EP4702278A1 - Luminaire for outdoor use, method of its manufacture and use of a luminaire in a paved surface - Google Patents

Luminaire for outdoor use, method of its manufacture and use of a luminaire in a paved surface

Info

Publication number
EP4702278A1
EP4702278A1 EP24721679.9A EP24721679A EP4702278A1 EP 4702278 A1 EP4702278 A1 EP 4702278A1 EP 24721679 A EP24721679 A EP 24721679A EP 4702278 A1 EP4702278 A1 EP 4702278A1
Authority
EP
European Patent Office
Prior art keywords
profile
luminaire
polyurethane resin
resin
side walls
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.)
Pending
Application number
EP24721679.9A
Other languages
German (de)
French (fr)
Inventor
Piet DEVRIESE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ledtechnic BV
Original Assignee
Ledtechnic BV
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Ledtechnic BV filed Critical Ledtechnic BV
Publication of EP4702278A1 publication Critical patent/EP4702278A1/en
Pending legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S4/00—Lighting devices or systems using a string or strip of light sources
    • F21S4/20—Lighting devices or systems using a string or strip of light sources with light sources held by or within elongate supports
    • F21S4/28—Lighting devices or systems using a string or strip of light sources with light sources held by or within elongate supports rigid, e.g. LED bars
    • 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
    • F21V15/013—Housings, e.g. material or assembling of housing parts the housing being an extrusion
    • 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
    • F21V31/00—Gas-tight or water-tight arrangements
    • F21V31/005—Sealing arrangements 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
    • F21V31/00—Gas-tight or water-tight arrangements
    • F21V31/04—Provision of filling media
    • 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
    • F21V7/00—Reflectors for light sources
    • F21V7/22—Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors
    • F21V7/28—Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors characterised by coatings
    • 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
    • F21W2111/00—Use or application of lighting devices or systems for signalling, marking or indicating, not provided for in codes F21W2102/00 – F21W2107/00
    • F21W2111/02—Use or application of lighting devices or systems for signalling, marking or indicating, not provided for in codes F21W2102/00 – F21W2107/00 for roads, paths or the like
    • 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
    • F21Y2103/00—Elongate light sources, e.g. fluorescent tubes
    • F21Y2103/10—Elongate light sources, e.g. fluorescent tubes comprising a linear array of point-like light-generating elements
    • 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]

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

Abstract

The present invention relates to a luminaire for outdoor use, comprising a longitudinally extending profile and a plurality of light-emitting elements, wherein the profile comprises a bottom and two side walls extending thereon, wherein the plurality of light-emitting elements are placed in a space defined by the bottom and the side walls of the profile and wherein the mentioned space is completely filled with a resin for watertightness, wherein at least the bottom and the side walls in the mentioned space are blasted, wherein at least a reflective powder coating is applied to the blasted bottom and side walls for reflecting light and adhering the resin. The invention also relates to a method for manufacturing a luminaire for outdoor use and a use of a luminaire for outdoor lighting integrated into a paved surface.

Description

LUMINAIRE FOR OUTDOOR USE, METHOD OF ITS MANUFACTURE AND USE OF A LUMINAIRE IN A PAVED SURFACE
TECHNICAL FIELD
The invention relates to a luminaire for outdoor use, more specifically a watertight luminaire with high light output. The invention also relates to a method for manufacturing it and to a use of the luminaire for outdoor lighting integrated into a paved surface.
PRIOR ART
Luminaires for outdoor use are known from the prior art. In recent years, profiles that extend in a longitudinal direction have been used more often for architectural purposes. These profiles are then placed as outdoor lighting along a path, bridge, facade, etc. An important requirement for luminaires is watertightness. Water seeping into a luminaire causes a leakage current, ultimately resulting in a power outage. It is also possible that water will irreparably damage a luminaire after a short or longer period of time. A traditional luminaire is therefore sealed using, for example, rubber seals. Due to aging, these rubber seals are no longer watertight, causing water to eventually seep into the luminaire.
Another approach is to completely fill the luminaire with a resin. Water ingress is therefore avoided because there is simply no room for the water in the luminaire. A disadvantage of such luminaires is that a light-emitting element cannot be replaced due to the presence of the resin. By using an LED as a light-emitting element, a long lifespan can still be achieved for the luminaire.
An example of such a luminaire is known from CA2726875 (CA '875). CA '875 describes, among other things, an embodiment of a luminaire wherein a printed circuit board with SMD LEDs thereon is placed in an aluminum profile. A resin has been applied over the SMD LEDs to protect the SMD LEDs against moisture. Such a luminaire has the disadvantage that due to a different coefficient of expansion of the resin, the printed circuit board and the aluminum profile, in case of large temperature differences the resin comes loose from the printed circuit board and the aluminum profile and ultimately moisture does penetrate into the luminaire, causing the luminaire to malfunction. Another disadvantage when using a resin is that volatile organic compounds (VOCs) cannot escape, which, for example, damages the silicone lens of the LEDs, resulting in reduced light output. The volatile organic compounds could possibly result in defects.
Another luminaire is known from US6354714 (US '714). This luminaire comprises a printed circuit board with LEDs placed in a profile. The profile is filled with a resin. The upper portion of the housing is covered with a reflective coating or tape. The luminaire of US '714 has similar disadvantages as the one disclosed in CA '875.
The present invention aims to solve at least some of the above problems or drawbacks.
SUMMARY OF THE INVENTION
In a first aspect, the present invention relates to a luminaire according to claim 1.
