AT13183U1 - LENS HOLDER FOR LEDS - Google Patents

Abstract

Lens holder for LEDs, comprising: - a cylindrically shaped element (2), - at least six releasable fastening elements (3), wherein two of the at least six releasable fastening elements (3) are arranged on the underside (5) of the cylindrically shaped element (2) and another two detachable fastening elements (3) are arranged on the upper side (4) of the cylindrically shaped element (2) and at least two releasable fastening elements (3) extend from the underside (5) of the cylindrically shaped element (2) in the vertical direction and at least two of the releasable fasteners (3) are parallel to each other, the cylindrically shaped element (2) having a longer inner diameter (D) on its upper side (4) than on its lower side (5) in a cross-sectional view.

Description

Austrian Patent Office AT 13 183 Ul 2013-08-15

description

LENS HOLDER FOR LEDS

[0001] The present invention generally relates to the flexible application of a lens over an LED mounted on a substrate, such as a printed circuit board (PCB), such that the lens is in a defined position relative to the LED (LED). Chip or SMD LED) of the LED module is mounted, which can be arranged in a profile.

Lenses are commonly used to achieve a predefined radiation pattern and / or a smaller viewing angle. The lens may be used in combination with other beam-shaping elements such as a reflector or other lens (e.g., a cover).

If lenses z. B. are in direct contact with the LED (i.e., without an air gap), they are considered as primary optics. On the other hand, if there is an air gap (or other optical element) in the light path from the LED to the lens, these are considered secondary optics.

Lenses as primary optics are common in the field of LED modules and are often used as immersion lenses. Such LED modules often consist of a substrate on which a lens (eg, a conical or funnel-shaped lens) is normally placed on the LED (s). Lenses can be positioned and / or fixed in lens holders by so-called overmolding, soldering or gluing. In addition, other attachment methods (such as bonding) may also be used to attach the lens in the lens holder.

From JP2006140281A an LED is known, which is attached by resin sealing on a metal holder.

The lens holder also has a protective function. It protects or minimizes the lens from mechanical and / or thermal influences.

It is of great importance that the lens is well positioned by the lens holder over the LED / encapsulation of the LED to provide a defined light cone shape, a predefined radiation pattern, and homogeneous light distribution along an LED module or LED light source (FIG. eg linear LED light engine).

The main object of the present invention is to provide a lens holder which improves the flexibility of lens mounting over an LED module and results in a simplified lens mounting process.

In LED components or light engines for homogeneous surface lighting, an LED module is mounted on / in a profile that is placed in the object to be illuminated. Typically, the LED module is soldered or glued in such a profile. This type of LED module assembly has the disadvantage of limited flexibility and requires a wide range of differently dimensioned LED modules to accommodate a wide variety of uses, such as e.g. differently sized poster boxes (promotional boxes) and sig-nages (neon writing) to match. Poster boxes are rectangular shaped boxes in which on one side (or on 2 sides) of the case a glowing picture (pictures) is shown. Sig-nages are differently shaped illuminated, usually small-sized, signs such. Illuminated letters.

Those cited LED module mounting concepts for surface lighting applications such as e.g. Signages limit the application possibilities of linear LED light engines, especially in the case of several small-sized LED modules within a (linear) profile. Mounting processes for linear light engines (light generators) that include a linear profile with mounted LEDs (or LED modules) and are known in the art are quite complicated and not cost effective.

Another object of the present invention is to provide a flexible lens holder 1/17 Austrian Patent Office AT 13 183 Ul 2013-08-15

To offer construction for / with (linear) profiles, which overcomes the mentioned disadvantages of the assembly concepts of the known methods of the prior art (for example soldering method known from EP1959505A1). The present invention provides a lens holder structure by which the individual and flexible attachment of lenses can be realized via LED modules that can be individually arranged in a profile. The proposed solution has the advantage that a simplified disassembly can be carried out. The LED module may e.g. in the case of a module defect simply be replaced in the LED light source. The lighting properties such as e.g. the light intensity can be adjusted to the application requirements by modifying the density and / or number of LED modules (or LED modules with different light emitting characteristics can be used) used in the profile placed in the light source without disassembly the entire light source and / or the application (eg poster box).

