DE102019100360B4 - LED retrofit light - Google Patents

Abstract

A lamp comprising a hollow base body (1), one or more LED filament units (4) and at least one end cap (10), the at least one end cap (10) comprising a connecting part (11) and a terminal cap (12, 24), wherein the hollow body (1) is mechanically connected to the connector (11) from a first side and the terminal cap (12, 24) is mechanically connected to the connector (11) from a second side,wherein the one or more LED filament units (4) mechanically retained by the connector (11), and wherein the hollow body (1) comprises a plurality of connector pins (2) extending through corresponding first openings in the connector (11) from the first side of the connector (11) to the second Extend side of the connecting part (11).

Description

Technical part

The present invention relates to an LED retrofit lamp, in particular to an LED retrofit lamp (retrofit lamp) for replacing halogen lamps of the R7s type.

background

Traditional R7s halogen bulbs consist of a glass tube to which ceramic end caps including terminals (also called electrodes) are attached. As a rule, the end caps are glued to the glass tube with a cement that hardens at temperatures above 200°C. At such temperatures, LED retrofit lights can be damaged.

In addition, the cement exhibits high expansion during hardening. This can cause the cement to leak out.

The pamphlet DE 10 2014 214 175 A1 describes a base for a lamp tube, the base having a fastening part for stationary fastening on a front side of the lamp tube and a connection part with at least one electrical contact element for making electrical contact with a lamp socket. The pamphlet DE 10 2009 054 994 A1 describes an end piece for a retrofit fluorescent lamp, the end piece having a housing part which is open on a first end face and a cover which can be closed off the first end face. The pamphlet DE 10 2018 123 971 A1 describes a lamp with a housing tube, an LED filament being arranged in the housing tube between a first end cap and a second end cap.

Summary of the Invention

In view of the known prior art, it is an object of the present invention to offer an improved LED retrofit lamp that overcomes the problems mentioned above.

This object is solved by a lamp according to the independent claim. Preferred embodiments are given by the dependent claims.

A lamp according to the present invention includes a hollow base, one or more LED filament units, and at least one end cap. In one embodiment, the lamp includes two end caps at opposite ends of the lamp. The body may be substantially elongate and together with the end caps defines the length of the lamp.

The at least one end cap includes a connector and a connector cap. The end caps are intended for mounting the lamp in a luminaire and for the electrical connection of the lamp to the luminaire.

The hollow body is mechanically connected to the connector from a first side, and the terminal cap is mechanically connected to the connector from a second side. The one or more LED filament units are mechanically retained by the connector.

In an embodiment with two end caps, the combination of the first end cap, hollow base body and second end cap thus defines a mechanically stable structure. In this structure, the LED filament units can be securely held between the two end caps.

Due to the mechanical connection of the end caps with the hollow body, there is no need to glue components with cement.

The hollow body includes a plurality of connector pins extending through respective first openings in the connector from the first side of the connector to the second side of the connector. The connecting pins can mechanically connect the hollow body to the connecting part of the end cap.

In particular, the connecting pins can be made of a deformable material and have deformed ends on the second side of the connecting part, so that the diameter of the deformed ends is larger than the diameter of the first openings. In other words, the connecting pins can extend from the hollow body through the respective first openings and be deformed on the opposite side of the hollow body, thus securing the hollow body and the connecting part to each other.

In particular, the connecting pins can be made from a plastic, in particular from a thermoplastic material such as polycarbonate (PC), polyethylene terephthalate (PET) or polystyrene (PS).

In one embodiment, the entire hollow body can consist of the same material. The hollow body can thus be produced without any problems using the extrusion or injection molding process.

If the connecting pins are made of a thermoplastic material, the free ends of the connecting pins on the second side of the connecting part can be deformed by heat-staking. The free ends of the connecting pins are heated to a temperature at which the material can be deformed, eg into a flange-like section. After the material cools down, the new shape is retained. Flange-like sections at the free end of the connecting pins can keep the hollow body firmly connected to the connecting part.

