Lighting device having solid state light source on bendable pcb

Abstract

The light generating device including at least one solid state light source, a monolithic support for the light source with first and second support parts bent relative to each other, and a housing having a housing wall. The light source is supported by the first support part, with the second support part in thermal contact with the housing wall. At least a portion of the support located between the light source and the housing wall is thermally conductive.

Claims

1. A light generating device comprising: a solid-state light source; a thermally conductive monolithic support supporting the light source, the support defining opposed first and second major surfaces, the support having a first support part, a second support part provided at an angle to the first support part, and a third support part provided at an angle to the first support part, with the first support part configured to support the light source; a housing comprising a housing wall; and electronics supported by the third support part and functionally coupled to the light source, wherein the second support parts is in direct contact with the first support part and in thermal contact with the housing wall, the third support part is in direct contact with the second support part and not to the first support part, and the light source and the electronics are arranged on the first major surface.

2. The light generating device according to claim 1, wherein the the support comprises a metal-core printed circuit board.

3. The light generating device according to claim 1, wherein the housing wall comprises an internal planar contact part, wherein the second support part is in physical contact with the internal planar contact part.

4. The light generating device according to claim 1, the support comprises one or more first mechanical connectors, the housing comprises one or more second mechanical connectors, and the first and the second mechanical connectors providing male-female connections.

5. The light generating device according to claim 1, wherein the electronics further comprise a communication device for control of the light source.

6. The light generating device according to claim 1, the second support part comprising a plurality of the second support parts indirect contact with the first support part and in thermal contact with the housing wall.

7. The light generating device according to claim 1, wherein more first further support parts are in direct contact with the first support part and in thermal contact with the housing wall, and none of the second support parts supports a light source or electronics.

8. A method of producing the light generating device according to claim 1, the method comprising: providing a light source, a thermally conductive support for the light source, and a housing comprising a housing wall, wherein the support comprises at least three support parts which are bendable relative to each other, wherein a first support part of the at least three support parts is configured to support the light source; bending the at least three support parts; introducing one or more of the at least three support parts in the housing wall; fixating the support to the housing; and configuring at least one of support parts in thermal contact with the housing wall.

9. The light generating device according to claim 1, wherein the first support part and the second support part define a first angle .sub.1 is selected from the range 35-145.

10. The light generating device according to claim 9, wherein the housing wall defines an opening, wherein the first support part is proximate the opening, and the housing wall and a plane P parallel to the opening define a second angle .sub.2.

11. The light generating device according to claim 1, wherein the first support part and the the second support part are bent relative to each other, and wherein the second support part and the third support part are configured bent relative to each other.

12. The light generating device according to claim 11, comprising the second support parts which are directly associated to the first support part and which is configured in thermal contact with the housing wall.

13. The light generating device according to claim 11, wherein at least two of the second support parts are in direct contact with the first support part.

14. The light generating device according to claim 11, the solid-state light source includes a plurality of light sources, the first support part has a circular shape, and wherein the first support supports the plurality of light sources.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:

(2) FIGS. 1a-1d schematically depict some embodiments;

(3) FIGS. 2a-2b schematically depict some further embodiments; and

(4) FIGS. 3a-3d schematically depict yet some further embodiments.

(5) The schematic drawings are not necessarily to scale.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(6) FIG. 1a schematically depicts supports 200-1 or 200-2 (collectively 2001 for the light source 100. Especially, the light source may comprise a solid state light source. Here, by way of example four light sources are depicted on two very schematically depicted embodiments of the support 200.

(7) The support 200 comprises at least two support parts 210-1 or 210-2 (collectively 2101. In variant I, there are two support parts, which are (virtually) separated by the dashed vertical lines, thereby providing four (possible) support parts 210, including three (possible) further support parts 212. The first support part 211-1 or 211-2 (collectively 211) of the support parts 210 is configured to support the light source 100. In variant II, the support 200 comprises two further support parts 212. Variants I and II are provides as non-limiting examples.

(8) The support 200 may further support electronics 400. The electronics 400 are physically coupled to one or more of the further support parts 212-1 or 212-2 (collectively 212) and in general functionally coupled to the light source 100 (functional coupling not shown). For instance, the electronics 400 may comprise a driver and/or the electronics 400 may further optionally comprise a communication device for control of the light source 100. The electronics may comprise further electronic components.

(9) Especially, the support 200 comprises a metal-core printed circuit board (see also FIG. 1b). The support 200 with light source 100 may also be indicated as element. Such element may thus be a metal-core printed circuit board (including a (functionally coupled) solid state light source).

