SUPPORT FOR LIGHT-EMITTING ELEMENTS AND LIGHTING DEVICE

Abstract

A lighting device comprises a support comprising a mounting section having at least one mounting face. The at least one mounting face has an arrangement direction and comprising at least two contact sections along the arrangement direction. The support further comprises a body section adjacent to the mounting section. The support further comprises a plurality of layered conductors connecting the body section to the at least one mounting face. The lighting device comprises at least one light-emitting element mounted along the arrangement direction of the at least one mounting face such that the at least one light-emitting element is in electrical contact to the at least two contact sections.

Claims

1. A lighting device comprising: a support comprising a mounting section having at least one mounting face, the at least one mounting face having an arrangement direction and comprising at least two contact sections along the arrangement direction; the support further comprising a body section adjacent to the mounting section; the support further comprising a plurality of layered conductors connecting the body section to the at least one mounting face; and at least one light-emitting element mounted along the arrangement direction of the at least one mounting face such that the at least one light-emitting element is in electrical contact to the at least two contact sections.

2. The lighting device of claim 1, further comprising: a socket connected to the body section for connection to a power source.

3. The lighting device of claim 1, wherein the body section has a length that extends parallel to the arrangement direction, such that the body section protrudes sidewards from the at least one mounting face.

4. The lighting device of claim 3, wherein the body section has an increased cross-sectional area with increasing distance from the mounting section.

5. The lighting device of claim 1, wherein an extension direction of the layered conductors extends substantially perpendicular to the arrangement direction of the at least one mounting face.

6. The lighting device of claim 1, wherein the layered conductors comprises an angled section.

7. The lighting device of claim 1, further comprising an insulating section separating two neighboring contact sections of the at least two contact sections.

8. The lighting device of claim 1, wherein the at least one light-emitting element is configured to emit a light of different wavelength than another light-emitting element.

9. The lighting device of claim 1, wherein a voltage is applied between any of the at least two contact sections when the body section is connected to a power source.

10. The lighting device of claim 1, wherein at least one contact section is not connected so that a voltage is not applied to the at least one contact section when the body section is connected to a power source.

11. A method for producing a lighting device, the method comprising: providing a support comprising a plurality of layered conductors connecting a body section to at least one mounting face of a mounting section; mounting at least one light-emitting element along an arrangement direction of at least one mounting face of the mounting section; and electrically connecting the at least one light-emitting element to at least one contact section of the at least one mounting face.

12. The method of claim 11, wherein the providing the support further comprises: stacking metallic sheets; and disposing insulating layers between the metallic sheets to form the plurality of layered conductors.

13. The method of claim 12, further comprising bending the metallic sheets to form an angled section.

14. The method of claim 13, wherein the angled section is substantially perpendicular.

15. The method of claim 11, wherein the mounting the at least one light-emitting element further comprises: providing a supporting layer; and mounting the at least one light-emitting element on the supporting layer.

16. The method of claim 15, further comprising mounting the at least one light-emitting element on the supporting layer via an adhesive.

17. The method of claim 15, wherein the mounting the at least one light-emitting element further comprises: attaching at least one suction nozzle to the supporting layer; and using the at least one suction nozzle to mount the at least one light-emitting element.

18. The method of claim 17, further comprising bending the supporting layer at a perforation to mount another light-emitting element.

19. The method of claim 11, further comprising providing solder paste to the at least one contact section of the at least one mounting face.

20. The method of claim 11, further comprising connecting the light-emitting device to a power supply via a socket.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0069] FIG. 1 shows a schematic representation of a first embodiment of a support in a side view;

[0070] FIG. 2 shows a schematic representation of the first embodiment of a support in a top view;

[0071] FIG. 3 shows a schematic representation of the first embodiment of a support in a front view;

[0072] FIG. 4 shows a schematic representation of the first embodiment of a support in a perspective view;

[0073] FIG. 5 shows a schematic representation of a first embodiment of a lighting device in a perspective view;

[0074] FIG. 6 shows a schematic representation of a second embodiment of a lighting device in a perspective view;

