LED lighting assembly

Abstract

The invention describes an LED lighting assembly comprising a reflector unit comprising a number of reflector regions; an LED carrier realized to support at least one LED arrangement; and at least one positioning feature for positioning the LED carrier relative to the reflector unit, wherein a positioning feature is arranged in the same plane as the optical center of the LED arrangement. The invention further describes a method of manufacturing such an LED lighting assembly.

Claims

1. An LED lighting assembly comprising: a reflector unit comprising a plurality of reflector regions and an aperture; an LED carrier at least partially disposed in the aperture in the reflector unit; at least one LED arrangement on the LED carrier, the at least one LED arrangement having an optical center; and a first positioning part on the LED carrier and a second positioning part on the reflector unit, the first positioning part and the second positioning part being complimentary to position the LED carrier relative to the reflector unit, the first positioning part and the second positioning part being in the same plane as the optical center of the LED arrangement.

2. The LED lighting assembly according to claim 1, wherein the first positioning part and the second positioning part comprise at least one of an X-axis positioning part configured to position the at least one LED arrangement relative to one of the plurality of reflector regions along an X-axis of a three-dimensional space, a Y-axis positioning part configured to position the at least one LED arrangement relative to one of the plurality of reflector regions along a Y-axis (Y) of the three-dimensional space or a Z-axis positioning part configured to position the at least one LED arrangement relative to one of the plurality of reflector regions (ll lo, ll hi) along a Z-axis of the three-dimensional space.

3. The LED lighting assembly according to claim 1, wherein the reflector unit is essentially a one-piece component, and the aperture in which the LED carrier is at least partially disposed is in a rear portion of the reflector unit.

4. The LED lighting assembly according to claim 1, further comprising a further positioning part configured to position the at least one LED arrangement relative to an axis of rotation of the LED carrier.

5. The LED lighting assembly according to claim 1, wherein the first positioning part comprises a protrusion formed on the LED carrier.

6. The LED lighting assembly according to claim 5, wherein the second positioning part comprises a planar surface of the reflector unit.

7. The LED lighting assembly according to claim 1, wherein the first positioning part and the second positioning part are an X-axis positioning part and a Z-axis positioning part, the X-axis positioning part and the Z-axis positioning part being a pair of protrusions on opposite faces of the LED carrier and complementary notches formed in the reflector unit.

8. The LED lighting assembly according to claim 7, wherein the X-axis and Z-axis positioning features lie along the Y-axis, which passes through the optical center of the at least one LED arrangement.

9. The LED lighting assembly according to claim 1, further comprising an assembly interface that secures the LED carrier relative to the reflector unit.

10. The LED lighting assembly according to claim 9, wherein the assembly interface comprises a plurality of spring-loaded elements configured to press the LED carrier against the reflector unit.

11. A method of manufacturing an LED lighting assembly, comprising: providing an LED carrier comprising a plurality of LED arrangements; providing a reflector unit comprising a plurality of reflector regions and an aperture; forming, in the same plane as an optical centre of the plurality of LED arrangements, a first positioning part on the LED carrier and a second positioning part on the reflector unit such that the first positioning part and the second positioning part are complimentary to position the LED carrier relative to the reflector unit; and arranging the LED carrier inn the aperture in the reflector unit with a sideways displacement of the LED carrier initially aligning the first and second positioning parts.

12. The method according to claim 11, further comprising moulding the reflector unit using a mould shaped to simultaneously form the reflector unit and the second positioning part.

13. The method according to claim 11, further comprising controlling a placement tool to use one of the first and second positioning parts as a reference during placing the LED arrangement on the LED carrier.

14. The method according to claim 11, wherein the step of arranging the LED carrier in the reflector unit comprises inserting the LED carrier into the reflector unit through an aperture formed in the reflector unit.

15. The method according to claim 11, further comprising providing a spring-loaded assembly interface to secure the LED carrier to the reflector unit.

