Patent Application
20250075866
The invention relates to an illumination system with LEDs, which are arranged in a mounting profile rail, and to an electrical terminal connection system of this LED profile system, together with its components and their installation. In particular, it relates to an illumination system in accordance with the independent claim(s) and/or a terminal connection system, together with an associated method for the terminal connection and installation of such an illumination system.
LED light profiles or LED illuminant profiles in a wide variety of forms of embodiment are of well-established prior art. For example, EP 3 336 420 shows an illumination system with a channel that has a permanently mounted power supply rail in its interior. Electrical connectors are attached to the lighting units that are to be mounted in the channel, before the latter are installed. These connectors are designed to provide a mechanical coupling between different sections of the channel, and also to couple the power rail sections of the power rail electrically to each other, and to establish electrical contact between the power rail and the lighting unit.
EP 3 312 506 shows a light-emitting diode strip with a flexible profile made of extruded plastic that is open on one side, and two electrical cables integrated inside a wall of the profile, which run parallel to each other in the wall and at the ends have plug-in connectors or free wire ends for purposes of linking the light-emitting diode strips to each other. Recesses up to the electrical cables in the wall form contact surfaces for the terminal connection of flexible cable carriers with chip light-emitting diodes arranged on the latter. The flexible cable carriers with the chip light-emitting diodes are protected from moisture or the effects of the weather by a transparent or translucent sealing compound that fills the inside of the profile. The flexible cable carriers are connected in parallel with the electrical cables, wherein the total current flows through the cables of the profile connected by means of plug-in connectors or free wire ends, and wherein the light-emitting diode strip is flexible in a direction vertical to the extensive direction.
DE 10 2014 103 974 shows a power rail for the terminal connection of light-emitting diodes, in particular of LED boards, consisting of a carrier profile with integrated electrical conductors for the electrical terminal connection of the LED light sources. The carrier profile is a one-piece extrusion moulding, in which the electrical conductors consist of conductor tracks arranged on the extrusion profile in a materially-bonded and/or form-fit manner.
DE 10 2013 208 400 describes an LED strip without a housing, with a flexible conductor film, on which LEDs and corresponding conductor tracks are provided. By the “piercing” of contact points at regular intervals on the LED strip, each LED is pierced separately into a flat cable provided as a power rail so as to establish contact.
The disadvantage of these solutions of known art is that they have a complex and static structure and have little flexibility, for example, but not only in terms of the electrical terminal connection. Their installation, that is to say, the manipulation during installation, is also complex and time-consuming, in particular when it comes to adjustment of length and/or shape. For example, their installation can also be difficult in many aspects or installation situations, in particular if structural tolerances are not adhered to, or if retrofitting involves predetermined conditions that were not fully known about beforehand. In most cases, prefabrication by the manufacturer or supplier is required. Transportation of the profiles to the installation site is time-consuming, in particular if the illumination is to extend over longer lengths. The systems are also often either not very modular, or have a large number of different components, which makes warehousing, configuration, ordering, etc. more difficult. Neither unconfigurable, static prefabricated illumination systems, nor complex modular systems with many special parts, are conducive to efficient warehousing, despatch, installation, etc. It should also be possible for the parts of the system to be produced in an unbroken process by one manufacturer, requiring none, or few, of the usually manual, intermediate installation steps; the system should preferably be delivered to the end customer by the more specialised raw material supplier for aluminium, plastic, electronics, etc. with no, or only a few, processing steps. The object of the present invention is therefore to create an improved device, or an improved system, which does not have the aforementioned disadvantages; what is sought, in particular, is an improved LED profile, or a terminal connection system, for an LED profile with very small dimensions. One example of a specific design has a cross-section of around 15 to 40 mm in width and height. The aim is to have small dimensions in the design, but still to allow relatively high currents. This means that long lengths can be implemented without an additional power supply. The aim is to provide a simpler, and in its embodiment a more flexible electrical terminal connection system for the profiles, which also enables a good and flexible configurability of the LED profiles, particularly in the course of their production and/or installation.
Here a variety of requirements for the electrical terminal connection system, which arise depending on the form of embodiment or configuration of the profile, or the configuration of the installation location, should be covered as flexibly as possible by a common system, e.g. with regard also to length adjustments, divisions, angles, cable outlet positions at the installation location, etc.
