Lamp and method for assembling a lamp

Abstract

A lamp is provided, the lamp comprising at least one LED module and a first housing part, wherein the LED module is sealed to the first housing part against environmental influences jointly by a first sealing member and a sealing compound.

Claims

1. A lamp comprising: at least one light-emitting diode (LED) module; and a first housing part; wherein the at least one LED module is sealed to the first housing part jointly by a first sealing member and a sealing compound such that the sealing joins the at least one LED module and the first housing part together and protects a connection between the at least one LED module and the first housing part against environmental influences, wherein the first sealing member at least partially surrounds a portion of the at least one LED module.

2. The lamp according to claim 1, wherein the sealing compound is at least partially filled into a hollow space in between a second housing part and the first housing part.

3. The lamp according to claim 1, wherein at least one of the sealing compound and the first sealing member is at least one of waterproof and dust protected.

4. The lamp according to claim 1, wherein the first sealing member is in direct contact with the sealing compound, and wherein the sealing compound is at least partially filled into a gap in between the first sealing member and the first housing part.

5. The lamp according to claim 1, wherein the first sealing member seals a mechanical connection between the at least one LED module and the first housing part.

6. The lamp according to claim 5, wherein the LED module comprises a connector through which connection leads of the at least one LED module are fed, and wherein the first sealing member is an O-ring that is positioned at the connector.

7. The lamp according to claim 1, wherein the at least one LED module comprises at least one light-emitting diode, and wherein the light-emitting diode is sealed by a second sealing member.

8. The lamp according to claim 7, wherein the at least one LED module comprises a light-transmitting cover and a carrier for mounting the at least one light-emitting diode, the light-transmitting cover being positioned at a topside of the at least one light-emitting diode that faces away from the carrier, wherein the second sealing member is positioned in between the light-transmitting cover and the carrier and frames the at least one light-emitting diode, and wherein the at least one light-emitting diode is sealed by the second sealing member, the light-transmitting cover, and the carrier.

9. The lamp according to claim 7, wherein at least one of the second sealing member is a sealing glue and the sealing compound is a potting glue.

10. The lamp according to claim 1, wherein the at least one LED module comprises a plurality of LED modules, each LED module comprising at least one light-emitting diode, wherein the sealing compound is at least partially positioned in a gap between the LED modules.

11. The lamp according to claim 10, wherein each LED module comprises a light-transmitting cover and a carrier, and wherein the LED modules are arranged on a first housing part of the lamp such that the carriers face each other and at least a part of a gap between the carriers is filled with the sealing compound.

12. The lamp according to claim 1, wherein at least one of the at least one LED module and the lamp is waterproof.

13. The lamp according to claim 1, wherein at least one of the at least one LED module and the lamp satisfies IP Code IP 65 according to IEC standard 60529.

14. A method for assembling a lamp, the method comprising: providing at least one light-emitting diode (LED) module, a first housing part, and a second housing part; mechanically connecting the at least one LED module to the first housing part, wherein the at least one LED module is sealed to the first housing part by a first sealing member; positioning the at least one LED module in the second housing part; and filling a sealing compound into a hollow space in between the second housing part and the at least one LED module, wherein the first sealing member and the sealing compound jointly seal the at least one LED module to the first housing part such that the sealing joins the at least one LED module and the first housing part together and protects the connection between the at least one LED module and the first housing part against environmental influences, wherein the first sealing member at least partially surrounds a portion of the at least one LED module.

15. The method according to claim 14, wherein providing the at least one LED module comprises: providing a light-transmitting cover and a carrier onto which at least one light-emitting diode is positioned; applying a second sealing member at least one of onto an outer frame of the cover and onto an outer frame of the carrier; and connecting the light-transmitting cover and the carrier, wherein a firm bond in between the light-transmitting cover and the carrier is provided by the second sealing member.

16. The method according to claim 14, wherein at least one of the sealing compound and the second sealing member is cured.

