METHOD AND DEVICE FOR POTTING AN LED LUMINAIRE POTTED IN A POTTING COMPOUND, AND LED LUMINAIRE

Abstract

An LED luminaire and potting method having the following steps: introducing a configured luminaire into an at least partly optically transparent potting mold (16), such that the luminaire does not come into contact with the walls of the potting mold; introducing an optically transparent potting compound (18) into the potting mold (16) until at least the luminaire is surrounded; and detecting a quantity of bubbles by an optical sensor or image detector (14), wherein the pressure in the vacuum chamber (11) is controlled in order to influence the bubbles and/or a pivot/inclination device (12) is controlled in order to move the vacuum chamber (11) and/or the potting mold (16) in order to expel detected gas/air bubbles (19) out of the optically transparent potting compound (18).

Claims

1. LED-luminaire-potting-method comprising the steps: introducing a luminaire configured to be potted with an optically transparent potting compound in an at least partially optically transparent potting mold (16), wherein the potting mold (16) is arranged in a vacuum chamber (11) and the luminaire is positioned in the potting mold (16) in such a way that the luminaire does not touch the walls of the potting mold; introducing an optically transparent potting compound (18) into the potting mold (16) until at least the luminaire is enclosed; detecting the quantity and quality of a bubble-freeness of the optically transparent potting compound (18) via an optical sensor or photo detector (14), wherein there occurs a regulation of the pressure in the vacuum chamber (11) for influencing the bubbles and/or a control of a pan/tilt apparatus (12) for movement of the vacuum chamber (11) and/or the potting mold (16) for expulsion of detected gas/air bubbles (19) from the optically transparent potting compound (18).

2. LED-luminaire-potting-method according to claim 1, characterized in that the introduction of an optically transparent potting compound (18) into the potting mold (16) continues until further additional components to be of the luminaire to be potted are enclosed.

3. LED-luminaire-potting-method according to claim 1 or 2, characterized in that other optional components of the LED luminaire and/or a common or respective support and/or reflector(s) and/or interfaces and/or electronic components are contacted/arranged/configured prior to introduction into the potting mold.

4. LED-luminaire-potting-method according to claim 1, 2 or 3, characterized in that the introduction of the configured LED light into a potting mold takes place, wherein at least one side surface of the potting mold has a convex geometry and that a panning of the potting mold about a focal axis of the concave shape of the casting compound occurs, whereby a good bubble expulsion is forced by rolling the bubbles over the concave bottom.

5. LED luminaire having at least one LED, at least one supply line electrical contacting the LED and supplying it with power, wherein the LED is disposed in a potting compound and has been prepared in particular with an LED luminaire-potting method according to any one of the preceding claims, characterized in that the at least one LED as well as optional components of the deep-sea LED light and/or common or respective carrier and/or interfaces and/or electronic components are completely enclosed by the potting compound.

6. LED luminaire according to the preceding claim, characterized in that a plurality of LEDs are arranged in at least one LED array and electrically contacted and can be supplied with energy via at least one supply line and/or a component for energy supply, wherein the at least one LED-array completely is enclosed by the potting compound.

7. LED luminaire according to one of the two preceding claims, characterized in that the at least one input lead having at least one coated wire is at least partially encased with a shrink tube and/or the LED luminaire comprises at least one reflector, which is in each case at least partially retained in the potting compound and or at least one side surface of the potting compound has a concave geometry.

8. LED luminaire according to one of the three preceding claims, characterized in that the LED is at least one UV-C-LED.

9. LED luminaire according to one of the four preceding claims, characterized in that a quartz glass window is provided in at least the emission direction of the LED-UV-C.

10. LED luminaire according to one of the five preceding claims, characterized in that the at least one UVC LED is functionally coupled with at least one area-of-influence LED and/or a control LED.

11. LED-potted-luminaire manufacturing apparatus comprising: a vacuum chamber (11), an at least partially optically transparent potting mold (16) for receiving a luminaire to be potted in an optically-transparent potting compound, a pressure measuring device (15) with a pressure controller for the pressure within the vacuum chamber (11), an image detector (14) for the detection of gas/air bubbles within the at least partially optically transparent potting mold (16), a pan/tilt apparatus (12) for direct or indirect panning and tilting of the at least partially optically transparent potting mold (16) by panning and/or tilting said at least partly optically transparent potting mold (16) or the vacuum chamber (11), an evaluation, storage, and control unit for controlling the pan/tilting device (12) and/or the pressure within the vacuum chamber (11).

