EP4160088A1 - Modular construction of an led light - Google Patents

Abstract

The invention relates to a lamp with at least: a device carrier (2), an LED module (3), a lens element (4), and a reflector (5), which are all designed as separate components and are mechanically connected in the lamp, wherein the LED module (3) rests against the device carrier (2) by a first form fit and the first form fit positions the LED module (3) in a longitudinal and transverse direction on the device carrier (2), the lens element (4) and the reflector (5) engage in one another by a second form fit and the second form fit only aligns the lens element (4) and the reflector (5) with one another, and the LED module (3) is aligned with respect to the reflector (5) by a third form fit, and wherein the reflector (5) is snapped into the equipment carrier (2).

Description

The present invention relates to the modular design of a lamp, in particular an interior lamp for illuminating workplaces, which has a number of separately formed components which are aligned with one another in the lamp.

Luminaires are preferably constructed in a modular manner because this makes it possible to always use the same modules for the design of different luminaires. The components can include, in particular, LED modules, which include one or more LEDs (Light Emitting Diodes, which is understood here to mean any form of semiconductor light source), reflectors and lenses made from different materials and using different manufacturing processes. However, different materials have different coefficients of thermal expansion. During thermal heating, the positioning of the components can therefore shift in relation to one another. However, this shift should have as little influence as possible on the optical system of the luminaire. Furthermore, there is also the problem that the different expansions of the components during operation of the lamp produce noises, which are particularly undesirable for interior lamps in office applications.

Nevertheless, modularity is very important for luminaires for cost design reasons. By using the same modules, many different variants of lights can be made possible with this structure. Such a wealth of variants would result in a much higher investment in tools for luminaires designed in one piece. However, the visible design of the luminaire variants should be as one-piece as possible, i.e. it should not be recognizable that the system is made up of several modules that are always the same. Furthermore, for automatic production, the assembly of the components in the lamp should be as simple as possible and finally, for reasons of sustainability, it is also advantageous if the components of the lamp can be separated from one another again according to type.

The object of the present invention is therefore to provide a modular lamp which is easy to construct and, despite thermal expansion of the module components, prevents optical defects and noise generation during operation of the lamp as far as possible.

The problem is solved by a lamp, in particular an interior lamp for office applications, according to claim 1.

The lamp according to the invention comprises at least one device mount, an LED module, a lens element and a reflector. These components are designed separately and mechanically connected in the lamp. However, the mechanical connection does not include a material connection. This means that the parts can also be separated from one another without being destroyed. A special feature of the lamp according to the invention is the design of the form-fitting connections, which align the individual components in the lamp with one another. A first positive connection between the LED module and the device mount positions the LED module relative to the device mount in a longitudinal and transverse direction of the device mount. The terms lengthwise and crosswise always refer to the expansion of the equipment carrier. However, if the device carrier has a square shape, the terms longitudinal and transverse direction are interchangeable. The lens element and the reflector are aligned with one another with a positive interlocking. This second form-fit provides that the lens element and the reflector engage directly with one another and is particularly helpful since the lens element and the reflector have a great influence on the optical properties of the system. These two components should therefore be aligned with one another as precisely as possible, which is made possible by the interlocking of the two components. Furthermore, a third positive connection is provided between the LED module and the reflector. Since the alignment of the LED module in relation to the reflector also has a major impact on the optical quality of the light, this positive fit is an advantage. Finally, it is provided that the reflector is snapped into the device carrier. This keeps the lamp together as a whole. A direct connection between the LED module or the lens element and the gear tray is therefore no longer necessary.

According to a preferred embodiment, there is no direct form fit between the LED module and the lens element. On the contrary, it is actually an advantage that the lens element can be moved freely in relation to the LED module. The LED module develops heat during operation, which can be transferred to the adjacent components. In order to avoid stresses between the LED module and a lens adjacent to it, it is therefore advantageous if the lens can move relative to the LED module. This does not have a major impact on the optical quality of the luminaire, small tolerances in the position between the lens element and the light source are acceptable in the LED module, because a displacement of an LED in relation to the optical axis of a large-area lens only has a very small effect on the generated light distribution of the lens. Apart from that, the LED module and the lens element are indirectly aligned with each other by the three mold locks mentioned above.

According to a preferred embodiment, the reflector is locked in the device mount in an insertion direction, which exerts a hold-down force on the lens element and/or the LED module in a direction towards the device mount, in order to close the lens element and/or the LED module in the luminaire hold. As a result, the snap-in connection between the reflector and the device mount can also be used to indirectly hold the lens element and the LED module on the device mount without additional components. Since the precise alignment of the lens element and the LED module in relation to the device mount is irrelevant for the optical properties of the light, these components also do not require their own connection to the device mount. The pressing down also makes it possible for the LED module to be pressed flat against the device mount, so that a good thermal connection is formed between the device mount and the LED module. This has the advantage that the device mount can also serve as a heat sink for the LED module, without separate fastening means being necessary in order to firmly connect the LED module directly to the device mount.