16. The LED lighting assembly of claim 1, further comprising a third positioning part, the first positioning part comprising an X-axis positioning part configured to position the at least one LED arrangement relative to one of the plurality of reflector regions along an X-axis of a three-dimensional space, the second positioning part comprising a Y-axis positioning part configured to position the at least one LED arrangement relative to one of the plurality of reflector regions along a Y-axis (Y) of the three-dimensional space, and the third positioning part comprising a Z-axis positioning part configured to position the at least one LED arrangement relative to one of the plurality of reflector regions along a Z-axis of the three-dimensional space.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 indicates a reflector unit and LED arrangements in relation to three axes of a coordinate system;

(2) FIG. 2 shows a perspective view of an embodiment of the inventive LED lighting assembly;

(3) FIGS. 3A and 3B show partial cross-sections through an embodiment of the LED lighting assembly;

(4) FIG. 4 shows a perspective view of another embodiment of the LED lighting assembly;

(5) FIG. 5 shows an assembly frame for an embodiment of the inventive LED lighting assembly;

(6) FIG. 6 shows a side view of the LED lighting assembly of FIG. 4;

(7) FIG. 7 shows a rear view of an embodiment of the inventive LED lighting assembly.

(8) In the drawings, like numbers refer to like objects throughout. Objects in the diagrams are not necessarily drawn to scale.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(9) FIG. 1 shows three views of a reflector unit 11 of an embodiment of the inventive LED lighting assembly, in a three-dimensional space defined by three axes. The diagram shows a front view into the reflector (top part of diagram), a side view (middle part of the diagram) and a plan view from above (lower part of diagram). The reflector unit 11 comprises an upper portion 11_hi and a lower portion 11_lo. When an LED carrier is arranged in this reflector unit 11, an upper LED arrangement will emit light into the upper portion 11_hi and a lower LED arrangement will emit light into the lower portion 11_lo. Each LED arrangement is represented by a point corresponding to its optical centre. The LED carrier optical centre C 10 is midway between the optical centres of the LED arrangements 2_hi, 2_lo. The diagram shows the X-axis and Y-axis passing through the optical centres of the LED arrangements 2_hi, 2_lo and the Z-axis passing through the intersection of the X-axis and Y-axis. The Z-axis is also the longitudinal axis of the reflector unit 11.

(10) FIG. 2 shows a perspective view of parts of an embodiment of the inventive LED lighting assembly 1. The diagram shows a reflector unit 11 with functionally separate reflector regions 11_lo, 11_hi as usedfor examplein automotive headlights. In this exemplary embodiment, a lower reflector region 11_lo is used to generate a low beam, and an upper reflector region 11_hi is used to generate a high beam. The reflector unit 11 is formed in one piece to include reflector regions 11_hi, 11_lo and an aperture 110. The diagram also shows an LED carrier 10 that comprises a front part 10F (to which LED arrangements are mounted) extending from a block-shaped part that includes a heatsink 101 and which also incorporates electronic circuitry and a power connector. The front part 10F of the LED carrier 10 will be inserted through the aperture 110 in the reflector unit 11 so that the LEDs are arranged at predefined positions within the reflector unit 11. The LED carrier 10 can be inserted into the reflector unit 11 and removed from the reflector unit 11 in the direction indicated by the arrow.

(11) In this exemplary embodiment, the LED carrier has inclined mounting surfaces or seats for receiving LEDs, and each mounting surface is inclined to face into the corresponding reflector region. An LED arrangement 2_hi is shown on the upper side of the LED carrier 10 (a corresponding LED arrangement on the lower side cannot be seen but may be assumed to be present). The position of the LED carrier 10 relative to the reflector unit 11 will be fixed by positioning features. The LED carrier 10 is formed to have protrusions 10X, 10Z or positioning feature first parts 10X, 10Z on opposite sides of the front part 10F (only one set can be seen here, on the top of the front part 10F). The reflector unit 11 is formed to have complementary second parts 11X, 11Z. In this embodiment, the position of the LED carrier 10 along both the X-axis and Z-axis will be fixed when the first parts 10X, 10Z engage with the second parts 11X, 11Z.

