Watertight LED arrangement

Abstract

A watertight LED arrangement (1) is provided that extends in a longitudinal direction (L). A strip-shaped LED board (3) is provided with a multiplicity of LEDs (2) on its upper side and at least one cable (4) is electrically connected to the LED board (3). A one-piece, elastically formed watertight sheath (6) surrounds the LED board (3) and defines a light emission wall (5) at least on its upper side opposite the LEDs (2), the sheath (6) receiving the LED board (3) in a form-fitting manner. A cavity (7) extends in the longitudinal direction (L) between the upper side of the LED board (3) and the light emission wall (5). At least a portion of a sealing element (10a) extends from the LED board (3) toward the light emission wall (5) and defines an edge of the cavity (7).

Claims

1. A watertight LED arrangement (1) extending in a longitudinal direction (L), comprising: a strip-shaped LED board (3) provided with a multiplicity of LEDs (2) on its upper side; at least one cable (4) electrically connected to the LED board (3); and a one-piece, elastically formed watertight sheath (6) which surrounds the LED board (3) and defines a light emission wall (5) at least on its upper side opposite the LEDs (2), the sheath (6) receiving the LED board (3) in a form-fitting manner; wherein the sheath bears directly against the underside of the LED board (3), and a cavity (7) extending in the longitudinal direction (L) is provided between the upper side of the LED board (3) and the light emission wall (5); and a sealing element (10a) provided on at least one end of the LED board (3), at least a portion of the sealing element (10a) extending from the LED board (3) toward the light emission wall (5) and defining an edge of the cavity (7); the sealing element (10a) including opposing end plates (10a′, 10a″) joined by a connector (10a′″).

2. The LED arrangement (1) according to claim 1, wherein the cable (4) projects outwardly from the underside of the LED board (3) and is passed through the underside of the sheath (6).

3. The LED arrangement (1) according to claim 1, wherein longitudinal edges of the LED board (3) are enclosed by the sheath (6) in a form-fitting manner.

4. The LED arrangement (1) according to claim 1, wherein the sheath (6) has a substantially cuboid outer shape, wherein in the upper region of the sheath (6) projecting protrusions (8) are formed, which project laterally transversely to the longitudinal direction (L) and extend in the longitudinal direction (L), the protrusions (8) terminating flush with the light emission wall (5).

5. The LED arrangement (1) according to claim 1, wherein the sheath (6) is made of silicon and/or PVC and/or PU.

6. The LED arrangement (1) according to claim 1, wherein a first sheath region (6a) forming the upper side and at least parts of the longitudinal sides of the sheath (6) and a second sheath region (6b) forming at least parts of the underside of the sheath (6) are manufactured in successive working steps, the sheath regions (6a, 6b) being connected to one another in a form-fitting manner in order to achieve the one-piece-formation of the sheath (6).

7. The LED arrangement (1) according to claim 6, wherein the first sheath region (6a) has a substantially U-shaped cross-section and includes recesses (9) extending in a longitudinal direction (L) for receiving the longitudinal edges of the LED board (3) in a form-fitting manner.

8. The LED arrangement (1) according to claim 7, wherein the at least a portion of the sealing element (10a) extending from the LED board (3) toward the light emission wall (5) includes a cross-section adapted to the U-shaped cross-section.

9. The LED arrangement (1) according to claim 1, wherein the connector (10e) includes a cross section smaller than a cross section of either end plate (10a′, 10a″).

10. The LED arrangement (1) according to claim 1, wherein at least one of the opposing end plates (10a′, 10a″) abut an end of the LED board (3).

