LED illumination profile system and connecting technique

Abstract

The invention relates to an illumination system (80) comprising at least one conductor-bar-free assembly profile rail (60) for accommodating at least one lighting unit (70) that is insertable into the assembly profile rail (60), and at least one supply connector (50) that is insertable into the assembly profile rail (60). In this case, the assembly profile rail (60) is in the form of an extruded plastics or aluminum profile and the lighting unit (70) is in the form of a long rigid strip which has at least one semiconductor light source (71) on its front surface and at least two exposed, continuous contacting conductor tracks (74) on its back surface. The lighting unit (70) further comprises a housing element (73) which is designed to be mechanically couplable to the assembly profile rail (60) and which is used to hold the lighting unit (70) in the assembly profile rail (60). The supply connector (50) comprises contact devices (52), by means of which it is possible to establish electrical coupling of the contacting conductor tracks (74) of the lighting unit (70) to those of a further lighting unit (70) and/or to a supply cable (67), and further comprises a housing element (56b) which is mechanically couplable to the assembly profile rail (60) or to the lighting unit (70) and which is used to hold the supply connector (50) in the assembly profile rail (60).

Claims

1. An illumination system comprising: at least one mounting profile rail (60a, 60b, 60c), without a power rail, for the accommodation of at least one lighting unit (70), which can be introduced into the mounting profile rail, and at least one supply connector (50a, 50b, 50c), which can be introduced into the mounting profile rail; wherein the mounting profile rail (60a, 60b, 60c) is designed as an extruded plastic or aluminum profile, wherein the at least one lighting unit (70) is designed as a long, rigid strip, on a front surface of which it has at least one semiconductor light source, and on its rear surface it has at least two exposed, continuous contacting conductor tracks, wherein the at least one lighting unit (70) furthermore comprises a translucent housing element (73), which is designed such that it can be mechanically coupled to the mounting profile rail, and with which the lighting unit can be held in the mounting profile rail, wherein the supply connector (50a, 50b, 50c) has contact devices for making an electrical coupling of the contacting conductor tracks of the lighting unit with those of a second lighting unit, and/or with a supply cable, and wherein the supply connector (50a, 50b, 50c) furthermore comprises a housing element, which can be mechanically coupled to the mounting profile rail (60a, 60b, 60c) or to the at least one lighting unit (70), and with which the supply connector is retained in the mounting profile rail.

2. The illumination system in accordance with claim 1, wherein the illumination system is designed such that supply connectors (50a, 50b, 50c) introduced into the mounting profile rail (60a, 60b, 60c), and a plurality of lighting units (70), which are also subsequently introduced into the mounting profile rail, electrically interconnect with one another in the mounting profile rail, wherein the supply connectors and lighting units can in each case be arranged to overlap each other within the mounting profile rail.

3. The illumination system in accordance with claim 1, wherein the housing element of the lighting unit (70) is designed as a diffuser (69, 73), or linear optics, and/or is designed as contact protection (ESD) and mechanical protection for the electronic components.

4. The illumination system in accordance with claim 1, wherein both the supply connectors (50a, 50b, 50c) and the at least one lighting unit (70) are mechanically connected to the mounting profile rail (60a, 60b, 60c), but not to each other.

5. The illumination system in accordance with claim 1, wherein the at least one lighting unit (70) is designed as a two-sided rigid PCB with the at least one semiconductor light source and a control circuit.

6. The illumination system in accordance with claim 1, wherein the at least one lighting unit (70) is designed as a two-sided rigid PCB, the PCB of the at least one lighting unit (70) has on the rear surface a first conductor track layer thickness, which is greater than that on the front surface, and/or wherein the at least one lighting unit (70) is designed such that it can be shortened in a predetermined grid pattern by blades that can be moved relative to each other, wherein each grid element can be operated on its own autonomously.

7. The illumination system in accordance with claim 1, wherein the supply connector (50a, 50b, 50c), when introduced onto the mounting profile rail (60a, 60b, 60c), can be moved in a longitudinal direction of the mounting profile rail.

