EP2535642A2 - Lighting device with thermal coupling element made of thermally conductive plastic - Google Patents

Lighting device with thermal coupling element made of thermally conductive plastic Download PDF

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Publication number
EP2535642A2
EP2535642A2 EP20120172129 EP12172129A EP2535642A2 EP 2535642 A2 EP2535642 A2 EP 2535642A2 EP 20120172129 EP20120172129 EP 20120172129 EP 12172129 A EP12172129 A EP 12172129A EP 2535642 A2 EP2535642 A2 EP 2535642A2
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EP
European Patent Office
Prior art keywords
coupling element
housing
heat
heat sink
luminaire according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP20120172129
Other languages
German (de)
French (fr)
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EP2535642A3 (en
EP2535642B1 (en
Inventor
Frank Drees
Thomas Goeke
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Trilux GmbH and Co KG
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Trilux GmbH and Co KG
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Publication of EP2535642A2 publication Critical patent/EP2535642A2/en
Publication of EP2535642A3 publication Critical patent/EP2535642A3/en
Application granted granted Critical
Publication of EP2535642B1 publication Critical patent/EP2535642B1/en
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V15/00—Protecting lighting devices from damage
    • F21V15/01—Housings, e.g. material or assembling of housing parts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V23/00—Arrangement of electric circuit elements in or on lighting devices
    • F21V23/06—Arrangement of electric circuit elements in or on lighting devices the elements being coupling devices, e.g. connectors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/502—Cooling arrangements characterised by the adaptation for cooling of specific components
    • F21V29/507—Cooling arrangements characterised by the adaptation for cooling of specific components of means for protecting lighting devices from damage, e.g. housings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/71—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks using a combination of separate elements interconnected by heat-conducting means, e.g. with heat pipes or thermally conductive bars between separate heat-sink elements
    • F21V29/713—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks using a combination of separate elements interconnected by heat-conducting means, e.g. with heat pipes or thermally conductive bars between separate heat-sink elements in direct thermal and mechanical contact of each other to form a single system
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/85—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems characterised by the material
    • F21V29/87—Organic material, e.g. filled polymer composites; Thermo-conductive additives or coatings therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V25/00—Safety devices structurally associated with lighting devices
    • F21V25/12—Flameproof or explosion-proof arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2131/00—Use or application of lighting devices or systems not provided for in codes F21W2102/00-F21W2121/00
    • F21W2131/10—Outdoor lighting
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2131/00—Use or application of lighting devices or systems not provided for in codes F21W2102/00-F21W2121/00
    • F21W2131/10—Outdoor lighting
    • F21W2131/103—Outdoor lighting of streets or roads
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • the present invention relates to a closed LED luminaire for outdoor use, for example as a street lamp, or in rooms with an aggressive or explosive atmosphere.
  • a closed LED luminaire for outdoor use, for example as a street lamp, or in rooms with an aggressive or explosive atmosphere.
  • a thermal coupling element made of a heat-conducting plastic, which is compatible with the plastic of the housing.
  • LEDs are now also used for moisture and explosion-proof luminaires.
  • the housing of such lights must naturally be tightly closed to prevent the ingress of moisture and flammable gases.
  • Even with LEDs only a share of about 20 to 30% of the absorbed electrical energy is converted into light and the rest is lost as heat loss. Compared to lighting with conventional lamps, the dissipation of this heat loss is much more difficult.
  • the temperature of the LED must be kept as low as possible, otherwise the efficiency and the lifetime are impaired.
  • LEDs also allow a particularly small design and emit virtually no heat, so that the heat dissipation must be done primarily by heat conduction, especially if due to the closed housing a cooling fluid flow not possible.
  • plastic is preferred, inter alia because it is lightweight and allows a protective insulation. But plastic has only a low thermal conductivity.
  • DE 10 2007 055 165 A1 describes an LED headlamp, in particular for use in vehicles, with a heat conducting element that extends from a heat source located in a headlight housing to a cooling element, which is at least partially arranged on the outside of the headlight housing.
  • the heat-conducting element is preferably a heat pipe.
  • DE 10 2006 057 569 A1 discloses a headlamp assembly with an integrated reflector and heat sink extending through the housing which conducts the heat of the LED through the housing wall.
  • a heat sink is provided for each LED, so that the structure is complicated.
  • the German utility model DE 20 2006 015 981 U1 describes an LED street lamp with a soupableitanssen. This includes a sealed housing containing the LED, a heat sink in communication with the outside air, and a plurality of heat sinks to the heat receiving end of which the LEDs are mounted while the heat release end passes through a sealed through hole and in the heat sink. Such an arrangement is complex in construction. In addition, the function of the perennial essential ingredient (CPU), a ableitanssen, which has only when installed in a down-beam street lamp is not important.
  • the invention has as its object to provide an LED lamp with a closed housing, wherein the heat dissipation to a communicating with the outside air heat sink is effected in a simple manner and regardless of the position of the lamp.
  • the luminaire should also be easy to manufacture and suitable for easy replacement of conventional or LED lights.
  • heat-conducting plastics for heat sinks in conjunction with metallic components for cooling electronic assemblies is known per se ( DE 10 2007 057 533 A1 ).
  • Such plastics include fillers with good thermal conductivity in the form of fine particles in a matrix of plastic.
  • the fillers may be electrically conductive, the heat-conducting plastic is in any case not electrically conductive when the proportion of the filler is below the percolation threshold.
  • the plastic of the lamp housing is compatible with the heat-conducting plastic. This means that these plastics are at least to some extent miscible in the solidified state and are so similar in their thermal behavior that when temperature changes to a compound of the two plastics no tensions occur which can destroy this connection. If in doubt, the skilled person can determine by suitable simple tests, whether compatibility of two plastics is given.
  • the housing and also the matrix of the heat-conducting plastic are preferably formed by thermoplastic materials. As a result, the production of the lamp according to the invention is facilitated.