17. The lamp according to claim 1, wherein: an end of the at least one LED module includes an end connector; and the portion of the at least one LED module at least partially surrounded by the first sealing member is the end connector.

18. The lamp according to claim 17, wherein the end connector is provided at an end of a light-transmissive cover of the at least one LED module.

19. The lamp according to claim 17, wherein the at least one LED module further includes an electrical connection lead that passes through the end connector.

20. The lamp according to claim 1, wherein the at least one LED module includes an end connector and an electrical connection lead, both of which extend through the first sealing member.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Preferred embodiments of the invention will be explained in the following, having regard to the drawings.

(2) FIG. 1 shows an embodiment of an LED module for a lamp according to the present invention.

(3) FIGS. 2A and 2B show embodiments of a lamp according to the present invention.

(4) FIGS. 3A and 3B show an embodiment of a method for providing an LED module and an embodiment of an LED module for a lamp according to the present invention.

(5) FIGS. 4A, 4B, 4C, 4D and 4E show an embodiment of a method for assembling a lamp and an embodiment of a lamp according to the present invention.

(6) FIGS. 5A, 5B, 5C and 5D show an embodiment of a method for assembling a lamp and an embodiment of a lamp according to the present invention.

(7) FIGS. 6 and 7 show embodiments of a lamp according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(8) In the following, preferred embodiments of the invention will be described with reference to the drawings. Here, elements that are identical, similar or have an identical or similar effect are provided with the same reference numerals in the figures. The figures and the size relationships of the elements illustrated in the figures among one another should not be regarded as to scale. Rather, individual elements may be illustrated with an exaggerated size to enable better illustration and/or better understanding.

(9) With reference to the schematic drawing of FIG. 1A, an embodiment of an LED module 2 for a lamp 1 according to the present invention is described in detail. The LED module 2 comprises a plurality of light-emitting diodes 20, a second sealing member 22, a light-transmitting cover 23, a carrier 24, a connector 25, connection leads 26, and a cooling body 27. The light-emitting diodes 20 are mounted on the carrier 24 and covered by the cover 23. The light-emitting diodes 20 are further framed by the second sealing member 22. The second sealing member 22 is positioned in between the cover 23 and the carrier 24.

(10) The cooling body 27 is connected to the carrier 24 in order to lead heat generated by the light-emitting diodes 20 away from said diodes. The cooling body 27 comprises cooling fans that are protrusions of the cooling body 27. The light-emitting diodes 20 are electrically conductively connected to the connecting leads 26. The connecting leads 26 are fed through the connector 25 for electrically connecting the light-emitting diodes 20.

(11) For connecting the cover 23 to the carrier 24 and the cooling body 27, the cover 23 comprises first terminals 231 that are adapted for engaging with the carrier 24 and/or the cooling body 27. Thereby, a mechanically releasable connection between the carrier 24 and the cover 23 may be provided. It is further or alternatively possible for the second sealing member 22 to provide an adhesive bond between the carrier 24 and the cover 23.

(12) With reference to the schematic drawing of FIGS. 2A and 2B, embodiments of a lamp 1 according to the present invention are described in detail. The lamp 1 comprises a plurality of LED modules 2. Here, further cooling bodies 27′ of further LED modules 2 are depicted for ease of understanding of the assembly. The LED module 2 of the lamp 1 according to FIG. 2A has been described in connection with FIG. 1A.

(13) The respective lamp 1 according to FIG. 2A or FIG. 2B further comprises a driver 3, a second housing part 4, a first housing part 5 with a middle pillar 52 and a sealing compound 41. The components of the lamp 1 are arranged in the second housing part 4.

(14) The LED modules 2 are positioned on the first housing part 5 around the middle pillar 52. Here, the carriers 24 and the cooling bodies 27 of the LED modules 2 face each other. The LED modules 2 may be positioned along a circle around the middle pillar 52. A main extension plane of each LED module 2 may run along a main extension direction of the middle pillar 52.

