WO2010052449A1 - Lighting device having means for preventing moisture ingress via an electrical cable - Google Patents

Lighting device having means for preventing moisture ingress via an electrical cable Download PDF

Info

Publication number
WO2010052449A1
WO2010052449A1 PCT/GB2009/002563 GB2009002563W WO2010052449A1 WO 2010052449 A1 WO2010052449 A1 WO 2010052449A1 GB 2009002563 W GB2009002563 W GB 2009002563W WO 2010052449 A1 WO2010052449 A1 WO 2010052449A1
Authority
WO
WIPO (PCT)
Prior art keywords
lighting device
casing
wire
stranded
electrical connector
Prior art date
Application number
PCT/GB2009/002563
Other languages
French (fr)
Inventor
Justin Maeers
Original Assignee
Collingwood Lighting Limited
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 Collingwood Lighting Limited filed Critical Collingwood Lighting Limited
Publication of WO2010052449A1 publication Critical patent/WO2010052449A1/en

Links

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
    • F21V27/00—Cable-stowing arrangements structurally associated with lighting devices, e.g. reels 
    • F21V27/02—Cable inlets
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S8/00—Lighting devices intended for fixed installation
    • 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
    • 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
    • F21W2131/40—Lighting for industrial, commercial, recreational or military use
    • F21W2131/401—Lighting for industrial, commercial, recreational or military use for swimming pools
    • 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]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5216—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases characterised by the sealing material, e.g. gels or resins