  • the thermal coupling element can be inserted in an opening of the housing wall and welded thereto, wherein the plastics of the two components partially merge together or are connected to a compatible additive.
  • Such welding can be carried out in known manner e.g. done with hot air or ultrasound.
  • the coupling element is also possible to use the coupling element as an insert in an injection mold for the housing wall and to overmold with the plastic of the latter.
  • a certain fusion of both parts can occur at the interface. This gives a very good and tight connection of the thermal coupling element with the housing wall.
  • the housing shell comprising the coupling element can also be injection-molded in a two-component process, for example, by first forming only the coupling element from the heat-conducting plastic and then further opening it for shaping the remaining housing shell. It is also possible to inject the materials for both components at the same time in the mold with a suitable vote of the filling pressures.
  • thermoplastic resin of the housing wall and the matrix of the heat-conducting plastic is preferably a polyolefin such as polyethylene, polypropylene, a polyamide, a polycarbonate, a vinyl polymer, polyethylene terephthalate or polybutylene terephthalate.
  • a polyolefin such as polyethylene, polypropylene, a polyamide, a polycarbonate, a vinyl polymer, polyethylene terephthalate or polybutylene terephthalate.
  • the filler in the heat-conducting plastic is preferably aluminum oxide, aluminum, copper, boron nitride or carbon in the form of graphite or nanotubes.
  • Suitable heat conductive Plastics have a thermal conductivity of more than 2, preferably about 10, more preferably more than 25 W / mK.
  • the housing of the lamp is preferably composed of at least two shells, wherein the coupling element is inserted into the wall of one of the shells.
  • these suitably have congruent edges.
  • For the manufacture of the lamp, these edges are connected together, so that a tightly closed housing is formed.
  • the LED or the PCB equipped with the LED should be mounted on the inside of the coupling element and any necessary operating devices and power supply lines should be installed.
  • the two shells of the housing are glued or welded together at the edges, for example by means of ultrasound. But it is also possible to connect the two housing shells by means of seals and fasteners such as resilient clips or screws tightly together.
  • Operating or ballasts required to operate the LED can be mounted both inside and outside the luminaire. If they are arranged inside the housing, then the same, correspondingly enlarged heat sink as for the LED can be used for their heat dissipation. There may also be a separate heat sink for the operating devices in the housing, which may be incorporated in the same way as that for the LED in the housing wall.
  • the LED board is expediently connected to the coupling element so that the best possible heat transfer is secured, for example by pressure elements such as screws with spring elements and / or use of a thermal compound.
  • the heat-conducting plastic of the coupling element is electrically insulating, you can dispense with the use of a separate board for mounting the LED. Instead, both the LED itself and the wiring required for powering the LED may be mounted on the coupling element itself. Also necessary for the power supply external connections can be guided by the coupling element. For example, the coupling element with the external connections made and the printed conductors on the inner surface can be molded by insert molding and the LED subsequently soldered. This latter step can also be done after encapsulation of the coupling element with the housing shell.
  • Belonging to the lamp according to the invention and the heat from the coupling element receiving and in contact with the outside air heat sink may consist of a metal such as aluminum, copper, iron or in turn also made of heat conductive plastic.
  • the proportion of the heat-conducting filler may even be above the percolation threshold, since a certain electrical conductivity of the heat sink in general does not disturb.
  • the heat sink may have structures for enlarging the free surface, such as pins or ribs and / or be traversed by air or other cooling fluid.
  • the coupling element built into the housing wall In order for the coupling element built into the housing wall to be able to dissipate the heat from the housing to the cooling body in communication with the outside air, a suitable thermal contact must exist between the two components. This can be produced for example by threaded bolts are installed in the coupling element, which penetrate the heat sink and this means Keep screwed nuts. The gap between the two components is expediently filled with a thermal grease. It is also possible to fasten the luminaire housing with pins frictionally engaged in the heat sink. If these pins are electrically isolated, they can also be used for power supply. Alternatively, the coupling element can be made in one piece with the heat sink, for example, as a unitary body of the same heat-conducting plastic.
  • the heat sink is advantageous to detachably connect the heat sink with the coupling element in the lamp housing, because in an exchange of the lamp usually the heat sink can be used. This avoids unnecessary material consumption.
  • the replaced light can be easily reconditioned, for example by opening the case and replacing the LED.
  • the housing is airtight closed.
  • a lamp 1 the housing of the two shells 5 (upper shell) and 3 (lower shell) is composed. Both shells have circumferential congruent flanges which are welded together.
  • the thermal coupling element 10 is inserted into the upper housing shell 5 so that it replaces a part of the wall thereof.
  • At the contact surface 24 of the heat-conducting plastic of the coupling element 10 is mixed with the plastic of the housing shell 5 and tightly welded.
  • the coupling element 10 is penetrated by contact pins 20, which are connected on the inside of the shell 5 with the wiring 18 on the coupling element 10.
  • the wiring 18 is connected to the light emitting diodes 16 and supplies them with power.
  • the coupling element 10 is in thermal contact with the heat sink 12, which is formed on the side facing away from the lamp side to ribs 14.
  • the contact pins 24 are frictionally fixed in the contact sleeves 22, which are drawn here only too much for clarity.
  • the contact sleeves are electrically insulated in the heat sink and connected to the pole of a power source.
  • the luminaire housing can be easily detached from the heat sink by pulling the contact pins 20 out of the sleeves 22.
  • the heat sink can then remain in the lighting arrangement.
  • Non-limiting examples of typical lengths of such lamps are between about 80 and 150 cm with a power consumption of less than 20 to over 150 W.
  • the contact pins 20 are first encapsulated with the thermally conductive plastic to form the coupling element 10. Thereafter, this coupling element is inserted into the mold for the upper housing shell 5 and molded with the plastic provided for this shell. Thereafter, the wiring 18 is connected to the contact pins 20 and the light emitting diodes attached to the wiring 18 and the coupling element 10, for example, soldered. Now, both housing shells 3 and 5 are welded together at the flanges 7 and there is an airtight luminaire housing. This is used with the contact pins 20 in the contact sleeves 22, wherein a thermal contact between the coupling element 10 and the heat sink 12 is formed and the lamp 1 is formed.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)

