a portion of a cylinder. A basic character of the arms is that they are in one direction relatively thin.
The front panel of the holder does not necessary exists of a solid material. The light exit window may be an opening and in such a situation the front panel is partly formed by a virtual plane defined by the opening. In a practical embodiment, the front panel of the holder is a side of the (assembled) holder which is opposite the mounting surface when the holder with carrier is fastened to the mounting surface of the another object.
Optionally, the holder comprises a contact protrusion which extends away from the front panel. A first end of the contact protrusion is opposite the second end of the contact protrusion, the first end comprises the contact surface and the second end is coupled to the front panel. It is relatively easy to manufacture at relatively low costs such contact protrusions. A protrusion does also not cost much material. In an embodiment, a plurality of contact protrusions are provided each having a first end and a second end. When a plurality of contact protrusions is provided, the contact surface is formed by the first ends of the contact protrusions. When several contact protrusions are used to bring a surface of the carrier in contact with the holder, space between the contact protrusions may allow the circulation of air, which is advantageous for transporting heat away from the solid state light emitters. The contact protrusion may have any shape which protrudes away from the front panels, such as a bar shape, rod shape, pyramid shape, and also a shape of a wall or a cylinder.
Optionally, said hooks are arranged to receive a force from the mounting surface of the another object when the holder is pressed against the mounting surface. The hooks are arranged to receive the force such that the reception of the force results in the moving of the hooks from the clamping position to the sidewards position. Thus, the moving of the hooks to the sidewards position is performed automatically when the holder is pressed against the mounting surface, which is, for example, the case then the holder is fastened to the mounting surface. Thus, the user does not have to intervene and the user does not have to move the hooks to the sidewards position. Thus, the buyer of the holder in which the carrier is provided is able to fasten the holder to the mounting surface by only providing the fastening means and when the holder is fastened, the hooks move and the carrier is capable of making a good contact to the mounting surface.
Optionally, when the hooks comprise, as discussed above, an arm with an clip, and when the hooks are arranged to receive the force, as discussed above, the hooks comprise an anchor bar that is provided at the free end of the arm. The anchor bars extend away from the free end in a direction away from the clips. The anchor bars are arranged to at least partially receive the force from the mounting surface of the another object when the holder is assembled to the carrier and when the holder is pressed to the mounting surface. Thus, the anchor bars are large enough and strong enough to receive the force such that when the force is received, the hooks move at least partially to the sidewards position. Anchor bars are, like arms and clips, easy to manufacture and not much material is needed to manufacture such anchor bars. The anchor bars are thus a cost effect means for receiving the force and moving the hooks at least partially to the sidewards position. It is to be noted that it is not required that the holder with carrier is fastened to the surface such that the anchor bars receive the force. In an embodiment, ends of anchor bars of the hooks slightly protrude out of the holder with carrier and when the holder with carrier is brought in contact with the mounting surface, the anchor bars first touch the mounting surface for receiving the force. In particular, when the holder with carrier is brought in contact with the mounting surface and the user pushes more to the holder with carrier (towards the mounting surface), the anchor bars receive an even larger force resulting in the movement of the hooks to the sidewards position. It is to be noted that, in an embodiment, the clips of the hooks may be arranged to also partially receive the force for, for example, completing the move of the hooks from the clamping position to the sidewards position.
Optionally, when the holder comprises arms, the arms of the hooks are slightly resilient for allowing a flexing from the clamping position to the sidewards position. The flexing may be initiated by the above discussed force that is received by, for example, the anchor bars. When such a force is not anymore received, the arms may flex back to their clamping position. It is relatively easy and cost effective to manufacture arms which are slightly resilient. For example, it is possible to manufacture an arm of a slightly flexible synthetic material which is relatively thin and has automatically a slightly resilient character.