8. The illumination system in accordance with claim 1, wherein the supply connector-contacting conductor track pairing is protected against polarity reversal.

9. The illumination system in accordance with claim 1, wherein the supply connector (50a, 50b, 50c), in the longitudinal direction of the mounting profile rail (60a, 60b, 60c), has in each case at least a first and a second electrically interconnected spring contact (52).

10. The illumination system in accordance with claim 1, wherein at least one of the supply connectors (50a, 50b, 50c) is designed as a corner supply connector with an angle of 90, whereby the lighting units (70) in two mounting profile rails (60a, 60b, 60c) can be connected around a corner.

11. The illumination system in accordance with claim 1, wherein at least one of the supply connectors (50a, 50b, 50c) is a flexible supply connector (58), in which there is a flexible cable connection (53) between a first supply connector end and a second supply connector end.

12. The illumination system in accordance with claim 1, wherein at least one of the supply connectors (50a, 50b, 50c) has as a terminal connection unit a spring-loaded terminal (53a), or an insulation displacement terminal for a cable, and is designed to connect the lighting unit electrically to a terminal connection cable from a power supply.

13. The illumination system in accordance with claim 1, wherein the supply connector (50a, 50b, 50c) has a further housing element, which is designed to produce a geometrically defined mechanical coupling between two mounting profile rails (60a, 60b, 60c).

14. The illumination system in accordance with claim 1, wherein the illumination system comprises at least one separate profile connector (66a, 66b), that provides a geometrically defined mechanical coupling between two mounting profile rails (60a, 60b, 60c).

15. An illumination system comprising: at least one mounting profile rail (60a, 60b, 60c), without a power rail, for the accommodation of at least one lighting unit (70), which can be introduced into the mounting profile rail, and at least one supply connector (50a, 50b, 50c), which can be introduced into the mounting profile rail; wherein the mounting profile rail (60a, 60b, 60c) is designed as an extruded plastic or aluminum profile, wherein the at least one lighting unit (70) is designed as a long, rigid strip, on a front surface of which it has at least one semiconductor light source, and on its rear surface it has at least two exposed, continuous contacting conductor tracks, wherein the at least one lighting unit (70) furthermore comprises a translucent housing element (73), which is designed such that it can be mechanically coupled to the mounting profile rail, and with which the lighting unit can be held in the mounting profile rail, wherein the supply connector (50a, 50b, 50c) has contact devices for making an electrical coupling of the contacting conductor tracks of the lighting unit with those of a second lighting unit, and/or with a supply cable, and wherein the supply connector (50a, 50b, 50c) furthermore comprises a housing element, which can be mechanically coupled to the mounting profile rail (60a, 60b, 60c) or to the at least one lighting unit (70), and with which the supply connector is retained in the mounting profile rail, wherein the electrical supply connector (50a, 50b, 50c) has, a PCB (51), or an over-moulded lead frame (51), with at least two spring contacts (52) on an under surface, a cable outlet (67) with at least two cable connections (53) on an upper surface, and a retaining element (56) which is designed to: snap onto a profile system (60); or magnetically attach to a profile system.

16. The illumination system in accordance with claim 15, wherein the spring contacts (52) of the supply connector (50a, 50b, 50c) are protected against polarity reversal.

17. The illumination system in accordance with claim 15, wherein the cable connections (53) of the supply connector (50a, 50b, 50c) are formed as spring-loaded terminals, insulation displacement terminals, and/or soldering lands, on the PCB (51) or over-moulded lead frame.

18. The illumination system in accordance with claim 1, wherein the illumination system comprises an electrical connector element, consisting of two supply connectors (50), that are connected to at least one cable (69), designed to establish an electrical connection between two lighting units.

19. The illumination system in accordance with claim 1, wherein the illumination system comprises an electrical connector element with an over-moulded lead frame, or a PCB (51), with at least a first group of two spring contacts (52) on an under surface, and a second group of two spring contacts (52) on the under surface, which in each case are electrically connected to respectively associated spring contacts of the first group, and a retaining element (56) which is designed to snap onto the mounting profile rail, such that the first group establishes contact with a first terminal connection element (74) of the at least one lighting unit (70), and the second group establishes contact with a second terminal connection element (74) of a second lighting unit (70), and in an installed state electrically connects them to one another.