Abstract

The lamp (1) has multiple light emitting diodes (LEDs) (16) arranged on a board in a hermetically sealed plastic housing, and a coupling element (10) is made of a thermally conductive plastic that is compatible with the plastic of the housing. The thermal coupling element is installed in an area adjacent to a heat sink to dissipate the heat generated by the LEDs. A heat sink (12) is formed in communication with the outside air. The heat-conductive plastic material is provided as a thermoplastic material, which is comprised of thermally conductive filler.

Description

Die vorliegende Erfindung betrifft eine geschlossene LED-Leuchte für die Verwendung im Außenbereich, beispielsweise als Straßenlaterne, oder in Räumen mit aggressiver oder explosionsgefährdeter Atmosphäre. Insbesondere betrifft sie eine solche Leuchte mit einem thermischen Koppelelement aus einem Wärme leitenden Kunststoff, der mit dem Kunststoff des Gehäuses kompatibel ist.The present invention relates to a closed LED luminaire for outdoor use, for example as a street lamp, or in rooms with an aggressive or explosive atmosphere. In particular, it relates to such a lamp with a thermal coupling element made of a heat-conducting plastic, which is compatible with the plastic of the housing.

In den letzten Jahren hat sich infolge des technischen Fortschritts auf dem Gebiet der Licht emittierenden Dioden (LED), der zu sinkenden Preisen und höherer Lichtausbeute geführt hat, deren Anwendungsbereich stark vergrößert. LED finden nun auch Anwendung für feuchtigkeit- und explosionsgeschützte Leuchten. Die Gehäuse solcher Leuchten müssen naturgemäß dicht geschlossen sein, um das Eindringen von Feuchtigkeit und zündfähigen Gasen zu verhindern. Auch bei LED wird nur ein Anteil von etwa 20 bis 30% der aufgenommenen elektrischen Energie in Licht umgewandelt und der Rest fällt als Verlustwärme an. Gegenüber Leuchten mit herkömmlichen Lampen ist die Ableitung dieser Verlustwärme sehr viel schwieriger. Einerseits muss die Temperatur der LED möglichst niedrig gehalten werden, weil sonst der Wirkungsgrad und die Lebensdauer beeinträchtigt werden. Andererseits ermöglichen LED auch eine besonders kleine Bauweise und strahlen so gut wie keine Wärme ab, so dass die Wärmeabfuhr hauptsächlich zunächst durch Wärmeleitung erfolgen muss, insbesondere wenn wegen des geschlossenen Gehäuses eine Kühlfluidströmung nicht möglich ist. Zudem wird als Gehäusematerial für viele Anwendungen Kunststoff bevorzugt, unter anderem weil er leicht ist und eine Schutzisolierung ermöglicht. Kunststoff hat aber nur eine geringe Wärmeleitfähigkeit.In recent years, as a result of the technological progress in the field of light-emitting diodes (LED), which has led to falling prices and higher luminous efficacy, their field of application has greatly increased. LEDs are now also used for moisture and explosion-proof luminaires. The housing of such lights must naturally be tightly closed to prevent the ingress of moisture and flammable gases. Even with LEDs, only a share of about 20 to 30% of the absorbed electrical energy is converted into light and the rest is lost as heat loss. Compared to lighting with conventional lamps, the dissipation of this heat loss is much more difficult. On the one hand, the temperature of the LED must be kept as low as possible, otherwise the efficiency and the lifetime are impaired. On the other hand, LEDs also allow a particularly small design and emit virtually no heat, so that the heat dissipation must be done primarily by heat conduction, especially if due to the closed housing a cooling fluid flow not possible. In addition, as a housing material for many applications plastic is preferred, inter alia because it is lightweight and allows a protective insulation. But plastic has only a low thermal conductivity.