(10) The variants I and II of the support on the left of the FIG. 1a may be planar. Hence, the first support part 211 and the associated second support part 212 (on the left of the FIG. 1a) may have a mutual angle of 180.

(11) The supports 200 in the two schematically depicted variants may be bent (when configured in the light generating device), e.g. along the dashed lines, and one or more of the further support parts 212 may be configured against a (planar) housing wall 310 of a housing 300 (very schematically depicted only part of the housing is depicted; see for a further possible embodiment of a housing FIG. 1c). For both variants, this is indicated in the two right drawings. Here, it is shown that the support 200 comprises at least two support parts 210 which are configured bent relative to each other. The bending angle between the first support part 211 and an adjacent further support part 212 is indicated with .sub.1. This angle is also indicated as first angle. The bending angle in variant I on the right is about 90. The mutual angle of the first support part 211 and the adjacent second support part 212 has thus changed from 180 (on the left in FIG. 1a) to 270 (on the right in FIG. 1a); the bending angle .sub.1 is 90. As in the variant II there are two further support parts 212, there may be different bending angles (though this is not necessarily the case). These bending angles are indicated with .sub.1 and .sub.12. The former is the bending angle between the first support part 211 and a further support part 212; the latter is, in this schematically depicted embodiment, the bending angle between two (adjacent) further support parts 212. As indicated above, the bending angle .sub.1 between the first support part 211 and an associated further support part 212 is in general also not 0, but in general within the range of larger than 0 and equal to or smaller than 180. In specific embodiments, the bending angle is larger than 45, such as equal to or larger than 60, though smaller values may also be possible. A bending angle .sub.12 between two (adjacent) further support parts may be selected from the range of 0-360, including in embodiments 180. This can also be seen in FIG. 1a, wherein the bending angle .sub.12 between two (adjacent) further support is 180 (i.e. a mutual angle of 360) in variant I (on the right), and the bending angle .sub.12 between two (adjacent) further support is 45 (i.e. a mutual angle of 225) in variant II (on the right).

(12) As schematically depicted, at least one of the at least two support parts 210 is configured in thermal contact with the housing wall 310, more especially at least one of the one or more further support parts 212 is configured in thermal contact with the housing wall 310. As indicated above, thermal contact may especially be achieved when there is physical contact. In both schematically depicted embodiments, (at least one of) the further support part(s) 212 is in physical contact with the housing wall 310.

(13) Referring to variant II, the support 200 comprises at least two further support parts 212. A further support part 212 directly associated to the first support part 211 is in thermal contact with the housing wall 310. Yet, a further support part 212 not directly associated to the first support part 211 but associated to the further support part 212 directly associated to the first support part 211 is functionally coupled to the electronics 400. Hence, in embodiments, the at least two further support parts 212 may comprise a first further support part and a second further support part. The first further support part is directly associated to the first support part 211 (and directly associated to the second further support part). The second further support part is directly associated to the first further support part and not to the first support part 211. Especially, the first further support part is in thermal contact with the housing wall 310, and the second further support part is functionally coupled to the electronics 400. Note that all three support parts 210 have bending angles. These angles may in specific embodiments be selected from the range of larger than 0 and equal to or smaller than 180, such as selected from the range of 15-165, such as 30-145 for the bending angle .sub.1, but may be different (or the same) for bending angles .sub.12 between further support parts 212.

(14) Reference 231 refers to electrical conductors, e.g. for functionally coupling the support 200, more especially the PCB, to a source of electrical power (not depicted).

(15) At least part of the support 200 between the light source 100 and the housing wall is thermally conductive. For instance, when using a MCPCB, the support may include a metal layer that is thermally conductive, such as an Al or a Cu layer.

(16) As indicated above, the support 200 may comprise a metal-core printed circuit board. Very schematically, an embodiment is depicted in FIG. 1b in cross-sectional view. Here, reference 203 refers to a copper layer which may provide one or more electrically conductive tracks for the light source(s). Reference 204 refers to a dielectric layer and reference 206 refers to a metal layer, such as Cu or Al, which is used as metal core. Optionally, in embodiments a further dielectric layer on the metal layer may be available (by which the dielectric layer may be sandwiched between dielectric layers).

(17) FIG. 1c further schematically depicts an embodiments of a light generating device 1000. The light generating device 1000 comprises the light source 100, the support 200 for the light source 100, and the housing 300 comprising the housing wall 310.