[0075] FIG. 7 shows a schematic representation of a second embodiment of a lighting device in a perspective view;

[0076] FIG. 8 shows a schematic representation of a third embodiment of a lighting device in a perspective view;

[0077] FIG. 9 shows a schematic representation of a fourth embodiment of a lighting device in a perspective view;

[0078] FIG. 10 shows a schematic representation of a fifth embodiment of a lighting device in a perspective view;

[0079] FIG. 11 shows a schematic representation of a sixth embodiment of a lighting device in a perspective view;

[0080] FIG. 12 shows a schematic representation of a seventh embodiment of a lighting device in a perspective view; and

[0081] FIG. 13a-d show schematic representations of an embodiment of a method for producing a lighting device.

DETAILED DESCRIPTION

[0082] The following description serves to deepen the understanding of the present invention and shall be understood to complement and be read together with the description as provided in the above summary section of this specification.

[0083] FIGS. 1, 2, and 3 show schematic representations of a first embodiment of a support 2 for at least one light-emitting element in a side view, top view, and front view, respectively. In FIG. 4, the first embodiment of a support 2 is shown in a perspective view.

[0084] As can be seen in particular in FIGS. 1 and 2, the support 2 comprises a mounting section 4 with three mounting faces 6a, 6b, 6c, wherein the mounting faces 6a, 6b, 6c have an arrangement direction 8. The mounting faces 6a, 6b, 6c are configured for accommodating light-emitting elements arranged along the arrangement direction 8. The mounting face 6b is arranged between the other two mounting surfaces 6a, 6c and is arranged substantially perpendicular to the other two mounting surfaces 6a, 6c.

[0085] A body section 10 is arranged adjacent to the mounting section 4 and is in thermal contact to the mounting section 4. The support 2 comprises conductors 12 for providing electric connection from the body section 10 to the mounting faces 6a, 6b, 6c, such that light-emitting elements may be provided with electrical power by connecting the body section 10 to a power source. The mounting section 4 and body section 10 comprise a layered structure of conductors 12 formed from metallic sheet material, in particular sheet material based on copper, and insulating layers 13 disposed in between the conductors 12.

[0086] An extension direction of the metallic sheet material forming the conductors 12 and the insulating layers 13 extends substantially perpendicular to the arrangement direction 8 of the mounting faces 6a, 6b, 6c in the mounting section. In part of the body section 10, the extension direction extends substantially parallel to the arrangement direction 8. The layered structure of conductors 12 and insulating layers 13 comprises an angled section 18, wherein a length of the body section 10 extends substantially parallel to the arrangement direction 8.

[0087] As can be seen in FIG. 1, the mounting faces 6a, 6b, 6c comprise contact sections 16 along the arrangement direction 8, each contact section 16 corresponding to a conductor 12 and being separated by an insulating section formed by the insulation layers 13. The metallic sheet material forming the conductors 12 comprises a main face and side faces, wherein each of the contact sections 16 is respectively formed by a side face of metallic sheet material.

[0088] As can be seen in particular from the front view in FIG. 3, the body section 10 protrudes sidewards from the mounting faces 6a, 6b, 6c relative to the arrangement direction 8. For instance, when a viewer faces the mounting face 6b, the body section extends beyond the edges of the mounting faces 6a, 6b, 6c. That is, the body section 10 has an increased width in comparison to the mounting section 4.

[0089] The body section 10 has an increasing cross-sectional area with increasing distance from the mounting section 4, which is in particular apparent from the top view in FIG. 2. The body section 10 has a triangular cross section with the mounting section 4 being arranged on an edge of the triangular cross section. The triangular cross section has an opening angle of 45°. As already mentioned above, the body section may provide an electrical connection to the at least one mounting face and may act simultaneously as a heat sink as well as a heat conductor, which is particularly advantageous when light-emitting elements with a high heat output are used, e.g. LED light sources for applications such as automotive head lighting. As the body section 10 protrudes sidewards from the mounting faces 6a, 6b, 6c, the volume of the body section 10 is enlarged, and the body section 10 provides significantly improved heat transfer from the mounting section 4 while at the same time providing effective electrical conductivity and optical properties suitable for retrofitting applications.