The aim is also to achieve a terminal connection system that can preferably be produced without the use of tools, or with minimal use of tools, and that can preferably also be easily disconnected for purposes of servicing. One object is to provide a type of flexible modular system to provide contact with, that is to say, the electrical connection of, LED profiles. For example, it should be possible to cut most parts to length manually, e.g. using cable duct shears that are to hand, and then to process these parts further (preferably both) directly, without further machining.
The object is achieved by means of the features of the independent claims. Advantageous developments are presented in the figures and in the dependent claims. The inventive system makes it possible to produce the individual sections in units of e.g. 3.0 metres, which are optimal for transportation. Advantages in loading and shipping in the wholesale sector ensue, as the shipping of longer units is technically difficult and therefore expensive.
In accordance with the invention, an illumination system is provided, comprising at least one mounting profile rail, without a power rail, for the accommodation of at least one lighting unit that can be introduced onto the mounting profile rail, and at least one supply connector that can be introduced onto the mounting profile rail.
Here the mounting profile rail is designed as an extruded plastic or aluminium profile. A profile in accordance with the invention preferably has a length of at least one metre. and a cross-section with a width and a height in each case in a range of approximately 15 to 50 mm, preferably approximately 20 mm or 25 mm. The profile has an essentially U-shaped or H-shaped cross-section. It therefore takes the form of a conventional extruded profile that does not require any particular post-processing or assembly with other components, and can, for example, be processed further directly by the manufacturer.
The lighting unit is designed as a long inflexible/rigid strip, for example with a length at least 10 times greater than the width and/or height. It is therefore long and flat, e.g. in the form of a strip or panel; in other words it is essentially cuboid with a width of 10 to 50 mm, a height of 1 to 15 mm and a length of more than 100 mm, preferably more than 300 mm, for example 560 mm or 1,400 mm.
At least one semiconductor light source, preferably a plurality of, that is to say, a series of semiconductor light sources such as LEDs, is mounted on the front surface of the lighting unit.
At least two exposed, continuous contacting conductor tracks are formed on the rear surface of the lighting unit. Ideally, three exposed conductor tracks are formed, as this provides protection against polarity reversal (reverse polarity protected).
The lighting unit also has a housing element, which can be mechanically coupled to the mounting profile rail, and with which the lighting unit is held in the mounting profile rail; in particular it can be snapped or clipped onto the latter with spring-loaded elements.
The supply connector of the illumination system has contact devices, by means of which an electrical coupling of the contacting conductor tracks of the lighting unit with those of another lighting unit, and/or with a supply cable, can be produced, or takes place. This creates an electrical coupling between the supply connector and one or two of the lighting units.
The supply connector also has a housing element, which can be mechanically coupled to the mounting profile rail or to the lighting unit, and with which the supply connector is held in the mounting profile rail. This can also be embodied such that the supply connector is only coupled to the housing 73 and not to the profile 60. In another form of embodiment, the supply connector can be mechanically coupled to the lighting unit, or specifically to its plastic cover/diffuser, and thereby can preferably have no mechanical connection to the mounting profile rail.
The illumination system is preferably designed such that supply connectors introduced onto the mounting profile rail electrically couple a plurality of subsequent lighting units in the mounting profile rail, which are also introduced onto the mounting profile rail, wherein the supply connectors and lighting units can be arranged so as to overlap each other in each case within the mounting profile rail. This makes it easy to assemble and configure the illumination system, in particular with little or no use of tools. At the same time, a safe and flexible electrical coupling is created.
The housing element of the lighting unit is preferably designed as a diffuser, or linear optics, or with Fresnel lenses, and/or is designed to provide contact protection (ESD) and mechanical protection of the electronic components as well as the light guidance, or itself also serves to guide the light. The housing element can also be made from transparent, clear plastic, which is clipped over the lighting face of the lighting unit, or which is pushed onto the latter. This protects the lighting elements from damage. An advantageous illumination and light distribution can also be achieved.