In one embodiment, the hollow body includes a reflective outer surface. The LED filament units can be arranged along the hollow body. A reflective outer surface of the hollow body can improve the light emission of the lamp since the light emitted from the LED filament units to the hollow body can be at least partly reflected to the outside. The outer surface of the hollow body can be white or a mirror surface. The outer surface of the hollow body can be coated to achieve the desired reflectivity. The hollow body can also be made from a plastic with good reflective properties (e.g. white plastic), resulting in a reflective (white) outer surface without the need for an additional coating step.

In one embodiment, the hollow body includes a plurality of concave wall segments. In this way, the wall elements of the hollow body can be adapted to the shape of the LED filament units. In particular, each LED filament unit can be arranged next to one of the wall segments of the hollow body. The concave shape of the wall elements makes it possible to reduce the overall diameter of the lamp and at the same time increase the radiation characteristics.

In one embodiment, the lamp further includes an electronic driver for driving the LEDs of the LED filament units. The electronic driver can be housed inside the hollow body. The input terminals of the electronic driver can be electrically connected to the connection caps, in particular each input terminal to a connection terminal (electrode) of the respective connection cap. The accommodation of the electronic driver inside the hollow base body at least partially shields the electronic driver from the heat generated by the LED filaments.

In one embodiment, each LED filament unit includes at least one metal lead extending through a corresponding second opening in the connector from the first side of the connector to the second side of the connector. The metal terminal can be firmly connected to the connection part, or it can only be held by the connection part without being firmly connected. Each LED filament unit may include two metallic terminals to provide electrical power to the LED filament unit. The two metal leads can be on opposite ends of the LED filament assembly. The metallic connections can be electrically connected to the output terminals of the electronic driver.

In an embodiment where the lamp includes more than one LED filament unit, the end cap further includes a filament connector that electrically connects the metallic terminals of the LED filaments. The filament connector can be a printed circuit board with electrically conductive traces to which the metal terminals of the LED filament units can be electrically connected, for example by soldering a metal terminal of a filament unit to the filament connector. The filament connector can also be electrically connected to the output terminals of the electronic driver, e.g. also by soldering.

In one embodiment, each LED filament unit includes an LED filament and a glass tube surrounding the LED filament. The metallic connectors protrude beyond the glass tube so that they can be electrically connected to the filament connector or electronic driver.

LED filaments are strip-shaped LED elements typically comprising a plurality of LEDs arranged in series on a strip-shaped substrate (e.g. metal, glass or sapphire materials). The LEDs can be coated with a coating to convert the light generated by the LEDs to a desired wavelength range.

The glass tube protects the LED filament and prevents the LED filament, which can become hot during operation, from being touched.

In one embodiment, the ends of the glass tube are sealed with a pinch seal. The metallic terminals are embedded in the pinch seals and extend outside of the pinch seal. The pinch seal can be achieved by heating the ends of the glass tube until they can be deformed, and then each end of the glass tube is squeezed until it is closed. The pinch seal can be gas-tight.

The inner volume of the glass tube closed with a pinch seal can be filled with a transparent potting material or a gas. Such filling can increase heat dissipation away from the LEDs on the LED filament. In particular, the inner volume can be filled with a gas with high thermal conductivity. The gas preferably contains helium and/or hydrogen. The gas can also be a gas mixture of different gases. Such a gas for heat dissipation enables the operation of the LED filament in a closed light source without additional heat sinks.

In one embodiment, the connection cap comprises a connection terminal and a cover which laterally surrounds the connection terminal. The terminal (electrode) may be configured to contact corresponding mounting terminals of a light fixture to electrically connect the lamp to the light fixture. The terminal can be held in the cover by a press fit. The terminal may be electrically connected to the input terminals of an electronic driver. In order to achieve an electrical connection between binding posts and input terminals, the binding terminal can extend inward (through corresponding holes in the end cap and filament connector) to the input terminals of the driver. Alternatively, a wire or other conductive element may be used to connect terminals and input terminals. Both options can be mixed, i.e. one terminal can extend inwards to an input terminal of the driver and the other terminal can be connected by a wire to another input terminal.

The cover may include snap hooks extending through respective third openings in the connector from the second side of the connector to the first side of the connector. Thus, the cover with the terminal is firmly connected to the connection part of the end cap without the need for glue or cement.