[0090] In particular, the illumination pattern of light sources such as halogen bulbs may be reproduced very closely with light-emitting elements mounted in the mounting faces 6a, 6b, 6c of the support 2. Each of the mounting faces 6a, 6b, 6c is configured for accommodating multiple light-emitting elements arranged along the arrangement direction 8. In this first embodiment, the mounting faces 6a, 6b, 6c each comprise six contact sections 16 along the arrangement direction 8, each contact section 16 corresponding to a conductor 12 and being separated by an insulating section 13. The arrangement direction may correspond to the extension direction of a filament in an incandescent light source.

[0091] A first embodiment of a lighting device 20 according to the invention is shown in FIG. 5, wherein the lighting device 20 comprises the first embodiment of a support 2 as depicted in FIGS. 1-4. Five light-emitting elements 22 are mounted along the arrangement direction 8 of each mounting face 6a, 6b, 6c. Each light-emitting element 22 is in electrical contact to two neighboring (alternating) contact sections 16.

[0092] In FIG. 6, a second embodiment of a lighting device 20 according to the invention is shown, wherein a socket 24 for connection to a power source is provided, wherein the socket 24 is connected to the body section 10 of the support 2. The support 2 is configured according to the first embodiment shown in FIGS. 1-4. The socket 24 represents a standard socket corresponding to a H7 halogen lamp in automobile applications.

[0093] FIG. 7 to FIG. 12 show respective further embodiments of a lighting device 20 according to the invention, wherein in contrast to the first embodiment of the invention shown in FIG. 5, a different control of the conductors 12a to 12f is illustrated enabling other functions of the multiple lighting functions of the lighting device 20, and/or comprising optional further structural features.

[0094] FIG. 7 shows an embodiment of the present invention that is based on the lighting device shown in FIG. 5. Each contact section 16 corresponds to a conductor 12a to 12f. Between two neighboring contact sections corresponding to the conductors 12a to 12f, a respective insulating section 13 is comprised by the support 2. Each light-emitting element 22 is a LED die. In order to enable multiple lighting functions, such as low beam, DRL, PL, or a combination thereof, and/or providing beam dynamics, such as boosting, dimming, fast switching, or a combination thereof, one or more voltages can be applied to any combination of the conductors 12a to 12f resulting in one or more voltages being applied to the LED dies. The one or more voltages may for instance be applied in a timely manner, e.g. in certain pre-defined time intervals, e.g. resulting in a running light enabled by the support. As shown in FIG. 5, conductor 12a is applied with a + polarity, conductor 12f is applied with a − polarity, while conductors 12b to 12e are not connected (as indicated by ‘NC’). This may for instance result in that all of the LED dies 22 of the example embodiment shown in FIG. 5 emit light as defined by the respective LED dies 22.

[0095] In FIG. 8, conductors 12a and 12b are applied with a voltage of alternating polarity (12a: + polarity, and 12b: − polarity), conductors 12e and 12f are applied with a second voltage (e.g. different from voltage applied to conductors 12a, 12b) of alternating polarity (12e: + polarity, and 12f: − polarity), and conductors 12c and 12d are not connected (as indicated by ‘NC’), resulting in that LED dies 22 coupled to the conductors 12a and 12b are switched on, and further, the LED dies 22 coupled to the conductors 12e and 12f are switched on, while the other LED dies 22 are switched off as well.

[0096] The example embodiment of a support 2 shown in FIG. 9 comprises an optional sensor 14a, wherein the sensor in FIG. 9 is a temperature sensor 14a and is mounted on the side of the support 2. Via the conductors 12c and 12d, information gathered by the temperature sensor 14a (e.g. temperature information indicative of a temperature value measured in the vicinity of the LED dies 22) can be read. Conductors 12c and 12d are applied with a voltage of alternating polarity (12c: − polarity, and 12d: + polarity), while the conductors 12a, 12b, and 12e, 12f are not connected (as indicated by ‘NC’). With this controlling of the conductors, information gathered by the temperature sensor 14a may be read. In case e.g. information of the temperature sensor 14b should not be read, the conductors 12c and 12d applied with a respective voltage as shown, can result in the respective LED dies connected via the conductors 12c, 12d being switched on.