Optionally, the arms are subdivided in a first portion and a second portion. The first portion is coupled to the front panel and the first portion is a portion of the arm at the based end of the arm. The second portion is consequently the other part of the arm which comprises the free end as well. When the hooks are in the camping position: i) first angles between the front panel and the first portions of the arms are in the range from 45 degrees to 80 degrees; the first angles are measured at a side of the arms that is facing away from a center of the carrier when the holder holds the carrier; ii) the second portions are arranged substantially perpendicular to the front panel and iii) second angles between the anchor bars and the second portions of the arms are within a range from 95 degrees to 120 degrees; the second angles are measure at a side of the arms that is facing away from the clips. It has been proven that hooks which have a shape according to this optional embodiment are effective and efficient for clamping the carrier in between the clips and the contact surface and for flexing towards the sidewards position such that the carrier can make a good contact with the mounting surface.
Optionally, the clips of the arms have a clipping surface for contacting the carrier when the holder is assembled to the carrier and when the holder is not fastened to the mounting surface. The clipping surfaces of the clips are arranged substantially perpendicular to the second portions of the arms.
Optionally, an outer surface of the holder has a substantially circuit cross-sectional shape seen in a plane that is substantially parallel to the light exit window. In another embodiment, the light exit window has a substantially circular shape. It is to be noted that the shape of the holder and/or light exit window is not limited to circular shapes only. In an embodiment, the shapes may be rectangular, square or elliptical. For particular applications of the holder particular shapes may be more appropriate than other shapes.
According to a second aspect, a lighting module is provide which comprises a holder according to any one of the above discussed embodiments, and which comprises a carrier comprising solid state light emitters. The holder holds the carrier.
Optionally, when the lighting module is not fastened to a mounting surface of another object, the carrier is clamped between the contact surface and the at least two hooks of the holder.
According to a fourth aspect of the invention, a luminaire is provided which comprises a holder according to the first aspect or comprises a lighting module according to the second aspect.
According to a fourth aspect, a method of manufacturing a holder for a lighting module is provided. The holder is for holding a carrier that comprises solid state light emitters. The method comprises the step of forming a holder from a synthetic material. The step of forming a holder at least comprises i) forming a light exit window for allowing the transmission of light into an ambient of the holder, the light being emitted, in use, by the solid state light emitters provided on the carrier, ii) forming a fastening element for receiving a fastening means for fastening the holder to a mounting surface of another object, iii) providing a contact surface for providing a stop position with which the carrier is in contact when the carrier is assembled in the holder and for holding the carrier between the contact surface and the mounting surface of the another object when the holder is fastened to the mounting surface of the another object, iv) forming at least two hooks being arranged for clamping the carrier to the contact surface when the holder is assembled to the carrier and being arranged for moving away from the carrier when the holder comprising the carrier is fastened to the mounting surface of the another object.
The lighting module and the method according to the second aspect and third aspect provide the same benefits as the holder according to the first aspect of the invention and have similar embodiments with similar effects as the corresponding embodiments of the system.
These and other aspects of the invention are apparent from and will be elucidated with reference to the embodiments described hereinafter.
It will be appreciated by those skilled in the art that two or more of the above-mentioned options, implementations, and/or aspects of the invention may be combined in any way deemed useful.
Modifications and variations of the holder, the lighting module, and/or the method, which correspond to the described modifications and variations of the holder, can be carried out by a person skilled in the art on the basis of the present description.
In the drawings:
It should be noted that items denoted by the same reference numerals in different Figures have the same structural features and the same functions, or are the same signals. Where the function and/or structure of such an item have been explained, there is no necessity for repeated explanation thereof in the detailed description.
The Figures are purely diagrammatic and not drawn to scale. Particularly for clarity, some dimensions are exaggerated strongly.
