EP2501991B1 - Reflector for a lighting device and lighting device - Google Patents

Description

The invention relates to a reflector for a lighting device, comprising at least one rear-side recess for a respective light source and at least one front-side reflector opening.

Reflectors are typically glued or clamped for mounting in LED lamps. In general, the problem arises that mechanical tolerances must be compensated. This has hitherto been solved by using one or more compensating elements, such as pressure springs.

DE 10 2004 004 778 A1 relates to a light-emitting diode illumination module with one or more light-emitting diode components and an optical device for beam shaping, which is arranged downstream of the light-emitting diode component in its emission direction. The optical device has, for each light-emitting diode component, a radiation-bundling optical element, which, viewed from the light-emitting diode component, is arranged downstream of a radiation-expanding optical element. The light-emitting diode illumination module also includes a radiation-shaping optical device for such a light-emitting diode illumination module. In this, a radiation-permeable plate is provided which has radiation-expanding and radiation-mixing structures on a first main surface. At least one radiation-bundling optical element is formed on a second main surface facing away from the first main surface, which is capable of bundling a radiation received by a light-emitting diode component prior to its penetration into the radiation-transmissive plate to a smaller opening angle of the radiation than the emission angle of the light-emitting diode component. The radiation-permeable plate with the radiation-expanding and radiation-mixing structures and the Radiation-bundling optical element are formed integrally from a radiation-permeable plastic.

US Pat. No. 6,478,454 B1 and US 2005/036307 A1 each disclose a lighting device with a reflector having at least one rear recess for each light source and at least one front-side reflector opening, and having at least one spring element.

It is the object of the present invention to provide a reflector for a lighting unit, which is particularly inexpensive to produce and allows a compact and effective tolerance compensation.

This object is achieved according to the features of the independent claims. Preferred embodiments are in particular the dependent claims.

The object is achieved by a reflector for a lighting unit, wherein the reflector has at least one rear-side recess for a respective light source and at least one front-side reflector opening.

A reflector may, in particular, be understood as meaning a generally beam-shaping element, which may in particular be designed as a reflecting element or as a diffusely reflecting element.

In general, at least part of the light emitted by the respective one light source can be deflected by the reflector.

In this case, the light source can be arranged below or in the rearward direction spaced from the associated recess. At least part of the light emitted by the light source then falls through the recess, can follow at least partially reflected by the reflector (possibly several times) and subsequently emerges through the reflector opening. In particular, for example, a light falling directly from the light source upwards or vertically or at a slight angle thereto through the recess can exit through the reflector opening without reflection.

The at least one rear-side recess can be introduced into a rear-side reflector base.

Alternatively, the light source may be at least partially inserted into the recess. The light emitted by it can then be wholly or partially reflected by the reflector and subsequently emerge through the reflector opening.

In the reflector at least one spring element is further integrated. Due to the integrated spring element, the reflector can be pressed for tolerance compensation with high accuracy. Misalignment of a separate spring element, e.g. by tilting, deleted. The reflector with integrated spring element is also cheaper to implement than a conventional reflector with the separate spring element. It can be saved at least one component. Also, a particularly compact design is possible.

The spring element preferably acts substantially parallel to the longitudinal axis of the reflector and / or parallel to a main emission direction of the lighting device and / or at least one light source of the lighting device.

The reflector may have a base made of metal or plastic. The reflector may e.g. be an injection-molded plastic base body whose reflector wall or reflector walls have been provided in particular subsequently with a reflective surface, e.g. with a reflective foil or a reflective coating.

The at least one spring element can in particular represent an integral part of the reflector.

It is an embodiment that the at least one spring element protrudes forward. In particular, an area above or in front of the at least one front side can be referred to as "forward" Reflector opening to be understood. By "forward" may in particular also be understood a region which lies with respect to a longitudinal axis of the reflector above the at least one front-side reflector opening. The light emitted by the at least one reflector is also radiated "forwards" into a corresponding front half-space. In particular, the longitudinal axis of the reflector can essentially also correspond to an axis of symmetry and / or an optical axis. By the at least one forwardly projecting spring element of the reflector can be pressed from the front in the rearward direction, wherein a manufacturing tolerance on a change of a spring travel of the at least one spring element is compensated. In particular, in more than one spring element, in particular in three or more spring elements, as well as a tilting of the reflector is easily tolerance compensated.