[0097] In contrast, in FIG. 11, another sensor 14b, e.g. a temperature sensor is comprised by the support, wherein this sensor 14b is located on a side of the support and is coupled to the conductors 12c, 12d, and 12e. Via this coupling, e.g. information gathered by the sensor 14b, and/or controlling of the sensor 14b is enabled.

[0098] In FIG. 12, a further sensor 14c, e.g. a temperature sensor 14c is comprised on a top side of the support. In this embodiment, the respective sensor 14c is coupled via the conductor 12a enabling information gathered by the respective sensor 14c (e.g. as disclosed above) at least to be read and/or to control the respective sensor 14c accordingly.

[0099] In FIG. 10, the LED dies 22 comprise a specific LED die 22a, which may be a LED die enabled to emit light of a wavelength resulting in the color of yellow and/or blue. In this way, e.g. emitting of cold-white or warm-white light may be enabled.

[0100] Example embodiment according to all exemplary aspects of the present invention enable one or more of the following features: each Cu (copper)-Stripe is an electrical port (e.g. conductor); addressing LED dies individually or in groups (all LEDs on) is enabled; addressing LEDs individually or in groups (welcome mode) is enabled; placing additional LEDs at different locations (e.g. a LED of another color, such as a blue LED) is enabled; and using polarity of LEDs to realize dual or multiple functions (e.g. turning LEDs on in a sequential, thus timely different manner) is enabled.

[0101] Between connectors, polarity may be different (prior art: higher order connector has higher potential). Further, LED dies can be turned off, sensor(s) are enabled, and/or other LED dies can be operated selectively. In a normal operation of example embodiments of the invention, all LED dies are operated in series (e.g. connector 1 has positive potential, last connector has negative potential, all connectors in between are isolated, thus series operation is realized).

[0102] FIG. 13a-d show schematic illustrations of a method for producing a lighting device according to the invention and in particular for producing the lighting device according to the first embodiment.

[0103] A support 2 is provided, e.g. configured according to the first embodiment shown in FIGS. 1-4. The support 2 may be provided by stacking of metallic sheets and disposing insulating layers between the metallic sheets, wherein the insulating layers can be formed by adhesive applied to the metallic sheets. The metallic sheets may be bent to form an angled section with a substantially perpendicular angle and a material removal may be performed to obtain a shape of the support 2 as depicted in FIGS. 1-4.

[0104] Light-emitting elements 22 are then mounted on the support 2 as shown in FIG. 13a-d. FIG. 13a represents a front view, wherein the light emitting elements 22 are removably fixed on a supporting layer 26, for instance an adhesive polyimide tape or an UV curable adhesive tape. The supporting layer 26 has predetermined bend lines in form of perforations 28 that divide the light-emitting elements 22 into groups, each group corresponding to a mounting face 6a, 6b, 6c. Solder paste as a contact material is applied on contact sections of the light-emitting elements 22 (not shown).

[0105] The supporting layer 26 is picked up by suction nozzles 30a, 30b, 30c of a holding device. Three suction nozzles 30a, 30b, 30c or three groups of suction nozzles 30a, 30b, 30c are used, each corresponding to a group of light-emitting elements 22 and a mounting face 6a, 6b, 6c. After the light-emitting elements 22 corresponding to mounting face 6b have been applied, as shown in a top view of the support 2 in FIG. 13b, the suction nozzles 30a, 30c are repositioned and rotated such that the supporting layer 26 is bent at the perforations 28 to conform the shape of the mounting faces 6a, 6b, 6c, as shown in FIG. 13c.

[0106] As an alternative, the supporting layer 26 may be cut into strips, each strip corresponding to a mounting face 6a, 6b, 6c (not shown) and the strips are applied in a similar manner.