DE 10 2007 055 165 A1 beschreibt einen LED-Scheinwerfer, insbesondere zur Verwendung in Fahrzeugen, mit einem Wärmeleitelement, dass sich von einer in einem Scheinwerfergehäuse befindlichen Wärmequelle zu einem Kühlelement erstreckt, welches zumindest teilweise außenseitig am Scheinwerfergehäuse angeordnet ist. Das Wärmeleitelement ist bevorzugt ein Wärmerohr. DE 10 2007 055 165 A1 describes an LED headlamp, in particular for use in vehicles, with a heat conducting element that extends from a heat source located in a headlight housing to a cooling element, which is at least partially arranged on the outside of the headlight housing. The heat-conducting element is preferably a heat pipe.

DE 10 2006 057 569 A1 offenbart eine Scheinwerferbaugruppe mit integriertem Reflektor und durch das Gehäuse sich erstreckendem Kühlkörper, welche die Wärme der LED durch die Gehäusewand leitet. Hierbei ist für jede LED ein Kühlkörper vorgesehen, so dass der Aufbau kompliziert ist. DE 10 2006 057 569 A1 discloses a headlamp assembly with an integrated reflector and heat sink extending through the housing which conducts the heat of the LED through the housing wall. Here, a heat sink is provided for each LED, so that the structure is complicated.

Das deutsche Gebrauchsmuster DE 20 2006 015 981 U1 beschreibt eine LED-Straßenleuchte mit einer Wärmeableitanordnung. Diese umfasst ein dicht geschlossenes Gehäuse, indem sich die LED befinden, einen mit der Außenluft in Verbindung stehenden Kühlkörper und eine Mehrzahl von Wärmeableitröhrchen, an deren wärmeaufnahmeende die LED angebracht sind, während das Wärmeabgabeende durch ein abgedichtetes Durchgangsloch und im Kühlkörper verläuft. Eine solche Anordnung ist im Aufbau aufwändig. Außerdem hängt die Funktion der Wärmeableitröhrchen von deren Lage ab, was nur beim Einbau in einer nach unten strahlenden Straßenleuchte keine Bedeutung hat.The German utility model DE 20 2006 015 981 U1 describes an LED street lamp with a Wärmeableitanordnung. This includes a sealed housing containing the LED, a heat sink in communication with the outside air, and a plurality of heat sinks to the heat receiving end of which the LEDs are mounted while the heat release end passes through a sealed through hole and in the heat sink. Such an arrangement is complex in construction. In addition, the function of the Wärmeableitröhrchen depends on their location, which has only when installed in a down-beam street lamp is not important.

Die Erfindung stellt sich die Aufgabe, eine LED-Leuchte mit einem geschlossenen Gehäuse zu schaffen, bei der die Wärmeableitung zu einem mit der Außenluft in Verbindung stehenden Kühlkörper auf einfache Weise und unabhängig von der Lage der Leuchte bewirkt wird. Die Leuchte soll außerdem einfach herzustellen und zum leichten Austausch von herkömmlichen oder LED-Leuchten geeignet sein.The invention has as its object to provide an LED lamp with a closed housing, wherein the heat dissipation to a communicating with the outside air heat sink is effected in a simple manner and regardless of the position of the lamp. The luminaire should also be easy to manufacture and suitable for easy replacement of conventional or LED lights.

Diese Aufgabe wird durch eine Leuchte nach dem Hauptanspruch gelöst.This object is achieved by a luminaire according to the main claim.

Die Verwendung von Wärme leitenden Kunststoffen für Kühlkörper in Verbindung mit metallische Bauteilen zur Entwärmung von elektronischen Baugruppen ist an sich bekannt ( DE 10 2007 057 533 A1 ). Solche Kunststoffe umfassen Füllstoffe mit guter Wärmeleitfähigkeit in Form feiner Teilchen in einer Matrix aus Kunststoff. Obwohl die Füllstoffe elektrisch leitfähig sein können, ist der Wärme leitende Kunststoff jedenfalls dann nicht elektrisch leitend, wenn der Anteil des Füllstoffs unter der Perkolationsschwelle liegt.The use of heat-conducting plastics for heat sinks in conjunction with metallic components for cooling electronic assemblies is known per se ( DE 10 2007 057 533 A1 ). Such plastics include fillers with good thermal conductivity in the form of fine particles in a matrix of plastic. Although the fillers may be electrically conductive, the heat-conducting plastic is in any case not electrically conductive when the proportion of the filler is below the percolation threshold.

Erfindungsgemäß ist der Kunststoff des Leuchtengehäuses kompatibel mit dem Wärme leitenden Kunststoff. Damit ist gemeint, dass diese Kunststoffe mindestens in gewissen Grenzen auch im erstarrten Zustand miteinander mischbar und in ihrem thermischen Verhalten so ähnlich sind, dass bei Temperaturänderung an einer Verbindung der beiden Kunststoffe keine Spannungen auftreten, welche diese Verbindung zerstören können. Im Zweifelsfall kann der Fachmann durch geeignete einfache Versuche feststellen, ob Kompatibilität zweier Kunststoffe gegeben ist.According to the invention the plastic of the lamp housing is compatible with the heat-conducting plastic. This means that these plastics are at least to some extent miscible in the solidified state and are so similar in their thermal behavior that when temperature changes to a compound of the two plastics no tensions occur which can destroy this connection. If in doubt, the skilled person can determine by suitable simple tests, whether compatibility of two plastics is given.