These objects are achieved according to the invention by the features of the independent claims. Furthermore, the dependent claims develop the central concept of the invention in a particularly advantageous manner.

According to the first aspect of the present invention, there is thus provided a lens holder for LEDs comprising a cylindrically shaped member and at least six releasable fasteners (3), wherein two of the at least six releasable fasteners (3) are at the bottom and the another two releasable fasteners are located at the top of the cylindrically shaped member, at least two releasable fasteners extending from the underside of the cylindrically shaped member in the vertical direction and at least two of the releasable fasteners being parallel to each other, the cylindrically shaped member having a longer inner diameter (D) at its upper side than at its lower side in a cross-sectional view.

The lens holder may consist of at least eight releasable fasteners.

Each releasable fastener may be parallel to each other in each releasable fastener pair.

At least four releasable fasteners may be snap contacts or sliding contacts.

At least four releasable fasteners may be substantially rectangular in shape.

At least two releasable fasteners, preferably the positioning elements, can position and / or fix an LED module.

At least two releasable positioning elements can elastically position and / or fix an LED module.

Further, the lens holder may include a positioning member for positioning and / or fixing a lens.

At least two releasable fasteners may mechanically secure or hold a lens.

The cylindrically shaped element may have a circular, elliptical or polygonal base.

The lateral surface of the cylindrically shaped element may be substantially curved and / or linear in its cross-sectional view.

Thus, according to another aspect of the present invention, it is a lens holder assembly that includes a lens holder, a lens and a profile. The profile includes at least two grooves for attachment of the releasable fasteners.

The lens holder assembly may include a plurality of lens holders and a plurality of Austrian Patent Office AT 13 183 Ul 2013-08-15

Lenses include.

The profile may be a linear profile.

The lens holder assembly may comprise an LED module or a plurality of LED modules.

The LED module may include at least one LED (LED chip or SMD LED) and color conversion means to convert a portion of the light generated by the LED (eg blue light) to a longer wavelength (e.g. yellow light), so that the mixture of the emitted light and the converted light results in a white light.

As the color converting agent, phosphors known in the art may be used for LEDs. One or more phosphors (phosphor blends) dispersed / blended into organic (e.g., silicone resin (s)) or inorganic matrices (e.g., ceramic materials) may be used on the LEDs. Optionally, in the case of different LEDs, different phosphor (s) or phosphor mixtures may be used to obtain a targeted light color / tone and color distribution.

The color conversion means could be applied directly to the LED, e.g. as a thin layer or blended / dispersed in an encapsulant (or potting material), e.g. a globe top (dome-shaped encapsulation) that covers the LED. The globe top can be applied to at least one LED or a plurality of LEDs on the LED module.

The LEDs used of the LED module could emit the same or different colors. The LEDs may also be phosphor converted LEDs (e.g., white light emitting LEDs) or monochromatic LEDs (eg, red light emitting LEDs).

The profile may have a channel, preferably comprise at least two channels to hold mounting elements.

The profile may have a recess (16), preferably at least two recesses for attachment of a cover plate.

The lens may be in the form of a funnel, a hemisphere or a portion thereof.

The lens may have a reflective and / or a refractive surface.

The lens may be a TIR lens.

The surface of the lens may be covered by a pattern and / or a diffuse layer and / or a reflective layer.

The lens holder may serve as a spacer of the lens over the LED module.

The lens holder may be designed so that there is an air gap between the light exit surface of the LED and the central part of the lens.

The LED module may include an LED and an encapsulant covering the LED.

The lens holder structure may comprise a cover plate.

The material of the lens may be made of glass or plastic (PMMA, PC, PMMI, PET, acrylic, silicone, epoxy, etc.) or a mixture thereof. Lenses coated with a thin metal film can also be used.

The invention proposes the use of the lens holder and a lens holder assembly in an LED light source. In particular, this application may be used in light sources such as e.g. be beneficial in linear light engines.

According to a further aspect of the present invention, a lens holder assembly is thus described, which comprises a plurality of lens holders, a plurality of lenses, a 3/17 Austrian Patent Office AT 13 183 Ul 2013-08-15

Variety of LED modules and a linear profile covers. The linear profile comprises at least two grooves for attachment of the releasable fasteners.