12. LED-potted-luminaire manufacturing apparatus according to the preceding claim, characterized in that the image detector is an active sensor, a camera, preferably supportable by a light source for back light (13) for fluoroscopy.

13. LED-potted-luminaire manufacturing apparatus according to one of the two preceding claims, characterized in that the vacuum chamber (11) is formed at least partially optically transparent so that the image detector can be arranged outside the vacuum chamber (11).

14. Potted luminaire manufacturing apparatus according to any one of the three preceding claims, characterized in that the pan/tilt device (12) is disposed within the vacuum chamber for exclusive panning of the at least partially optically transparent potting mold (16).

15. Potted luminaire manufacturing apparatus according to any one of the four preceding claims, characterized in that the at least partially optically transparent potting mold (16) is completely formed optically-transparent and/or at least one side of the at least partially optically transparent potting mold (16) has a concave geometry.

Description

[0113] Further advantages, features and possible applications of the present invention will become apparent from the following description taken in conjunction with the figures.

[0114] There is show in:

[0115] FIG. 1 an inventive LED luminaire with an LED on a substrate with a reflector in side view and in plan view;

[0116] FIG. 2 an inventive LED luminaire with an LED on a support in side view and in plan view;

[0117] FIG. 3 an inventive LED luminaire having an LED array of LEDs in each case on a support in side view and in plan view;

[0118] FIG. 4 an inventive LED luminaire with an LED on a support with an interface or an electronic unit and reflector in side view and in plan view;

[0119] FIG. 5 an inventive LED luminaire having an LED array of LEDs in each case on a support in side view and in plan view in a further variant;

[0120] FIG. 6 an inventive LED luminaire with an LED on a substrate with a reflector in side view and plano-concave geometry of the casting compound;

[0121] FIG. 7 an apparatus for producing luminaires cast in potting compound;

[0122] FIG. 8 a first embodiment of an inventive LED luminaire having a UV-LED for the anti-fouling applications;

[0123] FIG. 9 a second embodiment of an inventive LED luminaire having a UV-LED for the anti-fouling use; and

[0124] FIG. 10 a third embodiment of an inventive LED luminaire having a UV-LED for the anti-fouling applications.

[0125] FIG. 1 shows an example of an inventive LED luminaire (10) having a LED (1) on a support (2) with reflector (3) in side view and in plan view. The LED (1) is fixed, for example glued, on a metal support (2), e.g, of aluminum. On the carrier (2) is provided a reflector (3), which surrounds the LED (1) and allows a funnel-shaped focusing of the illumination direction. On the support, a respective supply line (4) is fixed, such as soldered, connected or crimped, which contacts the LED (1) and ensures a supply of electrical energy. The potting compound (5) is formed as a thin circular disc which completely envelopes the LED (1) and the carrier (2). The reflector (3) and the leads (4) are only potted in part.

[0126] FIG. 2 shows an example of an inventive LED luminaire (10) having a LED (1) on a support (2) in side view and in plan view. The LED (1) is fixed on a metal support (2). On the support, a respective supply line (4) is fixed, e.g., soldered, to contact the LED (1) and securely supply electrically energy. The potting compound (5) is formed as a thin rectangular plate that completely envelopes the LED (1) and the carrier (2). The leads (4) are potted only in part.

[0127] FIG. 3 shows an example of an inventive LED luminaire (10) comprising an LED array of four individual LEDs (1), each on a support (2), in side view and in plan view. The respective LED (1) of the LED array is fixed on a metal support (2). The supports (2) are connected in series by supply lines (4) to each other, the LEDs (1) electrical contact, respectively. The potting compound (5) is formed as a thin circular disc which completely includes the LEDs (1), the intermediate supply lines (4) between the individual LEDs (1) of the LED array and the carrier (2). The other leads (4) are cast only in part.

[0128] FIG. 4 shows an example of an inventive LED luminaire (10) having a LED (1) on a support (2) and an interface/component (6) in side view and in plan view. The LED (1) is fixed on a metal support (2). The support (2) is connected in parallel by leads (4) with an interface or an electronic module, which respectively electrically contact the LED (1). The potting compound (5) is formed as a thin circular disc which completely encompasses the LED (1) and the intermediate conductors as supply lines (4) between the LED (1), the interface or the electronic component and the carrier (2). The other leads (4) are cast only in part.