Definitions

  • Lighting Device Having Means For Preventing Moisture Ingress Via An Electrical Cable.
  • the present invention relates to a lighting device, and in particular to light fittings, having means for preventing the ingress of moisture into the appliance via. an electrical cable, and a method for manufacturing a lighting device.
  • Lighting devices such as light fittings frequently use multi-stranded electrical cables to connect the appliance to a power source. This is because multi-stranded cables are very flexible and robust. The flexibility enables the cables to follow non-linear paths and enables frequent repositioning and bending of the cable without appreciably work hardening the cable.
  • a lighting device such as a sealed light fitting is turned on heat given off by the light source, and sometimes other electrical components, causes the air inside the light fitting to expand, thereby increasing the pressure within the fitting. The increased pressure causes air to be forced out of the fitting via the multi-stranded electrical cable. The air flows through gaps located between the copper wire strands within an inner insulation sheath and via gaps between the inner insulation sheath and an outer insulation sheath.
  • EPl 873012, DE2531968, and US4,539,629 all disclose the use of a potting material, such as a resin, in order to provide moisture barriers in lighting devices.
  • a potting material such as a resin
  • US 2004/0145899 discloses the problem of wicking through the wiring and discloses the use of a potting material as a solution to this problem when used in conjunction with a liquid tight receptacle and crimping the wires to pins on the interior side of the receptacle.
  • resin provides a good s-eal between a solid wire and an insulation sheath it does not provide an effective barrier to moisture along the length of a multi-stranded wire.
  • the invention seeks to provide a lighting device, and particularly a lighting device, that mitigates at least one of the above-mentioned problems or provide an alternative solution thereto, and a method for manufacturing a lighting device.
  • a lighting device including a casing having a light emitting component, part of an electrical connector for connecting the component to a power source, blocking means and sealing means, wherein the casing includes a first part for housing the light emitting component and a second part for housing a section of the electrical connector, the electrical connector includes at least one multi-stranded electrical wire having an insulation sheath, said insulation sheath having a gap therein that exposes a section of the multi-stranded wire, the blocking means is arranged to block the flow of fluids through the electrical connector and includes a metallic filler material that is applied to the electrical wire in liquid or semi-solid form such that it flows into and fills the gaps between the multiple strands and solidifies to provide a substantially solid block of material, thereby binding the multiple strands together, and sealing means arranged to seal the first part of the casing from the second part of the casing and/or the blocking means to the insulating sheath.
  • the invention enables lighting devices to benefit from the use
  • the blocking means is applied at the gap in the insulation material and the gap is located within the casing. This makes it easy for the sealing means to provide an effective seal between the blocking means and the insulation.
  • the blocking means is applied to electrical wiring during manufacture of the lighting device. This provides a more consistent blocking effect than on-site installation as the manufacturing environment can be better controlled. Furthermore, locating the blocking means in the casing ensures there is minimal impact on the flexibility of the electrical cable and the casing protects the blocked part of the cable from being subject to loads, which may otherwise work harden that part of the cable. Thus it reduces the possibility of cable failure. It also provides a much more aesthetically acceptable solution to end users.
  • the filler material is applied to the multi-stranded cable to fill gaps between the strands in the electrical wire.
  • the filler material is selected to have a sufficiently low viscosity when in liquid or semi-solid form such that it flows readily between the strands in the multi-stranded wire.
  • the filler material thus provides a physical block to air and moisture moving along the gaps between the strands in the electrical wire. This arrangement has the advantage that the strands of electrical wire retain their integrity. Therefore the electrical connection along the multi-stranded wire remains substantially consistent and the mechanical strength of the wire is not compromised.
  • the lighting device can be a light fitting, and the light emitting component can include one of the following: a filament bulb, halogen lamp or an LED.
  • the casing can house other electrical components and may include a printed circuit board.
  • the filler material is selected such that it remains solid within the full operating temperature range of the wire. Since the filler material is typically applied to a small portion of the wire, the overall flexibility of the cable is not affected. The filler material has a lower melting temperature than the wires to which the filler material is applied.
  • the filler material is an electrically conducting material and may comprise a metallic alloy such as a solder.
  • the solder is heated up to its melting point and is applied to the exposed part of the electrical conducting wire. When it cools, the solder forms a substantially solid block of material.
  • the blocking means can include a non-stranded electrical connector that is electrically connected to the light emitter and to the multi- stranded electrical wire.
  • the non-stranded electrical connector is preferably substantially solid.
  • the non-stranded electrical connector is located between the light emitter and to the multi-stranded electrical wire.
  • the electrical connector can include a second multi-stranded electrical wire having a second insulation sheath, the second electrical wire having a second gap in the second insulation sheath.
  • the second multi-stranded electrical wire can be similarly arranged to the first wire in that blocking means, as described herein, can be included to block the flow of fluid along the second wire and the sealing means seals the blocking means to the second insulation sheath.
  • the first and second multi-stranded electrical wires can be fixed together by an outer sheath to form a two wired electrical cable. Additional multi-stranded wires can be included in the cable.
  • the second gap in the second insulation sheath can be located along the length of the second multi-stranded electrical wire such that it is longitudinally offset from the gap in the insulation sheath of the first multi- stranded electrical wire.
  • the blocking means includes an electrically conducting filler material that is applied to the second electrical wire in liquid or semi-solid form such that it flows into and fills the gaps between the multiple strands in the second wire and is arranged to solidify to provide a substantially solid block of material within the second wire, thereby binding the multiple strands together.
  • the sealing means can fully surround the blocking means and an adjacent portion of the insulation sheath.
  • the sealing means can be arranged to seal around the full part of the or each multi-stranded electrical wire located in the casing.
  • the sealing means can include a sealing material that is arranged to be applied to the or each electrical wire in liquid or semi-solid form and to solidify to provide a substantially solid seal.
  • the sealing material can include a resin and more preferably a silicon or an epoxy resin. Silicon or epoxy resins adhere well to metallic surfaces and therefore this type of resin provides a highly effective and robust seal when a solder is used as the filling material.
  • the casing can be arranged to include a partition for separating the first and second parts of the casing.
  • the partition may in include at least one through hole to enable the electrical connector to pass from one part of the casing into the other part of the casing.
  • the sealing means can be arranged to seal the partition to at least one side wall of the casing and to seal each hole formed in the partition by sealing against the electrical connector thereby effectively sealing the first part of the casing from the second part of the casing.