Such a luminaire is advantageous because a texture in the reflective powder coating ensures very good adhesion of the resin to the reflective powder coating. Because the reflective powder coating has been applied to both the bottom and the side walls, there is good adhesion to the resin over a large surface area, allowing greater forces to be absorbed. By blasting the bottom and side walls, texture has also been applied to the profile, so that the reflective powder coating adheres very strongly to the profile. Even in extreme temperature variations between -30°C and +60°C, the profile, reflective powder coating and resin remain bonded together, keeping the luminaire watertight. An additional advantage of blasting the profile is that the profile does not need to be chemically pretreated to ensure good adhesion of the reflective powder coating to the profile. This means there is one less source of volatile organic compounds that could potentially cause problems and defects. The reflective powder coating is also advantageous for a higher light output by reflecting light incident on the bottom and side walls.
Preferred embodiments of the device are set out in claims 2-9.
A specific preferred form concerns a luminaire according to claim 2.
The reflective powder coating has a gloss at 60° of at least 55% and at most 85%. This is possible because the reflective powder coating has a fine texture, which causes at least diffuse reflection. The fine texture ensures very good adhesion to the resin. By combining specular reflection with diffuse reflection, a very high reflection of the emitted light, at least reflectivity class A, is still achieved. The reflective powder coating therefore ensures both good adhesion of the resin and an increased light output.
In a second aspect, the present invention relates to a method according to claim 11.
This method has the advantage, among other things, that by blasting at least the bottom and side walls of the profile and by applying the reflective powder coating, the resin and the profile are very well bonded to each other, resulting in a luminaire that remains watertight even with very large temperature fluctuations between -30°C and +60°C. Additionally advantageous is that blasting is a relatively simple technique that is very suitable for treating a profile. It is particularly advantageous that blasting makes it unnecessary to chemically pre-treat the profile, resulting in fewer volatile organic components that can damage the light-emitting elements or lead to defects. It is also advantageous that the reflective coating leads to both an increased light output and better adhesion of profile and resin.
Preferred embodiments of the method are described in dependent claims 12-14.
In a third aspect, the present invention relates to a use according to claim 15.
This use results in an outdoor light that remains watertight even at very high stresses on the luminaire, due to both the different expansion and contraction with temperature fluctuations of the profile, the resin and the paved surface, and therefore has a long service life. By completely filling the profile with resin, the luminaire can also withstand pressure loads from a vehicle, for example, allowing the luminaire to also be integrated into a street surface.
DESCRIPTION OF THE FIGURES
Figure 1 shows a perspective view of a luminaire according to an embodiment of the present invention.
Figure 2 shows an exploded side view of a luminaire according to an embodiment of the present invention. Figure 3 shows a cross-section of a luminaire according to an embodiment of the present invention.
Figure 4 shows a longitudinal section of a luminaire according to an embodiment of the present invention.
Figure 5 shows a cross-section of a luminaire according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION
Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meanings as commonly understood by a person skilled in the art to which the invention pertains. For a better understanding of the description of the invention, the following terms are explained explicitly.
In this document, "a" and "the" refer to both the singular and the plural, unless the context presupposes otherwise. For example, "a segment" means one or more segments.
The terms "comprise," "comprising," "consist of," "consisting of," "provided with," "include," "including," "contain," "containing," are synonyms and are inclusive or open terms that indicate the presence of what follows, and which do not exclude or prevent the presence of other components, characteristics, elements, members, steps, as known from or disclosed in the prior art.
Quoting numeric intervals by the endpoints includes all integers, fractions, and/or real numbers between the endpoints, including those endpoints.
In the context of this document, Shore A and Shore D hardness are defined according to ASTM D2240-15:2021.
In the context of this document, extending substantially perpendicular to a plane, for example a wall or bottom of a profile, means that an angle between a direction in which something extends relative to the plane and the plane is 90° ± 15°, preferably 90° ± 10°, more preferably 90° ± 5° and even more preferably 90° ± 3°. In the context of this document, an LED is a light emitting diode and LEDs are lightemitting diodes.
In the context of this document, a paved surface is an outdoor surface used by persons and/or vehicles. Non-limiting examples of paved surfaces are streets, sidewalks, terraces, parking lots, etc.
In the context of this document, blasting is a surface treatment using a combination of air and a blasting medium.
In a first aspect, the invention concerns a luminaire for outdoor use.
The luminaire comprises a profile extending in a longitudinal direction. The profile is preferably an extruded profile. The profile is preferably a plastic or a metal profile, more preferably a metal profile. Examples of suitable metals are aluminum and stainless steel (SS). Most preferably, the profile is an aluminum profile. The profile comprises a bottom and two side walls extending thereon. Preferably, the side walls extend substantially perpendicular to the bottom of the profile. In that case, the side walls and the bottom form a profile with a U-shaped cross-section. Preferably, the side walls have equal dimensions.
The luminaire comprises a plurality of light-emitting elements. The plurality of lightemitting elements are placed in a space defined by the bottom and the side walls of the profile. The plurality of light-emitting elements are preferably placed in the said space along the longitudinal direction. The light-emitting elements are positioned to emit light during operation through an opening between the side walls and opposite the bottom. Preferably, the plurality of light-emitting elements are distributed evenly along the longitudinal direction in the said space. This is advantageous for a uniform light emission. The light-emitting elements are preferably LEDs. The LEDs can be placed as individual light-emitting elements in the mentioned space. Preferably, the LEDs are placed on at least one flexible or rigid printed circuit board.