The invention also proposes a method for mounting a lens as a second optic (secondary optics) over an LED in a profile. The method comprises the steps of mounting an LED module in a profile, mechanically holding a lens in a lens holder by releasable fasteners, and mounting the lens holder in a profile by releasable fasteners over an LED module.

Other features, advantages and objects of the present invention will become apparent to those skilled in the art upon reading the attached detailed description of the preferred embodiments, taken in conjunction with the drawings of the accompanying drawings.

Fig. 1 shows a perspective view of a lens holder according to the present invention

Invention Fig. 2 shows a lens mounted by a lens holder in a perspective view according to the present invention. Fig. 3 shows an LED module and a lens positioned through the lens holder and In a perspective view according to one of the embodiments of the present invention, FIG. 4 shows an LED module and a lens positioned and / or fixed by the lens holder in a cross-sectional view according to one of the embodiments 5 shows a cross-sectional view of a lens holder according to one embodiment of the present invention, and FIG. 6 shows another embodiment of a lens holder structure in a perspective view according to one embodiment of the present invention.

FIG. 1 shows an embodiment of the lens holder 1 according to the invention. As can be seen from Figure 1, the present invention proposes a lens holder 1, preferably made of a plastic material (other possible materials such as metal can also be applied in the form of a metal layer) as a positioning and / or fastening element for a secondary optic, such. a lens 8 before. The lens holder 1 may be used as a further optic, e.g. as a reflector (s), diffuser plate (s) are applied.

According to the invention, the lens 1 comprises a cylindrically shaped element 2 (which is basically a ring) and six releasable fastening elements 3. The releasable fastening elements 3 are arranged on both sides of the element 2. There are four fasteners 3 on the bottom 5 and another two detachable fasteners 3 on the top 4 of the cylindrically shaped element 2. Preferably, some of the releasable fasteners 3 serve as snap-in pins 10 on either side of the cylindrically shaped element 2. Alternatively, the detachable Fixing elements 3 may be arranged on both sides of the cylindrically shaped element 2. In addition, some of them may look like legs that extend directly from the bottom 5 of the cylindrically shaped member 2 and point downward in the vertical direction. In another embodiment of the present invention, all or some of the releasable fasteners 3 may extend directly downwardly from the cylindrically shaped element 2 and / or upwardly in the vertical direction.

Preferably, at least two releasable fastening elements 3 are arranged on the upper side 4 of the cylindrically shaped element 2 and extend upward in the vertical direction.

Preferably, two releasable fastening elements 3 are arranged on the underside 5 of the cylindrically shaped element 2, which serves as a positioning frame 18 for a LED Austrian Patent Office AT 13 183 Ul 2013-08-15

Module 12 serve. The latter two positioning racks 18 (also referred to as releasable fasteners 3) can resiliently position and / or fix the LED module 12. In principle, all remaining releasable fasteners 3 disposed on the underside 5 of the cylindrically shaped element 2 may be formed as legs, such as the positioning racks 18. Further, any releasable fasteners 3 or some of the elements 3 (on one or both sides of the cylindrically shaped element 2) may be formed as sliding elements or snap-in connections (or snap-in pins 10).

The releasable fasteners 3 may have a substantially regular shape (shown in FIG. 1). However, the invention is not limited to a rectangular shape but may have any shape. For example, the releasable fasteners 3 may have an elliptical, circular, triangular, or other shape, which may also be varied in its dimension (s) or shape over its longitudinal axis.

The releasable fastening elements 3 are within detachable element pairs 7 parallel to each other.

In particular, it can be seen that the releasable fasteners 3 are arranged not only within the pairs of elements 7 in parallel, e.g. on the underside 5 of the cylindrically shaped element 2, but also that the detachable element pairs 7 can be parallel to each other (better shown in FIG. 2).

In Figure 1 it is shown that the cylindrically shaped element 2 has a longer inner diameter (D) on its upper side (4) than on its underside (5) in the cross-sectional view.

The base of the cylindrical member 2 may be circular or elliptical. However, the invention is not limited to the above-mentioned shapes but may have any shape such as a rectangular shape.