Das Gehäuse und auch die Matrix des Wärme leitenden Kunststoffs werden bevorzugt durch thermoplastische Kunststoffe gebildet. Dadurch wird die Herstellung der erfindungsgemäßen Leuchte erleichtert.The housing and also the matrix of the heat-conducting plastic are preferably formed by thermoplastic materials. As a result, the production of the lamp according to the invention is facilitated.

Insbesondere kann das thermische Koppelelement in einer Öffnung der Gehäusewand eingefügt und mit dieser verschweißt werden, wobei die Kunststoffe der beiden Bauteile teilweise miteinander verschmelzen oder mit einem kompatiblen Zusatz verbunden werden. Ein solches Verschweißen kann in bekannter Weise z.B. mit Heißluft oder Ultraschall erfolgen. Ebenso ist es möglich, das Koppelelement als Einsatz in eine Spritzgussform für die Gehäusewand einzusetzen und mit dem Kunststoff der letzteren zu umspritzen. Auch hierbei kann eine gewisse Verschmelzung beider Teile an der Grenzfläche auftreten. Dadurch erhält man eine sehr gute und dichte Verbindung des thermischen Koppelelement mit der Gehäusewand.In particular, the thermal coupling element can be inserted in an opening of the housing wall and welded thereto, wherein the plastics of the two components partially merge together or are connected to a compatible additive. Such welding can be carried out in known manner e.g. done with hot air or ultrasound. It is also possible to use the coupling element as an insert in an injection mold for the housing wall and to overmold with the plastic of the latter. Here, too, a certain fusion of both parts can occur at the interface. This gives a very good and tight connection of the thermal coupling element with the housing wall.

Alternativ kann die das Koppelelement umfassende Gehäuseschale auch in einem Zweikomponentenverfahren spritzgegossen werden, indem beispielsweise die Form zunächst nur das Koppelelement aus dem Wärme leitenden Kunststoff bildet und danach für die Formung der übrigen Gehäuseschale weiter geöffnet wird. Es ist auch möglich, bei geeigneter Abstimmung der Fülldrücke die Materialien für beide Bauteile gleichzeitig in die Form zu spritzen.Alternatively, the housing shell comprising the coupling element can also be injection-molded in a two-component process, for example, by first forming only the coupling element from the heat-conducting plastic and then further opening it for shaping the remaining housing shell. It is also possible to inject the materials for both components at the same time in the mold with a suitable vote of the filling pressures.

Der thermoplastische Kunststoff der Gehäusewand und der Matrix des Wärme leitenden Kunststoffs ist bevorzugt ein Polyolefin wie Polyethylen, Polypropylen, ein Polyamid, ein Polycarbonat, ein Vinylpolymer, Polyethylenterephthalat oder Polybutylenterephthalat. Bei der Auswahl des Gehäusewerkstoffs können optische und ästhetische Anforderungen berücksichtigt werden.The thermoplastic resin of the housing wall and the matrix of the heat-conducting plastic is preferably a polyolefin such as polyethylene, polypropylene, a polyamide, a polycarbonate, a vinyl polymer, polyethylene terephthalate or polybutylene terephthalate. When choosing the housing material, optical and aesthetic requirements can be taken into account.

Der Füllstoff im Wärme leitenden Kunststoff ist bevorzugt Aluminiumoxid, Aluminium, Kupfer, Bornitrid oder Kohlenstoff in Form von Graphit oder Nanoröhrchen. Geeignete Wärme leitende Kunststoffe haben eine Wärmeleitfähigkeit von mehr als 2, bevorzugt etwa 10, besonders bevorzugt mehr als 25 W/mK.The filler in the heat-conducting plastic is preferably aluminum oxide, aluminum, copper, boron nitride or carbon in the form of graphite or nanotubes. Suitable heat conductive Plastics have a thermal conductivity of more than 2, preferably about 10, more preferably more than 25 W / mK.

Das Gehäuse der Leuchte ist bevorzugt aus mindestens zwei Schalen zusammengesetzt, wobei das Koppelelement in die Wand von einer der Schalen eingefügt ist. Bei der bevorzugten Verwendung von zwei Schalen haben diese zweckmäßig kongruente Ränder. Für die Herstellung der Leuchte werden diese Ränder miteinander verbunden, so dass ein dicht geschlossenes Gehäuse entsteht. Selbstverständlich sind vor dem Zusammenbau der Schalen die LED beziehungsweise die mit den LED bestückte Platine auf der Innenseite des Koppelelements anzubringen und gegebenenfalls erforderliche Betriebsgeräte und Stromzuführungen einzubauen.The housing of the lamp is preferably composed of at least two shells, wherein the coupling element is inserted into the wall of one of the shells. In the preferred use of two trays, these suitably have congruent edges. For the manufacture of the lamp, these edges are connected together, so that a tightly closed housing is formed. Of course, prior to assembly of the shells, the LED or the PCB equipped with the LED should be mounted on the inside of the coupling element and any necessary operating devices and power supply lines should be installed.

Bevorzugt werden die beiden Schalen des Gehäuses an den Rändern miteinander verklebt oder verschweißt, beispielsweise mittels Ultraschall. Es ist aber auch möglich, die beiden Gehäuseschalen mittels Dichtungen und Befestigungselementen wie federnde Clips oder Schrauben dicht miteinander zu verbinden.Preferably, the two shells of the housing are glued or welded together at the edges, for example by means of ultrasound. But it is also possible to connect the two housing shells by means of seals and fasteners such as resilient clips or screws tightly together.