The said space defined by the bottom and the side walls of the profile is filled with a resin for watertightness. Preferably, the mentioned space is completely filled with a resin. The resin is preferably a synthetic resin. The resin is transparent or translucent. According to a preferred embodiment, at least the bottom and the side walls in said space defined by the bottom and the side walls of the profile are blasted. Preferably, only the bottom and side walls in the said space defined by the bottom and the side walls of the profile are blasted. This is advantageous because it does not change an appearance of the profile outside the said space. For the blasting of a metal profile, such as aluminum or stainless steel, glass bead is preferably used. The glass beads preferably have a grain size between 200 pm and 300 pm. For the blasting of a plastic profile, a plastic blasting medium is preferably used. The blasting is beneficial for an improved adhesion of a reflective coating or resin to the profile, ensuring that the reflective coating or resin remains bonded to the profile during temperature fluctuations. This is particularly advantageous in a luminaire for outdoor use because even with different coefficients of expansion for the profile and the resin, the resin does not detach from the profile and the luminaire remains watertight.
According to a further embodiment, a reflective powder coating is applied at least on the blasted bottom and side walls in said space for reflecting light and adhering the resin.
Such a luminaire is advantageous because a texture in the reflective powder coating ensures very good adhesion of the resin to the reflective powder coating. Because the reflective powder coating has been applied to both the bottom and the side walls of the mentioned space, there is good adhesion with the resin over a large surface area, allowing for greater forces to be absorbed. By blasting the bottom and side walls, texture has also been applied to the profile, so that the reflective powder coating adheres very strongly to the profile. Even in extreme temperature variations between -30°C and +60°C, the profile, reflective powder coating and resin remain bonded together, keeping the luminaire watertight. An additional advantage of blasting the profile is that the profile does not need to be chemically pretreated to ensure good adhesion of the reflective powder coating to the profile. The profile is preferably not chemically pretreated. This means there is one less source of volatile organic compounds that could potentially cause problems and defects. The reflective powder coating is also advantageous for a higher light output by reflecting light incident on the bottom and side walls.
According to a preferred embodiment, the reflective powder coating has a gloss at 60° of at least 55% and at most 85% according to ISO 2813:2015. Preferably, the powder coating has a gloss at 60° of at least 60% and at most 80%. A gloss of at least 55% and at most 85% is possible because the reflective powder coating has a fine texture, causing at least diffuse reflection to occur. Due to the fine texture of the reflective powder coating, there is very good adhesion with the resin.
The reflective powder coating meets at least reflectivity class A according to EN 16268:2013, preferably at least reflectivity class A+. Reflectivity class A means that between 93.0 and 96.9% of the light incident on the reflective powder coating is reflected. For reflectivity class A+, this is 97.0% to 100.0%. By combining specular reflection with diffuse reflection, a very high reflection of the emitted light is still achieved. The reflective powder coating therefore ensures both good adhesion of the resin and an increased light output.
According to an embodiment, the reflective powder coating has a thickness of at least 100 pm. Preferably, the reflective powder coating has a thickness of at most 200 pm, more preferably at most 165 pm, even more preferably at most 130 pm. Such thickness ensures a very high reflection of light incident on the reflective powder coating, while a thicker layer no longer contributes to a higher reflection. A layer of such thickness can be applied electrostatically. A thicker layer of reflective powder coating may potentially flake off, which is negative for the good adhesion of the resin to the reflective powder coating and ultimately the watertightness of the luminaire.
According to a preferred embodiment, the reflective powder coating has an adhesion of 5 according to the ASTM D3359-23 standard. An adhesion of 5 means that when scratching the reflective powder coating, no reflective powder coating comes off the profile after a strip of tape has been pressed onto the reflective powder and then pulled off. An adhesion of 5 corresponds to very good adhesion of the reflective powder coating to the profile, which is particularly beneficial for ensuring the watertightness of the luminaire during temperature fluctuations.
According to a preferred embodiment, the reflective powder coating is a polyester- based powder coating. Polyester powder coatings are advantageous due to their high light reflection. As a result, these powder coatings are very suitable for achieving a very high reflectivity class in combination with a fine texture. In addition, polyester powder coatings are resistant to heat and UV radiation, such as sunlight, which is very beneficial in outdoor applications. According to an embodiment, the light-emitting elements are LEDs, where the LEDs are placed on at least one flexible or rigid printed circuit board. The at least one flexible or rigid printed circuit board is adhered or screwed to the bottom of the profile. This embodiment is advantageous for placing the at least one flexible or rigid printed circuit board in the space defined by the bottom and the side walls of the profile before the profile is filled with the resin.
According to a preferred embodiment, the light-emitting elements are LEDs, wherein the LEDs are placed on at least one rigid printed circuit board. The at least one rigid printed circuit board is placed at a distance from the bottom in the profile. Preferably, the at least one rigid printed circuit board is placed in the space defined by the bottom and the side walls of the profile using spacers. This embodiment is advantageous because the LEDs are surrounded by resin all around, which is very advantageous for the watertightness of the luminaire. The LEDs are held in place by the resin in the mentioned space. When the rigid printed circuit board is directly placed on the bottom of the profile, there is a chance of water ingress between the rigid printed circuit board and the bottom of the profile, especially when there are openings in the bottom of the profile, for example, for cable entry. Additionally advantageous is that no screws are required, which can, for example, cause holes in the bottom of the profile, or adhesives that can release volatile organic components that can damage the LEDs or lead to defects.
According to a preferred embodiment, the resin is a polyurethane resin. Polyurethane resin is very strong and can withstand heavy loads very well. It is resistant to shocks and abrasion, making it suitable for integration into a paved surface, such as a street, sidewalk, driveway, terrace, footpath, etc. Polyurethane resin is easy to process. Polyurethane resin has low heat development during curing, which is advantageous to prevent damage to the light-emitting elements during curing.