11. A method of manufacturing a watertight LED arrangement (1) extending in a longitudinal direction (L), comprising: obtaining an elongated LED board (3) extending in a longitudinal direction (L) and provided on its upper side with a plurality of LEDs (2) and having a predetermined length; connecting a cable (4) to the LED board (3); obtaining a substantially U-shaped first sheath region (6a) which is manufactured by extrusion from a watertight material and which forms an upper side defining a light emission wall (5) and at least parts of longitudinal sides of a sheath (6) of the LED arrangement (1) and has recesses (9) arranged opposite one another at a distance from the upper side and extending in the longitudinal direction (L) for receiving the longitudinal edges of the LED board (3) in a form-fitting manner; positioning the LED board (3) provided with the cable (4) in the recesses (9) of the first sheath region (6a) such that the upper side of the LED board (3) faces the light emission wall (5) and the free ends of the LED board (3) are arranged at approximately the same distance (a) from the free ends of the first sheath region (6a); closing end faces of the arrangement by inserting the assembly into a suitably formed casting mold; and casting a second sheath region (6b) forming at least a part of an underside of the sheath (6) and sealing the end faces of the sheath (6) using a watertight material and applying material of the second sheath region about a sealing element connector (10a′″) such that the material of the second sheath regions abuts opposing end plates (10a′, 10a″) of a sealing element (10a).

12. The method according to claim 11, wherein, after positioning the LED board (3), a cavity (7) formed between the upper side of the LED board (3) and the light emission wall (5) and extending in the longitudinal direction (L) is closed at the ends, in particular in that a sealing element (10a) which is provided on at least one free end of the LED board (3) and whose shape is adapted to the cross-sectional shape of the cavity (7) is angled in the direction of the light emission wall (5).

13. A watertight LED arrangement (1) extending in a longitudinal direction (L), comprising: a strip-shaped LED board (3) provided with a multiplicity of LEDs (2) on its upper side; at least one cable (4) electrically connected to the LED board (3); and a one-piece, elastically formed watertight sheath (6) which surrounds the LED board (3) and defines a light emission wall (5) at least on its upper side opposite the LEDs (2), the sheath (6) receiving the LED board (3) in a form-fitting manner; wherein the sheath bears directly against the underside of the LED board (3), and a cavity (7) extending in the longitudinal direction (L) is provided between the upper side of the LED board (3) and the light emission wall (5); and a sealing element abutting at least one end of the LED board (3), the sealing element extending upwardly in the direction of the light emission wall (5), the sealing element including opposing end plates (10a′, 10a″) joined by a connector (10a′″).

14. The LED arrangement (1) according to claim 13, wherein the cable (4) projects outwardly from the underside of the LED board (3) and is passed through the underside of the sheath (6).

15. The LED arrangement (1) according to claim 13, wherein the connector (10a′″) includes a cross-section smaller than either end plate (10a′, 10a″).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features and advantages of the present invention become clear by the following description of an LED arrangement according to an embodiment of the present invention or a method for manufacturing of the LED arrangement with reference to the enclosed drawing. There is

(2) FIG. 1 an end face view of an LED arrangement according to a first embodiment of the present invention;

(3) FIG. 2 a partial view of the LED arrangement cut along line II-II in FIG. 1;

(4) FIG. 3 a partial top view of an LED board of the LED arrangement shown in FIGS. 1 and 2;

(5) FIG. 4 a side view of the LED board shown in FIG. 3 with connected cable;

(6) FIG. 5 an end face view of a first sheath region of a sheath of the LED arrangement shown in FIGS. 1 and 2;

(7) FIG. 6 a partial view of the first sheath region cut along line VI-IV in FIG. 5;

(8) FIG. 7 an end face view of the first sheath region shown in the FIGS. 5 and 6, into which the LED board shown in the FIGS. 3 and 4 is inserted, wherein leaf regions provided at the free ends of the LED board are bent by 90 degrees in the direction of a light emission wall of the first sheath region;

(9) FIG. 8 a partial view cut along line VIII-VIII in FIG. 7;

(10) FIG. 9 an end face view of the arrangement shown in FIGS. 7 and 8 after casting a second sheath region;

(11) FIG. 10 a partial view cut along line X-X in FIG. 9;

(12) FIG. 11 an end face view analogue to FIG. 1 which shows a first sheath region according to a second embodiment of the present invention;

(13) FIG. 12 a side view of an end cap according to a first embodiment of the present invention;

(14) FIG. 13 an end face view of the end cap in the direction of arrow XIII in FIG. 12;

(15) FIG. 14 a view of the LED-arrangement shown in FIG. 2 in a shortened state, on which the end cap shown in FIGS. 12 and 13 is placed;

(16) FIG. 15A an end view of a sealing element;

(17) FIG. 15B a side of the sealing element of FIG. 15A;

(18) FIG. 15C a perspective view of the sealing element of FIG. 15A;

(19) FIG. 15D a top view of the sealing element of FIG. 15A;

(20) FIG. 16A an end view of an LED arrangement according to another embodiment of the present invention; and

(21) FIG. 16B a partial view of the LED arrangement cut along line B-B in FIG. 16A.