  • the blocking means prevents moisture ingress into the first part of the casing along the electrical connector.
  • the sealing means substantially fills the second part of the casing. Having a sealed casing enables the lighting device to be used in outdoor air and in under water applications such as swimming pools and ponds.
  • the first part of the casing can include a transparent member arranged to allow light to be emitted from the casing.
  • a method for manufacturing a lighting device including a casing having a light emitting component and part of an electrical connector for connecting the component to a power source, wherein the casing includes a first part for housing the light emitting component and a second part for housing a section of the electrical connector, the electrical connector includes at least one multi-stranded electrical wire having an insulation sheath, said method including removing a section of the insulation sheath to expose a section of the wire, applying a metallic filler material in liquid or semi-solid form to the exposed section of wire to fill gaps between the strands and allowing the filler material to solidify to provide substantially solid block of material that binds the strands together and blocks the flow of fluids along the multi-stranded electrical wire in use, and applying a sealant to the casing to seal the first part of the casing from the second part of the casing and
  • the method may include using a metallic alloy such as a solder as the filler material.
  • the method may include applying the sealant in liquid or semi-solid form and allowing the sealant to solidify to provide a substantially solid seal.
  • the sealant can include a resin, and preferably a silicon or an epoxy resin.
  • a lighting device including a casing having a light emitting component, part of an electrical connector for connecting the component to a power source, blocking means and sealing means, wherein the casing includes a first part for housing the light emitting component and a second part for housing a section of the electrical connector, the electrical connector includes at least one multi-stranded electrical wire having an insulation sheath, said insulation sheath having a gap therein that exposes a section of the multi-stranded wire, the blocking means is arranged to block the flow of fluids through the electrical connector and the sealing means is arranged to seal the first part of the casing from the second part of the casing and/or the blocking means to the insulating sheath.
  • Figure 1 is a diagrammatic end view of an electric cable including two multi- stranded copper wires (this wire is known in the art);
  • Figure 2 is a diagrammatic sectional view of a prior art light fitting illustrating air being forced out of the fitting along the cable of Figure 1 when the light is operated;
  • Figure 3 is a diagrammatic sectional view of the prior art light fitting of Figure 2 illustrating air being sucked into the fitting along the cable when the light is switched off;
  • Figure 4 is a sectional view of a first light fitting in accordance with the invention.
  • Figure 5 is an enlarged diagrammatic sectional view of an electric cable used in the light fitting of Figure 4.
  • Figure 6 is a sectional view of a second light fitting in accordance with the invention.
  • Figures 1 to 3 show a known flexible electrical cable 1 and a prior art light fitting 3 including the cable.
  • the flexible electrical cable 1 includes a flexible outer sheath 5, two multi- stranded wires 7, each wire 7 having multiple strands of copper wire 9 and a flexible insulating sheath 11. It can be seen from Figure 1 (in an exaggerated fashion) that there are gaps 13 between the strands of copper wire 9 and gaps 15 between the insulating sheaths 11.
  • Figures 2 and 3 show the light fitting 3 including the multi-stranded electrical cable 1 connected to a light bulb 17 housed in a casing 19 in a substantially sealed compartment 21. When the light bulb 17 is illuminated, it heats up the air inside the compartment 21 causing it to expand and thereby increasing the air pressure in the compartment 21. The increased air pressure causes the air 21 to exit the compartment 21 through the gaps 13,15 in the electrical cable. The air movement is indicated by arrows referenced 23 in Figure 2.
  • Air drawn into the casing 19 can contain moisture, particularly when the light fitting is located in damp or wet environment. The moisture can damage electrical components within the casing 19, for example it may corrode some of the electrical contacts. It also can form water droplets on an inner surface of a glass frontage 25.
  • Figure 4 shows a light fitting 103, including a flexible electrical cable 101, an LED light source 1 17, a casing 119 having a light source compartment 121 for housing the LED 117 and a cable receiving compartment 127 for housing part of the cable 101, a transparent panel 125, and sealant 129 in the form of a so-called "potting" compound.
  • the light compartment 121 is defined by the side wall(s) 131 of the casing, the transparent panel 125, which is typically glass or a plastics material, and a partition 133. Holes 135 are formed in the partition 133 to enable the cable 101 to be connected to the LED 117.
  • the electrical cable 101 includes a flexible outer sheath 105, two multi-stranded wires 107, each wire 107 having multiple strands of copper wire 109 and a flexible insulating sheath 11 1.
  • Each wire 107 has been treated by removing a section of the insulating sheath 11 1 at one end and applying a so called “tinning" material, such as a solder 126, to the multiple strands in a molten state.
  • the solder 126 flows into the gaps between the wires and solidifies, thereby bonding the strands together to produce a substantially solid wire along the exposed part of the wire.
  • Figure 5 shows a cross-section of the wires 107 in a region having been so treated (in an exaggerated fashion). The purpose of soldering the wires together is to block the flow of air and moisture along the gaps between the strands of wire.
  • the ends of the wires 107 are connected to the LED 117 via the holes 135.
  • the holes 135 are spaced apart to ensure that there is no short circuit between the wires 107 when located in situ.
  • the sealant 129 which is preferably a silicon or epoxy resin, is then poured into the cable receiving compartment 121 and is allowed to set such that it seals the light source compartment 121 from the cable receiving compartment 129 and form seals around each of the treated areas of the wires 107 and their respective insulating sheaths 111. This further ensures that no short circuits can occur and also prevents air from travelling along the gaps 1 15 between the insulating sheaths 1 11 from entering the light source compartment 121.
  • the sealant 129 substantially fills the cable receiving compartment 121.
  • a second embodiment of the invention is shown in Figure 6.
  • the second embodiment is similar to the first embodiment except that the holes 235 that enable the wires 207 to connect to the LED 217 are located closer together.
  • each of the wires 207 are located closer together, which increases the risk of a short circuit occurring by exposed parts of the wires 207 coming into contact with each other.
  • the parts of the wire strands 209 that are treated with solder 226, as described above, to prevent the flow of air between the strands of wire 209 are longitudinally offset from each other. This ensures that for adjacent parts of the wires 207, at least one of the wires 207 includes a section of insulating sheath 211 such that there is no metal on metal contact between the wires 207.
  • a silicon or epoxy resin 229 is similarly poured into the cable receiving compartment 227 and allowed to set such that it seals the light source compartment 221 from the cable receiving compartment 229 and form seals around each of the treated areas of the wires 207 and their respective insulating sheaths 21 1.
  • a solid electrical connector can be used in place of the filler material inside the casing.
  • solid, or non-stranded, electrical wires can extend through the holes in the partition.
  • the wires can be soldered to the LED and can be joined to the multi-stranded wire, for example by soldering or a screw connector.
  • the cable can include any suitable number of wires required for the application.