According to a further development of the aforementioned embodiment, the reflector exerts the hold-down force only with one or more point supports on the lens element. The point support serves to reduce noise (slip-stick effect) that can occur due to the different thermal expansion between the reflector and the lens element. Both components are aligned with each other by the third form fit. Nevertheless, when thermally heated, the two components can shift against each other in the longitudinal direction. However, such a displacement in a direction perpendicular to a pressing force can lead to the development of noise, because the two surfaces pressed against one another no longer easily slide over one another evenly. Due to the contact pressure, one surface remains on the other surface until the thermal stress is so great that the static friction is overcome and the surfaces then move jerkily against each other. This creates a frictional vibration that is acoustically perceptible and is particularly disruptive, especially in the case of interior lights. In the embodiment with the punctiform contact of the components pressed onto one another, the effect of frictional vibration is prevented because there are no larger surface sections which are pressed onto one another with a pressing force.

According to a preferred embodiment, the reflector has a contact protection which, together with the lens element, prevents an elongated object with a diameter of at least 3 mm from being inserted into the LED module in the area of conductor tracks of the LED module. The contact protection can, for example, on the front sides of the Reflector have a continuous surface, so that no gaps are formed in the lamp that allow access to the electrical conductors in the LED module with a gap of more than 3 mm. This prevents a thin metal object, eg a screwdriver or a piece of wire, from coming into contact with live parts of the lamp if the lamp is not properly maintained. Since the corresponding components of the lamp according to the invention are connected to one another by a form fit anyway, the operational safety of the lamp can be increased without great effort with the additional contact protection. Furthermore, this embodiment also has the advantage that an optically uniform appearance of the lamp is achieved.

According to a preferred embodiment, the reflector is designed as part of a luminaire grid that has inner walls that each surround one of a plurality of light exit openings of the luminaire. At least one LED of the LED module is preferably assigned to a light exit opening. Luminaire grids with reflective inner walls are preferred in interior lighting applications because of the improved protection against glare. However, the inner walls can also be light-absorbing. The modular construction according to the invention can be applied very easily to this type of luminaire, because the luminaire grid, which provides the reflective surfaces of the reflector, can be arranged over the lens element. In this embodiment, the lens element can comprise a plurality of individual lenses, which are each arranged in a light exit opening of the luminaire grid and are held with said form fit. Preferably, however, the individual lenses are also combined in one or more larger, preferably plate-shaped, lens elements, so that the lens element in each case extends over a number of light exit openings of the light grid and is positively connected to it.

According to a preferred embodiment, the first positive fit is formed by a protruding positioning element on the device mount, which engages in the recesses of the LED module, the engagement fixing the LED module relative to the device mount only in the longitudinal and transverse directions. As a result, the LED module is held centrally on the device mount. However, the LED module can be pushed onto the gear tray in the direction that is still free. The free direction of movement preferably corresponds exactly to the direction of insertion of the latching connection between the reflector and the equipment carrier. This fixes the LED module in all directions on the gear tray in connection with the reflector. A direct connection between the reflector and the LED module is not necessary. It is sufficient if the LED module has the Contact pressure of the reflector is held down indirectly by the lens element on the device carrier perpendicular to the transverse and longitudinal directions.

According to a preferred embodiment, the third positive connection is formed by interlocking positioning elements on the LED module and on the reflector, which fix the reflector to one another in relation to the LED module along a transverse direction of the device mount. In this embodiment, the reflector can expand in the longitudinal direction of the device mount relative to the LED module. This prevents thermal stresses in the luminaire, while still keeping the reflector centered with respect to the LED module.

According to a preferred embodiment, the second form fit is formed by a protruding web of the lens element, which engages in a groove of the reflector, the engagement fixing the reflector relative to the lens element only along a transverse direction. This embodiment is particularly preferred in the case of longer reflectors, e.g. Thermal stresses between the lens element and the reflector are prevented in that the reflector can extend in the longitudinal direction of the lens element or of the device mount, the lens element being held centered relative to the reflector transversely to the longitudinal extent of the lamp.

According to a preferred embodiment, the reflector has a plurality of elastic latching lugs on opposite side walls of the reflector for latching the reflector into the device carrier, which latches are latched into a corresponding number of recesses on two opposite sides of the device carrier. It is of particular advantage that the locking lugs are provided on two opposite side walls of the reflector or the device carrier, because this centers the reflector in the device carrier and also the insertion direction of the reflector is perpendicular to the transverse and longitudinal extent of the device carrier in the direction of the lens element and the LED module can take place. In this embodiment, it is therefore very easy to generate a depressing force on the lens element and the LED module by snapping the reflector into place, in order to indirectly hold all other components on the device mount, without a direct non-positive connection between the device mount and the LED module or the lens element is necessary.

