BE1023326B1 - IMPROVEMENTS IN OR RELATING TO LIGHT EMITTING DIODE MODULES - Google Patents

Abstract

Description is made herein of an LED module (500) comprising a PCBA (200) having an array of LED elements, an array of secondary lenses (300) and a lens holder (510). The secondary lens array (300) has a peripheral lip (360) and a plurality of boss portions (330a) which are compressed between the lens holder (510) and the PCBA (200) to form waterproof gaskets. water. The secondary lens array (300) also forms gaskets around wires connecting to terminal blocks on the PCBA (200) and effectively sticks to a base plate (100) on which the PCBA (200) is mounted.

Description

IMPROVEMENTS IN OR RELATING TO DIODE MODULES

EMITTING

Field of the invention

The present invention relates to improvements of or relating to light emitting diode modules, and more particularly to provide a seal to these modules.

Prior art of the invention

Light-emitting diode (LED) based luminaires often include LED modules comprising printed circuit boards (PCBs) on which LED elements are mounted with electrical connections to the PCB to provide power to the LEDs. The LED elements are typically arranged in a set or pattern and are mounted on the PCB, often referred to as a printed circuit board assembly (PCBA) that is suitable for the luminaire in which they will be used. Although each LED element comprises a light source with a primary optical element or a primary lens, secondary optical elements are often required to direct the light produced by these light sources in directions appropriate to the particular implementation in a luminaire. Lenses are typically used as secondary optical elements to direct light.

For outdoor use, these LED modules are mounted with their secondary optical elements in an enclosure having a glass or polycarbonate window to ensure adequate protection of the LED modules against ingress of water. The window, while allowing the light of the LED modules to be transmitted from the speaker, forms another optical interface that generates additional loss of light due to attenuation. Light losses of up to about 7% are typically common for glass windows used for outdoor fixtures.

It is possible to reduce these losses of light by using for the protection window the material in which the optical elements or secondary lenses are made. In such an assembly, the LED module is enclosed between a back surface and a surface formed by a set of secondary optical elements to form a sealed enclosure. Although such an arrangement may provide adequate protection for the LED module, it is nevertheless essential to provide wires connected to the LED module, and the watertightness around the wires that extend into the enclosure Sealed remains a source of water penetration if they are not properly surrounded by a suitable gasket material that maintains the tightness of the enclosure. CN-U-202947010 discloses a solution to this problem by providing a watertight cable pin or a gasket on a rear surface of such a sealed enclosure through which the wires enter the sealed enclosure. However, although such a solution is suitable for LED modules having their own heat sinks, it complicates the assembly of flat LED modules when they must be mounted on a flat surface of a luminaire body, since grooves and holes must be provided to allow wire and cable routing to the LED modules. WO-A-2011/053349 discloses a mounting system of an LED module in which a gasket is provided on a network of rigid secondary lenses and which is held in place by a cover. The cover forms, with a base on which the LED module is mounted, an interior space that encloses and compresses the gasket against the secondary lens array and the secondary lens array against the PCBA to form a sealed enclosure when all is screwed. The gasket provides a weatherproof seal and a rigid wire guide channel is provided for wiring the LED module. Such a rigid metal wire guide trough is described in US-B-7566147. The wire guide chute is tubular in shape and defines a solid internal passageway through which the wires pass and enter the sealed enclosure. A seal is placed between one end of the rigid metal wire guide chute and a housing in which the sealed enclosure is mounted.

However, WO-A-2011/053349 requires additional components to form a seal for the LED module but not for wiring, these additional components increasing not only the complexity of the mounting system but also the cost of a such system. In addition, the rigid metal wire guide trough disclosed in US-B-7566147 also increases complexity and cost, since the wires must be carefully threaded into the passage before the system can be mounted on the housing. Summary of the invention

It is therefore an object of the present invention to provide a simple system in which a secondary lens array also forms an exterior for an LED module.

Another object of the present invention is to provide a static seal between an LED module and a fixture on which it is mounted using a secondary lens array to provide a watertightness to the LED module.