The carrier 240 may be a printed circuit board or a solid substrate of a specific material on which one or more solid state light emitters 242 are provided. The solid state light emitters 242 are, for example, Light Emitting Diodes, Organic Light Emitting Diodes, or laser diodes. The carrier comprises a first side on which the solid state light emitters 242 are provided, and comprises a second side 244 which is opposite the first side. When the carrier 240 is a printed circuit board, electrically conductive paths are provided in the interior of the printed circuit board. When the carrier 240 is a substrate of another material, electrical wires may be provided on the first side of the carrier 240, or they may also be integrated into the interior of the carrier 240. In operation the solid state light emitters 242 emit light 246. When the carrier 240 with solid state light emitters 242 is assembled to the holder 210, the light 246 is transmitted through a light exit window 214 of the holder 210 into an ambient of the holder 210. It is to be noted that the light exit window 214 of the holder 210 may also comprise an optical element 216. The optical element 216 may be a diffuser, or a lens, or a transparent solid layer. Other optical element may also be provided in between the solid state light emitters 242 and the light exit window 214, such as one or more reflectors. The optical element 216 is drawn as a flat shaped element, but may also have a curved shape, such as a dome shaped diffuser.
The holder 210 comprises a front panel 218 which is a (virtual) panel of the holder 210 which comprises the light exit window 214. In particular, the term “virtual” is used because the light exit window 214 may comprise an optical element or may not comprise any specific other element or layer. When the holder 210 is fastened to another object, the front panel 218 is a panel of the holder 210 which is furthest away from the another object. The presented holder of
The holder 210 comprises a contact surface 226. The contact surface 226 may be a surface of a contact protrusion 224 that faces away from the front panel 218. The contact surface 226 may also be formed by surfaces of a plurality of contact protrusions 224. The contact protrusions 224 are coupled to the front panel 218 and protrude towards a position where the carrier 240 may be received by the holder. The contact surface 226 provides a stop position with which the carrier 240 is in contact when the carrier 240 is assembled in the holder and, when the holder 210 is fastened to the mounting surface of another object, the carrier 240 is provided in between the mounting surface and contact surface 226. In an embodiment, when the holder 210 is fastened to the mounting surface of another object, the carrier 240 is clamped in between the mounting surface and contact surface 226.
The holder 210 comprises at least two hooks 220. In
In
The hooks 220 are moveable to a sidewards position. In this sidewards position the hooks are at a location which is sidewards of the carrier 240. More in particular, the hooks are moved towards the sidewards position when the holder is fastened to the mounting surface of another object. This is schematically presented in
The holder 210 together with the carrier 240 with solid state light emitters 242 forms a lighting module 200.
In
In
The hook also comprises, at its free end 358, an anchor bar 360. The anchor bar 360 extends away from the free end 358 in a direction away from the clip 362. When the holder 310 is brought in contact with the mounting surface of the another object 150, the anchor bar receives a force from the another object 150. This force increases when the holder is pressed against the another object 150. The anchor bar has a specific shape which uses the force to move the arm from the clamping position at least for some distance towards the sidewards position. It might be that during this movement from the clamping position towards the sidewards position the clip 362 receives also a force to complete the move towards the sidewards position.
In
In summary, a holder for holding a carrier comprising solid state light emitters, a lighting module, a luminaire and a method of manufacturing a holder for a lighting module are provided. The holder comprises a light exit window, a fastening element, a contact surface and at least two hooks. The contact surface provides a stop position with which the carrier is in contact when the carrier is assembled in the holder. The at least two hooks are moveable between a clamping position and a sidewards position. When the holder is assembled to the carrier, i) and when said hooks are in the clamping position, said hooks are arranged for clamping the carrier between said hooks and the contact surface, and ii) when the holder is fastened to the mounting surface of the another object, said hooks are in the sidewards position, the sidewards positions is a position away from the carrier.
It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims.
In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb “comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
| Number | Date | Country | Kind |
|---|---|---|---|
| PCT/CN2013/001020 | Aug 2013 | CN | national |
| 13194174.2 | Nov 2013 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB14/63177 | 7/17/2014 | WO | 00 |
