Light emitting elements such as light emitting diodes (LED) are typically arranged on a substrate, such as on a printed circuit board, for supporting and electrically connecting the light emitting elements. Such substrates are typically rigid and may, thus, restrict the shape of a lighting device and hamper a provision of flexible lighting devices.
Support structures and lighting systems including the support structure and a lighting device are described. A support structure includes an inner housing portion, an outer housing portion and connection members. The inner housing portion is transparent and has at least one portion shaped to conform to the lighting device. The outer housing portion includes at least a bottom wall, a first side wall and a second side wall, each having reflective inner surfaces, to form a container. The connection members are transparent and mechanically connected between the inner housing portion and the outer housing portion to support the inner housing portion and divide a region of the container between the inner housing portion and the outer housing portion into first cavities, each enclosed by at least one of the bottom wall, the first side wall or the second side wall and at least one of the connection members.
A more detailed understanding can be had from the following description, given by way of example in conjunction with the accompanying drawings wherein:
Examples of different light illumination systems and/or light emitting diode (“LED”) implementations will be described more fully hereinafter with reference to the accompanying drawings. These examples are not mutually exclusive, and features found in one example may be combined with features found in one or more other examples to achieve additional implementations. Accordingly, it will be understood that the examples shown in the accompanying drawings are provided for illustrative purposes only and they are not intended to limit the disclosure in any way. Like numbers refer to like elements throughout.
It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms may be used to distinguish one element from another. For example, a first element may be termed a second element and a second element may be termed a first element without departing from the scope of the present invention. As used herein, the term “and/or” may include any and all combinations of one or more of the associated listed items.
It will be understood that when an element such as a layer, region, or substrate is referred to as being “on” or extending “onto” another element, it may be directly on or extend directly onto the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or extending “directly onto” another element, there may be no intervening elements present. It will also be understood that when an element is referred to as being “connected” or “coupled” to another element, it may be directly connected or coupled to the other element and/or connected or coupled to the other element via one or more intervening elements. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present between the element and the other element. It will be understood that these terms are intended to encompass different orientations of the element in addition to any orientation depicted in the figures.
Relative terms such as “below,” “above,” “upper,”, “lower,” “horizontal” or “vertical” may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.
Flexibility of lighting devices may be desirable for adjusting shapes of lighting devices to geometries of environments where lighting device are to be installed. For example, in automotive applications it may be desirable to provide flexible lighting devices that follow surfaces or outlines of a car body or of elements within a car interior. Similarly, flexible lightning devices may be of advantage if used for interior decoration.
For example, for automotive lighting applications, flexibility may add an additional degree of freedom for suitably designing appearances of lighting devices. In this way, for example, lighting devices for automotive lighting applications including turn lights, position lights, stop lights or daytime running lights may be improved.
While flexible LED strips may already exist, such LED strips often rely on use of dedicated light emitting diodes (LEDs), which are often larger high-power LEDs and which are often complex and expensive to use in implementations. In order to allow for use of smaller, less complex solutions, in particular, a suitable mechanical interface may be needed to enable mechanical coupling of such further developed flexible lighting devices.
The flexible transparent material 151 may include or be coated with a phosphor material. For example, if the light emitting elements 155 are LEDs configured for blue light transmission, the phosphor particles may be chosen for converting the emitted blue light at least in part into light of a yellow color such that a mixture of the light emitted from the light emitting elements may appear white. Use of phosphor may advantageously allow adjusting light emitted from the light emitting elements provided on the flexible substrate in terms of color, thus, for example, enabling white light emission from the lighting device.
In some embodiments, the LEDs may be small LEDs that may allow for particularly close spacing. In such embodiments, the small LEDs may be, for example, LEDs having a size between 150 μm×500 μm and 70 μm×200 μm. Further, in some embodiments, at least one of the light emitting elements may corresponds to or comprises a flip-chip LED chip. In some embodiments, a distance between neighboring light emitting elements may be around 1 mm. In this way, for example, up to 10 light emitting elements may be arranged per cm. Such high density arrangement may be of advantage as a highly homogeneous intensity/color distribution can be achieved even without using a special spatially adapted diffusor. Such high density arrangement of light emitting elements may allow use of a simple flat diffusor that may be arranged over transparent silicone to achieve a uniform emission area. Thus, the lighting device 150 may advantageously incorporate small, low power, LEDs, corresponding conductor tracks and an optical coupling element, such as the transparent material 153, to form a compact and mechanically reliable flexible light source.
In the example illustrated in
In embodiments, a special arrangement may be provided that not only may allow for securely mounting the lighting device inside of the outer housing portion but may also reduce an amount of material provided within the outer housing portion for this purpose. A further effect of the special arrangement may be that the cavities may allow for a deformation, such as an expansion and corresponding contraction, of the inner housing portion as a result of a thermal deformation of an inserted lighting device upon operation to be advantageously decoupled from the outer housing portion. Thereby, reliability of a lighting system comprising the support structure and a corresponding lighting device during a thermal cycle may be advantageously improved.
