EP2189049A1

EP2189049A1 - Illumination device and method for the production thereof

Info

Publication number: EP2189049A1
Application number: EP08830134A
Authority: EP
Inventors: Bakuri Lanchava; Robert Kraus
Original assignee: Osram GmbH
Current assignee: Osram GmbH
Priority date: 2007-09-12
Filing date: 2008-09-12
Publication date: 2010-05-26
Also published as: US20100301378A1; DE102007043401A1; WO2009033716A4; WO2009033716A1; CN101803478A; CN101803478B

Abstract

The invention relates to a method for the production of an illumination device, wherein a carrier, on which illumination means are attached, is provided with filler material, wherein an upper exterior layer is applied to the filler material, and wherein the arrangement comprising the carrier, filler material, and upper exterior layer is reduced to a predetermined thickness. The invention further relates to an illumination device.

Description

Confession

Lighting device and method for producing the same

The invention relates to a lighting device and a method for producing the lighting device.

Existing LED lighting devices often have the disadvantage that they are less robust and the process for their preparation are relatively expensive.

The object of the invention is to avoid the abovementioned disadvantages and in particular to propose a lighting device which has a high degree of robustness and to provide an efficient method for the production thereof.

This object is achieved according to the features of the independent claims. Further developments of the invention will become apparent from the dependent claims.

To solve the problem, a method for producing a lighting device is initially provided,

- In which a carrier, on which bulbs are mounted, is provided with filler material;

- In which an upper outer layer is mounted on the filler material;

- In which the arrangement of carrier, filler and upper outer layer is reduced to a predetermined thickness.

As a result, a robust lighting device is produced, wherein in particular at a predetermined temperature, the reduction to the desired thickness. The filling material guarantees high strength or

Robustness of the lighting device and in particular after Curing of the filler is a separation, eg by Zersagens, possible in partial lighting devices.

A development is that the light source is a light emitting diode.

Another development is that the thickness is adjusted by means of at least one roller, in particular by means of two rollers.

It is also a development that the carrier is a flex board, which is bestuckt with the bulbs.

It is also an embodiment that the filler between the carrier and the upper outer layer is introduced.

Within the framework of the production, it is therefore also possible for the filling material to be introduced between layers and subsequently for the lighting device to be reduced to a predetermined thickness.

Another embodiment consists in that the filling material comprises one of the following materials: plastic, in particular thermoplastic or foam;

- Paper.

For reinforcement, the filler can comprise or comprise glass fiber, carbon fiber or rock flour.

In particular, the filler material may have at least one of the following properties:

- water repellent; - translucent;

- Partial permeable. A further development is that the upper outer layer has openings.

It is also a development that a protective layer is applied between the filler material and the upper outer layer.

Another embodiment is that below the support layer, a lower outer layer is attached.

A next development is that an adhesive layer is applied between the carrier layer and the lower outer layer.

It is also an embodiment that a plug-in unit is provided on the carrier layer. In particular, the plug-in unit may comprise a combination of a plug and a socket, wherein the plug and the socket engage each other.

In a further development, a separation is performed along a connection axis between the plug and the socket.

This separation can be carried out in particular by a sawing along the connection axis, wherein the separation is in particular such that the plug-in unit is not damaged or destroyed.

A next embodiment consists in that the separation is carried out along the connection axis, in particular by means of announcements from above and from below and / or from at least one side.

An alternative development is that the

Plug-in unit two sockets and / or a double socket includes. In particular, the two jacks can be executed emstuckig.

It is also an embodiment that pins are inserted into the two jacks. In particular, a separation along the connection axis of the two jacks can be performed. Such a separation can be done by sawing along the connection axis.

It is also possible for a double bushing, into which pins have been inserted, to be severed, in particular to be shattered, along a desired separation point.

The above object is also achieved by a lighting device manufactured according to the method described herein.

Furthermore, the above object is achieved by a lighting device comprising - a support layer comprising lighting means;

an upper outer layer;

- A filling material, which is provided between the upper outer layer and the support layer.

A further development is that the carrier layer is a fitted with the bulbs Flex Board.

In particular, the lighting means may be a light-emitting diode (LED).

The filler may include any of the following materials:

- Plastic, in particular thermoplastic or foam; - Paper. For reinforcement, the filler may comprise or comprise glass fiber, carbon fiber or rock flour.

Furthermore, the filler may have at least one of the following properties:

- water repellent;

- translucent;

- Partially permeable.

Another development is that the upper outer layer has openings.

It is also a development that a protective layer is provided between the filling material and the upper outer layer.

A further embodiment consists in that below the carrier layer, a lower outer layer is provided, wherein the lower outer layer in particular comprises an aluminum alloy.

Furthermore, an adhesive layer may be provided between the carrier layer and the lower outer layer.

It is also possible that a plug-in unit is provided on the carrier layer.

In the context of a further embodiment, the lighting device has a cut surface along a side surface.

Embodiments of the invention are illustrated and explained below with reference to the drawings.