In one embodiment, the connecting part consists of a ceramic material, in particular a transparent ceramic material, such as a transparent aluminum oxide ceramic. Transparent aluminum oxide ceramics achieve a light transmission of up to 95% with good electrical insulation at the same time, especially at high temperatures. The connecting part can be produced using the hot press sintering process. Such transparent components are often used in high-pressure sodium lamps (HPSL). A transparent ceramic material can improve the appearance of the lamp and reduce shadows. The end cap connector and cover may be of the same or different materials. In particular, the connecting part can be made of a ceramic material and the cover can be made of a plastic such as polycarbonate (PC).

In one embodiment, the lamp is an R7s aftermarket lamp.

character list

• 1 eine Explosionszeichnung einer Ausführungsform einer Nachrüstlampe gemäß der vorliegenden Erfindung;
• 2 eine perspektivische Ansicht der in 1 dargestellten Ausführungsform einer Nachrüstlampe;
• 3 eine schematische Zeichnung einer Endkappe der in den vorherigen Zeichnungen dargestellten Ausführungsform einer Nachrüstlampe;
• 4 eine schematische Zeichnung eines Verbindungsteils einer Endkappe der in den vorherigen Zeichnungen dargestellten Ausführungsform einer Nachrüstlampe;
• 5 eine schematische Zeichnung einer Abdeckung einer Endkappe der in den vorherigen Zeichnungen dargestellten Ausführungsform einer Nachrüstlampe;
• 6 eine schematische Zeichnung eines hohlen Grundkörpers der in den vorherigen Zeichnungen dargestellten Ausführungsform einer Nachrüstlampe;
• 7 eine schematische Zeichnung einer LED-Filamenteinheit der in den vorherigen Zeichnungen dargestellten Ausführungsform einer Nachrüstlampe;
• 8 eine schematische Darstellung der in den vorherigen Zeichnungen dargestellten Ausführungsform einer Nachrüstlampe in einem teilmontierten Zustand;
• 9 eine schematische Zeichnung, die die elektrischen Verbindungen zwischen den LED-Filamenteinheiten und den Filamentverbindern zeigt.

The preferred embodiments of the invention are explained below with reference to the drawings. It is shown in:

• 1 an exploded view of an embodiment of a retrofit lamp according to the present invention;
• 2 a perspective view of in 1 illustrated embodiment of a retrofit lamp;
• 3 Figure 12 is a schematic drawing of an end cap of the retrofit lamp embodiment shown in the previous drawings;
• 4 Figure 12 is a schematic drawing of a connecting part of an end cap of the embodiment of an aftermarket lamp shown in the previous drawings;
• 5 Figure 12 is a schematic drawing of a cover of an end cap of the embodiment of a retrofit lamp shown in the previous drawings;
• 6 a schematic drawing of a hollow body of the embodiment of a retrofit lamp shown in the previous drawings;
• 7 Figure 12 is a schematic drawing of an LED filament assembly of the retrofit lamp embodiment illustrated in the previous drawings;
• 8th a schematic representation of the embodiment of a retrofit lamp shown in the previous drawings in a partially assembled state;
• 9 Figure 12 is a schematic drawing showing the electrical connections between the LED filament units and the filament connectors.

Detailed description of the invention

Preferred embodiments of the invention are described below with reference to the drawings. The same or similar elements or elements having the same effect may be identified by the same reference number in several drawings. The repetition of the description of these elements may be omitted to avoid redundant descriptions.

1 Figure 12 shows an exploded view of an embodiment of a retrofit lamp according to the present invention. The same embodiment is shown in a perspective view in FIG 2 shown. Various elements of the embodiment are in FIGS until shown.

The retrofit light includes a hollow base body 1 (see also ), which extends in a longitudinal direction L. The hollow base body 1 has a substantially hexagonal cross section. Instead of straight edges of a hexagon, however, the wall segments 3 of the hollow base body 1 are concave in shape in such a way that the cross section of the hollow base body 1 along the longitudinal direction L essentially does not change.

Connecting pins 2 protrude from the hollow base body 1 in the longitudinal direction L at both longitudinal ends of the hollow base body 1 . In the embodiment shown, three connecting pins 2 protrude from each longitudinal end. The connecting pins 2 protrude at points where two of the concave wall segments 3 meet. The three connecting pins 2 are evenly distributed over the circumference of the hollow base body 1 . In other embodiments, the number and/or arrangement of the connector pins may vary. The number and/or the shape of the walls of the hollow base body can also vary. In a further embodiment, the hollow base body can have a circular cross section.