(22) Same reference numbers subsequently refer to identical components of the same design.

DETAILED DESCRIPTION

(23) Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the technology is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the technology as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the technology.

Definitions

(24) As used herein, the singular forms “a” and “the” can include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an LED” can include one or more of such items, if the context so dictates.

(25) As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. As an arbitrary example, an object that is “substantially” enclosed is an article that is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend upon the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. As another arbitrary example, a composition that is “substantially free of” an ingredient or element may still actually contain such item so long as there is no measurable effect as a result thereof.

(26) As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint.

(27) Relative directional terms can sometimes be used herein to describe and claim various components of the present technology. Such terms include, without limitation, “upward,” “downward,” “horizontal,” “vertical,” etc. These terms are generally not intended to be limiting, but are used to most clearly describe and claim the various features of the technology. Where such terms must carry some limitation, they are intended to be limited to usage commonly known and understood by those of ordinary skill in the art in the context of this disclosure. In some instances, dimensional information is included in the figures. This information is intended to be exemplary only, and not limiting. In some cases, the drawings are not to scale and such dimensional information may not be accurately translated throughout the figures.

(28) As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary.

(29) Numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4 and sub-ranges such as from 1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5, individually.

(30) This same principle applies to ranges reciting only one numerical value as a minimum or a maximum. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described.

(31) Invention

(32) FIGS. 1 and 2 show a watertight LED (light-emitting diode) arrangement 1 extending in a longitudinal direction L according to a first embodiment of the present invention. LED arrangement 1 comprises a strip-shaped LED board 3 provided on its upper side with a multiplicity of LEDs 2, a cable 4 electrically connected to the LED board 3 and a watertight sheath 6 which surrounds the LED board 3. The sheath 6 is formed in one piece and is elastic, defines a light emission wall 5 at least on its upper side and receives the LED board 3 in a form-fitting manner. Furthermore, a cavity 7 extending in the longitudinal direction L is provided between the upper side of the LED board 3 and the light emission wall 5.

(33) The sheath 6 has an essentially cuboid outer shape, whereby in the upper region of the sheath 6 protrusions 8, which project laterally transversely to the longitudinal direction L and extend in the longitudinal direction L, are formed, the protrusions 8 terminating flush with the light emission wall 5. The protrusions 8 are used to clamp the LED arrangement 1 in a U-shaped groove of a profile which is not shown in detail and which can be used to mount the LED arrangement 1. Alternatively, it is also possible to do without such protrusions 8 as shown in FIG. 11 as an example. The sheath 6 presently consists of a first sheath region 6a and a second sheath region 6b, which are connected to each other by a material bond and form a one-piece unit. The first sheath region 6a defines the upper side and thus the light emission wall 5, the longitudinal sides and a small part of the underside as well as a part of the end faces of the sheath 6, whereas the second sheath region 6b defines a large part of the underside and a part of the end faces of the sheath 6. The first sheath region 6a has a substantially U-shaped cross section and in its lower region recesses 9 extending in a longitudinal direction L for receiving the longitudinal edges of the LED board 3 in a form-fitting manner. The second sheath region 6b has the shape of a U, seen in a longitudinal cut view, and bears to the underside of the LED board 3. Both sheath regions 6a and 6b are manufactured from a soft plastic, in particular a silicone and/or PVC and/or PU. The material of the first sheath region is advantageously partially transparent, so that the upper side of the LED board 3 is not visible from the outside through the material, when the LEDs 2 are switched off. The material of the first sheath region 6a can be colored or provided with a translucent and colored coating on its upper side, for example in a grey tone, which can be desirable for the later application of the LED arrangement 1 in order to adapt the appearance of the LED arrangement to colors of materials surrounding the latter, such as the color of tiles, mortar or the like. The material of the second sheath region 6b is advantageously transparent so that the underside of the LED board 3 is visible from the outside through the material. In this way, markings provided on the other side of the LED board 3, which are not shown here, can be identified from the outside, such as markings that define positions at which the LED board 3 can be shortened. However, it should be clear that the sheath regions 6a and 6b can also be manufactured from a uniform material.