A further object of the present invention is to provide a watertight wiring for an LED module using a secondary lens array without the need for other static gaskets or gaskets.

According to one aspect of the present invention, there is provided a watertight light-emitting diode module comprising: a base plate; a printed circuit board mounted on the base plate; a plurality of light-emitting diodes mounted on the printed circuit board; at least two electrical connections mounted on the printed circuit board and electrically connected to supply current to each of the plurality of light emitting diodes; a secondary lens array on the plurality of light-emitting diodes on the printed circuit board, the secondary lens array comprising a plurality of secondary lens elements and being configured to provide a cover portion for each of the electrical connections and a sheath portion for each wires connected to each of the electrical connections; and a lens holder mounted on the secondary lens array, the lens holder comprising a plurality of apertures formed therein for accommodating one of the secondary lens elements and being configured to compress at least a portion of the secondary lens array to forming at least one gasket between the lens holder and the base plate to prevent ingress of water around the printed circuit board.

By forming the secondary lens array in a compressible material, it is possible to use the same material for the static seals formed by compressing portions of the secondary lens array between portions of the printed circuit board, the base plate. and the lens holder.

This has the advantage of providing watertight connections without incurring additional expense to implement separate static seals.

Although in a preferred embodiment, the entire secondary lens array is made of the same material, it will be readily understood that it is possible to use materials different from those used for portions of the secondary lens array that they will be used as static seals.

In one embodiment, the secondary lens array includes a peripheral lip portion that extends on a surface of the base plate.

This offers the advantage of effectively sealing the printed circuit board in the secondary lens array to prevent the ingress of water.

The base plate can form one of: a heat sink and a part of a luminaire body on which the module will be mounted.

In one embodiment, the lens holder includes a skirt portion disposed around its periphery, the skirt portion being configured to compress the peripheral lip portion of the secondary lens array against the surface of the base plate.

Providing a skirt portion in the lens holder with appropriate dimensions relative to the printed circuit board and the secondary lens array provides the means for compressing the peripheral lip portion of the secondary lens array to form a static seal between the skirt portion and the surface of the base plate.

Advantageously, the skirt portion has at least two portions cut therein, each cut portion being configured to substantially align with a relevant sheath portion and to provide access to a connection in the corresponding cover portion of the secondary lens array. for a wire passing through the sheath portion.

Each wire cover portion is configured to form a gasket around a wire inserted therethrough.

The cut portions provide access for the wires and also provide a flange for supporting the wires so that they do not undergo excessive bending that may affect the static seals formed around the wires by the sheath portions of the secondary lens array.

In one embodiment, the secondary lens array includes a plurality of network mounting holes formed therein, each network mounting hole having a network boss portion associated therewith and configured to pass through a corresponding mounting hole formed in the printed circuit board.

In addition, the lens holder further includes a plurality of lens holder mounting holes formed therein, each lens holder mounting hole having a lens holder engaging portion associated therewith and which is configured to engage a corresponding network boss portion of the secondary lens array and to compress the array boss portion against the corresponding mounting hole formed in the printed circuit board and against the surface of the base plate for form a seal with it.

By providing projection portions associated with the mounting holes of the secondary lens array and the mounting holes of the lens holder, static seals can easily be provided around the mounting holes to prevent water penetration through the mounting holes. mounting between the secondary lens array and the printed circuit board.

A plurality of mounting screws are preferably provided for mounting the lens holder and the secondary lens array on the base plate on which the printed circuit board is mounted, with each mounting screw passing through one of the door mounting holes. lens and its associated lens holder boss portion and in an associated hole in the base plate.

It is preferred that the secondary lens array comprises an optical grade silicone material. In this case, the secondary lens array can be molded in one piece. In addition, the natural flexibility of the silicone material allows its use as a gasket thus avoiding the need for additional static seals that are applied either in liquid form or in solid form.

In one embodiment, the lens holder is molded in one piece. In this case, the lens holder may comprise one of polycarbonate, polyphenylene sulfide, polybutylene terephthalate and polyamide.

According to another aspect of the present invention, there is provided a luminaire comprising at least one watertight light-emitting diode module as described above.