It is still an embodiment that the at least one spring element is designed as an obliquely forwardly directed, one-sided clamped beam. The beam is elastically pivotable in particular at its restraint. This is particularly simple and compact to implement. The spring element can also be regarded as a one-sided lever. Its free end may then serve as a point of attachment for a member pressing on the front of the reflector, e.g. a cover plate, serve.

It is an alternative embodiment that the at least one spring element is designed as a two-sided clamped beam. For example, the forward protrusion can be achieved by bending an area between the two clamped ends, e.g. in the form of an inverted "U".

It is a particular embodiment that the reflector has at least one rearwardly projecting positioning element, in particular spacers. By the least a spring element, the reflector can be securely fixed even at a tolerance-prone distance between the front of the reflector and the front side of the reflector pressing element. In particular, a distance to the at least one light source can be precisely maintained by the at least one positioning element, which enables a precisely reproducible beam guidance.

It is an alternative embodiment that the at least one spring element is integrated in a respective support element of the reflector. A support member may be aligned in particular in a rearward direction and support the reflector back accordingly. By the at least one integrated spring element is at a compression of the reflector, e.g. when placing a cover plate, the reflector pushed forward, e.g. on the cover plate. For example, the reflector can be mounted without a spacer or "floating" with respect to the at least one light source.

It is a particular embodiment that the reflector is constructed at least in two parts from a reflector holder and at least one reflector insert, wherein the at least one reflector insert has at least one of the recesses and at least one of the front reflector openings. The at least one reflector insert has in particular the reflective surfaces. The at least one reflector insert can be inserted from the front into the reflector holder, wherein the at least one spring element is integrated in a respective support element of the reflector holder. In this embodiment, the at least one spring element can press the reflector in particular against a cover plate, which in turn pushes the at least one reflector insert into the reflector holder and thus held there.

In general, the at least one reflector insert can be exactly one of the recesses and exactly one of the front reflector openings exhibit. In particular, a plurality of reflector inserts may each have exactly one of the recesses and exactly one of the front reflector openings. As an alternative, the at least one reflector insert may have a plurality of the recesses and exactly one of the front reflector openings, for example in the case of reflector surfaces running into one another.

In general, the reflector may be formed in one piece or in several pieces. The one-piece design (including the at least one spring element) has the advantage that the manufacture and assembly can be carried out inexpensively, e.g. by means of an injection molding process. The injection molding process can e.g. be carried out in one or more stages. Also, no mismatching of the individual functional components (reflector holder, reflector recess (s), spring element (s), etc.) occur more. In addition, the one-piece reflector has a high stability and accuracy of fit.

The object is also achieved by a lighting device which has at least one such reflector. Due to the integrated spring element, the reflector can be pressed for tolerance compensation with high accuracy, e.g. by means of a translucent cover plate. Mispositioning, e.g. by tilting a separate spring element deleted. The reflector with integrated spring element is also cheaper to implement than a conventional reflector with the separate spring element. It can be saved at least one component. Also, a particularly compact design is possible.

It is a further development that the at least one front-side reflector opening is covered by means of a covering element pressing on the reflector.

It is still a further development, in particular if the reflector has at least one rearwardly projecting spacer, that the at least one light source is arranged on a light source carrier and the at least one spacer is seated on the light source carrier. Thus, the at least one spring element can hold the reflector securely and in a defined position relative to the at least one light source.

It is also a development, in particular if the at least one spring element is integrated in a respective support element of the reflector, that the at least one light source is arranged on a light source carrier and the light source carrier and the respective support element are arranged on a housing of the lighting device. As a result, the light sources and the reflector can be mounted independently of the housing without direct mechanical contact. In particular, such a floating positioning of the reflector over the at least one light source is easily possible.