[0129] FIG. 5 shows an example of an inventive LED luminaire (10) comprising an LED array of five individual LEDs (1), each on a support (2), in side view and in plan view. The respective LEDs (1) of the LED array are fixed on a metal support (2). The supports (2) are connected to each other in series by supply lines (4), electrical connecting the LEDs (1), respectively. The potting compound (5) is formed as a thin rectangular plate that completely includes the LEDs (1), the intermediate compounds as supply lines (4) between the individual LEDs (1) of the LED array and the carrier (2). The other leads (4) are cast only in part.

[0130] FIG. 6 shows an example of an inventive LED luminaire (10) having a LED (1) on a support (2) with reflector (3) in side view. The LED (1) is fixed on a metal support (2). On the carrier (2) is provided a reflector (3), which includes the LED (1) and allows a funnel-shaped focusing of the illumination direction. On the support, a supply line (4) is fixed, comprising a varnish-coated wire (9), which is fixed on the carrier (2), for example, is soldered, and electrically contacts the LED (1) and is enclosed by a shrink sleeve (7). The potting compound (5) is formed as a thin plano-concave disc, which completely encompasses the LED (1) and the carrier (2). The reflector (3) and the leads (4) are cast only in part.

[0131] FIG. 7 shows an example of an inventive apparatus for producing cast-in potting compound lights. In an optically transparent vacuum chamber (11), which may also be partially optically transparent or may be provided with a window, there is, in an optically transparent potting mold (16), a luminaire, here for example an LED with a reflector (17) and not shown supply lines (4), kept free. An optically transparent potting compound (18) surrounds the LED with a reflector (17), wherein the reflector protrudes from the optically transparent potting compound (18). By a pressure measuring device (5), the control of the pressure can be monitored, by which the air bubble size of an air bubble (9) in the optically transparent potting compound (18) can be influenced. The air bubble (9) is detected by an image detector (14) by the optically transparent vacuum chamber (11), which qualitatively and quantitatively determines, through the optically transparent potting mold (16) into the optically transparent potting compound (18), a status of bubbles (9) and forwards this to a not shown evaluation, storage and control unit. By this control unit a pan/tilt apparatus (12) is controlled in its movement, which moves the optically transparent vacuum chamber (11) and the optically transparent potting mold (16) such that the air bubbles (9) are expelled from the optically transparent potting compound (18). The image detector can be to be actively operated, and also be supported by a suitable light source for backlight (13).

[0132] In FIG. 8 a first embodiment of an inventive LED luminaire with a UV LED is shown for the anti-fouling applications.

[0133] Reference is made to the previously illustrated embodiments in general. Here, a UV-LED 1 is supported on a carrier 2. In addition, a control LED 20 and a sphere-of-influence LED 21 is provided on this carrier 2 to detect the area of influence or to control the function. Further, a quartz glass window 22 is additionally arranged. This unit is referred to as LED light segment 0.

[0134] FIG. 9 shows a second embodiment of an inventive LED luminaire having a UV-LED for the anti-fouling applications.

[0135] There is shown a pipe 25, in which four UV-LED luminaires 0 keep the pipe free, whereby an antifouling is realized.

[0136] FIG. 10 illustrates a third embodiment of an inventive LED luminaire having a UV-LED for anti-fouling applications.

[0137] Here, a cooling water inlet 24 is shown, wherein a UV-LED luminaire segment 0 keeps the inlets free. The LED luminaire segment 0 has integrated electronics with constant current supply and clocking 23.

LIST OF REFERENCE NUMBERS

[0138] 0 LED luminaire segment [0139] 1 LED, UV LED, UV-LED-C [0140] 2 carrier [0141] 3 reflector [0142] 4 lead [0143] 5 potting compound [0144] 6 interface or electronic component [0145] 7 shrink tubing [0146] 8 concave base [0147] 9 coated wire [0148] 10 LED luminaire [0149] 11 optically transparent vacuum chamber [0150] 12 pan/tilt device [0151] 13 light source for backlighting [0152] 14 image detector [0153] 15 pressure gauge [0154] 16 optically transparent potting mold [0155] 17 LED with reflector [0156] 18 optically transparent potting compound [0157] 19 bubble [0158] 20 control LED [0159] 21 sphere-of-influence LED [0160] 22 quartz glass window [0161] 23 electronics with constant current supply and/or clock [0162] 24 cooling water intake [0163] 25 pipe