20. The illumination system in accordance with claim 1, wherein at least a first and a second longitudinal web or longitudinal groove is formed on each side face of the mounting profile rail (60a, 60b, 60c), wherein the first is designed for the mechanical accommodation of the supply connector (50a, 50b, 50c) and the second is designed for the accommodation of the lighting unit (70).

21. The illumination system in accordance with claim 3, wherein an additional diffuser (79, 73) is mounted in front of the lighting unit (70), in or on the mounting profile rail (60a, 60b, 60c).

22. A method for installation or connection of an LED illumination system to a supply voltage, comprising: installing one or a plurality of mounting profile rails (60a, 60b, 60c) of the illumination system at an installation site; introducing at least one electrical supply connector (50a, 50b, 50c) onto the mounting profile rail, wherein at least one of the supply connectors is connected to a supply cable (67), and the supply connector can be moved in the longitudinal direction of a profile of the profile rail; introducing at least one lighting unit (70) onto the mounting profile rail (60a, 60b, 60c), above the supply connector (50a, 50b, 50c), so that the latter establishes contact with a continuous, rear surface, supply conductor track (74) of the lighting unit, wherein the lighting units are shortened at least in a predetermined grid pattern, and/or are butted against one another lengthwise, so as to adapt them to the length of the profile, wherein a supply connector is introduced beforehand at each of the butt joints, such that it overlaps both abutting lighting units; mounting a translucent cover (69, 73) on the mounting profile rail (60a, 60b, 60c).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Here:

(2) FIGS. 1a and 1b show an example of a form of embodiment of an inventive illumination system for an LED illumination profile in differing perspective (exploded) views,

(3) FIG. 2a shows a view of a form of embodiment of an inventive illumination system in a partial cross-section from the front,

(4) FIG. 2b shows a view of a form of embodiment of an inventive illumination system in a partial cross-section from the rear,

(5) FIG. 2c shows a cross-section of an exemplary form of embodiment of an illumination system,

(6) FIGS. 3a to 3c show views of an exemplary form of embodiment of a lighting element for an inventive illumination system,

(7) FIGS. 4a to 4f show views of an exemplary form of embodiment of various supply connectors of an inventive illumination system,

(8) FIGS. 5a to 5c show views of an example of an inventive illumination system in an assembled state.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(9) FIG. 1a shows inventive components of an LED illumination system 80 for the emission of light by way of a light cover 69, as seen in an exploded view from the rear side of the profile, that is to say, the terminal connection side. The mounting profile rail 60, also referred to as profile 60 for short, is designed, for example, as an aluminium profile with a U-shaped, alternatively also an H-shaped, cross-section, which can be connected on the end face to an end cap, or terminal connection cap, or to a further profile. The illumination system 80 is supplied with electricity by way of a cable 67, preferably but not necessarily with a separated extra-low voltage (SELV) of, for example, 48 V, 24 V, 12 V, or 5 V. This cable 67 is electrically connected to an inventive electrical supply connector 50a, as a type of plug-in element, which is designed to be attachable to the profile 60 by way of clip elements 56, preferably in a form that can later be detached. The current is conducted from the cable 67 to an inventive lighting unit 70 by way of this electrical supply connector 50a, also referred to as the connector 50 for short. In the mounted state the electrical connector 50 can here preferably be moved along the profile axis in the profile 60, and/or along the lighting unit 70, for example in order to be able to stow the terminal connection cable 67 in the profile, or to readjust the position in the course of the installation. After the connector 50 has been introduced, the lighting units 70 are also clipped onto the profile 60. Since the profiles 60 are usually longer (e.g. 2 m, 2.5 m, 3 m, 4 m, or 5 m) than the lighting units 70 (e.g. 0.56 m, 1.4 m, etc.), an electrical connection between the lighting units 70 is inventively produced with a further supply connector 50b that is introduced onto the profile. This can also take place around a corner 66b, or by way of a butt joint, as shown in the case of supply connector 50c. The lighting unit 70 around the corner is here shortened to the profile length in accordance with its grid pattern. To improve the light emission, as protection and/or for better optics, a translucent cover 69, for example in the form of a diffuser or an optical element, can also be mounted on the mounting profile rail. In the example shown, the diffuser is provided on a roll 85 and its length is adjusted on site using cable duct shears (alternatively also using pliers or shears with a saw or a knife, etc.).