Abstract

A lighting device (103) including a casing (119) having a light emitting component (117), part of an electrical connector (101) for connecting the component (117) to a power source, wherein the casing (119) includes a first part (121) for housing the light emitting component (117) and a second part (127) for housing a section of the electrical connector (101), the electrical connector (101 ) includes at least one multi-stranded electrical wire (107) having an insulation sheath (111), said insulation sheath (111) having a gap therein that exposes a section of the strands of wire (109), the blocking means (126) is arranged to block the flow of fluids through the electrical connector, said blocking means (126) including metallic filler material that is applied to the electrical wire (107) in liquid or semi-solid form such that it flows into and fills the gaps between the multiple strands and solidifies to provide a substantially solid block of material, thereby binding the multiple strands together and sealing means (129) is arranged to seal the first part (121) of the casing from the second part (127) of the casing and/or the blocking means (126) to the insulating sheath (111). A method for manufacturing the lighting device (103) is also disclosed.

Description

Lighting Device Having Means For Preventing Moisture Ingress Via An Electrical Cable.
The present invention relates to a lighting device, and in particular to light fittings, having means for preventing the ingress of moisture into the appliance via. an electrical cable, and a method for manufacturing a lighting device.
Lighting devices such as light fittings frequently use multi-stranded electrical cables to connect the appliance to a power source. This is because multi-stranded cables are very flexible and robust. The flexibility enables the cables to follow non-linear paths and enables frequent repositioning and bending of the cable without appreciably work hardening the cable. However when a lighting device such as a sealed light fitting is turned on heat given off by the light source, and sometimes other electrical components, causes the air inside the light fitting to expand, thereby increasing the pressure within the fitting. The increased pressure causes air to be forced out of the fitting via the multi-stranded electrical cable. The air flows through gaps located between the copper wire strands within an inner insulation sheath and via gaps between the inner insulation sheath and an outer insulation sheath.
When the light is turned off, the air inside the fitting cools and contracts causing a reduction in pressure within the fitting. This causes air to be drawn into the fitting through the same gaps. Frequently light fittings are used in damp environments such as outdoor applications, and also in submersed conditions such as swimming pools and ponds. When air is drawn along cables in moist or wet conditions, moisture is also drawn into the light fitting. This can be fatal to the light fitting, for example by corroding electrical contacts or short circuiting the device. At best, moisture drawn into the fitting causes water droplets to form inside the casing, which can reduce the operating effectiveness of the light and also look unsightly.
Similar problems can occur in other types of lighting devices. EPl 873012, DE2531968, and US4,539,629 all disclose the use of a potting material, such as a resin, in order to provide moisture barriers in lighting devices. However none of those documents specifically addresses the problem of moisture ingress into a lighting device between the gaps in a multi-stranded electrical cable. US 2004/0145899 discloses the problem of wicking through the wiring and discloses the use of a potting material as a solution to this problem when used in conjunction with a liquid tight receptacle and crimping the wires to pins on the interior side of the receptacle. However, it does not disclose this problem in the context of multi-strand wires. While resin provides a good s-eal between a solid wire and an insulation sheath it does not provide an effective barrier to moisture along the length of a multi-stranded wire.
Accordingly the invention seeks to provide a lighting device, and particularly a lighting device, that mitigates at least one of the above-mentioned problems or provide an alternative solution thereto, and a method for manufacturing a lighting device.
According to one aspect of the invention, there is provided a lighting device including a casing having a light emitting component, part of an electrical connector for connecting the component to a power source, blocking means and sealing means, wherein the casing includes a first part for housing the light emitting component and a second part for housing a section of the electrical connector, the electrical connector includes at least one multi-stranded electrical wire having an insulation sheath, said insulation sheath having a gap therein that exposes a section of the multi-stranded wire, the blocking means is arranged to block the flow of fluids through the electrical connector and includes a metallic filler material that is applied to the electrical wire in liquid or semi-solid form such that it flows into and fills the gaps between the multiple strands and solidifies to provide a substantially solid block of material, thereby binding the multiple strands together, and sealing means arranged to seal the first part of the casing from the second part of the casing and/or the blocking means to the insulating sheath. Thus the invention enables lighting devices to benefit from the use of multi- stranded electrical cables without suffering from the downside of moisture ingression into the appliance along the cable due to pressure variations within the casin Όg.-
The blocking means is applied at the gap in the insulation material and the gap is located within the casing. This makes it easy for the sealing means to provide an effective seal between the blocking means and the insulation. The blocking means is applied to electrical wiring during manufacture of the lighting device. This provides a more consistent blocking effect than on-site installation as the manufacturing environment can be better controlled. Furthermore, locating the blocking means in the casing ensures there is minimal impact on the flexibility of the electrical cable and the casing protects the blocked part of the cable from being subject to loads, which may otherwise work harden that part of the cable. Thus it reduces the possibility of cable failure. It also provides a much more aesthetically acceptable solution to end users.