[0107] The solder paste is subjected to a reflow after positioning of the light-emitting elements 22 such that the solder paste permanently connects the light-emitting elements 22 to the contact sections 16 of the mounting faces 6a, 6b, 6c. The supporting layer 22 may be removed from the light-emitting elements after reflow (e.g. when adhesive polyimide tape is used) or before reflow (e.g. when using UV curable adhesive tape that can be exposed to UV light to reduce adhesion to the light-emitting elements 22). A light-emitting device 20 is obtained as shown in FIG. 13d. Example embodiments of the present invention enable e.g. an architecture that is 100% compatible to the H7 architecture of car lights. Further, it is possible to incorporate multiple lighting functions (low beam, DRL (Daytime Running Light), PL (Position Light), etc.) and/or providing beam dynamics (boosting, dimming, fast switching, etc.) with the same retro fit lighting module by enabling that a voltage can be applied between any of the contact sections when connected to a power source.

[0108] A support for light-emitting elements may comprise a mounting section (4) with at least one mounting face (6a, 6b, 6c). The at least one mounting face (6a, 6b, 6c) may be arranged in an arrangement direction (8) and may be configured for accommodating at least one light-emitting element (22) arranged along the arrangement direction (8). The support may comprise a body section (10) arranged adjacent to the mounting section (4). The support may comprise conductors (12) for providing electric connection from the body section (10) to the at least one mounting face (6a, 6b, 6c). The at least one mounting face (6a, 6b, 6c) may comprise at least two contact sections (16) along the arrangement direction (8). Each contact section may correspond to a conductor (12). The body section (10) may protrude sidewards from the at least one mounting face (6a, 6b, 6c).

[0109] The body section (10) may be at least in sections an increasing cross-sectional area with increasing distance from the mounting section (4), in particular a triangular cross section at least in sections with the mounting section (4) being arranged on an edge of the triangular cross section. The triangular cross section may have an opening angle of 0° to 90°, in particular 30° to 45°.

[0110] The mounting section (4) and/or body section (10) may comprise a layered structure of conductors (12) and insulating layers (13).

[0111] The conductors (12) may comprise a metallic sheet material. The metallic sheet material may be based on copper.

[0112] The metallic sheet material may comprise a main face and side faces. Each of the contact sections (16) may be respectively at least partially formed by a side face of the metallic sheet material.

[0113] An extension direction of the layered structure of conductors (12), in particular of the metallic sheet material, and insulating layers (13) in the mounting section (4) may extend substantially perpendicular or substantially parallel to the arrangement direction (8) of the at least one mounting face.

[0114] The layered structure of conductors (12) and insulating layers (13) may comprise an angled section (18). A length of the body section (10) may extend substantially parallel to the arrangement direction (8).

[0115] The mounting section (4) may comprise at least two mounting faces (6a, 6b, 6c) being arranged adjacent to each other. At least two mounting faces (6a, 6b, 6c) may be arranged at an angle to each other or substantially parallel to each other.

[0116] The mounting section (4) may comprise three mounting faces (6a, 6b, 6c). One of the three mounting faces (6b) may be arranged between the other two mounting surfaces (6a, 6c). One of the three mounting faces (6b) may be arranged between the other two mounting surfaces (6a, 6c) with an enclosing angle of 45° to 135°, in particular 45° to 75° or substantially perpendicular to the other two mounting surfaces (6a, 6c).

[0117] The at least one mounting face (6a, 6b, 6c) may be configured for accommodating multiple light-emitting elements (22) arranged along the arrangement direction (8). The at least one mounting face (6a, 6b, 6c) may comprise at least three alternating contact sections (16) along the arrangement direction (8). Each alternating contact section (16) may correspond to a conductor (12) and may be separated by an insulating section.

[0118] A lighting device may comprise a support (2) according to any of embodiments discussed herein. The lighting device may comprise at least one light-emitting element (22) mounted along the arrangement direction (8) of at least one mounting face (6a, 6b, 6c). The at least one light-emitting element (22) may be in electrical contact to at the least two contact sections (16).

[0119] The lighting device may comprise a socket (24) for connection to a power source. The socket (24) may be connected to the body section (10).