Figur 1

zeigt eine perspektivische Ansicht einer Leuchte gemäß einer Ausführungsform.

Figur 2

zeigt eine Seitenansicht der Leuchte in Explosionsdarstellung.

Figur 3

zeigt eine perspektivische Ansicht der Leuchte in vergrößerter Darstellung.

Figur 4

zeigt eine Seitenansicht der Leuchte.

Figur 5

zeigt einen Querschnitt durch die Leuchte.

Figur 6

zeigt einen Querschnitt eines vergrößerten Abschnitts der Leuchte ohne Geräteträger.

Figur 7

zeigt eine Aufsicht auf einen vergrößerten Abschnitt des Reflektors der Leuchte.

Further advantages and characteristics of the present invention will become clear from the following description of a preferred embodiment given in connection with the enclosed figures. The figures show the following:

figure 1

12 shows a perspective view of a lamp according to an embodiment.

figure 2

shows a side view of the lamp in an exploded view.

figure 3

shows a perspective view of the lamp in an enlarged representation.

figure 4

shows a side view of the lamp.

figure 5

shows a cross section through the lamp.

figure 6

shows a cross-section of an enlarged portion of the lamp without gear tray.

figure 7

shows a plan view of an enlarged portion of the reflector of the lamp.

The lamp in the illustrated embodiment comprises a device mount 2, in which an LED module 3, a lens element 4 and a reflector 5, which is designed as a lamp grid, are arranged. The equipment carrier 2 has an approximately U-shaped cross section perpendicular to a longitudinal extension. The equipment carrier is preferably formed from sheet metal. The LED module 3 rests flat on the inside of the bottom of the U-shaped device mount 2 . The LED module 3 includes a printed circuit board on which a number of LEDs are arranged in a row and electrically contacted. The LED module 3 is simply inserted into the device carrier from below and is held on the floor of the device carrier 2 by being pressed down by the reflector 5 and the lens element 4 . As for example in the figure 1 shown, the reflector 5 is inserted into the device carrier and snapped into recesses 21 in the side walls of the U-shaped device carrier 2 with locking lugs 54 on the side walls of the reflector 5 . Reflector 5 is snapped into place by a movement perpendicular to the flat extension of LED module 3 in the direction of the bottom of device mount 2. Before reflector 5 is snapped into device mount 2, lens element 4 is still inserted into reflector 5. Through this the reflector 5 presses with the lens element 4 onto the LED module 3 and thereby holds all the components of the light in the gear tray 2.

The LED module 3 is positioned on the device mount 2 . For this purpose, recesses 30 are provided on the long sides of the LED module, which engage in corresponding projections 20 on the equipment carrier, such as in figure 5 shown. The interlocking of the positioning elements 20 with the recesses 30 fixes the LED module in the longitudinal direction and in the transverse direction with respect to the equipment carrier. However, the LED module is merely inserted into the equipment carrier and is not directly connected to it perpendicularly to the transverse and longitudinal direction, but only held by the reflector or the lens element 4 . The interlocking of the positioning elements 20 with the recesses 30 is also referred to as the first positive connection in this application.

The lens element 4 has a positioning element in the form of a web 41 and the reflector 5 has a positioning element in the form of a groove-shaped depression 53 . As on the front of the lamp in the figure figure 3 As can be seen, the lens element 4 engages with the web 41 in the groove 53 of the reflector 5 . As a result, the lens element is fixed in the transverse direction to the reflector. The form fit between the web 41 and the groove 53 is also referred to as the second form fit in this application.

For the alignment of the LED module 3 to the reflector 5, the reflector has positioning elements 51 which engage in recesses 32 of the LED module 3, as shown in FIG figure 5 shown. This form fit between the recess 32 on the LED module 3 and the positioning element 51 on the reflector 5 is also referred to as the third form fit in this application.

Finally, to mount the lamp, the reflector 5 with the lens element 4 is snapped into the device carrier 2 and clamps the LED module 3 on the floor of the device carrier 2 .

The center mounts 31, 54, 52 and 40 are used to position the components in the center. In this way, the longitudinal expansion of the different components flows outwards. The outer mounts 32 and 51 have sufficient clearance to prevent contact even during thermal expansion.