The filler material is applied to the multi-stranded cable to fill gaps between the strands in the electrical wire. The filler material is selected to have a sufficiently low viscosity when in liquid or semi-solid form such that it flows readily between the strands in the multi-stranded wire. When set, the filler material thus provides a physical block to air and moisture moving along the gaps between the strands in the electrical wire. This arrangement has the advantage that the strands of electrical wire retain their integrity. Therefore the electrical connection along the multi-stranded wire remains substantially consistent and the mechanical strength of the wire is not compromised.
Advantageously the lighting device can be a light fitting, and the light emitting component can include one of the following: a filament bulb, halogen lamp or an LED. The casing can house other electrical components and may include a printed circuit board. The filler material is selected such that it remains solid within the full operating temperature range of the wire. Since the filler material is typically applied to a small portion of the wire, the overall flexibility of the cable is not affected. The filler material has a lower melting temperature than the wires to which the filler material is applied.
The filler material is an electrically conducting material and may comprise a metallic alloy such as a solder. The solder is heated up to its melting point and is applied to the exposed part of the electrical conducting wire. When it cools, the solder forms a substantially solid block of material.
Advantageously the blocking means can include a non-stranded electrical connector that is electrically connected to the light emitter and to the multi- stranded electrical wire. The non-stranded electrical connector is preferably substantially solid. The non-stranded electrical connector is located between the light emitter and to the multi-stranded electrical wire.
Advantageously the electrical connector can include a second multi-stranded electrical wire having a second insulation sheath, the second electrical wire having a second gap in the second insulation sheath. The second multi-stranded electrical wire can be similarly arranged to the first wire in that blocking means, as described herein, can be included to block the flow of fluid along the second wire and the sealing means seals the blocking means to the second insulation sheath. Advantageously the first and second multi-stranded electrical wires can be fixed together by an outer sheath to form a two wired electrical cable. Additional multi-stranded wires can be included in the cable.
Advantageously the second gap in the second insulation sheath can be located along the length of the second multi-stranded electrical wire such that it is longitudinally offset from the gap in the insulation sheath of the first multi- stranded electrical wire. This helps to prevent short circuits from occurring, for example if the sealing means provides an imperfect seal. Advantageously the blocking means includes an electrically conducting filler material that is applied to the second electrical wire in liquid or semi-solid form such that it flows into and fills the gaps between the multiple strands in the second wire and is arranged to solidify to provide a substantially solid block of material within the second wire, thereby binding the multiple strands together.
Advantageously the sealing means can fully surround the blocking means and an adjacent portion of the insulation sheath. The sealing means can be arranged to seal around the full part of the or each multi-stranded electrical wire located in the casing.
Advantageously the sealing means can include a sealing material that is arranged to be applied to the or each electrical wire in liquid or semi-solid form and to solidify to provide a substantially solid seal. The sealing material can include a resin and more preferably a silicon or an epoxy resin. Silicon or epoxy resins adhere well to metallic surfaces and therefore this type of resin provides a highly effective and robust seal when a solder is used as the filling material.
The casing can be arranged to include a partition for separating the first and second parts of the casing. The partition may in include at least one through hole to enable the electrical connector to pass from one part of the casing into the other part of the casing. The sealing means can be arranged to seal the partition to at least one side wall of the casing and to seal each hole formed in the partition by sealing against the electrical connector thereby effectively sealing the first part of the casing from the second part of the casing. The blocking means prevents moisture ingress into the first part of the casing along the electrical connector. Preferably the sealing means substantially fills the second part of the casing. Having a sealed casing enables the lighting device to be used in outdoor air and in under water applications such as swimming pools and ponds.
Advantageously the first part of the casing can include a transparent member arranged to allow light to be emitted from the casing. According to another aspect of the invention there is provided a method for manufacturing a lighting device including a casing having a light emitting component and part of an electrical connector for connecting the component to a power source, wherein the casing includes a first part for housing the light emitting component and a second part for housing a section of the electrical connector, the electrical connector includes at least one multi-stranded electrical wire having an insulation sheath, said method including removing a section of the insulation sheath to expose a section of the wire, applying a metallic filler material in liquid or semi-solid form to the exposed section of wire to fill gaps between the strands and allowing the filler material to solidify to provide substantially solid block of material that binds the strands together and blocks the flow of fluids along the multi-stranded electrical wire in use, and applying a sealant to the casing to seal the first part of the casing from the second part of the casing and / or applying the sealant around the filled section of wire to form a seal with the insulating sheath.
The method may include using a metallic alloy such as a solder as the filler material.
The method may include applying the sealant in liquid or semi-solid form and allowing the sealant to solidify to provide a substantially solid seal. Advantageously the sealant can include a resin, and preferably a silicon or an epoxy resin.
According to another aspect of the invention there is provided a lighting device including a casing having a light emitting component, part of an electrical connector for connecting the component to a power source, blocking means and sealing means, wherein the casing includes a first part for housing the light emitting component and a second part for housing a section of the electrical connector, the electrical connector includes at least one multi-stranded electrical wire having an insulation sheath, said insulation sheath having a gap therein that exposes a section of the multi-stranded wire, the blocking means is arranged to block the flow of fluids through the electrical connector and the sealing means is arranged to seal the first part of the casing from the second part of the casing and/or the blocking means to the insulating sheath.