According to a further embodiment, the said space defined by the bottom and the side walls of the profile is filled with a first polyurethane resin and with a second polyurethane resin.
The first polyurethane resin has a Shore A hardness of at most 85, preferably at most 80, and more preferably at most 75. Preferably, the first polyurethane resin has a Shore A hardness of at least 45, more preferably at least 55, and even more preferably at least 65. Preferably, the polyurethane resin is formed by mixing a polyol blend with a hydrophilic polyisocyanate, preferably a water-dispersible polyisocyanate based on hexamethylene diisocyanate (HDI). A hydrophilic polyisocyanate is advantageous as a crosslinker. Preferably, the polyol blend has a density at 20°C of at least 1050 kg/m3 and at most 1090 kg/m3. Preferably, the polyol blend has a viscosity at 20°C of at least 950 mPas and at most 1010 mPas. Optionally, a flexibilizing agent is also added when forming the polyurethane resin.
The second polyurethane resin has a Shore D hardness of at least 60, preferably at least 65. Preferably, the second polyurethane resin has a Shore D hardness of at most 85, more preferably at most 80, and even more preferably at most 75. Preferably, the polyurethane resin is formed by mixing a polyol blend with a hydrophilic polyisocyanate, preferably a water-dispersible polyisocyanate based on hexamethylene diisocyanate (HDI). Preferably, the polyol blend has a density at 20°C of at least 1080 kg/m3 and at most 1120 kg/m3. Preferably, the polyol blend has a viscosity at 20°C of at least 3900 mPas and at most 4200 mPas. Preferably, the polyurethane resin is free of flexibilizing agent.
The first polyurethane resin covers the plurality of light-emitting elements. The second polyurethane resin covers the first polyurethane resin. The first polyurethane resin is softer and more flexible than the second polyurethane resin. This is advantageous because with large temperature fluctuations, the luminaire can deform significantly. In a direction transverse to the longitudinal direction of the profile, over a distance of two meters the profile can curl up to a few centimeters. This creates large stresses between the profile and the polyurethane resin. Due to the fact that the first polyurethane resin covering the light-emitting elements is softer and more flexible, the high stresses are only limitedly transferred to the light-emitting elements, which is advantageous for avoiding damage to the light-emitting elements. This is particularly advantageous in combination with a previously described embodiment wherein the light-emitting elements are LEDs on at least one rigid printed circuit board, wherein the at least one rigid printed circuit board is placed at a distance from the bottom in the profile. Here, the at least one rigid printed circuit board is not screwed or glued to the bottom of the profile using glue or screws, so that less stresses are transferred to the light-emitting elements when the profile deforms. The second polyurethane resin is much harder than the first polyurethane resin and forms a visible and accessible surface of the luminaire. The second polyurethane resin is much more resistant to scratches, stress, and impact, forming a sturdy outer surface of the luminaire and protecting the light-emitting elements from external mechanical stress. The second polyurethane resin remains intact under load from people and even vehicles, ensuring the watertightness of the luminaire is maintained. As a result, the luminaire is very suitable for integration into paved surfaces. Because the first polyurethane resin and the second polyurethane resin have a fairly similar composition, the first polyurethane resin and the second polyurethane resin are very well bonded to each other, which is also advantageous to ensure the watertightness of the luminaire.
According to a preferred embodiment, the profile comprises two additional guide walls. The two additional guide walls extend from the bottom of the profile between the two side walls. Preferably, the guide walls extend substantially perpendicular to the bottom of the profile. A guide wall has a lower height than a side wall. The height is measured in a direction transverse to the bottom of the profile. This means that the height of both guide walls is lower than the height of a lowest side wall. Preferably, both guide walls have an equal height and both side walls have an equal height, where the height of the guide walls is lower than the height of the side walls. Preferably, a guide wall has a height that is at least 20% lower than the height of the side walls.
The guide walls are advantageous for the correct positioning and guiding of the lightemitting elements, particularly when using LEDs placed on a rigid or flexible printed circuit board. This embodiment is particularly advantageous with a previously described embodiment with a first polyurethane resin and a second polyurethane resin. The first polyurethane resin is then used to fill a space defined by the bottom and the guide walls of the profile, and the second polyurethane resin to fill a remaining part of the space defined by the side walls and the bottom of the profile. This is particularly advantageous to maintain the watertightness of the luminaire in an exceptional situation where the first polyurethane resin and the second polyurethane resin do become separated. The second polyurethane resin then still forms a watertight shell around the light-emitting elements.
According to a preferred embodiment, the side walls of the profile comprise at a free end an inwardly directed protrusion. With inwardly directed is meant that a free end of the protrusion is directed straight or at an angle towards an opposite side wall. The protrusion is preferably an integral part of the side wall. The protrusions are beneficial for transferring stresses between the resin and the reflective powder coating on the side walls. When the profile curls due to temperature fluctuations, the protrusions essentially press the resin into the space defined by the bottom and the side walls of the profile, reducing shear forces between the resin and the reflective powder coating.
According to a preferred embodiment, the profile comprises at least one opening in the bottom. The resin fills the opening completely. Preferably, there is at least one opening per meter length of the profile. This embodiment is advantageous for evacuating volatile organic compounds from the luminaire. The resin and the at least one opening in the bottom form a pathway along which the volatile organic compounds can migrate. The at least one opening is preferably free of wiring. Preferably, the profile includes specific openings for the passage of cables. This embodiment is particularly advantageous in combination with a previously described embodiment with a first polyurethane resin and a second polyurethane resin. The softer first polyurethane resin has a more open structure than the second polyurethane resin, through which volatile organic compounds can migrate. The at least one opening is therefore preferably completely filled by the first polyurethane resin. In combination with a previously described embodiment with guide walls, the at least one opening is preferably arranged between the two guide walls in the bottom.