In one form of embodiment, both the supply connectors and the lighting unit are preferably mechanically connected to the mounting profile rail, but not to each other. In particular, this connection can take place using snap-on hooks or similar. This means that during installation, the profile can first be adjusted in length and installed, the supply connectors can then be clipped onto it, and an electrical supply provided by way of at least one of these; the lighting elements can then be clipped into place over the supply connectors, which can also be cut to length as necessary. A supply connector is positioned at each of the butt joints between the lighting units.
The mounting profile rail and the lighting unit can preferably have different lengths. For example, a length grid pattern for the mounting profile (typically 1 m, 2 m, 2.5 m, 3.0 m) can differ from the length grid pattern for the lighting unit (typically 560 mm or 1.4 m). In other words, the mounting profile can be shortened and/or divided apart to any length, and the lighting unit can be shortened at least into a predetermined grid pattern.
The lighting unit is preferably designed as a long and flat, two-sided rigid PCB, together with the semiconductor light sources and a control circuit. In particular, the semiconductor light sources on the lighting unit can here be covered or moulded with a plastic protective cap.
The conductor track cross-sections on the supply conductor tracks can preferably have a conductor cross-section with the following geometry: thickness: 0.035 mm to 0.35 mm, preferably 0.07-0.14 mm, e.g. 0.1 mm; width: 5 mm to 20 mm, preferably 7.5 mm-12.5 mrn, e.g. 10 mm. In one form of embodiment, the PCB of the lighting unit has, on the rear surface with the supply conductor tracks, a first conductor track layer thickness that is greater than that on the front surface with the LEDs. For example, there can be a copper thickness of 0.035 mm to 0.35 mm, preferably 0.07-0.14 mm, e.g. 0.1 mm, on the rear surface, and 0.01-0.035 mm on the front surface. Alternatively, the conductor track layer thickness on the front surface can also be identical to that on the rear surface. They can also be plated through, so that both conductor tracks carry the power line simultaneously.
The lighting unit is preferably designed such that it can be shortened in accordance with a predetermined marked-out grid pattern, in particular from 20 mm to 100 mm, in particular, 30 mm to 50 mm, or 50 mm to 70 mm. For example, it can be sheared off by means of blades that move relative to each other (e.g. with cable duct shears or similar). Optionally, the PCB can also be designed with a predetermined breaking point, and/or the grid pattern can be marked-out on the PCB. Each grid element can preferably be operated on its own autonomously. Optionally, the circuit within a grid element can also be designed such that it can be shortened further without any loss of function—wherein the remainder must be disposed of by the start of the next grid element—for example, the control circuit is in each case arranged at the start of the grid element,
The supply connector, when introduced, is preferably designed to slide in the longitudinal direction of the mounting profile rail. This means that after insertion onto the profile, it can be pushed along the profile into a correctly overlapping position before the lighting element is introduced.
The supply connector-contacting conductor track pairing is preferably designed to be protected against reversal of polarity, wherein in particular the contacting conductor tracks and/or the supply connector-contact devices are arranged with mirror symmetry. This means that the polarity does not need to be taken into account in the course of installation, even in the case of a DC supply.
The supply connector is preferably designed with two ends, each with a first and a second spring contact, which are electrically connected to each other. This enables a safe, reliable contact to be established, even in the event of installation-related inclined positions.
At least one of the supply connectors is preferably designed as a “corner supply connector” with an angle of 90°, with which the lighting units in two mounting profile rails can be connected around a corner.
At least one of the supply connectors is preferably designed as a “flexible supply connector”, in which there is a flexible cable connection between a first supply connector end and a second supply connector end. This allows connections to be made at any angle.
At least one of the supply connectors preferably has a spring-loaded terminal for a cable as a “terminal connection unit”; this is designed to connect the lighting unit electrically to a terminal connection cable from a power supply. Optionally, each supply connector can also be designed with cable connections in order that it can be introduced flexibly.
The supply connector preferably has a further housing element, which is designed to create geometrically-defined mechanical coupling between two mounting profile rails, in particular at an angle of 0 degrees or 90 degrees. This can be produced, for example, by way of appropriately designed contact surfaces for the profile. At the same time a stable connection of the profiles can be established.
The illumination system preferably comprises at least one separate profile connector element, which is designed to create a geometrically defined mechanical coupling between two mounting profile rails, in particular at an angle of 0 degrees or 90 degrees. This can be produced, for example, by way of appropriately designed contact surfaces for the profile.