Embodiments of the invention will now be described by way of example only with reference to the drawings, wherein:
Figure 1 is a diagrammatic end view of an electric cable including two multi- stranded copper wires (this wire is known in the art);
Figure 2 is a diagrammatic sectional view of a prior art light fitting illustrating air being forced out of the fitting along the cable of Figure 1 when the light is operated;
Figure 3 is a diagrammatic sectional view of the prior art light fitting of Figure 2 illustrating air being sucked into the fitting along the cable when the light is switched off;
Figure 4 is a sectional view of a first light fitting in accordance with the invention;
Figure 5 is an enlarged diagrammatic sectional view of an electric cable used in the light fitting of Figure 4; and
Figure 6 is a sectional view of a second light fitting in accordance with the invention.
Figures 1 to 3 show a known flexible electrical cable 1 and a prior art light fitting 3 including the cable.
The flexible electrical cable 1 includes a flexible outer sheath 5, two multi- stranded wires 7, each wire 7 having multiple strands of copper wire 9 and a flexible insulating sheath 11. It can be seen from Figure 1 (in an exaggerated fashion) that there are gaps 13 between the strands of copper wire 9 and gaps 15 between the insulating sheaths 11. Figures 2 and 3 show the light fitting 3 including the multi-stranded electrical cable 1 connected to a light bulb 17 housed in a casing 19 in a substantially sealed compartment 21. When the light bulb 17 is illuminated, it heats up the air inside the compartment 21 causing it to expand and thereby increasing the air pressure in the compartment 21. The increased air pressure causes the air 21 to exit the compartment 21 through the gaps 13,15 in the electrical cable. The air movement is indicated by arrows referenced 23 in Figure 2.
When the light bulb 17 is switched off, the air in the compartment 21 cools and contracts thereby reducing the air pressure in the compartment 21. This causes air to be sucked into the compartment 21 via the gaps 13,15 in the electrical cable 1. This is illustrated in Figure 3, wherein in the movement of air is referenced by numeral 23. Air drawn into the casing 19 can contain moisture, particularly when the light fitting is located in damp or wet environment. The moisture can damage electrical components within the casing 19, for example it may corrode some of the electrical contacts. It also can form water droplets on an inner surface of a glass frontage 25.
A first embodiment of the invention is shown in Figures 4 and 5. Figure 4 shows a light fitting 103, including a flexible electrical cable 101, an LED light source 1 17, a casing 119 having a light source compartment 121 for housing the LED 117 and a cable receiving compartment 127 for housing part of the cable 101, a transparent panel 125, and sealant 129 in the form of a so-called "potting" compound.
The light compartment 121 is defined by the side wall(s) 131 of the casing, the transparent panel 125, which is typically glass or a plastics material, and a partition 133. Holes 135 are formed in the partition 133 to enable the cable 101 to be connected to the LED 117.
The electrical cable 101 includes a flexible outer sheath 105, two multi-stranded wires 107, each wire 107 having multiple strands of copper wire 109 and a flexible insulating sheath 11 1. Each wire 107 has been treated by removing a section of the insulating sheath 11 1 at one end and applying a so called "tinning" material, such as a solder 126, to the multiple strands in a molten state. The solder 126 flows into the gaps between the wires and solidifies, thereby bonding the strands together to produce a substantially solid wire along the exposed part of the wire. Figure 5 shows a cross-section of the wires 107 in a region having been so treated (in an exaggerated fashion). The purpose of soldering the wires together is to block the flow of air and moisture along the gaps between the strands of wire.
The ends of the wires 107 are connected to the LED 117 via the holes 135. The holes 135 are spaced apart to ensure that there is no short circuit between the wires 107 when located in situ. Furthermore the sealant 129, which is preferably a silicon or epoxy resin, is then poured into the cable receiving compartment 121 and is allowed to set such that it seals the light source compartment 121 from the cable receiving compartment 129 and form seals around each of the treated areas of the wires 107 and their respective insulating sheaths 111. This further ensures that no short circuits can occur and also prevents air from travelling along the gaps 1 15 between the insulating sheaths 1 11 from entering the light source compartment 121. Preferably the sealant 129 substantially fills the cable receiving compartment 121.
A second embodiment of the invention is shown in Figure 6. The second embodiment is similar to the first embodiment except that the holes 235 that enable the wires 207 to connect to the LED 217 are located closer together. This means that each of the wires 207 are located closer together, which increases the risk of a short circuit occurring by exposed parts of the wires 207 coming into contact with each other. To mitigate the risk of this occurring, the parts of the wire strands 209 that are treated with solder 226, as described above, to prevent the flow of air between the strands of wire 209 are longitudinally offset from each other. This ensures that for adjacent parts of the wires 207, at least one of the wires 207 includes a section of insulating sheath 211 such that there is no metal on metal contact between the wires 207. A silicon or epoxy resin 229 is similarly poured into the cable receiving compartment 227 and allowed to set such that it seals the light source compartment 221 from the cable receiving compartment 229 and form seals around each of the treated areas of the wires 207 and their respective insulating sheaths 21 1.
It will be appreciated by the skilled person that modifications can be made to the above embodiments that fall within the scope of the invention, for example other light sources such as a filament blub or halogen lamp can be used in place of the LED. Alternative suitable materials can be used to fill the gaps between the strands of wire and seal the treated areas with the insulating sheaths.
A solid electrical connector can be used in place of the filler material inside the casing. For example, solid, or non-stranded, electrical wires can extend through the holes in the partition. The wires can be soldered to the LED and can be joined to the multi-stranded wire, for example by soldering or a screw connector.
The cable can include any suitable number of wires required for the application.