Preferably, the at least one light source comprises at least one light-emitting diode. If several LEDs are present, they can be lit in the same color or in different colors. A color can be monochrome (eg red, green, blue etc.) or multichrome (eg white). The light emitted by the at least one light-emitting diode can also be an infrared light (IR LED) or an ultraviolet light (UV LED). Several light emitting diodes can produce a mixed light; eg a white mixed light. The at least one light-emitting diode may contain at least one wavelength-converting phosphor (conversion LED). The at least one light-emitting diode can be in the form of at least one individually housed light-emitting diode or in the form of at least one LED chip. Several LED chips can be mounted on a common substrate ("submount"). The at least one light emitting diode may be equipped with at least one own and / or common optics for beam guidance, eg at least one Fresnel lens, Collimator, and so on. Instead of or in addition to inorganic light-emitting diodes, for example based on InGaN or A-lnGaP, it is generally also possible to use organic LEDs (OLEDs, eg polymer OLEDs). Also z. B. diode lasers are used. Alternatively, the at least one light source may have, for example, at least one diode laser.

Among other things, LED light sources are characterized by high efficiency, a long service life, a fast response time and a comparatively low sensitivity to shocks and vibrations. In addition, LED light sources are suitable for installation in optical systems, in particular reflectors. For this reason, LED light sources can be used in lighting units in which incandescent or discharge lamps have hitherto often been used, in particular in lamps for general lighting but also in special lighting applications, for example aerodrome lighting. Conventionally, halogen reflector lamps have hitherto been used for this purpose.

However, the invention is not limited to semiconductor light-emitting elements (light-emitting diodes, diode lasers, etc.), but may also include light sources of other types, e.g. Miniature incandescent or discharge lamps include.

Fig.1

zeigt in Ansicht von schräg oben bzw. vorne einen Reflektor gemäß einem ersten Ausführungsbeispiel;

Fig.2

zeigt in Seitenansicht einen Ausschnitt aus einer Leuchtvorrichtung mit dem Reflektor gemäß dem ersten Ausführungsbeispiel;

Fig.3

zeigt in Seitenansicht einen weiteren Ausschnitt aus der Leuchtvorrichtung mit dem Reflektor gemäß dem ersten Ausführungsbeispiel;

Fig.4

zeigt in Seitenansicht noch einen weiteren Ausschnitt aus der Leuchtvorrichtung mit dem Reflektor gemäß dem ersten Ausführungsbeispiel;

Fig.5

zeigt in Ansicht von schräg oben einen Reflektor gemäß einem zweiten Ausführungsbeispiel;

Fig.6

zeigt in Ansicht von schräg unten bzw. hinten den Reflektor gemäß dem zweiten Ausführungsbeispiel;

Fig.7

zeigt in Ansicht von schräg oben einen Reflektorhalter eines Reflektors gemäß einem dritten Ausführungsbeispiel;

Fig.8

zeigt in Ansicht von schräg oben den Reflektor gemäß dem dritten Ausführungsbeispiel;

Fig.9

zeigt in Ansicht von schräg unten den Reflektor gemäß dem dritten Ausführungsbeispiel;

Fig.10

zeigt in Ansicht von schräg oben den Reflektor gemäß dem dritten Ausführungsbeispiel mit zugehörigen Leuchtdioden;

Fig.11

zeigt als Schnittdarstellung in Seitenansicht eine weitere Leuchtvorrichtung mit dem Reflektor gemäß dem dritten Ausführungsbeispiel;

Fig.12

zeigt als Schnittdarstellung in Seitenansicht noch eine weitere Leuchtvorrichtung mit dem Reflektor gemäß dem dritten Ausführungsbeispiel.

In the following figures, the invention will be described schematically with reference to exemplary embodiments. In this case, the same or equivalent elements may be provided with the same reference numerals for clarity.

Fig.1

shows in oblique view from above or front a reflector according to a first embodiment;

Fig.2

shows a side view of a section of a lighting device with the reflector according to the first embodiment;

Figure 3

shows a side view of another section of the lighting device with the reflector according to the first embodiment;

Figure 4

shows a side view of yet another section of the lighting device with the reflector according to the first embodiment;

Figure 5

shows in oblique view from above a reflector according to a second embodiment;

Figure 6

shows in a view obliquely from below or behind the reflector according to the second embodiment;

Figure 7

shows in oblique view from above a reflector holder of a reflector according to a third embodiment;

Figure 8

shows in oblique view from above the reflector according to the third embodiment;

Figure 9

shows in a view obliquely from below the reflector according to the third embodiment;

Figure 10

shows in oblique view from above the reflector according to the third embodiment with associated light-emitting diodes;

Figure 11

shows a sectional side view of a further lighting device with the reflector according to the third embodiment;

Figure 12

shows a sectional view in side view yet another lighting device with the reflector according to the third embodiment.