(34) The LED board is provided at each of its two opposite free ends with a leaf region 10 bent in the direction of the light emission wall 5, the shape of which is adapted to the cross-sectional shape of the cavity 7. The function of these leaf regions 10 is described in more detail below.

(35) The cable 4 is connected to the underside of the LED board 3, is preferably fixed to the underside of the LED board 3 using an adhesive, for example, over a predetermined distance in the longitudinal direction L, and then extends outwards through the second sheath region 6b. Accordingly, the cable 4 is strain-relieved and sealed by the second sheath region 6b.

(36) In the following, with reference to FIGS. 3 to 10, the manufacture of LED board 1 using a method according to an embodiment of the present invention is described.

(37) In a first step, LED board 3 is provided in a suitable predetermined length, see FIG. 3.

(38) In a further step, the cable 4 is connected to the LED board, presently to the rear side of the LED board. The cable 4 is advantageously attached to the rear side of the LED board over a predetermined distance in a longitudinal direction L, for example by use of a suitable adhesive or the like.

(39) The first sheath region 6a, which was previously manufactured by extrusion, is then provided, see FIGS. 5 and 6.

(40) Then, as shown in FIGS. 7 and 8, the LED board 3 provided with the cable 4 is positioned in the opposite recesses 9 of the first sheath region 6a such that the upper side of the LED board 3 and thus the LEDs 2 face to the light emission wall and the free ends of the LED board 3 are arranged at approximately the same distance from the free ends of the first sheath region 6a. Then the cavity 7 between the upper side of the LED board 3 and the light emission wall 5, extending in the longitudinal direction is closed at the end in the present case by bending the respective leaf regions 10 of the LED board 3, whose shape is adapted to the cross-sectional area of the cavity 7, by about 90 degrees in the direction of the light emission wall 5. In case that the LED board 3 is not provided with leaf regions 10, the end face closure of the cavity 7 can also be effected by correspondingly arranging sealing elements extending upwards in the direction of the light emission wall, in particular in the form of a blade or a film, the shape of which is preferably adapted to the cross sectional area of the cavity 7, for example in the form of adhesive strips or small plates. The length of the LED board 3 and the first sheath region 6a should be selected such that a distance a, which is advantageously at least 3 mm, is now set in the longitudinal direction between the leaf regions 10 and the corresponding free ends of the first sheath region 6a, so that the step described below can be carried out without problems.

(41) Now the end faces of the arrangement thus obtained are closed, for example by using suitable plates 11, which can form part of a casting device. Now a liquid plastic is poured from above onto the underside of the LED board 3 and into the spaces between the leaf regions 10 of the board 3 and the plates 11 to form the second sheath region 6b. The material of the second sheath region 6b joins with that of the first sheath region 6a, resulting in a watertight, one-piece formed sheath 6.

(42) In total, the method described above is characterized by the fact that LED arrangements 1 can be produced in any length in small quantities, in particular in small and medium series, simply and inexpensively. The manufacturing of the first sheath region 6a by extrusion is advantageous in that the light emission wall 5 can be produced with a high surface quality and flatness. The casting of the second sheath region 6b is not critical with regard to the surface quality to be achieved, since the underside of the LED arrangement 1 does not represent a visible surface. The cavity 7 ensures a constant color temperature or light color in the longitudinal direction L of the LED arrangement. A further advantage is that the materials of the two sheath regions 6a and 6b are freely selectable. The positioning of the cable 4 on the rear side of the LED board 3 makes it possible to arrange several LED arrangements 1 directly next to each other without optical interruption, which would not be possible if the cable was positioned on the end face of the LED arrangement.