Claims

A lighting device, including a casing having a light emitting component, part of an electrical connector for connecting the component to a power source, blocking means and sealing means, wherein the casing includes a first part for housing the light -emitting component and a second part for housing a section of the electrical connector, the electrical connector includes at least one multi- stranded electrical wire having an insulation sheath, said insulation sheath having a gap therein that exposes a section of the multi-stranded wire, the blocking means is arranged to block the flow of fluids through the electrical connector and includes a metallic filler material that is applied to the electrical wire in liquid or semi-solid form such that it flows into and fills the gaps between the multiple strands and solidifies to provide a substantially solid block of material, thereby binding the multiple strands together, and the sealing means is arranged to seal the first part of the casing from the second part of the casing and/or the blocking means to the insulating sheath.
A lighting device according to claim 1, wherein the lighting device is a light fitting and the light emitting component is a one of the following: an LED, a filament bulb and a halogen lamp.
A lighting device according to claim 1 or 2, wherein the filler material comprises a metallic alloy such as a solder.
A lighting device according to any one of the preceding claims, wherein the blocking means includes a non-stranded electrical connector that is electrically connected to the light emitter and to the multi-stranded electrical wire.
A lighting device according to any one of the preceding claims, including a second multi-stranded electrical wire having a second insulation sheath, the second electrical wire having a second gap in the second insulation sheath. A lighting device according to claim 5, wherein the blocking means includes an electrically conducting filler material that is applied to the second electrical wire in liquid or semi-solid form such that it flows into and fills the gaps between the multiple strands in the second wire and is arranged to solidify to provide a substantially solid block of material within the second wire, thereby binding the multiple strands together.
A lighting device according to claim 5 or 6, wherein the second gap in the second insulation sheath is located along the length of the second multi-stranded electrical wire such that it is longitudinally offset from the gap in the insulation sheath of the first multi-stranded electrical wire.
A lighting device according to any one of the preceding claims, wherein the sealing means is arranged to seal fully around the blocking means.
A lighting device according to any one of the preceding claims, wherein the sealing means includes a sealing material that is arranged to be applied to the or each electrical wire in liquid or semi-solid form and to solidify to provide a substantially solid seal.
A lighting device according to claim 9, wherein the sealing material includes a resin and more preferably a silicon resin or an epoxy resin.
A lighting device according to any one of the preceding claims, wherein the first and second parts of the casing are separated by a partition.
A lighting device according to claim 11, wherein the sealing means substantially fills the second part of the casing.
A method for manufacturing a lighting device including a casing having a light emitting component and part of an electrical connector for connecting the component to a power source, wherein the casing includes a first part for housing the light emitting component and a second part for housing a section of the electrical connector, the electrical connector includes at least one multi- stranded electrical wire having an insulation sheath, said method including removing a section of the insulation sheath to expose a section of the wire, applying a metallic filler material in liquid or semi-solid form to the exposed section of wire to fill gaps between the strands and allowing the filler material to solidify to provide substantially solid block of material that binds the strands together and blocks the flow of fluids along the multi-stranded electrical wire in use, and applying a sealant to the casing to seal the first part of the casing from the second part of the casing and / or applying the sealant around the filkd section of wire to form a seal with the insulating sheath.
A lighting device according to claim 13, wherein the filler material comprises a metallic alloy such as a solder.
A method according to claim 13 or 14, wherein the sealant includes a resin, and preferably a silicon resin or an epoxy resin.
PCT/GB2009/002563 2008-11-04 2009-10-29 Lighting device having means for preventing moisture ingress via an electrical cable WO2010052449A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0820176A GB2465145A (en) 2008-11-04 2008-11-04 Lighting Device Preventing Moisture Ingress
GB0820176.6 2008-11-04

Publications (1)

Publication Number Publication Date
WO2010052449A1 true WO2010052449A1 (en) 2010-05-14