The lateral surface of the cylindrically shaped element 2 is substantially curved in a cross-sectional view, but may also be linear or a combination of the cited. The lateral surface of the cylindrically shaped element is conical but is not limited thereto.

Figure 2 shows that a lens 8 is held mechanically by the lens holder 1 by two releasable fasteners 3, preferably by snap-in pins 10 or snap-in connections according to the invention (the snap-in pins 10 are shown in Figure 1). The lens 1 comprises a positioning element 6, e.g. a hole (also shown in Figure 1) which provides an adjustment option for the lens orientation / centering z. Example, in the case of a structured surface lens 8, in which the predetermined pattern alignment 20 has a high importance. The lens 8 can be adjusted elastically by the releasable fastening elements 3 and / or by the positioning element 6. Alternatively, the positioning element 6 can be formed as a detachable fastening element 3.

The combination of lens 8 and lens holder 1 (which may also be considered as a frame) thus provides a flexible unit that can be easily handled in a lens mounting process, e.g. in the case of a manufacturing process for LED light sources. This leads to greatly reduced production costs, throughput times and significantly reduces rejects.

As can be seen from Figure 2, the lens holder 1 with the lens 8 is preferably characterized by " snap " (or terminals) connected. In the illustrated embodiment, this is achieved by snap-in connections 10 (or other releasable attachment means) on the peripheral edge of the lens 8.

In contrast to the prior art, therefore, no additional attachment for holding the lens 8 and the holder 1 is necessary, for. By attaching a silicone resin (or another type of adhesive), although such additional attachment may be covered by the invention.

As FIG. 2 shows, the lens 8 is represented by a substantially funnel-shaped body. However, the invention is not limited thereto. For example, the lens may be in the form of a vault ball or a part thereof.

Preferably, glass is used as the material for the lens 8. Other materials such as plastics may also be used in accordance with the present invention. Combinations of said materials or thinner metal layers, such as a mirror glass lens, may also be used. A mirrored surface of the lens may be disposed on its outer and / or inner surface. The lens 8 may also be partially covered by the layer (s).

FIG. 3 shows an LED module 12 which is positioned and / or fixed by the positioning frame 18 of the lens holder 1. In addition, the lens holder 1 mechanically holds a funnel-shaped lens 8. The surface pattern 20 of the lens is aligned by the positioning member (hole) 6 of the holder 1.

This mounting of the LED module 12 has the advantage of a non-rigid fixation, which has no influence on the reliability of the attachment of the lens in the lens holder 1. The positioning rack 18 (alternatively releasable fastening elements 3) can absorb the environmental influences, which are manifested by dimensional deviations during operation. Its differences would otherwise lead to loads between the LED module 12 and the lens 8 (and / or lens holder 1). In addition, no further fasteners should be used to secure the LED module 12 in / on e.g. a profile 13 are applied, although such additional attachment can also be applied by the invention. For example, the LED module 12 may be replaced by e.g. a thermal conductive foil, pad or paste, aluminum-aluminum adhesive are mounted in a profile 13.

The use of a thermally conductive adhesive has the added effect of improving the thermal properties of the structures.

As can be seen in Figures 4 (and 3), the lens holder 1 (and / or the lens 8) is positioned so that the central portion 21 of the lens 8 from the light exit surface of the LED (or the encapsulation 17) through an air gap is disconnected. Preferably, there is no air gap between the lower portion 22 of the lens 8 and the substrate 24 of the LED module 12. The lens 8 is attached directly to the LED module 12 through its lower portion 22.

Light emitted from the top of the LED (and / or encapsulation 17) is passed through the air gap before entering the lens 8 at its center 21. When it passes the lens 8 at its central portion 21, the angle of the light rays is vertically refracted, so that a narrower emission beam angle of the LED module 12 is achieved.

Preferably, the bottom surface of the lower portion 22 of the lens 8 is planar. The base of the central portion 21 of the lens 8 may be flat or curved.

An LED (an LED die or an SMD LED) is mounted on the substrate 24 of the LED module 12 and preferably covered by a transparent encapsulation 17. Preferably, the LED module is a COB (chip-on-board) module. The LED module may also include an electronic component 23.