An LED filament unit 4 is arranged next to each concave wall segment 3 (see also ). Since the hollow body 1 of the illustrated embodiment comprises six walls 3, the embodiment comprises six LED filament units 4. However, the number of LED filament units may vary and does not necessarily correspond to the number of walls.

Each LED filament unit 4 comprises an LED filament 5 including a plurality of LEDs arranged on a substrate. The outermost LEDs of the LED filament 5 are electrically connected to corresponding metal terminals 6 . The LED filament 5 is surrounded by a glass tube 7 . The two ends of the glass tube 7 are closed around the metal connections 6 with a pinch seal, so that the free ends of the metal connections 6 protrude beyond the pinch seal 8 and thus beyond the glass tube 7 .

An electronic driver 9 is located in the hollow interior of the hollow base body 1.

At both ends of the hollow body 1 is an end cap 10 (see also ) attached to the hollow body 1. The end cap 10 comprises a connecting part 11 (see also ) made of a ceramic material and a cover 12 (see also ) made of a plastic such as polycarbonate (PC).

The cover 12 includes a tubular portion 13 and a flange-like portion 14 near an end of the tubular portion 13. In another embodiment, the flange-like portion 14 may be at the end of the tubular portion 13. Three snap hooks 15 are provided on the outer circumference of the flange-like section 14 . In other embodiments, the number and/or the arrangement of the snap hooks can vary.

The connecting part 11 comprises a cylindrical wall 16 and a connecting plate 17 inside the cylindrical wall 16. The connecting plate 17 comprises three first openings 18 for receiving the connecting pins 2 of the hollow body 1. The connecting plate 17 further comprises six second openings 19 for receiving the metal terminals 6 of the LED filament units 4. The connector plate 17 also includes three third openings 20 for receiving the snap hooks 15 of the cover 12. The connector plate 17 may also have a central opening 25 for receiving the inner end of the tubular portion 13 of the cover 12.

Next to every third opening 20 there is a projection 21 which extends radially from the cylinder wall 16 inwards. When the cover 12 is assembled on the connecting part 11, the projections 21 engage in the flange-like section 14 of the cover 12, as a result of which a desired angular orientation between the cover 12 and the connecting part 11 is ensured and assembly is simplified.

Each end cap 10 further includes a filament connector 23 located between connector 11 and cover 12 . The filament connector 23 electrically connects one of the metallic terminals 6 of each LED filament unit 4 to each other and to the output terminals ment of the electronic driver 9. The metallic connections 6 can be soldered to the filament connector 23.

The filament connector 23 is designed as a printed circuit board with electrically conductive conductor tracks, with which the metal connections 6 of the LED filament units 4 can be electrically connected. The filament connector 23 is further electrically connected to the output terminals of the electronic driver 9 to supply electric power from the electronic driver 9 to the LED filament units 4 .

The conductive traces on the filament connectors 23 can be arranged such that two groups of three LED filament units 4 are electrically connected in parallel, while the LED filament units 4 in each group are electrically connected in series. this is in 9 shown schematically showing two filament connectors 23. The LED filament units 4 are indicated schematically by lines with arrows next to them between the two filament connectors 23. The conductive paths on the filament connectors 23 are represented schematically by thick straight lines on the filament connectors 23 . Those skilled in the art will understand that the actual conductive traces have a different shape and specifically run around the openings of the filament connectors 23 rather than through them. The traces marked L+ and L- are connected to the corresponding input terminals of the electronic driver, for example by wires or other conductive elements.

Other electrical connection schemes are also possible, e.g. series connection of all LED filament units, which can be chosen according to the operating parameters of the LED filament units and the electronic driver.

Each end cap 10 further includes a terminal 24 which is retained in the tubular portion 13 of the cover 12, preferably by means of an interference fit. The cover 12 and the terminal 24 together form a terminal cap. The connector clip 24 is made of metal and is designed to contact a corresponding mounting clip of a light fixture to electrically connect the lamp to the light fixture. The connection terminals 24 of both end caps 10 are electrically connected to the input terminals of the electronic driver 9 .