According to a preferred embodiment, the resin extends longitudinally to the ends of the luminaire. At the ends of the luminaire, no end walls are present at least at an upper side of the luminaire. With the upper side of the luminaire, a side of the luminaire is meant that lies between the side walls and opposite the bottom of the profile. If the profile comprises end walls, then the resin extends above the end walls, as described in a later embodiment. If the profile does not comprise end walls, the resin extends longitudinally to the end of the bottom and the side walls. This embodiment is advantageous for assembling a long luminaire using multiple profiles placed next to each other in the longitudinal direction, wherein there is no clearly visible interruption of the resin at the upper side of the luminaire, creating an apparently continuous light-emitting surface.
In combination with a previously described embodiment in which the said space defined by the bottom and the side walls of the profile is filled with a first polyurethane resin and with a second polyurethane resin, the first polyurethane resin preferably extends in the longitudinal direction beyond the light-emitting elements, but not to the ends of the luminaire. The second polyurethane resin extends in the longitudinal direction preferably to the ends of the luminaire and therefore shields the first polyurethane resin in the longitudinal direction. This is advantageous because the softer first polyurethane resin is thereby protected at the ends of the luminaire from mechanical influences by the harder second polyurethane resin. The applicant also noted that this is particularly advantageous for a very good watertightness of the luminaire.
According to an embodiment, the resin extends in a direction transverse to the bottom of the profile beyond the side walls. Preferably, the resin extends in a direction transverse to the longitudinal direction of the profile and parallel to the bottom up to above the side walls. If the profile includes end walls, then the resin preferably extends along the length of the profile to above the end walls. With end walls, walls are meant at the ends of the profile, which close off the profile in the longitudinal direction. This embodiment is advantageous when integrating the luminaire into a surface, such as a paved surface, a wall surface, etc., when placing luminaires next to each other according to this embodiment, to create a continuous light-emitting surface that is not interrupted by side walls and any end walls.
According to an embodiment, the profile comprises two channel walls that extend on the bottom of the profile. The channel walls preferably extend substantially perpendicular to the bottom of the profile. In that case, the channel walls and the bottom form a U-shape in cross-section. Preferably, the channel walls have equal dimensions. The channel walls are located on a different side of the bottom of the profile than the side walls. This means that the channel walls and the side walls extend in opposite directions on the bottom of the profile. The channel walls are advantageous for forming a channel on an underside of the luminaire. Cables can be routed in this channel to connect luminaires with each other and with the electrical network. Specific openings for routing electrical cables to the light-emitting elements therefore preferably emerge in this channel. Preferably, the at least one opening filled with resin, as in a previously described embodiment, also emerge in this channel, so that volatile organic compounds can be discharged via the channel.
According to an embodiment, the profile is curved in a plane parallel to the bottom. This embodiment is advantageous for forming composite luminaires that form a curved line in a surface. In a second aspect, the invention relates to a method for manufacturing a luminaire for outdoor use.
The method comprising the steps of:
- providing a profile extending in a longitudinal direction;
- placing a plurality of light-emitting elements in a space defined by a bottom and side walls of the profile;
- completely filling the mentioned space with a resin for watertightness.
The profile is preferably an extruded profile. The profile is preferably a plastic or a metal profile, more preferably a metal profile, most preferably an aluminum profile.
The plurality of light-emitting elements are preferably arranged in the longitudinal direction in the space defined by the bottom and the side walls of the profile. The light-emitting elements are positioned to emit light during operation through an opening between the side walls and opposite the bottom. Preferably, the plurality of light-emitting elements are evenly distributed along the length of the mentioned space. Preferably, the LEDs are placed on at least one flexible or rigid printed circuit board.
Preferably, the mentioned space is completely filled with resin. The resin is preferably a synthetic resin. The resin is transparent or translucent.
According to a preferred embodiment, at least the bottom and the side walls are blasted in the space defined by the bottom and side walls of the profile before placing the plurality of light-emitting elements in the said space. Preferably, only the bottom and side walls in the said space defined by the bottom and the side walls of the profile are blasted. This is advantageous because it does not change an appearance of the profile outside the said space. The blasting is beneficial for an improved adhesion of a reflective coating or resin to the profile, ensuring that the reflective coating or resin remains bonded to the profile during temperature fluctuations. This is particularly advantageous in a luminaire for outdoor use because even with different coefficients of expansion for the profile and the resin, the resin does not detach from the profile and the luminaire remains watertight.
According to a further embodiment, after blasting at least the bottom and side walls in the said space defined by the bottom and side walls of the profile, a reflective powder coating is applied for reflecting light and adhering the resin to the blasted bottom and side walls of the profile.
This method has the advantage, among other things, that by blasting at least the bottom and side walls of the profile and by applying the reflective powder coating, the resin and the profile are very well bonded to each other, resulting in a luminaire that remains watertight even with very large temperature fluctuations between -30°C and +60°C. Additionally advantageous is that blasting is a relatively simple technique that is very suitable for treating a profile. It is particularly advantageous that blasting makes it unnecessary to chemically pre-treat the profile, resulting in fewer volatile organic components that can damage the light-emitting elements or lead to defects. Preferably, the profile is not chemically pretreated. It is also advantageous that the reflective coating leads to both an increased light output and better adhesion of profile and resin.