The transparent encapsulant 17 comprises a polymer matrix, such as e.g. Silicone resin (a mixture of polymers can also be used) that can be filled. The fillers mentioned z. Color conversion substances (organic and inorganic phosphors such as phosphors) and / or scattering particles (TiO 2, SiO 2, Al 2 O 3, BaTiO 3, BaSO 4, etc.). Preferably, the encapsulation is a globe top. The globe top over the LED can e.g. dispensing or other techniques known in the art.

For the provision of a white-appearing, radiating color, UV or blue light emitting LEDs in combination with green, greenish yellow, yellow, and / or red light emitting phosphors (eg, garnets) may be used , Orthosilicates, nitrides and / or SiAIONe) (or their combination). LED dice or SMD LEDs may be applied to the LED module 12 by known techniques cited in the prior art.

Figure 5 shows a lens holder assembly 11 according to one aspect of the present invention in cross-sectional view. The lens 8 is mechanically held by the lens and said lens / lens holder unit is mounted in the grooves 14 of the profile 13 by releasable fasteners 3 of the lens holder 1. The profile 13 provides two channels 15 for receiving mounting elements, e.g. Screws for mounting an end cap to cover the end of the profile 13.

The profile 13 comprises two recesses 16 for mounting and / or fixing a cover plate which covers the lens holder 11.

Figure 6 shows a lens holder assembly 11 according to another aspect of the present invention in perspective view. A plurality of lens arrays are applied in the grooves 14 of a linear profile 13 by releasable fasteners 3 of the lens holder 1. A plurality of LED modules 12 are mounted on / in said profile 13. The positioning of said LED modules 12 is realized by the positioning racks 18 of the lens holder 1.

The lens holder assembly 11 of Fig. 6 may be used in an LED light source, such as a light source. be applied to a linear light engine. The LED light source (or linear LED light engine) is used in illuminated enclosures such as guidance systems, poster boxes, light boxes, showcases or in refrigerated counters.

During the manufacture of an LED light source according to the present invention, in the first step, the lens 8 and the bracket 1 are assembled together (eg, " Clipped ", " Snapped ") and as a unit by fasteners 3 via the LED module 12 placed in / on a profile 13. In a second step, the end caps of the profile 13 are fastened by using channels 15 for receiving the mounting elements. Alternatively, in a further step, a cover plate can be attached to the profile 13 by mounting in the recesses 16.

This method enables easier fabrication using standard and standard manufacturing equipment, resulting in the production of highly efficient LED light sources in limited and simplified process steps. 7/17 Austrian Patent Office AT 13 183 Ul 2013-08-15 LIST OF REFERENCE SIGNS: 1 Lens holder 2 Cylindrical shaped element 3 Detachable fastening element 4 Upper side of the cylindrically shaped element 5 Positioning element (hole) 6 Detachable fastener pair 7 Lens 8 Base of cylindrical shaped element 9 snap-in pin 10 lens holder assembly 11 LED module 12 profile 13 groove 14 channel 15 recess 16 encapsulation 17 positioning frame 18 inlet 19 pattern 20 center of the lens 21 lower portion of the lens 22 electronic component 23 substrate of the LED module 8/17

Claims (29)