Fig.1 shows in oblique view from above a one-piece reflector 1 according to a first embodiment. The reflector 1 may have been produced, for example, by means of a plastic injection molding process. The reflector 1 has four cup-shaped or funnel-shaped reflector depressions 2 which are rotationally symmetrical about a longitudinal axis L and are designed to be reflective or diffusely reflecting on their inner walls 3. The inner walls 3 may for example be parabolic, hyperbolic or shaped as a freeform surface. At their backs, which belong to a reflector base 4, the reflector recesses 2 are each equipped with a central rear recess 6. At the front side 7 of the reflector 1, each of the reflector recesses 2 has a front-side reflector opening 8.

Through the respective rear recess 6, light emitted by a light source arranged thereunder can fall through, or a light source can protrude from the rear or below into the recess 6. The light emitted by the light source can be subsequently reflected at least partially on the reflector recesses 2 and then emerge at the associated reflector opening 8. In some cases, light emitted perpendicularly from the light source (which runs parallel to the longitudinal axis L) or light whose angle to the longitudinal axis L is less than or equal to an opening angle of the reflector depression 2 can emerge without reflection from the reflector depression 2 through the associated reflector opening 8.

In an upper edge 9 of the reflector 1 four rotationally symmetrical to the longitudinal axis L arranged spring elements 10 are integrated here. The spring elements 10 respectively project forward (in the direction of the longitudinal axis L) beyond the remaining reflector 1 and thus represent the uppermost or furthest forwardly arranged points P1 of the reflector 1. The spring elements 10 are each designed as two-sided clamped beams, which are formed centrally in the form of an inverted "U" 11. The bottom of the "U" 11 thus represents the foremost point P1 of the reflector 1, but this is not a compelling design.

The reflector 1 further comprises four rotationally symmetrical to the longitudinal axis L arranged, rearwardly or rearwardly projecting spacer 12. The spacers 12 define the lowermost or rearmost point P2 of the reflector 1.

Fig.2 shows a side view of a section of a lighting device 13 with the reflector 1 according to the first embodiment. The reflector 1 is supported on the spacers 12 on an LED carrier 14 (eg a circuit board) on which four light-emitting diodes (o.Fig.) Are mounted. The LED carrier 14 in turn rests on a housing 16. By the LED carrier 14 projects a cable bushing 15 for an electrical connection of the carrier plate, for example, to a remote driver (o.Fig.). The respective spring element 10 projects beyond the front 7 by a height b (projection).

Figure 3 shows a side view of another section of the lighting device 13, which is now placed on the reflector 1 from the front or top of a translucent cover 17 made of plastic. The translucent cover 17 has a substantially disc-shaped or plate-shaped upper side 18 and a laterally encircling edge 19, that is to say it is configured here in a substantially cup-shaped manner in the opposite direction.

The fact that the top 18 of the cover 17 presses on the reflector 1, the spring elements 10 are pressed down and press the reflector 1 on the support 14, wherein a distance between the respective rear recess 6 and the LED support 14 through the Spacer 12 is determined. The spacers 12 also delimit the LED carrier 14 laterally, so that they serve as general positioning elements, which also prevent a lateral offset of the reflector 1 with respect to the LED carrier 14 here. By the spring elements 10, a top tolerance of the cover 17 can be compensated in a simple and compact manner, up to a height b of the supernatant.

Figure 4 shows in side view yet another section of the lighting device 13 with the attached cover 17, and now through one of the reflector recesses 2. Through the rear recess 6 projects a light-emitting diode 20, which throws their light partly on the inside 3 of the reflector recess 2 and partially directly from the reflector opening 8. The edge 19 of the cover 17 has at least one latching lug 21, by means of which the cover 17 can be latched to the housing 16.

Figure 5 shows in oblique view from above a reflector 31 according to a second embodiment. Figure 6 shows the reflector 31 in oblique view from below. Referring to Fig.5 and Fig.6 the reflector 31 is similar to the reflector 1 constructed according to the first embodiment, but now only three reflector recesses 2 are present, the spacers 32 are integrally formed on a respective outer side 33 of the reflector recesses 2 and in the upper edge 9 of the reflector 31 three rotationally symmetrical to the Longitudinal axis L arranged spring elements 34 are integrated.