In some embodiments, the first cavities may be void, which may, in at least some embodiments, be understood to mean that the first cavities are not filled with a filling material, such as a transparent silicone material. In at least some embodiments, being void may additionally or alternatively be understood to mean that first cavities may include air. In such embodiments, the first cavities may not only advantageously allow for a reduction of material and the described improvement of reliability during the thermal cycle but may also contribute to an advantageous flexibility of the support structure. In addition, by suitably adjusting a shape of the first cavities, which may be accomplished, for example, by suitably adjusting a shape of one or more connection members, an advantageous degree of freedom in design may be provided, which may allow adjusting properties of light emitted by a lighting system comprising the support structure and the lighting device. Further, adjusting a shape of the one or more first cavities may allow for suitably adjusting an intensity of emitted light as a function of a light emission angle.
While
In an exemplary embodiment, the inner housing portion may essentially be tube-shaped or half-tube-shaped and may extend along the length direction (e.g., the entire length direction) of the support structure. In other words, in an exemplary embodiment, a cross-section of the inner housing portion may at least in part correspond to a circular segment. Such shape of the inner housing portion may be beneficial in terms of mechanical stability while, in particular, omission of edges within outer surfaces of the inner housing portion may help to achieve a homogeneous light distribution.
In an exemplary embodiment, the support structure may comprise at least two first cavities arranged in between the at least one outer wall of the outer housing portion and the inner housing portion. The at least two first cavities may be at least in part separated by the at least one connection member. In an exemplary embodiment, the at least one first cavity and/or the at least two first cavities may be arranged in between at least two outer walls of the outer housing portion (e.g., inside of the outer housing portion). In an exemplary embodiment, one, more or all of the at least one first cavity may extend along the entire length direction of the support structure.
In an exemplary embodiment, the inner housing portion, the outer housing portion and the at least one connection member may be flexible. Thus, the support structure may be suitable for receiving a flexible lighting device such as a flexible light emitting diode (LED) strip. The inner housing portion may be at least in part made or fully made of a transparent material and may correspond to a cavity or tube into which the lighting device can be inserted.
In the example illustrated in
Optical diffusor 170 may be made from a suitable transparent material, such as transparent flexible silicone. The suitable transparent material may comprise suitable particles, such as TiO2 particles, which may be embedded therein for diffusing light emitted from lighting device 150.
While outer walls 111, 111.1, 111.2, 111.3, 111.4, 112, 112.3, 112.4, 113, 113.1, 113.2, 113.3, 113.4, 114.1, 114.4 forming the outer housing portion 110 may suitably be made of a material of white appearance, with inner surfaces configured for reflecting light emitted from lighting device 150, such as a flexible silicone material with TiO2 particles embedded therein, the inner housing portion 130 and connection walls 121, 122, 123, 124, 125 may entirely or at least in part be advantageously be made of an optically transparent material, such as a flexible transparent silicone material. In this way, the at least one connection member may advantageously allow for an enhanced intensity of light output by a lighting system comprising the support structure and a corresponding lighting device.
In some embodiments, at least one connection member may be configured to compensate for a thermal deformation of the inner housing portion. In other words, in such embodiments, at least one connection member may be configured to decouple a thermal deformation of the inner housing portion from the outer housing portion. In some embodiments, thermal deformation of the inner housing portion may be understood as a deformation of the inner housing portion as a result of a deformation of a lighting device inserted in the inner housing portion upon operation of the lighting device. To this end, in some embodiments, the at least one connection member may be elastic (e.g., may be able to be deformed and to then return to its original shape). In other words, the at least one connection member may provide for a spring function as a result of which a position of a lighting device inserted into the inner housing portion with respect to the outer housing portion may remain essentially unchanged even though the lighting device and, thus, the inner housing portion may expand (or contract) upon operation of the lighting device.
In some embodiments, at least one connection member may at least in part be essentially wall-shaped. In other words, in some embodiments, at least one connection member may correspond to or comprises a connection wall. Further, in some embodiments, the outer housing portion may comprise (e.g., be formed from) at least one outer wall, and a thickness of the at least one essentially wall-shaped connection member may be smaller than a thickness of the at least one outer wall. In some embodiments, a ratio of the thickness of the at least one essentially wall-shaped connection member to the thickness of the at least one outer wall may be smaller than 8/10, or even, in some embodiments, smaller than 6/10. In other words, at least one connection member may correspond to one or more thin walls by means of which the inner housing portion may be mechanically connected to and, thus, supported by, the outer housing portion. For example, a thickness of the at least one essentially wall-shaped connection member may be approximately 0.5 mm, and a thickness of the at least one outer wall may be approximately 1.0 mm. Such a special arrangement of the thin walls may advantageously allow suitably holding and supporting the lighting device within the outer housing portion while decoupling any thermal deformation of the inner housing portion from the outer housing portion.