(18) FIG. 1c is e.g. a cross-sectional view of a conically or (square) pyramidal shaped housing 300. In specific embodiments, the first support part 211 and the further support part 212 are configured under a first angle .sub.1 larger than a predefined bent angle .sub.B (see also FIG. 1d). As schematically depicted, the housing wall 310 defines an opening 317, wherein the first support part 211 is configured at the opening 317. The housing wall 310 and a plane P parallel to the opening 317 define a second angle .sub.2 larger than the predefined bent angle .sub.B (see also FIG. 1d). In specific embodiments, the first angle .sub.1 may be selected from the range of 0.5-20, such as 2-10 larger than a predefined bent angle .sub.B.

(19) Reference 320 indicates one or more stop and/or fixating elements. In this way, the position of the support 200 can be defined and/or the support 200 can be fixated.

(20) Reference 1030 indicates a lamp cap, like e.g. an E27 cap (of course other caps may also be possible). Reference 1040 indicates a light transmissive window, such as e.g. of PMMA or PC.

(21) Reference 1d schematically depicts aspects in relation to the bending angle .sub.1 and the bent angle .sub.B. As indicated on https://www.thefabricator.com/thefabricator/article/bending/bending-basics-the-hows-and-whys-of-springback-and-springforward, a bending angle is different from a bent angle. This is related to springback, as known to a person skilled in the art. Springback may occur when the material angularly tries to return to its original shape after being bent. When fabricating on the press brake, an operator may overbend to the bending angle, which is angularly past the required bent angle, compensating for the springback. Overbending to the bending angle allows the desired bent angle to be attained when the part is released from pressure (see FIG. 1d). The tensile strength and thickness of the material, type of tooling, and the type of bending influence springback, as known to a person skilled in the art. Reference d indicates the thickness of the support 200. In the case of a MCPB, the thickness may e.g. be in the range of about 0.5-2.0 mm.

(22) FIGS. 2a and 2b schematically depict embodiments and variants wherein the housing wall 310 comprises an internal planar contact part 315 for light generating device 1000-1 and 1000-2 (collectively 1000), wherein the further support part 212 can be arranged in physical contact with the internal planar contact part 315. In FIGS. 2a and 2b on the left side a cross-section of a circular housing 300 is depicted, wherein two and four internal planar contact parts 315 are available. Other number of internal planar contact parts 315 may of course also be possible. FIG. 2a on the right shows two cross-sections or side views of two possible bent supports 200, each having a single first support part 211 and two further support parts 212, which may be configured in the housing. Note that in FIG. 2a on the left a cross-sectional view is shown, and on the right a side view or cross-sectional view in a plane perpendicular to the cross-sectional view of the left drawing. In FIG. 2b, on the right a top view (or cross-sectional view) of an unbent support 200 is schematically depicted, which may be after folding, configured in the housing 300 on the left.

(23) As indicated above, FIG. 1c schematically depicts that a plurality of support parts 212 may be configured in thermal contact with the housing wall 310; FIGS. 2a, 2b, but also FIG. 3a schematically depict embodiments and variants wherein the support 200 comprises a plurality of further support parts 212. One or more of these, or even all of the plurality of further support parts 212 may be configured in thermal contact with the housing wall 310.

(24) With reference to FIG. 3a, the support may further support electronics 400. The electronics 400 are physically coupled to the further support part 212 and functionally coupled to the light source 100 (functional coupling not shown). For instance, the electronics 400 may comprise a driver 410 and/or the electronics 400 may further optionally comprise a communication device 420 for control of the light source 100. As schematically depicted in this embodiments, two different further support parts 412 comprise each different electronics 400. Further, as schematically depicted further support parts 412 without electronics are configured between the first support part 411 and the further support parts 412 comprising electronics 400. The intermediate further support parts 412 may be used for thermal contact with the housing wall (not depicted in this drawing). FIG. 3a schematically depict a plurality of variants. Here, by way of example electronics 400 are available. Especially, the electronics 400 are physically coupled to the further support part 212 and functionally coupled to the light source 100 (not shown). For instance, the electronics 400 comprise a driver 410 and/or the electronics 400 comprise a communication device 420 for control of the light source 100.

(25) As schematically depicted in the variants in FIG. 3a, the electronics may be physically coupled to a subset of the plurality of further support parts 212, see variants I-III with electronics 400 on a single further support part 212, and variant IV wherein electronics 400 are on two support parts 212. Further, in the schematically depicted embodiments the support 200 comprises 2-8 further support parts 212, with two further support parts 212 in variants I-II and VI, three in variant III, four in variant V, and six in variant IV. Note that many more variants may be possible.