(10) FIG. 1b shows the same inventive illumination system 80 as before, but viewed from the front of the profile, that is to say, the lighting side. The elements shown have already been described above, or will be described in detail in what follows. In accordance with the invention, a plurality of profile elements 60 can also be connected to each other, electrically and/or mechanically. On the right-hand side of the figure is an angled profile connection 66b with a rigid connecting element 50c between 60a and 60b. Particularly in the case of longer profiles, instead of or in addition to a connection, inventive supply points can also be implemented with connectors 50 at any number of advantageous points. This means that the lighting can also be switched on and off in sections.

(11) The corner joint 66b shown in the example has a right angle. In order to implement other angles in accordance with the invention, the profiles need only be cut at a different angle; no further modifications are absolutely necessary. Shown here is a form of embodiment in which a rigid corner supply connector is mounted on the profile system 60; this is electrically connected to the respective electrical terminal connection conductor tracks of the lighting units 70 on both sides.

(12) FIG. 2b and FIG. 2c each show in perspective a partial cross-sectional view of an inventive illumination system 80, with the components that have already been explained above.

(13) FIG. 2c shows a cross-sectional view through a supply connector 50 in the assembled illumination system 80. Here the supply connector 50 is held in the mounting profile rail 60 by its sprung latching lugs or hooks 56, which are designed as housing elements. Its printed circuit board (PCB) 51 carries the spring contacts 52 and is fixed in the plastic housing, e.g. in a form fit or a force fit, either clipped or snapped-in, or bonded or moulded in. The spring contacts establish contact in each case with the rear surface longitudinal conductor tracks 74 of the lighting elements 70, so as to supply the latter with power. As shown here, these lighting elements 70 are also to be supplied with power in the mounting profile rail 60 by way of a translucent plastic cover 73. As shown here, these lighting elements 70 are also fixed in, that is to say, snapped onto, the mounting profile rail 60, by way of a translucent plastic cover 73. Here the lighting elements 70 are designed as a double-sided printed circuit board (PCB) 71, which has the LEDs 71 on the front surface, and the exposed conductor tracks 74 on the rear surface, which are preferably continuous over the length of the PCB. The rear surface can be designed with a thicker layer of copper, so that the conductor cross-section is sufficiently high to keep the voltage drop along the illumination profile sufficiently low, in particular, such that there is no noticeable loss of brightness.

(14) FIG. 3a shows a form of embodiment of a lighting unit 70 in detail. Here a cover 73 made from a translucent plastic is shown, which can be designed to be clear, an optical element, or an optical diffuser. A long, flat PCB 72 with a series of LEDs 71, and also preferably with a control circuit for the latter, which is not shown here, is fitted on or in this cover. On the opposite side to the LEDs 71 there are at least two, preferably three, longitudinal conductor tracks 74, by way of which the LEDs are supplied with power. They are exposed and contact can therefore be established with them directly. The lighting unit can preferably be divided into a defined grid pattern (e.g. 5 cm, 7 cm, 10 cm, 15 cm), wherein each part can be operated autonomously. The dividing points can be marked-out, and/or provided with a predetermined breaking point. Preferably, the lighting unit can be divided without machining, that is to say, it can be cut with shears and/or fractured.

(15) FIG. 3b shows the lighting unit of FIG. 3a in an assembled state, in which the PCB 72 is clipped, snapped, or pushed in under the cover 73.