The electrical supply connector for the electrical connection, that is to say. the supply of a lighting unit installed in the mounting profile rail, preferably has:
In particular, the retaining device can be a plastic part with at least one spring-mounted clip or snap-on element. This is assembled in one piece with the PCB to form the electrical connector, e.g. with a snap-on connection, a form-fit connection, by adhesive bonding, or by injection moulding. Here the holding devices are preferably designed such that they can be moved relative to the profile axis on the electrical terminal connection element in the assembled state, preferably without requiring much force.
The spring contacts are preferably designed and arranged with PCB spring contacts to protect against a reversal of polarity. A plurality of these spring contacts can preferably be arranged, electrically connected to each other, so as to establish contact with the same electrical pole. For example, there can be at least three PCB spring contacts, preferably arranged with mirror symmetry about a central axis, and electrically connected symmetrically about this central axis, preferably in the form of high-current spring contacts, or high-current spring fingers, similar to those used, for example, for establishing contact with batteries in mobile devices. This ensures a simple and reliable establishment of contacts, in particular at higher currents.
The cable connections are preferably designed as spring-loaded terminals, insulation displacement terminals, and/or soldering lands on the PCB, or in the over-moulded lead frame, (or are designed as connectors). This means that a cable, which, for example, may already be drawn up into a ceiling, can be attached to the electrical connector directly on site for purposes of power supply.
The invention also relates to an electrical terminal connection element, which is constructed with at least one electrical supply connector, as described above. In particular, this can have a cable outlet leading laterally or upwards in relation to the profile for purposes of terminal connection to a supply voltage.
The invention also relates to an electrical connector element, comprising two electrical supply connectors, as described in this document, which are connected to at least one cable, in particular a multi-pole cable. The cable is preferably flexible, e.g. a stranded cable, and can be constructed as a two-pole or a multi-pole cable, or preferably from a plurality of individual strands. In particular, this can be used to provide a connection for at least one, and optionally a plurality of, safety low DC voltages for purposes of supplying the LEDS with an operating voltage. Optionally, a data connection can also be provided for bus control of the LEDs, in particular this is also reverse polarity protected or tolerant, in particular with a symmetrical terminal connection arrangement on the plug and/or socket side.
This enables a preferably flexible connection to be made between a plurality of profiles, which can preferably also be routed around angles or corners thanks to the flexibility. With the already described ability to move the electrical connector elements (along the profile and relative to the electrical terminal connection elements), a simple installation can be provided, as the profiles can still be moved relative to each other after electrical connection by sliding the electrical connector elements along the electrical terminal connection elements. This electrical connector element can in particular be designed so as to establish an electrical connection between two inventive electrical terminal connection elements, which are described here.
The invention also relates to an electrical supply connector element with an over-moulded lead frame, or a PCB, with at least a first group of at least two spring contacts on an under surface, and a second group of at least two spring contacts on the under surface, which in each case are electrically connected to the respectively related spring contacts of the first group. Furthermore, the electrical connector element has a (preferably plastic) clip element, which is designed to snap onto the mounting profile rail. The first group establishes contact with a first lighting element, and the second group establishes contact with a second lighting element, which means that they are electrically connected to each other when in the installed state.
At least one first and one second longitudinal web or longitudinal groove is preferably formed on each side face of the mounting profile rail, wherein the first is designed to accommodate the supply connector mechanically, and the second is designed to accommodate the lighting unit.
An additional diffuser is preferably mounted in front of the lighting unit, in or on the mounting profile rail, in particular it is snapped into place. Here the diffuser can be provided as a “flat, continuous” strip, e.g. from a roll, in particular, as an extruded profile made from a plastic such as PMMA or PC.
A third longitudinal web or longitudinal groove is preferably formed on each side surface of the mounting profile rail for the accommodation of the diffuser.
Thus, in accordance with the invention, an electrical terminal connection system is provided, designed for the electrical supply of a linear LED lighting unit, which is fixed in a profile system; for example, in an illuminant profile for the illumination of a room or building, in which a series of LEDs are arranged on the inside in an essentially U- or H-shaped profile made from metal, plastic, etc., preferably by simply clamping, pushing or clipping the electrical connection onto the profile, preferably without the use of adhesive.