Austrian Patent Office AT13183U1 2013-08-15 Claims 1. A lens holder for LEDs, comprising: - a cylindrically shaped element (2), and - at least six releasable fastening elements (3), two of the at least six detachable fastening elements (3) on the underside ( 5) of the cylindrically shaped element (2) are arranged, further two detachable fastening elements (3) are arranged on the upper side (4) of the cylindrically shaped element (2) and at least two releasable fastening elements (3) extend from the underside (5) of the cylindrically shaped element (2) extend in the vertical direction and at least two of the releasable fastening elements (3) are parallel to each other, wherein the cylindrically shaped element (2) has a larger inner diameter (D) on its upper side (4) than on its underside (5) in a cross-sectional view. 2. lens holder (1) according to claim 1, characterized in that the lens holder (1) comprises at least eight releasable fastening elements (3). 3. lens holder (1) according to claim 1 or 2, characterized in that the releasable fastening elements (3) in each case a releasable fastener pair (7) are parallel to each other. 4. lens holder (1) according to any one of the preceding claims, characterized in that at least four releasable fastening elements (3) latching pins (10) or sliding contacts. 5. lens holder (1) according to any one of the preceding claims, characterized in that at least four releasable fastening elements (3) have a substantially rectangular shape. 6. lens holder (1) according to any one of the preceding claims, characterized in that at least two releasable fastening elements (3), preferably positioning racks (18), an LED module (12) position and / or fasten. 7. lens holder (1) according to claim 6, characterized in that at least two detachable positioning racks (18) an LED module (12) elastically position and / or fasten. 8. lens holder (1) according to any one of the preceding claims, characterized in that the lens holder (1) further comprises a positioning element (6) for positioning and / or attachment of a lens (8). 9. lens holder (1) according to any one of the preceding claims, characterized in that at least two releasable fastening elements (3) mechanically fasten or hold a lens (8). 10. lens holder (1) according to any one of the preceding claims, characterized in that the cylindrically shaped element (2) has a circular, elliptical or polygonal base (9). 11. A lens holder (1) according to any one of the preceding claims, characterized in that the lateral surface of the cylindrically shaped element (2) in a cross-sectional view is substantially curved and / or linear. 9/17 Austrian Patent Office AT 13 183 Ul 2013-08-15 A lens holder assembly (11), comprising: - a lens holder (1) according to any one of the preceding claims, - a lens (8) and - a profile (13), the profile (13) having at least two grooves (14) for fixing the includes releasable fasteners (3). 13. A lens holder assembly (11) according to claim 12, characterized in that the lens holder (1) comprises a plurality of lens holders (1) and a plurality of lenses (8). 14. A lens holder assembly (11) according to claim 12 or 13, characterized in that the lens holder assembly (11) comprises an LED module (12) or a plurality of LED modules (12). 15 lens holder assembly (11) according to any one of claims 12 to 14, characterized in that the profile (13) is a linear profile. 16. lens holder assembly (11) according to any one of claims 12 to 15, characterized in that the profile (13) has a channel (15), preferably at least two channels (15) for receiving mounting elements. 17. lens holder assembly (11) according to any one of claims 12 to 16, characterized in that the profile (13) comprises at least one recess (16), preferably at least two recesses, for fastening a cover plate. 18. lens holder assembly (11) according to any one of claims 12 to 17, characterized in that the lens (8) has the shape of a funnel, a hemisphere or parts thereof. 19. A lens holder assembly (11) according to any one of claims 12 to 18, characterized in that the lens (8) has a reflective and / or a refractive surface. 20. A lens holder assembly (11) according to any one of claims 12 to 19, characterized in that the surface of the lens (8) is covered by a pattern and / or a diffuse layer and / or a reflective layer. 21 lens holder assembly (11) according to any one of claims 14 to 20, characterized in that the lens holder (1) acts as a spacer which holds the lens (8) above the LED module (12). 22. A lens holder assembly (11) according to any one of claims 12 to 21, characterized in that the holder 1 is formed so that it holds the lens (8) so that it has an air gap between the light exit surface of the LED and the central portion (21 ) of the lens (8). 23. A lens holder assembly (11) according to any one of claims 14 to 22, characterized in that the at least one LED module (12) comprises an LED and an encapsulation and the encapsulation covers the LED. 24. A lens holder assembly (11) according to any one of claims 12 to 23, characterized in that the lens holder assembly (11) comprises a cover plate. 25. lens holder assembly (11) according to any one of claims 12 to 24, characterized in that the material of the lens (8) glass or plastic or a mixture of these. 10/17 Austrian Patent Office AT13183U1 2013-08-15 26. Use of a lens holder (1) according to one of claims 1 to 11, in an LED light source. 27. Use of a lens holder assembly (11) according to any one of claims 12 to 25, in an LED light source. 28. The use of a lens holder (1) or a lens holder assembly (11) according to claim 26 or 27 in a light source, wherein the LED light source is a linear light engine. 29. A method for mounting a lens (8) in a profile (13), comprising the following steps: - mounting an LED module (12) in a profile (13), - mechanically holding a lens (8) in a lens holder (1 ) by releasable fasteners (3) according to one of claims 1 to 11, and - attaching the lens holder (1) via an LED module (12) in a profile (13) by releasable fastening elements (3). For this 6 sheets drawings 11/17