(16) FIG. 3c shows the same in a view from below onto the longitudinal conductor tracks 74. In the example shown 3 conductor tracks 74a, 74b, 74c are formed. In this form of embodiment, reverse polarity protection can be achieved, by the outer conductor tracks 74a and 74c carrying in each case a first pole of the supply voltage and the central conductor track 74b carrying a second pole of the supply voltage. This means that the lighting unit 70 or the supply connector 50a can be mounted in any position, and also rotated through 180 degrees without the risk of polarity reversal and damage to the lighting unit 70. Alternatively, there are also other arrangements and configurations of the contacts in the lighting unit 70 and/or the supply connector that can be used to prevent polarity reversal. The conductor track widths on the rear surface of the lighting unit are preferably designed such that their sum results in approximately the same conductor cross-section for each of the poles.

(17) FIG. 4a shows a detailed view of a form of embodiment of an inventive electrical supply connector 50a from the contact surface or under surface, which is exposed when introduced into the profile. The latter has a cable outlet 67, that is to say, a terminal connection for the cable 67, spring contacts 52 on its under surface or contact surface facing the lighting unit, together with a connector housing with clip elements 56 as elements of its plastic housing for purposes of mechanical coupling with the mounting profile rail 60. Here the symmetrical arrangement of the spring contacts 52 can also be discerned.

(18) With the supply connector 50a shown, contact can be established with a cable 67 by way of spring contacts 52 on the conductor tracks 74, (74a, 74b, 74c)see also FIG. 2c and FIG. 3c. This form of embodiment of the electrical connector 50 is designed with a printed circuit board (PCB) 51, and a plastic housing as the connector housing. The PCB carries the spring contacts 52 and is fixed in the plastic housing, e.g. in a form fit or a force fit, either clipped or snapped-in, or bonded or moulded in. In an alternative form of embodiment, the electrical connector can also be designed as an over-moulded lead frame or as an MID (moulded interconnect device), or spatial circuit carrier, or as a plastic over-moulded module with an over-moulded lead frame. The plastic housing is primarily designed to be snapped onto the profile 60, in a subsequently releasable manner, by way of the clip-on or snap-on elements 56, or optionally also by magnets, so that contact is established between the spring contacts 52 and the conductor tracks 74a, 74b, 74c. The cable connections 53 for the cable 67 are shown here. In particular, these can be designed as solder contacts/pads and/or as spring-loaded terminals, or insulation displacement terminals, or as crimp connections, screw terminals, etc.

(19) FIG. 4b shows a side view of a mounting profile rail; this is designed as a U-shaped long profile, which has continuous webs or grooves 68a, 68b, 68c on its side walls, which are designed to provide mechanical support for the supply connectors 50 (by way of 68a), lighting units 70 (by way of 68b) and the cover 69 (by way of 68c) that are introduced in the mounting profile rail 60.

(20) FIG. 4c shows the electrical supply connector 50b as it is introduced downwards in the figure into a profile system. This has a first and a second end, that is to say, a left-hand and aright-hand end, the spring contacts 52 of which are in each case connected to each other lengthwise. This makes it possible to establish electrical contact between the rear conductor tracks 74 of a first lighting unit 70 and the first end, and between the tracks of a second lighting unit 70 and the second end. The rigid PCB can be configured to be continuous between the ends or, in another form of embodiment, a flexible connection can also be made, for example by way of cables or a flexible PCB.

(21) FIG. 4d shows the supply connector 50b again from the other side. In this form of embodiment the spring contacts 52, and their electrical connections with a PCB 51 are implemented. In the example shown of a form of embodiment of such a PCB 51, the spring contacts 52 are shown in a view from the side of the lighting unit. These are embodied multiple times per electrical poletwice in the example shownin order to ensure a secure contact, and/or to provide a sufficient contact for the amperage to be transmitted. Here the arrangement of the spring contacts 52 is symmetrical about the (longer) central axis of the PCB 51, wherein the central spring contacts 52 carry a first pole of the supply voltage, and the second pole is connected to the outer spring contacts 52 on both sides. If the connecting element 50 is thus mounted, rotated through 180 degrees, the same polarity is obtained (reverse polarity protection).