According to a preferred embodiment, the profile is partially filled with a first polyurethane resin, after which the profile is further filled with a second polyurethane resin. The first polyurethane resin covers the plurality of light-emitting elements. The second polyurethane resin covers the first polyurethane resin.
The first polyurethane resin has a Shore A hardness of at most 85, preferably at most 80, and more preferably at most 75. Preferably, the first polyurethane resin has a Shore A hardness of at least 45, more preferably at least 55, and even more preferably at least 65. Preferably, the polyurethane resin is formed by mixing a polyol blend with a hydrophilic polyisocyanate, preferably a water-dispersible polyisocyanate based on hexamethylene diisocyanate (HDI). Optionally, a flexibilizing agent is also added when forming the polyurethane resin.
The second polyurethane resin has a Shore D hardness of at least 60, preferably at least 65. Preferably, the second polyurethane resin has a Shore D hardness of at most 85, more preferably at most 80, and even more preferably at most 75. Preferably, the polyurethane resin is formed by mixing a polyol blend with a hydrophilic polyisocyanate, preferably a water-dispersible polyisocyanate based on hexamethylene diisocyanate (HDI). Preferably, the polyurethane resin is free of flexibilizing agent. The first polyurethane resin is softer and more flexible than the second polyurethane resin. Due to the fact that the first polyurethane resin covering the light-emitting elements is softer and more flexible, the high stresses are only limitedly transferred to the light-emitting elements, which is advantageous for avoiding damage to the light-emitting elements. The second polyurethane resin is much harder than the first polyurethane resin and forms a visible and accessible surface of the luminaire. The second polyurethane resin is much more resistant to scratches, stress, and impact, forming a sturdy outer surface of the luminaire and protecting the light-emitting elements from external mechanical stress. The second polyurethane resin remains intact under load from people and even vehicles, ensuring the watertightness of the luminaire is maintained. As a result, the luminaire is very suitable for integration into paved surfaces.
According to a preferred embodiment, at least one opening is made in the bottom of the profile before filling the profile. When filling the profile, the at least one opening is completely filled with resin.
This embodiment is advantageous for evacuating volatile organic compounds from the luminaire. The resin and the at least one opening in the bottom form a pathway along which the volatile organic compounds can migrate. This embodiment is particularly advantageous in combination with the previously described embodiment with a first polyurethane resin and a second polyurethane resin. The softer first polyurethane resin has a more open structure than the second polyurethane resin, through which volatile organic compounds can migrate. The at least one opening is therefore preferably completely filled by the first polyurethane resin.
According to a preferred embodiment, the profile is placed in a mold before filling the profile with resin. This embodiment is advantageous if the resin must extend above the side walls of the profile, viewed in a direction transverse to the bottom of the profile. This embodiment is also advantageous if the profile does not include end walls. With end walls, walls are meant at the ends of the profile, which close off the profile in the longitudinal direction. By using a mold, it is possible to fill a profile without end walls with resin or to fill the resin to above the side walls of the profile. The benefits of such a luminaire were previously described for a luminaire according to the first aspect. This embodiment is also advantageous in combination with a previously described embodiment wherein there is at least one opening in the bottom of the profile that is completely filled with resin, to prevent the resin from flowing away from the profile during filling.
One skilled in the art will appreciate that a luminaire according to the first aspect is preferably manufactured by carrying out a method according to the second aspect and that a method according to the second aspect is preferably carried out in the manufacture of a luminaire according to the first aspect. Each feature described in this document, both above and below, can therefore relate to any of the three aspects of the present invention.
In a third aspect, the invention relates to the use of a luminaire according to the first aspect for outdoor lighting integrated into a paved surface.
This use results in an outdoor light that remains watertight even at very high stresses on the luminaire, due to both the different expansion and contraction with temperature fluctuations of the profile, the resin and the paved surface, and therefore has a long service life. By completely filling the profile with resin, the luminaire can also withstand pressure loads from a vehicle, for example, allowing the luminaire to also be integrated into a street surface.
In what follows, the invention is described by way of non-limiting examples and figures illustrating the invention, and which are not intended to and should not be interpreted as limiting the scope of the invention.
DESCRIPTION OF THE FIGURES
Figure 1 shows a perspective view of a luminaire according to an embodiment of the present invention.