Each of the spring elements 34 is formed as an obliquely forwardly or upwardly (in the longitudinal direction L) directed, cantilever beam. The free end 35 of the spring elements 34 represents the highest or the most forward projecting point P1. Presses the cover 17 on the front side 7 of the reflector 31, it pivots the spring elements 34 elastically downwards, whereby the reflector 31 on the Support plate can be pressed, and to compensate for manufacturing and assembly tolerances. In particular, the maximum tolerance dimension may substantially correspond to the extent of the projection of the free end 35, which represents the furthest projecting point P1, over the front side 7 of the reflector 31.

Again, the reflector 31 is integrally formed as a plastic part.

Figure 7 shows in oblique view from above a reflector holder 40 of a reflector 41 according to a third embodiment. The reflector holder 40 made of plastic has three insertion openings 42 each for use of a reflector insert 46 (see further figures) made of aluminum, the reflector inserts 46 can be placed on corresponding edges or annular grooves 43 and positioned in these. The reflector holder 40 here has three rearwardly directed (directed against the longitudinal direction L) support elements 44, whose rear ends are formed as insertion pins 51. Instead of a forward projecting spring element, a U-shaped spring element 45 is integrated into each of the support elements 44, which acts on the upper edge 9 of the reflector holder 40. In a load applied from the front to the surface 7 of the reflector holder 40, the spring element 45, which can be supported by means of the support elements 44, for example, on a housing of a lighting device and / or an LED support, elastically deformed and exerts a forward (in the longitudinal direction L) directed counterforce, which now pushes the reflector holder 40 forward.

Figure 8 shows in oblique view from above or front and Figure 9 shows in a view obliquely from below the reflector 41 according to the third embodiment, now in each of the insertion openings 42 from the front, a respective reflector insert 46 is inserted. The reflector insert 46 sits on the associated annular groove 43. Without further action, the reflector inserts 46 loosely rest on the insertion openings 42. For their fixation, the reflector inserts 46 can be pressed, for example, into the insertion openings 42, eg by a light-permeable cover (o.Fig.).

Each of the reflector inserts 46 has a rear-side recess 6 and a front-side reflector opening 8, wherein the inner side 3 of the respective reflector insert 46 is designed to be reflective. The reflection behavior of the now four-part reflector 41 is similar to the reflection behavior of the reflector 31 and therefore will not be further described here.

Figure 10 shows in oblique view from above the reflector 41 with associated light-emitting diodes 47th Figure 11 shows a sectional view in side view of a lighting device 61 with the reflector 41st

Referring to Figure 10 and Figure 11 the emitter surfaces of the LEDs 47 are inserted into the rear recesses 6. The LEDs 47 are supported on respective LED carriers 48, which in turn are screwed by screws 49 to the housing. The reflector 41 holds the reflector inserts 46 floating over the light emitting diodes 47, ie, that the reflector 41 is not supported on the LED supports 48, but the LED support 48 and the reflector 41 are both supported on the common housing 50, which here is formed locally as a heat sink. The reflector 41 is inserted with its insertion pins 51 into corresponding bores 52 of the housing 50.

For fixing the reflector 41, this is made from the front by means of a circular disk-shaped translucent cover (o.Fig.), Eg similar to a cover 53 Figure 12 covered. The cover can be inserted into a circumferential annular groove 54 of the housing and fastened there. The cover presses from above on the upper edges of the reflector inserts 46, which project slightly beyond the surface 7 of the reflector holder 40. Thus, the spring elements 45 of the reflector holder 40 are compressed and the reflector inserts 46 remain in a press contact with the cover, whereby they are pressed into the insertion openings 42 and fixed there. A spring travel of the spring elements 45 can provide a tolerance compensation.

Figure 12 shows a sectional view in side view yet another lighting device 62 with the reflector 41. The reflector 41 is covered by the cover 53 and pressed into the housing 50. The cover 53 is substantially circular disk-shaped and has a fresnel pattern 55 on its underside.