Here a modular construction, and a flexible, simple adaptability to on-site conditions, are key aspects. For example, the profiles are preferably adapted on site in each case to the local conditions of the construction site, or the room, by adjusting, for example, their length, cutting them at an angle, and connecting them in the vicinity of an existing power outlet, etc. It is preferable for recourse to be made to a standard modular system with preferably few parts that can be flexibly introduced, and the parts in this modular system should also be easy to transport. They should also be easy to assemble and customise, preferably without the use of special tools, and in just a few operational steps.
The inventive system also allows, without great effort, the use of a plurality of supply points along an LED profile illumination system, to compensate, for example, for the voltage drop along the LED strip, using a plurality of supply cables. Here the plurality of supply points is flexible, and the exact positions of the cable outlets are not important, as the terminal connection system provides tolerances and variability in the axial direction.
The lighting units in the system in accordance with the invention are designed as strips, or are strip-shaped—i.e. flat and elongated—printed circuit boards made of an insulating material such as, for example, printed circuit board materials of known art such as FR4, FR3, etc., on or in which flat, metallic conductor tracks are formed. The exposed conductor tracks, in particular on the rear surface, can be designed as gold-plated contact surfaces with which electrical contact can be established. The lighting unit is preferably operated with a very low voltage or SELV, for example with 12 V, 24 V, or 48 V, in particular using direct voltage (DC).
The number of conductor track strips preferably corresponds to the number of poles or connections of the LED strip. In a particular form of embodiment, one pole of the supply can also be routed by way of the metal profile system itself, and, accordingly, the electrical terminal connection element can also have one less pole, e.g. therefore, only one single pole or conductor track strip.
Here the LED lighting units are preferably PCB strips or . . . , on which LEDs and possibly at least some of their control circuitry are mounted. PCB strips or tapes can be separated into sections in discrete lengths, usually at defined cut-through points, so that their length can be adjusted in discrete steps in a grid pattern. The cut-through points are preferably visually marked-out. Here, each grid element can preferably be designed to be operable autonomously, e.g. each has its own electronic control circuit for the LEDs—even if these can be configured together, as described, for example, in WO 2020/194236 for flexible LED strips, which is hereby incorporated as a reference, in particular with regard to this aspect.
In accordance with the invention, electrical supply connectors can be plugged, snapped, or clipped, onto the inside of the profile. In an optional form of embodiment, they can also be attached onto the lighting unit or its housing element. Here the supply connectors can be attached such that a snapped-on electrical connector on the electrical terminal connection element can be moved along the profile direction. This allows a terminal connection system to be provided that is flexible in its position and can be adapted to the conditions during installation or fitting, for example, or compensation can be made for build tolerances in the cable outlet or similar. Installation can also be simplified if the terminal connection cables have room to manoeuvre in the longitudinal direction as the profile is guided towards the ceiling. This allows the terminal connection cable to be pushed onto the profile, since the supply connector that is connected to it can move in the profile and continue to fulfil its function.
The longitudinal conductor tracks on the rear surface are preferably designed as at least three symmetrically arranged longitudinal conductor tracks. In particular, at least one central contact carries a negative pole of an LED supply voltage and at least one—preferably both—outer contacts each carry a positive pole of the LED supply voltage. In particular, the positive pole and negative pole are each electrically connected to the associated longitudinal conductor track of the lighting unit. In particular, the conductor tracks are designed with a sufficient cross-section, in particular with a sufficient width, to conduct the currents required for the LEDs, but at the same time with sufficient distances from each other, and from the edge, to avoid short circuits, and to enable secure contacts by plugging on the terminal connection system connector. The conductor tracks, in particular at least on the rear surface of the lighting unit that is not populated with LEDs, can also have a layer height of 200 μm or more. In accordance with the invention, this allows significantly higher currents to be transported and there is a significantly lower voltage drop.
