LED LAMP WITH MOLDED HOUSING/HEATSINK

Abstract

The solution relates to lighting technology, namely to LED lamps powered directly from the AC mains. The technical result is to simplify the design, improve heat dissipation and reduce the labor intensity of manufacturing high-power lamps of general use, resistant to external influences >IP65, and with a minimum cost and labor intensity. In some cases, the LED lamp contains a radiator housing made in the form of a hollow cylindrical body made of an optically transparent material; a flexible aluminum printed circuit board, on a mounting surface of which LEDs and a driver are mounted; end caps, at least one of which is provided with means for connecting to a power supply network, while the flexible printed circuit board is configured in the form of a roll, the mounting surface is disposed outward, and part of the board with the driver is bent inside the roll, while the light-emitting surface of the LEDs is immersed in a transparent material housing, and the mounting surface of the configured printed circuit board has direct thermal contact with the transparent material.

Claims

1-6. (canceled)

7. An LED lamp, containing: a hollow cylindrical housing, the walls of which are made of an optically transparent material, equipped with end caps, one of which has means of connection to a power supply network; and a flexible printed circuit board having a mounting surface, on one part of which there are LEDs, and on another part of the mounting surface are disposed driver components, wherein the flexible printed circuit board is placed in a cavity of the hollow cylindrical housing in such a way that the one part of the mounting surface on which the LEDs are installed is rolled up in a form of a roll with the mounting surface being disposed outward, while the LEDs are immersed in the wall of the cylindrical housing, wherein the other part of the flexible printed circuit board carrying the driver components is bent inside said roll of the printed circuit board, wherein, a seating surface of the printed circuit board is connected by adhesion forces to a material of the wall of the hollow cylindrical housing.

8. The LED lamp according to claim 1, wherein the driver components are arranged as a sequential driver.

9. The LED lamp according to claim 1, wherein a thickness of a layer of the optically transparent material on at least one of: (i) a surface of the flexible printed circuit board, (ii) a housing of each of the LEDs, and (iii)it’s a light-emitting surface of each of the LEDs is 0.2-0.5 mm.

10. The LED lamp according to claim 1, wherein the optically transparent material contains phosphor particles.

11. The LED lamp according to claim 1, wherein the LEDs are mounted on a part of a perimeter surface of the flexible printed circuit board that is in the form of the roll.

12. The LED lamp according to claim 1, wherein the end caps are provided with through holes to remove convection heat.

13. The LED lamp according to claim 1, wherein the flexible printed circuit board has a raised relief surface between the LEDs.

Description

THE FIGURES SHOW

[0014] FIG. 1 - volumetric image of a disassembled version of the lamp,

[0015] FIG. 2 is a side view of the lamp shown in FIG. 1, assembled,

[0016] FIG. 3 - scan of the version of the printed circuit board of the lamp shown in FIG. 1,

[0017] in FIGS. 4 and 5 - a cross-section of variants of a lamp with a printed circuit board in the material of the body/radiator.

POSITIONS IN THE FIGURES INDICATE:

[0018] 1 - body/radiator., [0019] 2 - development of a flexible printed circuit board, [0020] 3 - LEDs, [0021] 4 - flexible printed circuit board configured in a roll, [0022] 5 - driver components, [0023] 6 - first end cap of the body, [0024] 7 - means for connecting to the power supply network (base), [0025] 8 - the second end cap of the body, [0026] 9 - part of the board with the driver, [0027] 10 - technological protrusions on the printed circuit board.

[0028] All components are installed on SMT machines in one installation, therefore, a sequential power supply is used that does not have external components (filters, etc.) that require fixing in the holes of the printed circuit board.

[0029] The flat printed circuit board 2 (FIG. 3) is rolled into a roll with the mounting surface outward and installed in a mandrel, in which the transparent material is placed on the emitting surface of the LEDs and on the mounting surface of the printed circuit board, after curing the transparent material, the LEDs and the mounting surface of the printed circuit board are fixed transparent material. Thus, the transparent material performs several functions: it forms the lamp body and the cooling radiator, the radiation diffuser, and ensures the isolation of live parts from contact.

[0030] To form the body, various transparent materials can be used that have high light transmittance and temperature resistance, withstand thermal contact with the LED body without destruction, and do not poison the LED. For example, among a number of known transparent resins (acrylic, epoxy, polyurethane), the most suitable are polyurethane resin-based compounds with a thermal conductivity that, at a distance of less than 1 mm from the light-emitting surface of the LED and to the outer surface of the diffuser, provides sufficient heat exchange with atmospheric air.

[0031] Also the thermal conductivity and efficiency of such a body / heat sink is quite good due to the good adhesion and lack of air between the PCB and the body.

[0032] End caps 6 and 8 can be glued. The second plug 8 can be transparent, and then, if there are 2 bends in the configured flexible printed circuit board with installed LEDs, the lamp will provide a full illumination angle. The presence of through holes (not shown in the drawings) in the end caps provides efficient convection cooling of the back side of the printed circuit board.

[0033] The LED lamp has a point radiation, which is not very good for indoor lighting, but this effect can be reduced by installing LEDs with a small pitch or forming a transparent (matte) material with added phosphor or diffuser particles, which will simultaneously improve heat transfer from the LEDs to the external heat exchange surface.

[0034] For effective cooling, it is advisable to maintain the temperature of the board and the diffuser at the level of 70 - 75° C., then there is radiant heat radiation along with convection. When using efficient LEDs (>200 Im / W), the real luminous flux efficiency will be ~ 160-170 Im / W (losses in the diffuser ~ 5%, losses when the LEDs are heated to 85° C. (crystal) ~ 10%). Then, with a power of 30 W on LEDs, the luminous flux can reach 5000 Im. The overall efficiency of the lamp will be lower by the value of the driver efficiency (~ 0.89) and will be about 147 Im / W.