Für den Betrieb der LED erforderliche Betriebs- oder Vorschaltgeräte können sowohl innerhalb als auch außerhalb der Leuchte angebracht werden. Sind sie innerhalb des Gehäuses angeordnet, dann kann zu ihrer Entwärmung derselbe, entsprechend vergrößerte Kühlkörper wie für die LED verwendet werden. Es kann auch ein separater Kühlkörper für die Betriebsgeräte im Gehäuse vorhanden sein, der auf gleiche Weise wie jener für die LED in die Gehäusewand eingegliedert sein kann.Operating or ballasts required to operate the LED can be mounted both inside and outside the luminaire. If they are arranged inside the housing, then the same, correspondingly enlarged heat sink as for the LED can be used for their heat dissipation. There may also be a separate heat sink for the operating devices in the housing, which may be incorporated in the same way as that for the LED in the housing wall.

Die LED-Platine wird zweckmäßig mit dem Koppelelement so verbunden, dass ein möglichst guter Wärmeübergang gesichert ist, beispielsweise durch Andruckelemente wie Schrauben mit Federelementen und/oder Verwendung einer Wärmeleitpaste.The LED board is expediently connected to the coupling element so that the best possible heat transfer is secured, for example by pressure elements such as screws with spring elements and / or use of a thermal compound.

Da der Wärme leitende Kunststoff des Koppelelement elektrisch isolierend ist, kann man auf die Verwendung einer separaten Platine für die Montage der LED verzichten. Stattdessen können sowohl die LED selbst als auch die für die Stromversorgung der LED erforderliche Verdrahtung auf dem Koppelelement selbst angebracht werden. Auch die für die Stromversorgung notwendigen Außenanschlüsse können durch das Koppelelement geführt werden. Beispielsweise kann das Koppelelement mit den durchgeführten Außenanschlüsse und den Leiterbahnen auf der Innenfläche durch Einsatzspritzgießen geformt und die LED danach angelötet werden. Dieser letztere Schritt kann auch nach dem Umspritzen des Koppelelement mit der Gehäuseschale erfolgen.Since the heat-conducting plastic of the coupling element is electrically insulating, you can dispense with the use of a separate board for mounting the LED. Instead, both the LED itself and the wiring required for powering the LED may be mounted on the coupling element itself. Also necessary for the power supply external connections can be guided by the coupling element. For example, the coupling element with the external connections made and the printed conductors on the inner surface can be molded by insert molding and the LED subsequently soldered. This latter step can also be done after encapsulation of the coupling element with the housing shell.

Der zur erfindungsgemäßen Leuchte gehörende und die Wärme aus dem Koppelelement aufnehmende und mit der Außenluft in Verbindung stehende Kühlkörper kann aus einem Metall wie Aluminium, Kupfer, Eisen oder seinerseits ebenfalls aus Wärme leitendem Kunststoff bestehen. In diesem letzteren Fall kann der Anteil des Wärme leitenden Füllstoffs sogar über der Perkolationsschwelle liegen, da eine gewisse elektrische Leitfähigkeit des Kühlkörpers im Allgemeinen nicht stört. Die Kühlkörper kann Strukturen zur Vergrößerung der freien Oberfläche, wie Zapfen oder Rippen aufweisen und/oder auch von Luft oder einem anderen Kühlfluid durchströmt sein.Belonging to the lamp according to the invention and the heat from the coupling element receiving and in contact with the outside air heat sink may consist of a metal such as aluminum, copper, iron or in turn also made of heat conductive plastic. In this latter case, the proportion of the heat-conducting filler may even be above the percolation threshold, since a certain electrical conductivity of the heat sink in general does not disturb. The heat sink may have structures for enlarging the free surface, such as pins or ribs and / or be traversed by air or other cooling fluid.

Damit das in die Gehäusewand eingebaute Koppelelement die Wärme aus dem Gehäuse zum mit der Außenluft in Verbindung stehenden Kühlkörper ableiten kann, muss ein geeigneter thermischer Kontakt zwischen beiden Bauteilen bestehen. Dieser lässt sich zum Beispiel herstellen, indem im Koppelelement Gewindebolzen eingebaut sind, welche den Kühlkörper durchdringen und diesen mittels aufgeschraubter Muttern halten. Der Spalt zwischen beiden Bauteilen wird zweckmäßig mit einer Wärmeleitpaste ausgefüllt. Es ist auch möglich, das Leuchtengehäuse mit Zapfen reibschlüssig im Kühlkörper zu befestigen. Wenn man diese Zapfen elektrisch isoliert, können sie auch zur Stromversorgung dienen. Alternativ kann das Koppelelement mit dem Kühlkörper einstückig ausgeführt sein, beispielsweise als einheitlicher Körper aus demselben Wärme leitenden Kunststoff.In order for the coupling element built into the housing wall to be able to dissipate the heat from the housing to the cooling body in communication with the outside air, a suitable thermal contact must exist between the two components. This can be produced for example by threaded bolts are installed in the coupling element, which penetrate the heat sink and this means Keep screwed nuts. The gap between the two components is expediently filled with a thermal grease. It is also possible to fasten the luminaire housing with pins frictionally engaged in the heat sink. If these pins are electrically isolated, they can also be used for power supply. Alternatively, the coupling element can be made in one piece with the heat sink, for example, as a unitary body of the same heat-conducting plastic.