The longitudinal conductor tracks in the supply terminal connection-length region are preferably provided in a reverse polarity protected arrangement, in particular one that is symmetrical about a longitudinal central axis of the lighting unit PCB strip. This provides reverse polarity protected contacts, in which it does not matter in which direction a contacting terminal connection system connector is plugged on, or in which orientation the lighting unit is introduced. In addition to the convenience and avoidance of terminal connection errors, this also allows the cable outlet to be positioned on either the one surface or the other. This symmetry, or reverse polarity protection in the electrical sense, can here be provided either by the electrical terminal connection element, or by the electrical connector that establishes contact with it, or by both components. Designs in which the (electrical) symmetry is produced by the electrical connector may involve less design effort, in that, the associated electrical terminal connection element does not necessarily also have to be (electrically) symmetrical, which means, for example, that structurally complex crossings of conductor paths on the lighting unit can be avoided (optionally, however, optical symmetry can still be formed, e.g. to make the polarity reversal safety apparent to the user).
The invention also relates to an LED illumination profile, in particular as an extruded aluminium profile, and with at least one electrical connection system that is described here. The aluminium profile can in particular be designed in a U-shaped or H-shaped basic form, in particular with two side walls and a preferably continuous transverse web connecting the side walls in the interior, which is spaced apart from the edge of the side walls. The profile has longitudinally continuous grooves or webs in the interior on the side walls; these are designed to hold the supply connectors, lighting units, and/or the optional diffuser, or a cover.
The invention also relates to an LED illumination system with a preferably translucent (e.g. opaque or opalesque) cover and at least one LED illumination profile as described here. Preferably, this LED illumination system comprises at least one end cap for the aluminium profile.
The invention also relates to a method for the mounting or connection of an LED illumination system to a supply voltage, which comprises:
Many advantages can be implemented with the present invention, for example:
Further advantages, features and details of the invention ensue from the following description, in which examples of embodiment of the invention are described with reference to the figures.
The list of reference symbols, as well as the technical content of the patent claims and figures, forms part of the disclosure. The figures are described in a coherent and comprehensive manner. Identical reference symbols indicate identical components, reference symbols with different indices indicate components with identical or similar functions.
Here:
The corner joint 66b shown in the example has a right angle. In order to implement other angles in accordance with the invention, the profiles need only be cut at a different angle; no further modifications are absolutely necessary. Shown here is a form of embodiment in which a rigid corner supply connector is mounted on the profile system 60; this is electrically connected to the respective electrical terminal connection conductor tracks of the lighting units 70 on both sides.
With the supply connector 50a shown, contact can be established with a cable 67 by way of spring contacts 52 on the conductor tracks 74, (74a, 74b, 74c)—see also
Due to the reverse polarity protection of this inventive form of embodiment, the terminal connection side can be changed by turning the angled cable connection through 180°.
This is particularly important and advantageous in the case of profiles with mitre cuts (since these are then no longer symmetrical). This results in error minimisation and simplification for the customer, as there is no longer any need for sketches of how this must be produced on site.
Contact is made between the open longitudinal conductor paths 74a, 74b and 74c and supply connectors 50a and 50b, one of which is used for power supply, and the other for electrical connection by way of a butt joint 66a between two lighting units 70.
In the case of a single-colour LED (2-pole), for example, the LED series arrangement on the lighting unit is preferably connected with 0.75 mm2 cable. The cross-section should be as large as possible in order to minimise the voltage loss along the cable. This is in contrast to the ever smaller LEDs/solder pads on the lighting units. If the LEDs are multi-coloured, e.g. RGB (4-pole) or RGBW (5-pole), it is almost impossible to use 0.75 mm2. The cross-section must therefore be reduced in this case. Cables with a cross-section of 1.0-1.5 mm2 would be ideal for cable lengths of up to 10 metres. As shown in the figures, this can be inventively achieved by using linear conductor tracks 74 on the rear of the lighting units, which are simply connected to the terminal connector 50 in the profile. In this way, a supply point can also be made at any/any point(s) of the lighting units or the profile with a connector 50, and at the same time the linear conductor tracks 74 also ensure the necessary conductor cross-sections, for which larger conductor cross-sections can also be implemented.
| Number | Date | Country | Kind |
|---|---|---|---|
| PCT/IB2021/057271 | Aug 2021 | WO | international |
This application is a National Stage completion of PCT/IB2022/057316 filed Aug. 5, 2022, which claims priority from International Application PCT/IB2021/057271 filed Aug. 6, 2021.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2022/057316 | 8/5/2022 | WO |