In contrast to the lighting device 61, the LEDs 56 are now mounted on a common, substantially circular LED carrier 57 (board or the like) and do not dip into the associated rear recess 6 a. Rather, the light-emitting diodes 56 radiate a predominant part of the light emitted by them, in particular substantially all of the light emitted by them, through the respective recess 6.

Through the housing 50 and the LED support 57 runs a cable bushing 58, which connects the wired front of the LED support 57 with a receiving space 59 for a driver. The visible here part of the housing 50 is also formed substantially as a heat sink.

Of course, the present invention is not limited to the embodiments shown.

Thus, the reflector according to the third embodiment may also be integrally formed, e.g. made of plastic.

Also, the inner sides of the reflector recesses can merge into one another and form a common reflector inner side, which is illuminated by means of a plurality of recesses.

LIST OF REFERENCE NUMBERS

1

reflector

2

reflector cavity

3

inner wall

4

reflector bottom

6

recess

7

Front of the reflector

8th

reflector opening

9

upper edge of the reflector

10

spring element

11

reverse U

12

spacer

13

lighting device

14

LED support

15

Grommet

16

casing

17

translucent cover

18

Top of the cover

19

Edge of the cover

20

led

21

locking lug

31

reflector

32

spacer

33

Outside of the reflector pits

34

spring element

35

free end of the spring elements

40

reflector holder

41

reflector

42

insertion opening

43

ring groove

44

support element

45

spring element

46

reflector insert

47

led

48

LED support

49

screw

50

casing

51

insert pin

52

drilling

53

cover

54

ring groove

55

Fresnel pattern

56

led

57

LED support

58

Grommet

59

accommodation space

61

lighting device

62

lighting device

b

Got over

L

longitudinal axis

P1

foremost point of the reflector

P2

rearmost point of the reflector

Claims (12)

1. Reflector (1; 31; 41) for a lighting apparatus (13; 61; 62), having

   - at least one rear recess (6) for a respective light source (20; 47; 56) and at least one front reflector opening (8),

   - wherein at least one spring element (10; 34; 45) is integrated into the reflector (1; 31; 41).
2. Reflector (1; 31) according to Claim 1, wherein the at least one spring element (10; 34; 45) projects toward the front.
3. Reflector (31) according to Claim 2, wherein the at least one spring element (34) is in the form of a bar which is directed obliquely toward the front and is clamped on one side.
4. Reflector (1) according to either of Claims 1 and 2, wherein the at least one spring element (10) is in the form of a bar which is clamped on two sides.
5. Reflector (1; 31) according to one of Claims 2 to 4, wherein the reflector (1; 31) has at least one space (12; 32) which projects to the rear.
6. Reflector (41) according to Claim 1, wherein the at least one spring element (45) is integrated into a respective supporting element (44) of the reflector (41).
7. Reflector (41) according to Claim 6, wherein

   - the reflector (41) is constructed in at least two parts from a reflector holder (40) and at least one reflector insert (46), wherein the at least one reflector insert (46) in each case has at least one of the recesses (6) and at least one of the front reflector openings (8),

   - the at least one reflector insert (46) can be inserted into the reflector holder (40) from the front, and

   - the at least one spring element (45) is integrated into a respective supporting element (44) of the reflector holder (40).
8. Reflector (41) according to Claim 7, wherein the at least one reflector insert (46) has precisely one of the recesses (6) and precisely one of the front reflector openings (8).
9. Reflector (1; 31) according to one of Claims 1 to 6, wherein the reflector (1; 31) is of integral design.
10. Lighting apparatus (13; 61; 62), having at least one reflector (1; 31; 41) according to one of the preceding claims, wherein the at least one front reflector opening (8) is covered by means of a covering element (17; 53) which presses on the reflector (1; 31; 41).
11. Lighting apparatus (13) according to Claim 10, having a reflector (1; 31) according to Claim 5, wherein the at least one light source (20) is arranged on a light source carrier (14), and the at least one spacer (12; 32) sits on the light source carrier (14).
12. Lighting apparatus (61; 62) according to Claim 10, having a reflector (41) according to one of Claims 6 to 8, wherein the at least one light source (47; 56) is arranged on a light source carrier (48; 57), and the light source carrier (48; 57) and the respective supporting element (44) are arranged on a housing (50) of the lighting apparatus (61; 62).

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