Es ist vorteilhaft, den Kühlkörper lösbar mit dem Koppelelement im Leuchtengehäuse zu verbinden, weil bei einem Austausch der Leuchte in der Regel der Kühlkörper weiter verwendet werden kann. Dadurch wird unnötiger Materialverbrauch vermieden. Die ausgetauschte Leuchte kann leicht aufgearbeitet werden, beispielsweise indem man das Gehäuse öffnet und die LED ersetzt. Bei der besonders bevorzugten Ausführungsform ist das Gehäuse luftdicht geschlossen.It is advantageous to detachably connect the heat sink with the coupling element in the lamp housing, because in an exchange of the lamp usually the heat sink can be used. This avoids unnecessary material consumption. The replaced light can be easily reconditioned, for example by opening the case and replacing the LED. In the most preferred embodiment, the housing is airtight closed.

Die Erfindung wird nun anhand des in Figur 1 im Längs- und Querschnitt (a bzw. b) dargestellten Ausführungsbeispiels näher erläutert.The invention will now be described with reference to the in FIG. 1 in the longitudinal and cross-section (a and b) illustrated embodiment explained.

In der Figur erkennt man eine Leuchte 1, deren Gehäuse aus den beiden Schalen 5 (obere Schale) und 3 (untere Schale) zusammengesetzt ist. Beide Schalen weisen umlaufende kongruente Flansche auf, die miteinander verschweißt sind. Das thermische Koppelelement 10 ist so in die obere Gehäuseschale 5 eingefügt, dass es einen Teil von deren Wand ersetzt. An der Kontaktfläche 24 ist der Wärme leitende Kunststoff des Koppelelement 10 mit dem Kunststoff der Gehäuseschale 5 vermischt und dicht verschweißt. Das Koppelelement 10 wird von Kontaktstiften 20 durchsetzt, die auf der Innenseite der Schale 5 mit der Verdrahtung 18 auf dem Koppelelement 10 verbunden sind. Die Verdrahtung 18 ist mit den Leuchtdioden 16 verbunden und versorgt diese mit Strom. Auf der Außenseite der Schale 5 steht das Koppelelement 10 in thermischem Kontakt mit dem Kühlkörper 12, der auf der von der Leuchte abgewandten Seite zu Rippen 14 geformt ist. Die Kontaktstifte 24 sind reibschlüssig in den Kontakthülsen 22 festgelegt, die hier nur zur Verdeutlichung zu weit gezeichnet sind. Die Kontakthülsen sind im Kühlkörper elektrisch isoliert und mit dem Polen einer Stromquelle verbunden. In diesem Fall kann das Leuchtengehäuse durch Herausziehen der Kontaktstifte 20 aus den Hülsen 22 leicht vom Kühlkörper gelöst werden. Der Kühlkörper kann dann bei der Beleuchtungsanordnung verbleiben. Nicht beschränkende Beispiele für typische Längen solcher Leuchten liegen zwischen etwa 80 und 150 cm bei einer Leistungsaufnahme von weniger als 20 bis über 150 W.In the figure can be seen a lamp 1, the housing of the two shells 5 (upper shell) and 3 (lower shell) is composed. Both shells have circumferential congruent flanges which are welded together. The thermal coupling element 10 is inserted into the upper housing shell 5 so that it replaces a part of the wall thereof. At the contact surface 24 of the heat-conducting plastic of the coupling element 10 is mixed with the plastic of the housing shell 5 and tightly welded. The coupling element 10 is penetrated by contact pins 20, which are connected on the inside of the shell 5 with the wiring 18 on the coupling element 10. The wiring 18 is connected to the light emitting diodes 16 and supplies them with power. On the outside of the shell 5, the coupling element 10 is in thermal contact with the heat sink 12, which is formed on the side facing away from the lamp side to ribs 14. The contact pins 24 are frictionally fixed in the contact sleeves 22, which are drawn here only too much for clarity. The contact sleeves are electrically insulated in the heat sink and connected to the pole of a power source. In this case, the luminaire housing can be easily detached from the heat sink by pulling the contact pins 20 out of the sleeves 22. The heat sink can then remain in the lighting arrangement. Non-limiting examples of typical lengths of such lamps are between about 80 and 150 cm with a power consumption of less than 20 to over 150 W.

Bei der Herstellung der gezeigten Leuchte werden zunächst die Kontaktstifte 20 mit dem wärmeleitenden Kunststoff zur Bildung des Koppelelements 10 umspritzt. Danach wird dieses Koppelelement in die Form für die obere Gehäuseschale 5 eingesetzt und mit dem für diese Schale vorgesehenen Kunststoff umspritzt. Danach wird die Verdrahtung 18 mit den Kontaktstiften 20 verbunden und die Leuchtdioden an der Verdrahtung 18 bzw. am Koppelelement 10 befestigt, beispielsweise angelötet. Nun werden beide Gehäuseschalen 3 und 5 an den Flanschen 7 miteinander verschweißt und es entsteht ein luftdichtes Leuchtengehäuse. Dieses wird mit den Kontaktstiften 20 in die Kontakthülsen 22 eingesetzt, wobei ein thermischer Kontakt zwischen Koppelelement 10 und Kühlkörper 12 entsteht und die Leuchte 1 gebildet wird.In the manufacture of the luminaire shown, the contact pins 20 are first encapsulated with the thermally conductive plastic to form the coupling element 10. Thereafter, this coupling element is inserted into the mold for the upper housing shell 5 and molded with the plastic provided for this shell. Thereafter, the wiring 18 is connected to the contact pins 20 and the light emitting diodes attached to the wiring 18 and the coupling element 10, for example, soldered. Now, both housing shells 3 and 5 are welded together at the flanges 7 and there is an airtight luminaire housing. This is used with the contact pins 20 in the contact sleeves 22, wherein a thermal contact between the coupling element 10 and the heat sink 12 is formed and the lamp 1 is formed.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
Leuchtelamp
33
untere Gehäuseschalelower housing shell
55
obere Gehäuseschaleupper housing shell
77
Flansche mit SchweißnahtFlanges with weld
1010
Koppelelementcoupling element
1212
Kühlkörperheatsink
1414
Rippenribs
1616
Leuchtdioden (LED)Light emitting diodes (LED)
1818
Verdrahtungwiring
2020
Kontaktstiftecontact pins
2222
Kontakthülsencontact sleeves
2424
Kontaktflächecontact area