Show it: Fig.l a schematic cross section through a lighting device;

FIG. 2 shows a printing down of the lighting device to a predetermined thickness; FIG.

3 is a schematic representation in which the reduction of the height of the arrangement is achieved up to the predetermined thickness of two rollers;

4 shows a lighting device comprising a plug and a socket, the lighting device having at a compound thereof a desired separation point;

5 shows a lighting device comprising a double socket, wherein the lighting device has a desired separation point through the double socket.

Fig.l shows a schematic cross section through a lighting device comprising a flex board 3, which is bestuckt with light sources, here LEDs 4. The flex board 3 is connected via an adhesive layer 15 to a lower outer layer 1. On the flex board 3 Fullmaterial 7 is provided on the Fullmateπal 7 are a protective layer 16 and above an upper outer layer 2, which in particular has openings 14 attached.

The lighting device presented here has, in particular, a lower outer layer 1, a populated LED module (flex board 3 with LEDs 4) as well as filler 7 and an upper outer layer 2. The remaining components shown in Fig.l are optional and may partially or completely complement the lighting device.

The outer layers 1 and 2 have a protective function relative to the lighting device substantially. you are in particular carried out so that a light emission through the outer layers 1 and / or 2 each flat or, for example, only at designated locations is possible.

In particular, the outer layers 1 and 2 may have at least one of the following properties:

- at least partially translucent;

- diffusely scattering;

- openings at specified locations.

Moreover, it is possible to at least partially form the outer layers 1 and / or 2 depending on the respective application as a reflective layer (e.g., diffused or specular, metallic gloss, etc.).

In particular, the LED module comprises the carrier with the LEDs, in particular a flex board equipped with LEDs or a circuit board equipped with LEDs.

The LED module can be embodied as a functional lighting module with light sources, in particular with light emitting diodes, which have different colors. Further, the lighting module may include electrical leads, circuits, e.g. Current limiter or driver, and terminal contacts, which are arranged on a base, have. This pad can serve as the lower outer layer 1 of the lighting device.

In particular, the terminals or connection contacts may be such that a simple separation of

Lighting device in subareas is possible. In this case, preferably a modular concept of several

(pluggable) lighting devices and thus efficiently a large linear or planar lighting device can be realized. In particular, one of the following materials may be provided as filling material:

- plastic;

- thermoplastic; - foam.

In this case, the filling material preferably has at least one of the following properties:

- water repellent; - translucent;

- Partial permeable.

The approach presented here is preferably also suitable for producing a flat, in particular a linear, lighting device.

The bestuckte Flex-Board 3 is provided with 7 Fullmaterial. The upper outer layer 2 is applied to the filling material 7 and printed down to a predetermined thickness. Superfluous filling material 7 can escape laterally (see Fig.2).

In particular, different functional units, i. different carriers with different components and different functions in the form of bands ("endless belts") are combined in a rolling process.

3 shows a schematic representation, m the reduction of the height of the arrangement up to the predetermined

Thickness is achieved by means of two rollers 5 and 6. At a given process temperature, the individual layers are combined into a layer system (rolled). The outer layers 1, 2 are preferably made of an aluminum alloy and are pressed together from above or from below by the rollers 6 and 5. In particular, the filling material is formed into a full layer. Optionally, an adhesive layer 15 may be provided between the first outer layer 1 and the flex board 3 and / or between the filler material 7 and the second outer layer 2. Also, an adhesive layer between the assembled flex board 3 and the filler 7 may be provided.

Another aspect of the approach presented here is that a plug-in unit is provided on the carrier layer. Such a plug-in unit serves, for example, as

Plug concept of connecting other components, e.g. of lights. In particular, the plug concept can be used to assemble several, in particular flat (partial) lighting devices after their separation and thereby provide surface lights in almost any shape and with almost any degree.

4, male-female pairs (i.e., plug 8 and socket 9) are arranged on or along a so-called nominal separation point 10, in particular soldered. When severing (for example, sawing) the lighting device at this desired separation point 10, it is achieved that plug 8 and socket 9 can be pulled apart. In particular, when cutting, make sure that the male / female pair is not damaged. This can e.g. can be achieved by the light emitting device from above and from below, possibly also of at least one side, is sawn.

Preferably, the flex board 3 is designed and with

Target disconnect points 10 provide that after dicing the resulting (sub) lighting device has an equal number of plugs 8 and sockets 9 at opposite ends (or sides), so that the thus obtained (sub) lighting devices suitable for merging into blocks are. In an alternative embodiment according to FIG. 5, the flex board 3 is fitted along the desired separation point 10 with two bushes or one (emstuckigen) double bushing 11, wherein the bushings are preferably connected to each other with inserted pins 13. When separating, for example, sawing, along the desired separation point 10, the pins 13 are severed or announced. This results in substantially smooth surfaces, ie filled by the pin stumps openings in the jacks 11. The pin stubs are pushed only during the actual mating process by the fingers of the plug into the depth of the socket. Unused sockets thus remain protected against external influences by these pin stumps.