(12) This can be seen more clearly in FIG. 3A and FIG. 3B, which show an LED arrangement 2_hi after the LED carrier 10 has been inserted into the reflector unit 11. Here, the LED arrangement 2_hi comprises three series-connected LEDs. In FIG. 3A, the optical centre of the LED arrangement is indicated by the small circle in the centre of the middle LED. A similar arrangement of LEDs is mounted in a seat 10_lo on the underside of the LED carrier 10 front part, as shown in FIG. 3B, which also shows the LED carrier optical centre C. Once the positioning feature P.sub.X, P.sub.Z is completed by engaging the first parts 10Z, 10Z and the second parts 11X, 11Z, the LED carrier 10 is prevented from moving in the Z-direction and in the X-direction. In this exemplary embodiment, the X-axis and Z-axis positioning features P.sub.X, P.sub.Z are realised jointly, but it will be understood that these could easily be realised separately. The diagrams also show a further positioning feature P.sub.R that acts to prevent a rotation movement of the LED carrier 10 with respect to the reflector unit 11. This is achieved by a projection 10R formed on the body of the LED carrier 10 and shaped to engage with or lie against a surface of the reflector unit 11.

(13) FIG. 4 shows a perspective view of another embodiment of the inventive LED lighting assembly 1. An assembly frame 12 is used in this exemplary embodiment to assist in holding the LED carrier 10 in place relative to the reflector unit 11. The assembly frame 12 may be realised in one piece with the reflector, for example, or may be realised as a separate component. The elements 10, 11, 12 are shown prior to insertion of the LED carrier 10 into the reflector unit 11. The diagram also shows the sequence of movements during insertion, namely a forward movement d.sub.fore to insert the LED carrier through the aperture 110, a sideways or lateral displacement d.sub.side to bring the first parts 10X, 10Z into place relative to the second parts 11X, 11Z, and then a backwards displacement d.sub.back to engage the first and second parts of the positioning features P.sub.X, P.sub.Z.

(14) Here, the LED carrier 10 comprises a pin 102 at the top and bottom of the heatsink portion 101, and these pins 102 will fit into slots 122 of the assembly frame 12. A locking element 13 is also shown. This can be pushed into place once the LED carrier 10 has been correctly inserted into the reflector unit 11, andby means of recesses 103 on the LED carrier 10will serve to lock the LED carrier 10 to the assembly frame 12. This can be seen more clearly in FIG. 5, which shows a view from behind (without the LED carrier for the sake of clarity). The diagram shows the locking element 13 with a pair of hooks 130 that can engage with the correspondingly shaped recesses 103 on the LED carrier 10. To remove the LED carrier 10, a user can manually deflect the hooks 130 to release the LED carrier 10 from the assembly.

(15) FIG. 6 shows a side view of the LED lighting assembly 1 after insertion of the LED carrier 10 into the reflector unit 11.

(16) FIG. 7 shows a rear view of an embodiment of the inventive LED lighting assembly 1 in its completely assembled state. The LED carrier 10 comprises any circuitry necessary to connect the LED arrangement(s) with a power interface 102. This can be connected to a power supply in the usual manner using a suitable cable.

(17) Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.

(18) For the sake of clarity, it is to be understood that the use of a or an throughout this application does not exclude a plurality, and comprising does not exclude other steps or elements. The mention of a unit or a module does not preclude the use of more than one unit or module.

REFERENCE SIGNS

(19) LED lighting assembly 1

(20) LED carrier 10

(21) front part 10F

(22) seat 10_lo, 10_hi

(23) heatsink 101

(24) positioning feature first part 10X, 10Y, 10Z, 10R

(25) power supply interface 102

(26) reflector unit 11

(27) reflector region 11_hi, 11_lo

(28) positioning feature second part 11X, 11Y, 11Z, 11R

(29) reflector unit aperture 110

(30) vertical bar 111

(31) assembly frame 12

(32) assembly frame aperture 120

(33) cantilever spring 121

(34) lock 13

(35) low-beam LED arrangement 2_lo

(36) high-beam LED arrangement 2_hi

(37) axes X, Y, Z

(38) positioning feature P.sub.X, P.sub.Y, P.sub.Z, P.sub.R

(39) optical centre C

(40) foreword movement d.sub.fore

(41) lateral displacement d.sub.side

(42) backward displacement d.sub.back