The luminaire (1) includes a profile (2) that extends in a longitudinal direction. The profile (2) in this embodiment is an extruded aluminum profile. It is clear that other materials are also eligible. The profile includes a bottom (3) and side walls (4) that extend substantially perpendicular to the bottom (3). The side walls (4) include an inwardly directed protrusion (5) at a free end. This means that a free end of a protrusion (5) on a side wall (4) is directed towards an opposite side wall (4). In this specific embodiment, the protrusions (5) are directed almost straight towards the opposite side walls (4). The protrusions (5) are an integral part of the side walls (4). The profile (2) includes two additional guide walls (6). The guide walls (6) extend substantially perpendicular to the bottom (3) from the bottom (3) between the side walls (4). The guide walls (6) have a lower height than the side walls (4). The height is measured in a direction transverse to the bottom (3). The profile (2) comprises two channel walls (7) that extend substantially perpendicular to the bottom (3). The channel walls (7) are located on a different side of the bottom (3) than the side walls (4). The channel walls (7) and the side walls (4) extend in opposite directions on the bottom (3). Light-emitting elements (8) have been placed in a space defined by the bottom (3) and the side walls (4). More precisely, the light-emitting elements have been placed in a space defined by the bottom (3) and the guide walls (6). The lightemitting elements (8) in this specific embodiment are LEDs on a rigid printed circuit board. The bottom (3) and the side walls (4) are blasted in the space defined by the bottom (3) and the side walls (4). The profile (2) is not chemically pretreated. On the blasted bottom (3) and the blasted side walls (4), a reflective polyester powder coating (11) has been applied. The profile (2) is not blasted outside the space defined by the bottom (3) and the side walls (4) in this specific embodiment, in order not to affect the appearance of the profile (2) outside the mentioned space. It is clear that the profile (2) may be completely blasted. The reflective powder coating (11) is beneficial for reflecting light. The space defined by the guide walls (6) and the bottom (3) is filled with a first polyurethane resin (10). The first polyurethane resin (10) has a Shore A hardness of at least 45 and at most 85. The first polyurethane resin (10) covers the light-emitting elements (8). A remaining portion of the space defined by the side walls (4) and the bottom (3) is filled with a second polyurethane resin (9). The second polyurethane resin (9) has a Shore D hardness of at least 60 and at most 85. The second polyurethane resin (9) covers the first polyurethane resin (10). The second polyurethane resin (9) covers the first polyurethane resin (10). The reflective powder coating (11) is advantageous for adhering the first polyurethane resin (10) and the second polyurethane resin (9) to the profile (2). The first polyurethane resin (10), the second polyurethane resin (9), the reflective powder coating (11), and the profile (2) remain bonded to each other even with very large temperature variations, from -30°C to +60°C, ensuring the luminaire (1) remains watertight and highly suitable for outdoor use. The profile (2) does not include end walls. The first polyurethane resin (10) extends longitudinally beyond the rigid printed circuit board, but not to ends of the luminaire (1). The second polyurethane resin (9) extends longitudinally to ends of the luminaire (1) and thereby shields the first polyurethane resin (10) longitudinally. This is clearly visible in Figure 4. The second polyurethane resin (9) extends in a direction transverse to the bottom (3) beyond the side walls (4). The first polyurethane resin (10) extends in a direction transverse to the longitudinal direction of the profile (2) and parallel to the bottom (3) extending below the guide walls (6).
Figure 2 shows an exploded side view of a luminaire according to an embodiment of the present invention.
The luminaire (1) in Figure 2 corresponds to the luminaire (1) in Figure 1. Clearly visible is how the protrusions (5) hook into the second polyurethane resin (9) and press the second polyurethane resin (9) into the space defined by the bottom (3) and the side walls (4) when the profile (2) curls up.
Figure 3 shows a cross-section of a luminaire according to an embodiment of the present invention.
The luminaire (1) in Figure 3 corresponds to the luminaire (1) in Figure 1. The crosssection is at the level of an opening (12) in the bottom (3) of the profile (2). The first polyurethane resin (10) completely fills the opening (12). The opening (12) and the first polyurethane resin (10) form a pathway along which volatile organic compounds from the luminaire (1) can migrate.
Figure 4 shows a longitudinal section of a luminaire according to an embodiment of the present invention.
The luminaire (1) in Figure 4 corresponds to the luminaire (1) in Figure 1. The longitudinal section is at the level of one end of the luminaire (1). Clearly visible is how the first polyurethane resin (10) extends longitudinally beyond the rigid printed circuit board with the light-emitting elements (8), but not to the end of the luminaire (1). The second polyurethane resin (9) extends longitudinally to the end of the luminaire (1) and thereby shields the first polyurethane resin (10) longitudinally, which protects the first polyurethane resin (10) against mechanical influences and provides better watertightness.
Figure 5 shows a cross-section of a luminaire according to an alternative embodiment of the present invention. The luminaire (1) in Figure 5 is very similar to the luminaire (1) in Figure 3. The luminaire (1) in Figure 5 has no channel walls (7) and is mainly intended for installation in, for example, railings of a bridge or outdoor staircase or for installation on the underside of a canopy. The first polyurethane resin (10) extends in a direction transverse to the bottom (3) beyond the side walls (4) and has a dome-shaped crosssection. This is advantageous for a wide distribution of the light so that a bridge or staircase surface or a surface under the canopy are illuminated as widely as possible.
The numbered elements in the figures are:
1. Luminaire
2. Profile
3. Bottom
4. Side wall
5. Protrusion
6. Guide wall
7. Channel wall
8. Light-emitting element
9. Second polyurethane resin
10. First polyurethane resin
11. Reflective powder coating
12. Opening
EXAMPLES
Two luminaries have been subjected to an endurance test. A first luminaire A corresponds to the luminaire presented in Figure 1. A second luminaire B is almost identical to the luminaire A. In both cases the bottom and the side walls are blasted in the space defined by the bottom and the side walls, but for Luminaire B no reflective powder coating is applied.
The endurance test subjects the luminaires A and B to conditions exceeding normal operating conditions. The endurance test is made up of four different phases that are repeated continuously and repetitively one after the other.
In a first phase the luminaires A and B are subjected to a cold climate. Both the luminaires are put in a freezer at a temperature of -30° C for a period of 120 hours. In a second phase the luminaires A and B are immersed in water at 20° C ± 5° C. A lowest part of the luminaires A and B is at a depth of 4 m. The luminaires A and B are immersed for a period of 72 hours. The luminaires A and B are alternatingly switched on for 1 hour and switched off for 1 hour.
In a third phase the luminaires A and B are put into a climate chamber at a controlled temperature of 60°C during 8 hours. The luminaires A and B are subsequently brought back to a temperature of 20°C ± 5° C during a period of 16 hours. After this period, the luminaires A and B are put again into the climate chamber for another 8 hour period at 60°C for a new cycle. This cycle is repeated during a period of 120 hours. The luminaires A and B are alternatingly switched on for 2 hours and switched off for 2 hours.