In some embodiments, at least one connection member may comprise at least one first wall portion mechanically connected to the outer housing portion and at least one second wall portion mechanically connected to the inner housing portion. Thereby, the first wall portion and the second wall portion may be mutually mechanically connected at an angle. In some embodiments, the angle may be between 60° and 120°, between 70° and 110°, between 80° and 100°, and/or 90°±5°. Such a geometry of at least one connection member may provide an advantageous elasticity or spring function and enable the at least one connection member to move with and thus to compensate for deformations of the inner housing portion caused by thermal expansion and contraction of an inserted lighting device upon operation. The geometry may advantageously reduce wear of the at least one connection member caused by such repeated movement.
In an exemplary embodiment, the inner housing portion may be configured to enable light emitted from an inserted lighting device to be transmitted in all directions. Thereby, light emitted from an inserted lighting device may be transmitted towards inner walls of the inner housing portion. With the at least one inner surface of the outer housing portion being at least partially reflective (e.g., diffuse reflective), light emitted from an inserted lighting device may be reflected either back into the outer housing or towards a light output or exit face of the outer housing to be emitted to the outside. Light reflected back into the outer housing portion may eventually leave the outer housing via said light output face after one or more further reflections by inner walls of the inner housing portion. In this way, the outer housing portion 110 may advantageously serve as mix box for light emitted from lighting device 150 inserted in the inner housing portion. Light emitted via a light output or exit face of the lighting system 1000, which, in the illustrated example, corresponds to diffusing element 170, may thus advantageously be made homogeneous in terms of color and appearance. Outer housing portion 110 with inner reflective (e.g., diffuse reflective) surfaces may thus advantageously help to reduce or even prevent hot spots or regions, such as spots or regions of higher intensity and/or changed color, in a distribution of intensity and/or color of light emitted from the lighting system 1000. The diffusing element 170 may further contribute to this advantageous effect. For example, the provision of outer housing portion 110 may advantageously enable the support structure to be particularly suitable for flexible lighting devices as the mixing box property of the outer housing portion 110 may help to compensate for hot spot/regions, which may be caused, for example, by bending the flexible lighting device.
In an exemplary embodiment, the inner housing portion, the outer housing portion and the at least one connection member may be integrally formed. For example, the inner housing portion, the outer housing portion and the at least one connection member may advantageously be fabricated in a same process, for example, by extruding or by molding. For example, a 2K extrusion process may be advantageously employed for forming the inner housing portion, the outer housing portion and the at least one connection member in a same process. Alternatively, a 2K molding process may be employed. In some embodiments, 2K molding may comprise or correspond to 2K injection molding by means of which it may be possible that two materials and/or colors are molded into one plastic part. Thus, providing the inner housing portion, the outer housing portion and the at least one connection member as an integral component may be advantageous not only as it may allow fabricating a reliable and stable component, but, in addition, in terms of production simplification.
In some embodiments, the outer housing portion, the inner housing portion and the at least one connection member may be formed from transparent silicone, which may enable advantageous flexibility of the support structure. Thereby, in some embodiments, the outer housing portion may comprise at least one outer wall formed from white diffusive reflective silicone. In some embodiments, the outer housing portion may thus comprise at least one outer wall formed from a silicone matrix including metal oxide particles. In some embodiments, the metal oxide particles may correspond to or comprise TiO2 particles. The choice of this material may advantageously allow light emitted from a lighting device inserted in the inner housing portion to be redirected towards a light emission face of the outer housing portion. Further, in some embodiments, the outer housing portion, the inner housing portion and/or the at least one connection member may be formed from or comprise silicone with particles of a diffusive material, such as metal oxide (e.g., TiO2) particles, embedded therein. The choice of this material may advantageously allow light emitted from a lighting device inserted in the inner housing portion to be made homogeneous in intensity and color.
In the example illustrated in
The support structure 100.1 may include two first cavities 191.1, 192.1 arranged in between upper wall 114.1 inner housing portion 130.1. These two first cavities 191.1, 191.2 may be separated by a connection wall 123.3. As in case of the first cavities of
In embodiments, the inner housing portion 130.2 may be essentially half-tube shaped, and a flexible transparent material, such as a flexible transparent silicone 185, may be provided covering an upper side of the inserted lighting device 150 not covered by the half-tube shaped inner housing portion 130.2. Further, in the example illustrated in
Having described the embodiments in detail, those skilled in the art will appreciate that, given the present description, modifications may be made to the embodiments described herein without departing from the spirit of the inventive concept. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described.
Number | Date | Country | Kind |
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20188645 | Jul 2020 | EP | regional |
This application claims the benefit of U.S. Provisional Patent Application No. 63/034,202, which was filed on Jun. 3, 2020, and European Patent Appln. No. 20188645.4, which was filed on Jul. 30, 2020, the contents of which are hereby incorporated by reference herein.
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Number | Date | Country | |
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20210381663 A1 | Dec 2021 | US |
Number | Date | Country | |
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63034202 | Jun 2020 | US |