(43) In case that LED arrangement 1 is to be shortened for later installation, it must be cut at the appropriate position and then sealed in a watertight manner again. For sealing, an end cap 12 shown in FIGS. 12 and 13 is preferably used according to an embodiment of the present invention. The end cap 12 has an essentially rectangular shape when viewed from the front, analogue to the LED arrangement 1, and an essentially triangular shape when viewed from the side. In other words, the side walls 13 are each with a chamfer 14, which, in the inserted state as shown in FIG. 14, tapers towards the light emission wall 5 of the sheath 6 of LED arrangement 1. Starting from the inclined end face 15, an outward projecting projection 16, whose cross-section is adapted to the cross-section of the cavity 7 of the LED arrangement, extends in longitudinal direction L, so that it can be inserted into the cavity 7.

(44) To shorten the LED arrangement, it is cut in a first step, whereby the course of the cut edge 17 is selected according to the inclination of the chamfers 14 of the end cap 12. In a further step, the end cap 12 is placed in the direction of the arrow 18 on the free end of the LED arrangement 1, whereby the projection 16 of the end cap 12 is inserted into the cavity 7 of the LED arrangement 1. The watertight connection between the end cap 12 and the LED arrangement 1 is realized by a watertight adhesive. The advantage of the end cap 12 is that it is not visible, or at least hardly visible, from the outside, starting from the light emission wall 5 of LED arrangement 1, thus achieving a very harmonious appearance.

(45) FIGS. 15A through 16B illustrate a more detailed example of a sealing element 10a that can be incorporated into the assembly. The sealing element includes opposing end plates 10a′, 10a″ that can be spaced or separated from one another by a connector 10a′″. The sealing element can be formed from a variety of materials, but is generally polymeric in nature and can be formed from a material to which one or both the sheath materials 6a, 6b readily bond. It is also generally pliable in its entirety. In one embodiment of the technology, either or both end plate 10a′, 10a″ can include a cross-section adapted to the U-shaped cross-section. In this manner, the end plates can fit snugly within the first sheath 6a and end plate 10a″ can form an edge of the cavity 7 such that fluids are prevented from entering the cavity. In particular, the end plate 10a″ can serve to prevent the fluid of the second sheath 6b material from flowing into the cavity when the second sheath is formed. Thus, the end plate 10a″ can abut or be in contact with the LED board 3.

(46) The connector (10a′″) can include a cross section smaller than a cross section of either end plate (10a′, 10a″). In this manner, the sealing element 10a can be positioned in a suitable casting mold after the LED board 3 is positioned within the U-shaped cross-section of the first sheath material 6a. Once in position, the second sheath 6b material, in liquid form, can be applied, for example, as shown at arrow 20. The material then forms the second sheath and also fills the area around the connector 10a′″. In this manner, the end plate 10a′ can form the end of the assembly. The sealing element 10a thus serves to prevent the liquid of the second sheath 6b material from entering the cavity 7, due to end plate 10a″, and from exiting or contacting the casting mold, due to end plate 10a′. As the sealing element can be formed in its entirety from a pliable material, the entire watertight LED arrangement retains its resilience in that area.

(47) It should be clear that the above described embodiments are only examples and should not be considered as restrictive. Rather, modifications are possible without leaving the scope of protection of the present invention, which is defined by the attached claims.

REFERENCE CHARACTER LIST

(48) 1 LED arrangement 2 LED 3 LED board 3 Cable 4 Light Emission Wall 5 Sheath 6a First Sheath Region 6b Second Sheath Region 7 Cavity 8 Protrusion 9 Recess 10 Leaf Region 10a Sealing Element 10a′ Sealing Element End Plate 10a″ Sealing Element End Plate 10a′″ Sealing Element Connector 11 Plate 12 End Cap 13 Side Wall 14 Chamfer 15 End Face 16 Projection 17 Cutting Edge 18 Arrow 20 Arrow L Longitudinal Direction a Distance

(49) It is to be understood that the above-referenced arrangements are illustrative of the application of the principles of the present technology. Numerous modifications and alternative arrangements can be devised without departing from the spirit and scope of the present technology as set forth in the examples.