Claims (10)

Leuchte, insbesondere für den Außenbereich, mit einer Mehrzahl auf einer Platine angeordneter lichtemittierender Dioden (LED) in einem geschlossenen Gehäuse aus Kunststoff, einem mit der Außenluft in Verbindung stehenden Kühlkörper und mindestens einem thermischen Koppelelement aus einem wärmeleitenden Material, welches in den zum Kühlkörper benachbarten Bereich der Gehäusewand eingebaut ist, zum Ableiten der von den LED erzeugten Wärme zum Kühlkörper, dadurch gekennzeichnet, dass das mindestens eine Koppelelement aus einem wärmeleitenden Kunststoff besteht, der mit dem Kunststoff des Gehäuses kompatibel ist.Luminaire, in particular for outdoor use, with a plurality arranged on a board light emitting diodes (LED) in a closed housing made of plastic, a communicating with the outside air heat sink and at least one thermal coupling element made of a thermally conductive material which is adjacent to the heat sink Region of the housing wall is installed, for deriving the heat generated by the LED heat to the heat sink, characterized in that the at least one coupling element consists of a thermally conductive plastic, which is compatible with the plastic of the housing. Leuchte nach Anspruch 1, dadurch gekennzeichnet, dass der wärmeleitende Kunststoff ein thermoplastischer Kunststoff ist, der einen wärmeleitenden Füllstoff umfasst, und dass das Gehäuse aus einem thermoplastischen Kunststoff besteht.Luminaire according to claim 1, characterized in that the thermally conductive plastic is a thermoplastic material which comprises a heat-conductive filler, and that the housing consists of a thermoplastic material. Leuchte nach Anspruch 2, dadurch gekennzeichnet, dass das Koppelelement mit der Gehäusewand verschweißt oder umspritzt ist.Luminaire according to claim 2, characterized in that the coupling element is welded or encapsulated with the housing wall. Leuchte nach Anspruch 2 oder 3, dadurch gekennzeichnet, dass der thermoplastische Kunststoff ein Polyolefin, Polyamid, Polycarbonat, Polyethylenterephthalat oder Polybutylenterephthalat ist.Luminaire according to claim 2 or 3, characterized in that the thermoplastic material is a polyolefin, polyamide, polycarbonate, polyethylene terephthalate or polybutylene terephthalate. Leuchte nach Anspruch 2 bis 4, dadurch gekennzeichnet, dass der wärmeleitende Füllstoff Aluminiumoxid, Aluminium, Kupfer, Bornitrid oder Kohlenstoff in Form von Graphit oder Nanoröhrchen ist.Luminaire according to claim 2 to 4, characterized in that the heat-conductive filler is alumina, aluminum, copper, boron nitride or carbon in the form of graphite or nanotubes. Leuchte nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das Gehäuse aus mindestens zwei Schalen zusammengesetzt ist, wobei das Koppelelement in die Wand von einer der Schalen eingefügt ist.Luminaire according to one of the preceding claims, characterized in that the housing is composed of at least two shells, wherein the coupling element is inserted into the wall of one of the shells. Leuchte nach Anspruch 6, dadurch gekennzeichnet, dass die Schalen zur Bildung des geschlossenen Gehäuses miteinander verklebt oder verschweißt sind.Luminaire according to claim 6, characterized in that the shells are glued or welded together to form the closed housing. Leuchte nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das Koppelelement gleichzeitig die Platine bildet, auf der die LED mit ihrer Verdrahtung angebracht sind.Luminaire according to one of the preceding claims, characterized in that the coupling element simultaneously forms the board on which the LEDs are mounted with their wiring. Leuchte nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das Koppelelement mit dem Kühlkörper einstückig ausgeführt ist.Luminaire according to one of the preceding claims, characterized in that the coupling element is designed in one piece with the heat sink. Leuchte nach einem der vorangehenden Ansprüche 1 bis 8, dadurch gekennzeichnet, dass zum Austausch das Gehäuse mit dem Koppelelement vom Kühlkörper gelöst werden kann.Luminaire according to one of the preceding claims 1 to 8, characterized in that the housing with the coupling element can be detached from the heat sink for replacement.
EP12172129.4A 2011-06-16 2012-06-15 Lighting device with thermal coupling element made of thermally conductive plastic Active EP2535642B1 (en)

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EP2535642B1 (en) 2015-10-28

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