(26) In variants II-V, at least two of the further support parts 212 are directly associated to the first support part 211. In variants I and VI there is only one further support part 212 directly associated to the first support part 211; in variant I there is also a further support part associated to the first support part 211 via another further support part 212.

(27) In essentially all schematically depicted embodiments, a plurality of light sources 100 are functionally coupled to the (first support part 211 of the) support 200. Variant V schematically depicts an embodiment wherein the first support part 211 has a circular shape, and wherein the first support part 211 is configured to support the plurality of light sources 100.

(28) Referring to FIG. 3a, all embodiments and variants depict a monolithic support 200, such as a monolithic MCPCB. By providing the right structure, and e.g. smaller and broader pieces, or e.g. indentations, bending may be facilitated.

(29) The width of support between two support parts 210 may differ from the width of the support parts 210. This is indicated with reference 213. A smaller width may be beneficial for bending. Such connecting support piece (213), which is also part of the monolithic support 200, may also consist of more than one part. In other words, there may be more than one connecting support pieces 213 between support parts 210.

(30) FIG. 3b also schematically depicts an embodiment wherein the housing and the support 200 may comprise one or more male-female connections 250. Here, the support 200 comprises one or more first mechanical connectors 251. The housing, here the housing wall 310, comprises one or more second mechanical connectors 252. The one or more first mechanical connectors 251 and the one or more second mechanical connectors 252 provide the one or more male-female connections 250.

(31) Amongst others with the above embodiments, it is possible to produce the light generating device 1000 as defined herein, with a method comprising: (a) providing a light source 100, a support 200 for the light source 100, and a housing 300 comprising a housing wall 310, wherein the support 200 comprises at least two support parts 210 which are bendable relative to each other, wherein a first support part 211 of the at least two support parts 210 is configured to support the light source 100; and (b) bending the at least two support parts 210, introducing one or more of the at least two support parts 210 in the housing wall 310, fixating the support 200 to the housing 300, and configuring at least one further support part 212 in thermal contact with the housing wall 310, wherein at least part 206 of the support 200 between the light source 100 and the housing wall is thermally conductive.

(32) FIG. 3c schematically depicts an embodiment of a light generating device 1000 showing a number of embodiments and variants described above. FIG. 3d schematically depicts a perspective top view of the opening 317, here the internal planar contact part 315 with second mechanical connector 252 at the most remote internal side of the housing wall 310 is depicted. Likewise, this schematically depicted at the internal side of the housing wall 310 closer to the viewer, indicated with the thinner drawn lines.

(33) The term plurality refers to two or more.

(34) The terms substantially or essentially herein, and similar terms, will be understood by the person skilled in the art. The terms substantially or essentially may also include embodiments with entirely, completely, all, etc. Hence, in embodiments the adjective substantially or essentially may also be removed. Where applicable, the term substantially or the term essentially may also relate to 90% or higher, such as 95% or higher, especially 99% or higher, even more especially 99.5% or higher, including 100%.

(35) The term comprise includes also embodiments wherein the term comprises means consists of.

(36) The term and/or especially relates to one or more of the items mentioned before and after and/or. For instance, a phrase item 1 and/or item 2 and similar phrases may relate to one or more of item 1 and item 2. The term comprising may in an embodiment refer to consisting of but may in another embodiment also refer to containing at least the defined species and optionally one or more other species.

(37) Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

(38) The devices, apparatus, or systems may herein amongst others be described during operation. As will be clear to the person skilled in the art, the invention is not limited to methods of operation, or devices, apparatus, or systems in operation.

(39) It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims.

(40) In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim.

(41) Use of the verb to comprise and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. Unless the context clearly requires otherwise, throughout the description and the claims, the words comprise, comprising, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of including, but not limited to.

(42) The article a or an preceding an element does not exclude the presence of a plurality of such elements.

(43) The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In a device claim, or an apparatus claim, or a system claim, enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

(44) The invention also provides a control system that may control the device, apparatus, or system, or that may execute the herein described method or process. Yet further, the invention also provides a computer program product, when running on a computer which is functionally coupled to or comprised by the device, apparatus, or system, controls one or more controllable elements of such device, apparatus, or system.

(45) The invention further applies to a device, apparatus, or system comprising one or more of the characterizing features described in the description and/or shown in the attached drawings. The invention further pertains to a method or process comprising one or more of the characterizing features described in the description and/or shown in the attached drawings.

(46) The various aspects discussed in this patent can be combined in order to provide additional advantages. Further, the person skilled in the art will understand that embodiments can be combined, and that also more than two embodiments can be combined. Furthermore, some of the features can form the basis for one or more divisional applications.