After the third phase, the second phase is repeated as a fourth phase. After the fourth phase, the first phase is restarted.
After every second and fourth phase, the working condition of the luminaires A and B is checked. The adhesion of the resin is checked visually. At random moments, insulation resistance test and electric strength tests are applied as described in section 10 of IEC 60598-1 :2020 (10.2.1 and 10.2.2).
Luminaire B failed after 672 hours. Luminaire A is still passing the tests after 20940 hours.

Claims

1. Luminaire for outdoor use, comprising a longitudinally extending profile and a plurality of light-emitting elements, wherein the profile comprises a bottom and two side walls extending thereon, wherein the plurality of light-emitting elements are placed in a space defined by the bottom and the side walls of the profile and wherein the mentioned space is filled with resin for watertightness, characterized in that at least the bottom and the side walls in the mentioned space are blasted, wherein at least a reflective powder coating is applied to the blasted bottom and side walls for reflecting light and adhering the resin.
2. The luminaire according to claim 1, characterized in that the reflective powder coating at least meets reflectivity class A according to EN 16268:2013 and has a gloss at 60° of at least 55% and at most 85% according to ISO 2813:2014.
3. The luminaire according to claim 1 or 2, characterized in that the reflective powder coating has an adhesion of 5 according to ASTM D3359-23.
4. The luminaire according to any of the preceding claims 1-3, characterized in that the reflective powder coating is a polyester-based powder coating.
5. The luminaire according to any of the preceding claims 1-4, characterized in that the resin is a polyurethane resin.
6. The luminaire according to claim 5, characterized in that the mentioned space is filled with a first polyurethane resin and a second polyurethane resin, wherein the first polyurethane resin has a Shore A hardness of at most 85, wherein the second polyurethane resin has a Shore D hardness of at least 60, wherein the first polyurethane resin covers the plurality of light-emitting elements and wherein the second polyurethane resin covers the first polyurethane resin.
7. The luminaire according to any of the preceding claims 1-6, characterized in that the profile comprises two additional guide walls, wherein the two additional guide walls extend from the bottom of the profile between the two side walls, wherein a guide wall has a lower height than a side wall and wherein the height is measured in a direction perpendicular to the bottom.
8. The luminaire according to any of the preceding claims 1-7, characterized in that the side walls of the profile comprise an inwardly directed protrusion at a free end.
9. The luminaire according to any of the preceding claims 1-8, characterized in that the profile has at least one opening in the bottom, wherein the resin completely fills the opening.
10. The luminaire according to any of the preceding claims 1-9, characterized in that the resin extends longitudinally to the ends of the luminaire, wherein at the ends of the luminaire there are no end walls present at least on an upper side.
11. Method for manufacturing a luminaire for outdoor use, comprising the steps of:
- providing a profile extending in a longitudinal direction;
- placing a plurality of light-emitting elements in a space defined by a bottom and side walls of the profile;
- completely filling the mentioned space with a resin for watertightness; characterized in that, before placing the plurality of light-emitting elements in the said space defined by the bottom and the side walls of the profile, at least the bottom and the side walls in the said space are blasted, after which a reflective powder coating is applied at least to the blasted bottom and side walls to reflect light and adhere the resin.
12. The method according to claim 11, characterized in that the profile is partially filled with a first polyurethane resin, wherein the first polyurethane resin has a Shore A hardness of at most 85 and wherein the first polyurethane resin covers the plurality of light-emitting elements, after which the profile is further filled with a second polyurethane resin, wherein the second polyurethane resin has a Shore D hardness of at least 60 and wherein the second polyurethane resin covers the first polyurethane resin.
13. The method according to claim 11 or 12, characterized in that at least one opening is made in the bottom of the profile before filling the profile, wherein when the profile is filled, the at least one opening is completely filled with resin.
14. The method according to claim 11, 12 or 13, characterized in that the profile is placed in a mold before filling the profile with resin.
15. Use of a luminaire according to any of claims 1-10 for outdoor lighting integrated into a paved surface.
EP24721679.9A 2023-04-28 2024-04-26 Luminaire for outdoor use, method of its manufacture and use of a luminaire in a paved surface Pending EP4702278A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
BE20235342A BE1031564B1 (en) 2023-04-28 2023-04-28 OUTDOOR LIGHTING FIXTURE, METHOD OF MANUFACTURING AND USE OF A LIGHTING FIXTURE IN A HARD SURFACE
PCT/EP2024/061600 WO2024223863A1 (en) 2023-04-28 2024-04-26 Luminaire for outdoor use, method of its manufacture and use of a luminaire in a paved surface

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EP4702278A1 true EP4702278A1 (en) 2026-03-04

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6354714B1 (en) * 2000-04-04 2002-03-12 Michael Rhodes Embedded led lighting system
AT506384B1 (en) * 2008-02-07 2013-05-15 Schrutek Elmar Ing LIGHTING EQUIPMENT
DE202008012002U1 (en) * 2008-09-09 2009-01-02 Reetec Gmbh Regenerative Energie- Und Elektrotechnik Luminaire with LED units
CA2726875A1 (en) 2009-12-21 2011-06-21 Virginia Optoelectronics, Inc. Waterproof flexible and rigid led lighting systems and devices
KR20180133131A (en) * 2017-06-05 2018-12-13 미미라이팅주식회사 High reflection- matte powder coating composition for LED illumination and LED illumination coated by the same that

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