(22) FIG. 4e and FIG. 4f each show a view of a supply connector 50c, which is designed for a 90 degree corner connection. Here there is a 90 degree angled strip PCB 51, in each case with spring contacts 52 at either end. This allows connections to be made around a corner. Alternatively, other angles are, of course, also possible. Alternatively, two terminal connection supply connectors 50a can also be configured with cables to form a longitudinal or angled connector, with which any angle can be implemented, and/or any lengths of the supply connector can be implemented.

(23) FIG. 5a, FIG. 5b, and FIG. 5c show an inventively equipped LED illumination system with the terminal connection side of the profile 60 facing downwards in the figures. These comprise an overview and two related detailed views. In each of the said detailed views of the profile 60, the supply terminal connection connector 50a or 50b is shown in a partial cross-sectional region. The lighting units 70 have three longitudinal conductor tracks 74a, 74b and 74c, which are open or exposed, and with which electrical contact can be established from the viewing side. In the example shown, the two conductor tracks 74a and 74c form a common pole for the supply to the lighting unit 70, and the central conductor track 74b forms a second pole. Since these in general have to carry the same current, their cross-sectional areas can be the same as shown, but their widths can be different, even though they are the same thickness. The conductor tracks are preferably symmetrically disposed about the longitudinal axis of the profile. In other embodiments, a reverse polarity protected arrangement in accordance with the invention can also have more than two poles, for example for purposes of controlling the switching state, colour, or brightness, for an illumination bus system.

(24) Due to the reverse polarity protection of this inventive form of embodiment, the terminal connection side can be changed by turning the angled cable connection through 180.

(25) This is particularly important and advantageous in the case of profiles with mitre cuts (since these are then no longer symmetrical). This results in error minimisation and simplification for the customer, as there is no longer any need for sketches of how this must be produced on site.

(26) Contact is made between the open longitudinal conductor paths 74a, 74b and 74c and supply connectors 50a and 50b, one of which is used for power supply, and the other for electrical connection by way of a butt joint 66a between two lighting units 70.

(27) In the case of a single-colour LED (2-pole), for example, the LED series arrangement on the lighting unit is preferably connected with 0.75 mm.sup.2 cable. The cross-section should be as large as possible in order to minimise the voltage loss along the cable. This is in contrast to the ever smaller LEDs/solder pads on the lighting units. If the LEDs are multi-coloured, e.g. RGB (4-pole) or RGBW (5-pole), it is almost impossible to use 0.75 mm.sup.2. The cross-section must therefore be reduced in this case. Cables with a cross-section of 1.0-1.5 mm.sup.2 would be ideal for cable lengths of up to 10 metres. As shown in the figures, this can be inventively achieved by using linear conductor tracks 74 on the rear of the lighting units, which are simply connected to the terminal connector 50 in the profile. In this way, a supply point can also be made at any/any point(s) of the lighting units or the profile with a connector 50, and at the same time the linear conductor tracks 74 also ensure the necessary conductor cross-sections, for which larger conductor cross-sections can also be implemented.

LIST OF REFERENCE SYMBOLS

(28) 50(a, b, c) Supply connector, electrical connector 51 PCB, printed circuit board, over-moulded lead frame, MID 52 Spring contact, contact device 53, 53a Cable connection, spring-loaded terminal, solder contact/pad 56 Clip element, connector housing, connector retaining clip, clip 60(a, b, c) Mounting profile rail, profile, LED illumination profile 61 Terminal connection side, profile rear side 66a Straight profile connection, butt joint 66b Angled profile joint, corner joint, mitre joint 67 Cable outlet, cable 68a, b, c Groove or web on profile side wall, or side wall of the profile 69 Light cover, cover, light screen, diffuser 70 Lighting unit, LED board, 71 LED (front surface) 72 LED print, LED circuit board 73 Cover, diffuser, housing element 74(a, b, c) Conductor track, longitudinal conductor track (rear surface) 80 Electrical LED connection system, connection set 85 Roll 86 Separation or cutting tool, cable duct shears