(15) The sealing compound 41 is at least partly filled into a hollow space in between the LED modules 2, the first housing part 5, the driver 3, and the second housing part 4. In particular, the sealing compound 41 is partially positioned in a gap 51 in between the LED modules 2 and the first housing part 5. Said gap 51 occurs due to the middle pillar 52 of the first housing part 5 only partly extending along the LED modules 2. In other words, a maximum extension of the LED modules 2 along the main extension plane is larger than a maximum extension of the middle pillar 52 along its main extension direction.

(16) Inside the middle pillar 52, a further connector 53 may be provided. The further connector 53 may be suitable for electrically connecting further LED modules 2 that may be positioned on top of the middle pillar 52.

(17) The first housing part 5 further may comprise protrusions 55 extending out of the middle pillar 52 into the gap 51. Said protrusions 55 may enable a better connection of the LED modules 2 to the first housing part 5. The protrusions 55 may also allow for improving adherence of the sealing compound 41 in the gap 51.

(18) With reference to the schematic drawings of FIGS. 3A and 3B, a method for providing an LED module 2 for a lamp according to the present invention is described in detail. In a first method step, shown in FIG. 3A, a cover 23, a second sealing member 22 and a carrier 24 are provided. In a further method step, the cover 23, the second sealing member 22 and the carrier 24 are connected in order to provide an LED module 2 (shown in FIG. 3B).

(19) As shown in FIG. 3A, a plurality of light-emitting diodes 20 is mounted to the carrier 24. Further, a cooling body 27 is attached to the carrier 24. The cover 23 comprises first terminals 231 and the carrier 24 comprises second terminals 241. By means of the first terminals 231 and the second terminals 241, a mechanically releasable connection of the cover 23 to the carrier 24 may be provided.

(20) The second sealing member 22 is positioned such that it frames the light-emitting diodes 20. The second sealing member 22 has a similar shape to an outer rim of the cover 23 and the carrier 24. In particular, the second sealing member 22, the cover 23 and the carrier 24 are shaped rectangular.

(21) The second sealing member 22 may also be provided as a liquid adhesive, for example a sealing glue, that is applied to the cover 23 and/or the carrier 24. The cover 23 and the carrier 24 may then be connected due to an adhesive bond.

(22) With reference to the schematic drawings of FIGS. 4A to 4E, method steps of a method for assembling a lamp 1 according to the present invention are described in detail. FIG. 4A shows a first method step, where an LED module 2 and a first sealing member 21 are provided. In the shown embodiment, the first sealing member 21 is an O-ring. The LED module 2 comprises a connector 25 through which connecting leads 26 of the LED module 2 are fed. The connector 25 may be a flange or may be similar to a flange.

(23) In a second method step (FIG. 4B), the O-ring is positioned at the connector 25 such that it surrounds the connecting leads 26. As shown in FIG. 4C, a first housing part 5 is provided. The first housing part has a disc-shaped holding part 56, comprising further connectors 53 that enclose cavities 53 in the first housing part 5, and a middle pillar 52. The further connector 53 may be adapted for being connected with the connector 25 of the LED module 2. For this, the LED module 2 may be positioned onto the first housing part 5.

(24) The middle pillar 52 has indentations 521 that may help to improve a connection of a second housing part 4 of the lamp 1 to the first housing part 5. For example, the middle pillar 52 may be flexible due to the indentations 521; in this case, a part of the second housing part 4 may be plugged into the middle pillar 52, wherein size differences of the middle pillar 52 and the part of the second housing part 4 due to manufacturing may be compensated by the flexibility given by the indentations 521.

(25) FIG. 4D shows an enlargement of the LED module 2 and the first housing part 5 that are connected to each other. The O-ring 21 is positioned at the connector 25 and the further connector 53, thereby sealing the connecting leads 26 of the LED module 2.