8th shows a schematic representation of the embodiment of a retrofit lamp in the partially assembled state. 8th 12 shows in particular how a metallic terminal 6 of each of the six LED filament units 4 extends through the second openings 19 of the connecting part 11 of the end cap 10. FIG. It can also be seen how the connecting pins 2 of the hollow body 1 extend through the first openings 18 of the connecting part 11 of the end cap 10. The filament connector includes corresponding holes through which the metal terminals 6 and connector pins 2 extend.

In If the free ends of the connecting pins 2 have not yet been deformed by hot staking or another suitable method, ie the connecting part 11 is not attached to the hollow body 1 . In addition, the metal terminals 6 are not soldered to the filament connector 23 yet.

Although the invention has been illustrated and described in detail by the embodiments discussed above, it is not limited to these embodiments.

Other variants can be derived by a person skilled in the art without departing from the scope of the appended claims.

In general, "a" or "an" may be taken as singular or plural, particularly to mean "at least one", "one or more", etc., unless expressly excluded, e.g. by the term "exactly a", etc.

In addition, unless expressly excluded, numerical values may include the exact value as well as a common tolerance interval.

Features presented in the embodiments, in particular in different embodiments, can be combined or replaced without departing from the scope of the invention.

Reference List

1

hollow body

2

connecting pins

3

wall segments

4

LED filament unit

5

LED filament

6

metallic connection

7

glass tube, glass tube

8th

pinch seals

9

electronic driver

10

end cap

11

connection part

12

cover

13

tubular section

14

flange-like section

15

snap hook

16

cylindrical wall

17

connection plate

18

first opening

19

second opening

20

third opening

21

head Start

22

score

23

filament connector

24

terminals

25

central opening

Claims (13)

Lamp comprising a hollow base body (1), one or more LED filament units (4) and at least one end cap (10), wherein the at least one end cap (10) comprises a connecting part (11) and a connection cap (12, 24), wherein the hollow base body (1) is mechanically connected to the connecting part (11) from a first side and the connection cap (12, 24) is mechanically connected to the connecting part (11) from a second side, wherein the one or more LED filament units (4) are mechanically held by the connector (11), and wherein the hollow body (1) comprises a plurality of connector pins (2) extending through respective first openings in the connector (11) from the first side of the connecting part (11) to the second side of the connecting part (11). lamp after claim 1 wherein the connecting pins (2) are made of a deformable material and have deformed ends on the second side of the connecting part (11). A lamp as claimed in any preceding claim, wherein the hollow body (1) includes a reflective outer surface. A lamp as claimed in any preceding claim, wherein the hollow body (1) comprises a plurality of concave walls (3). A lamp according to any one of the preceding claims, further comprising an electronic driver (9) housed inside the hollow body (1). A lamp as claimed in any preceding claim, wherein each LED filament unit (4) comprises at least one metallic lead (6) extending through a corresponding second opening in the connector (11) from the first side of the connector (11) to the second side of the connector (11) extends. lamp after claim 6 wherein the lamp comprises more than one LED filament units (4) and wherein the end cap (10) further comprises a filament connector (23) electrically connecting the metal terminals (6) of the LED filament units (4). lamp after claim 6 wherein each LED filament unit (4) comprises an LED filament (5) and a glass tube (7) surrounding the LED filament (5), the metallic terminals (6) extending beyond the glass tube (7). . lamp after claim 8 , wherein the ends of the glass tube (7) are closed with a pinch seal (8), the metallic connections (6) being embedded in the pinch seals (8). lamp after claim 9 , wherein the glass tube (7) is filled with a transparent potting material or a gas. Lamp according to one of the preceding claims, wherein the connection cap (12, 24) comprises a connection terminal (24) and a cover (12) which surrounds the connection terminal (24) laterally, the cover (12) comprising snap hooks (15) which extend through respective third openings (20) in the connector (11) from the second side of the connector (11) to the first side of the connector (11). A lamp according to any one of the preceding claims, wherein the connecting part (11) is made of a ceramic material. A lamp as claimed in any preceding claim, wherein the lamp is an aftermarket R7s lamp.

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