Referring to the figure 6 It is also shown how the reflector 5 is designed in order to provide the force for holding down the lens element 4 and the LED module 3. The In the area of two opposite edges, reflector 5 has almost punctiform elevations 56, which form the contact with the underlying component. Due to the fact that only punctiform supports are formed in the direction of the hold-down force, no flat sections are pressed against one another. This is used to reduce noise (slip-stick effect) that could result from the heating of components lying flat on one another. The small contact surface ensures that the slip-stick effect is reduced as much as possible when the snap-in hooks 54 are snapped into the recesses 21 of the equipment carrier.

Furthermore, in the illustrated embodiment, a touch guard 55 is also provided on the reflector 5, which completely fills the area up to the LED module 3 on one end face of the reflector, as shown in FIG figure 4 shown. In this way, the LED module 3 cannot be touched by a narrow object, such as a screwdriver, since it is completely enclosed. However, the contact protection is only necessary in the area of the conductor track of the LED module 3 and if no conductor track is provided on the end face of the LED module 3, the end face of the LED module 3 can also protrude.

The lamp described above is shown in an elongated variant, the reflector 5 being shown as a single row of lamp grids, each enclosing a small light-emitting area. In other embodiments, however, the lamp can also be made wider. For example, two or more grids can be provided side by side in the transverse direction to the longitudinal extension of the lamp. In other embodiments, the lamp can also be designed with a square cross section. In this case, the longitudinal and transverse dimensions are the same.

The equipment carrier 2 can be mounted in a housing according to the embodiment of the lamp. For this purpose, for example, fastening springs 6 are provided on the outer side of the equipment carrier 2, which can be snapped into recesses in a housing (not shown in the figures). For example, several device mounts can be snapped into place one behind the other or next to one another in the housing in order to build up modular lights with different longitudinal and transverse dimensions.

REFERENCE LIST

2

equipment carrier

3

LED module

30

Positioning to the device carrier

31

Positioning transversely and longitudinally

32

positioning across

4

lens element

40

Positioning lengthwise/crosswise

41

Cross bar for positioning

5

reflector

51

positioning across

52

Positioning crosswise/longitudinally

53

Groove for positioning across

54

detent

55

touch protection

56

point support

6

Fastening spring on the device carrier

Claims (10)

Light up with at least: - a device carrier (2), - an LED module (3), - a lens element (4), and - a reflector (5), which are all designed as separate components and are mechanically connected in the luminaire, the LED module (3) being in contact with the equipment carrier (2) by means of a first form fit and the first form fit positioning the LED module on the equipment carrier (2) in a longitudinal and transverse direction, wherein the lens element (3) and the reflector (5) engage in one another by a second form fit and the second form fit only aligns the lens element (3) and the reflector (5) with one another, and the LED module (3) is aligned with respect to the reflector (5) by a third positive fit, and wherein the reflector (3) is snapped into the equipment carrier (2). Luminaire according to Claim 1, in which no direct form fit is formed between the LED module (3) and the lens element (4). Luminaire according to one of the preceding claims, wherein the reflector (5) is latched into the device mount (2) in an insertion direction which exerts a hold-down force on the lens element (4) and/or the LED module (3) in a direction towards the device mount (2) exerts to keep the lens element (4) and / or the LED module (3) in the lamp. Luminaire according to Claim 5, in which the reflector (5) exerts the hold-down force only with one or more point supports (56) on the lens element (4). Luminaire according to one of the preceding claims, wherein the reflector (5) has a contact protection (55) which, together with the lens element (3), prevents the introduction of an elongated object with a diameter of at least 3 mm to the LED module at least in the area of conductor tracks of the LED module is prevented. Luminaire according to one of the preceding claims, in which the reflector (5) is designed as part of a luminaire grid which has inner walls which each surround one of a plurality of light exit openings in the luminaire, with at least one LED of the LED module (3) preferably being in each case one of the light exit openings assigned. Luminaire according to one of the preceding claims, wherein the first positive connection is formed by a protruding positioning element (20) on the equipment carrier (2), which engages in a recess (30) of the LED module (3), the engagement affecting the LED Module (3) relative to the equipment carrier (2) only in the longitudinal and transverse directions. Luminaire according to one of the preceding claims, wherein the third form fit is formed by interlocking positioning elements (32, 51) on the LED module (3) and the reflector (5), which position the reflector (5) relative to the LED module (3). set to each other along a transverse direction of the device carrier (2). Luminaire according to one of the preceding claims, wherein the second form fit is formed by a protruding web (41) of the lens element (4) which engages in a groove (53) of the reflector (5), the engagement facing the reflector (5). the lens element (4) only along a transverse direction. Luminaire according to one of the preceding claims, in which the reflector (5) has a plurality of elastic latching lugs (54) on opposite side walls of the reflector (5) for latching the reflector (5) into the equipment carrier (2), which lugs fit into a corresponding number of recesses ( 21) snapped into place on two opposite sides of the equipment carrier (2).

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