[0120] A method for producing a lighting device (20) may comprise providing a support (2) according to any of the embodiments discussed herein. The method may comprise mounting at least one light-emitting element (22) along an arrangement direction (8) of at least one mounting face (6a, 6b, 6c). The at least one light-emitting element (22) may be brought into electrical contact to a contact sections (16).

[0121] The method may comprise a stacking of metallic sheets and disposing insulating layers (13) between the metallic sheets. The metallic sheets may be bent to form an angled section (18). The angled section may be a substantially perpendicular angle.

[0122] The method may comprise a material removal, in particular after a stacking of metallic sheets.

[0123] The mounting of the at least one light-emitting element (22) may comprise removably fixing the at least one light-emitting element (22) on a supporting layer (26). The mounting may comprise applying a contact material on the at least one light-emitting element (22). The mounting may comprise applying the at least one light-emitting element (22) fixed on the supporting layer (26) to the at least one mounting face (6a, 6b, 6c). The contact material may connect the at least one light-emitting element (22) to the contact sections (16).

[0124] Applying the at least one light-emitting element (22) fixed on the supporting layer (26) to the at least one mounting face (6a, 6b, 6c) may comprise bending the supporting layer (26) to conform to the shape of the at least one mounting face (6a, 6b, 6c). The supporting layer (26) may have at least one predetermined bend line (28). The bend line may be a material weakening such as a material reduction or a perforation. Applying the at least one light-emitting element (22) fixed on the supporting layer (26) to the at least one mounting face (6a, 6b, 6c) may comprise a cutting of the supporting layer (26).

[0125] In the present specification, any presented connection in the described embodiments is to be understood in a way that the involved components are operationally coupled. Thus, the connections can be direct or indirect with any number or combination of intervening elements, and there may be merely a functional relationship between the components.

[0126] Moreover, any of the methods, processes and actions described or illustrated herein may be implemented using executable instructions in a general-purpose or special-purpose processor and stored on a computer-readable storage medium (e.g., disk, memory, or the like) to be executed by such a processor. References to a ‘computer-readable storage medium’ should be understood to encompass specialized circuits such as FPGAs, ASICs, signal processing devices, and other devices.

[0127] The expression “A and/or B” is considered to comprise any one of the following three scenarios: (i) A, (ii) B, (iii) A and B. Furthermore, the article “a” is not to be understood as “one”, i.e. use of the expression “an element” does not preclude that also further elements are present. The term “comprising” is to be understood in an open sense, i.e. in a way that an object that “comprises an element A” may also comprise further elements in addition to element A.

[0128] It will be understood that all presented embodiments are only exemplary, and that any feature presented for a particular example embodiment may be used with any aspect of the invention on its own or in combination with any feature presented for the same or another particular example embodiment and/or in combination with any other feature not mentioned. In particular, the example embodiments presented in this specification shall also be understood to be disclosed in all possible combinations with each other, as far as it is technically reasonable and the example embodiments are not alternatives with respect to each other. It will further be understood that any feature presented for an example embodiment in a particular category (method/apparatus/computer program/system) may also be used in a corresponding manner in an example embodiment of any other category. It should also be understood that presence of a feature in the presented example embodiments shall not necessarily mean that this feature forms an essential feature of the invention and cannot be omitted or substituted.

[0129] The statement of a feature comprises at least one of the subsequently enumerated features is not mandatory in the way that the feature comprises all subsequently enumerated features, or at least one feature of the plurality of the subsequently enumerated features. Also, a selection of the enumerated features in any combination or a selection of only one of the enumerated features is possible. The specific combination of all subsequently enumerated features may as well be considered. Also, a plurality of only one of the enumerated features may be possible.

[0130] The sequence of all method steps presented above is not mandatory, also alternative sequences may be possible. Nevertheless, the specific sequence of method steps exemplarily shown in the figures shall be considered as one possible sequence of method steps for the respective embodiment described by the respective figure.

[0131] The invention has been described above by means of example embodiments. It should be noted that there are alternative ways and variations which are obvious to a skilled person in the art and can be implemented without deviating from the scope of the appended claims.