Other advantages:

The approach presented here allows mass production of lighting devices with almost arbitrarily large (light) surfaces for use e.g. as building walls, wall coverings, etc.

Furthermore, mechanical properties and in particular a robustness of the lighting device can be significantly increased on the basis of the sandwich structure presented here.

Also, the outer layers as well as the full layer are suitable as protection against external influences, e.g. from moisture. As a result, a higher reliability of the lighting device is achieved.

The presented connector concepts allow a reliable and contact-safe connection of the lighting device even after their separation (eg by sawing into subregions). LIST OF REFERENCE NUMBERS

1 lower outer layer

2 upper outer layer

3 carriers, in particular flex board

4 LED, LED

5 lower roller

6 upper roller

7 filling material

8 plugs

9 socket

10 nominal separation point

11 double socket

12 socket hole

13 male pin

14 openings in the outer layer

15 adhesive layer

16 protective layer

Claims

claims

1. A method for producing a lighting device

- In which a carrier (3), are mounted on the lighting means (4), provided with Fullmateπal (7);

- In which an upper outer layer (2) on the Fullmateπal (7) is attached;

- In which the arrangement of carrier (3), filler (7) and upper outer layer (2) to a predetermined

Thickness is reduced.

2. The method of claim 1, wherein the lighting means is a light emitting diode.

3. The method according to any one of the preceding claims, wherein the thickness is adjusted by means of at least one roller, in particular based on two rollers.

4. The method according to any one of the preceding claims, wherein the carrier is a flex board, which is bestuckt with the bulbs.

5. The method according to any one of the preceding claims, wherein the filling material between the carrier and the upper

Outer layer is introduced.

6. The method according to any one of the preceding claims, wherein the filling material comprises one of the following materials:

- plastic;

- thermoplastic;

- foam;

- Paper.

7. The method according to any one of the preceding claims, wherein the filling material has at least one of the following properties:

- water repellent; - translucent;

- Partial permeable.

8. The method according to any one of the preceding claims, wherein the filling material comprises glass fiber, carbon fiber or rock flour.

9. The method according to any one of the preceding claims, wherein the upper outer layer has openings.

10. The method according to any one of the preceding claims, wherein between the filling material and the upper outer layer, a protective layer is attached.

11. The method according to any one of the preceding claims, wherein below the support layer, a lower

Outer layer is attached.

12. The method of claim 11, wherein an adhesive layer is applied between the carrier layer and the lower outer layer.

13. The method according to any one of the preceding claims, wherein a plug-in unit is provided on the carrier layer.

14. The method of claim 13, wherein the plug-in unit comprises a combination of a plug and a socket, wherein the plug and the socket engage with each other.

15. The method of claim 14, wherein along a

Connecting axis between the plug and the socket a separation is performed.

16. The method of claim 15, wherein the separation along the connection axis is carried out, in particular by means of sawing from above and from below and / or from at least one side.

17. The method of claim 13, wherein the plug-in unit comprises two sockets and / or a double socket.

18. The method of claim 17, wherein the two sockets are made in one piece.

19. The method according to any one of claims 17 or 18, wherein pins are inserted into the two sockets.

20. The method according to any one of claims 17 to 19, wherein a separation along the connection axis of the two

Bushings is performed.

21. Lighting device produced by a method according to one of claims 1 to 20.

22. Lighting device comprising

- A support layer (3) comprising lighting means (4);

an upper outer layer (2);

- A filling material (7) which is provided between the upper outer layer (2) and the carrier layer (3).

23. A lighting device according to claim 22, wherein the carrier layer is a populated with the bulbs Flex Board.

24. Lighting device according to one of claims 22 or 23, wherein the lighting means is a light emitting diode.

25. Lighting device according to one of claims 22 to 24, wherein the Fullmateπal one of the following

Materials includes:

- plastic;

- thermoplastic;

- foam; - Paper.

26. Lighting device according to one of claims 22 to 25, wherein the Fullmateπal has at least one of the following properties: - water repellent;

- translucent;

- Partial permeable.

27. Lighting device according to one of claims 22 to 26, wherein the Fullmateπal glass fiber, carbon fiber or

Includes rock flour.

28. Lighting device according to one of claims 22 to 27, wherein the upper outer layer has openings.

29. Lighting device according to one of claims 22 to 28, wherein between the filler material and the upper outer layer, a protective layer is provided.

30. A lighting device according to any one of claims 22 to 29, wherein below the carrier layer, a lower outer layer is provided, wherein the lower outer layer in particular comprises an aluminum alloy.

31. A lighting device according to any one of claims 22 to 30, wherein an adhesive layer is provided between the carrier layer and the lower outer layer.

32. A lighting device according to any one of claims 22 to 31, wherein on the Tragerscnicht a plug-in unit is provided.

33. Lighting device according to one of claims 22 to 32, which has a cut surface along a side surface.