(26) In FIG. 4E, an assembly of the first housing part 5 and a plurality of LED modules 2 is shown. The LED modules 2 are positioned on the disc-shaped holding part 56 of the first housing part 5 such that the cooling bodies 27 and the carriers 24 of the LED modules 2 face each other. The LED modules 2 surround the middle pillar 52 of the first housing part 5.

(27) With reference to the schematic drawings of FIGS. 5A to 5C, further method steps of a method for assembling a lamp 1 according to the present invention and a lamp 1 according to present invention are described in detail. In FIG. 5A, an assembly with a plurality of LED modules 2 and a first housing part 5 is provided. Said assembly is connected to a driver 3. The driver 3 comprises electronic components for controlling the LED modules 2 and in particular the light-emitting diodes 20 of the LED modules 2. Further, a cap 6 is provided on a side of the assembly facing away from the driver 3. The cap 6 comprises perforations 61 that may improve heat dissipation of the lamp 1.

(28) As shown in FIG. 5B, a second housing part 4 is provided. The second housing part 4 may be composed of several truncated cones and/or cylinders. The second housing part 4 preferably is adjusted for receiving the driver 3 and at least part of the assembly comprising the first housing part 5 and the LED modules 2.

(29) In FIG. 5C, the second housing part 4 is put over the driver 3 and connected to the first housing part 5. Then, a sealing compound 41 is filled into the second housing part 4. FIG. 5D shows an inside of the lamp 1 of FIG. 5C, where the second housing part 4 is not shown for ease of understanding. In FIG. 5D, the sealing compound 41 is already cured. The sealing compound 41 encloses parts of the driver 3 and is in direct contact with the first housing part 5. Thereby, a seal of the LED modules 2 and at least parts of the driver 3 is provided.

(30) With reference to the schematic drawings of FIGS. 6 and 7, embodiments of a lamp 1 according to the present invention are described in detail. Here, FIG. 6 shows the lamp 1 as shown in FIG. 2A and FIG. 7 shows a lamp 1 as shown in FIG. 2B, wherein in both figures an enlarged cutout of the lamp 1 is shown. Each lamp 1 comprises a sealing compound 41 for sealing a hollow space in between an LED module 2, a first housing part 5 and a driver 3 and enclosed by a second housing part 4. In the embodiment of FIG. 7, a further connector 53 of the first housing part 5 extends through the middle pillar 52 and along the entire LED modules 2.

(31) As can be seen in the respective cutout, the sealing compound 41 may be filled into a gap between the first sealing member 21 and the first housing part 5. The sealing compound 41 may then be in direct contact with the first sealing member 21. By this, the sealing by the first sealing member 21 may be further improved due to the sealing compound 41. Further, in the case of breakage of the sealing by one of the first sealing member 21 or the sealing compound 41, the remaining sealing means may still seal the LED module 2, thereby making the lamp 1 more reliable.

(32) The invention is not restricted by the description based on the embodiments. Rather, the invention comprises any new feature and also any combination of features, including in particular any combination of features in the patent claims, even if this feature or this combination itself is not explicitly specified in the patent claims or exemplary embodiments.

LIST OF REFERENCE NUMERALS

(33) 1 Lamp

(34) 2 LED module

(35) 20 Light-emitting diode

(36) 22 Second sealing member

(37) 21 First sealing member

(38) 23 Light-transmitting cover

(39) 231 First terminals

(40) 24 Carrier

(41) 241 Second terminals

(42) 25 Connector

(43) 26 Connection leads

(44) 27 Cooling body

(45) 3 Driver

(46) 4 Second housing part

(47) 41 Sealing compound

(48) 5 First housing part

(49) 51 Gap

(50) 52 Middle pillar

(51) 521 Indentation

(52) 53 Further connector

(53) 54 Cavity

(54) 55 Protrusion

(55) 56 Holding part

(56) 6 Cap

(57) 61 Perforation