Family

ID=40138295

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2009/002563 WO2010052449A1 (en) 2008-11-04 2009-10-29 Lighting device having means for preventing moisture ingress via an electrical cable

Country Status (2)

Country Link
GB (1) GB2465145A (en)
WO (1) WO2010052449A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3176502A1 (en) * 2015-12-01 2017-06-07 Collingwood Lighting Limited Method for manufacturing a lighting unit & lighting unit
US10364002B2 (en) 2015-07-30 2019-07-30 Koninklijke Philips N.V. Water lock to prevent water ingress

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11894649B2 (en) 2020-10-30 2024-02-06 Amphenol Corporation Electrical connector and method of making the same

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2531968A1 (en) * 1975-07-17 1977-02-03 Stahl Niederlassung Kuenzelsau Explosion proofed lighting unit with protected interior - has solid state light source and housing filled with cast resin material
US5743622A (en) * 1996-08-14 1998-04-28 Architectural Landscape Lighting Landscape light with anti-wicking elements and elongated base
EP1873012A1 (en) * 2006-06-19 2008-01-02 Prime Global Brands Ltd. Trailer lamp assembly

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4290094A (en) * 1980-04-14 1981-09-15 Henning Jensen Underwater or weatherproof light
US4539629A (en) * 1984-02-10 1985-09-03 Gty Industries Spa light
US4851072A (en) * 1986-11-04 1989-07-25 Owens-Illinois Plastic Products Inc. Label application apparatus having a magazine with retaining fingers
US7011436B2 (en) * 2003-01-28 2006-03-14 Genlyte Thomas Group, Llc In-grade light fixture with hydraulic isolation

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2531968A1 (en) * 1975-07-17 1977-02-03 Stahl Niederlassung Kuenzelsau Explosion proofed lighting unit with protected interior - has solid state light source and housing filled with cast resin material
US5743622A (en) * 1996-08-14 1998-04-28 Architectural Landscape Lighting Landscape light with anti-wicking elements and elongated base
EP1873012A1 (en) * 2006-06-19 2008-01-02 Prime Global Brands Ltd. Trailer lamp assembly

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10364002B2 (en) 2015-07-30 2019-07-30 Koninklijke Philips N.V. Water lock to prevent water ingress
US10730594B2 (en) 2015-07-30 2020-08-04 Koninklijke Philips N.V. Water lock to prevent water ingress
EP3176502A1 (en) * 2015-12-01 2017-06-07 Collingwood Lighting Limited Method for manufacturing a lighting unit & lighting unit
GB2544975A (en) * 2015-12-01 2017-06-07 Collingwood Lighting Ltd Method for manufacturing a lighting unit & lighting unit
GB2544975B (en) * 2015-12-01 2017-12-06 Collingwood Lighting Ltd Method for manufacturing a lighting unit & lighting unit

Also Published As

Publication number Publication date
GB0820176D0 (en) 2008-12-10
GB2465145A (en) 2010-05-12

Similar Documents

Publication Publication Date Title
KR101285245B1 (en) Windowpane having an electrical flat connecting element
CA2702704C (en) Electronic apparatus for lighting applications
JP2011081918A (en) Water stop structure of electric wire, and method of forming the water stop structure
KR20060129364A (en) Method for joining a connecting element to an electric conductor made of aluminum and electric conductor produced according to said method
JP6639793B2 (en) Wire with terminal and method of manufacturing the same
JP2009152012A (en) Water cutoff method for electric wire, and electric wire with water cutoff part formed by water cutoff method
ES2687051T5 (en) Plug-in connection with a plug-in connector and a cable connected to it
US20180017238A1 (en) Housing for lighting devices, corresponding lighting device and method
WO2010052449A1 (en) Lighting device having means for preventing moisture ingress via an electrical cable
KR20150041013A (en) Hermetic terminal with fully insulated direct wire connection
JP2014220097A (en) Wire with terminal
CN107342646B (en) Split assembly with seal for electrically cross-connecting a plurality of stator wires
US8614399B2 (en) Electric junction box
JP6766659B2 (en) Manufacturing method of electric wire with terminal and electric wire with terminal
DE102011113929B4 (en) Electromechanical circuit construction
JP2014203725A (en) Electric wire with terminal
WO2016181525A1 (en) Solar cell module and solar cell module manufacturing method
US10819107B2 (en) Electronic unit comprising an ESD protective arrangement
KR20120101062A (en) Method for establishing a sealed connection
WO2010052207A2 (en) Connecting device for a photovoltaic solar module
JP2009038299A (en) Holder connector for led and its connection structure
US9686823B2 (en) Electric heater
EP3176502B1 (en) Method for manufacturing a lighting unit & lighting unit
JP2017073402A (en) Waterproof connector
CN110857756A (en) Double-color line lamp structure

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 09751957

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 09751957

Country of ref document: EP

Kind code of ref document: A1