Brief description of the drawings

For a better understanding of the present invention, reference will now be made, by way of example only, to the accompanying drawings in which:

Figure 1 illustrates a perspective top view of an assembly of printed circuit boards;

FIG. 2 illustrates a perspective top view of a secondary lens array according to the present invention;

Fig. 3 is an enlarged perspective view of a terminal end of the secondary lens array of Fig. 2;

Fig. 4 is an end view of the terminal end of the secondary lens array of Fig. 2;

Fig. 5 illustrates a perspective top view of a lens holder for the secondary lens array of Fig. 2 according to the present invention;

Figure 6 illustrates an enlarged perspective view of the terminal end of an assembled LED module according to the present invention;

Fig. 7 illustrates a sectional view of the terminal-side end of the assembled LED module taken along the line VII-VII of Fig. 4;

Fig. 8 illustrates a sectional view of the terminal-side end of the assembled LED module taken along line VIII-VIII of Fig. 3; and

FIG. 9 illustrates a sectional view of the assembled LED module taken along line IX-IX of FIG. 7.

Description of the invention

The present invention will be described in connection with particular embodiments and with reference to certain drawings but the invention is however not limited thereto. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn to scale for illustrative purposes.

Although the present invention is described with reference to LED modules suitable for luminaires, it will be readily appreciated that the invention is not limited to such an implementation and can be used in any LED module. , especially if it requires to prevent the ingress of water.

The terms "circuit board assembly" and "PCBA" as used herein refer to a printed circuit board (PCB) on which a set of LED elements are mounted. These terms also include wiring connections to provide power to each LED element.

The term "light emitting diode module" or "LED module" as used herein refers to a PCBA, a secondary lens array, and a lens holder for mounting the secondary lens array on the PCBA. It is essential that each element of the secondary lens array is properly aligned with an associated LED element in the PCBA LED array.

The term "lens array" as used herein refers to an arrangement or pattern of at least one lens element. In the embodiment described below, each lens array comprises twelve lens elements that are integrally formed as a single component. However, it will be appreciated that a lens array may comprise any number of lens elements arranged to form the lens array.

The term "secondary lens array" as used herein refers to a lens array in which the lens elements are designed as light beam formers to create a predetermined light distribution and which are positioned on elements. Associated LEDs of the LED array Such lens arrays are typically used as secondary lenses in luminaires for street lighting applications According to the present invention, the secondary lens array is molded as a single component in a material of optical quality silicone.

The term "silicone material" as used herein refers to an optical grade silicone material having a Shore 00 hardness value in the range of 60 to 100. As will readily be understood, these values range from soft to moderately hard and will affect the flexibility, flexibility and durability of the lens networks made from these materials. The silicone materials are also resistant to high temperatures (eg, temperatures exceeding 85 ° C and possibly up to 150 ° C) and therefore offer the ability to use in the luminaire less expensive material used to heat sinks.

The silicone lenses used as secondary lenses may have different sizes and structures depending on their optical properties and allow the operation of lighting devices incorporating such lenses in higher temperature ranges. This means that it is possible either to increase the operating temperature range while using conventional heat sinks for heat dissipation or to reduce the amount of heat sinks required for heat dissipation without negatively affecting the operation. of the luminaire. Of course, reducing the amount of material required for heat dissipation can be cost-effective.

It will be readily appreciated that the optical properties of the silicone lenses must be maintained for all operating temperatures and not degrade over time during operation at higher temperatures. In addition, silicone is resistant to ultraviolet radiation (UV) damage and is a good candidate for use in lenses exposed to outdoor conditions or in the open air.

According to the present invention, the silicone lenses are formed as a secondary lens array which not only meets the requirements for higher operating temperatures but is also compressible in predetermined areas (non-lens areas) to form static seals between the PCBA and the lens holder.

According to the present invention, by using a silicone material suitable for the secondary lens array, it is possible to easily provide a sealed enclosure in which the secondary lens array forms at least one watertight seal or static seal preventing the penetration of water into the enclosure as described in more detail below.

FIG. 1 illustrates a PCBA 200 comprising a PCB 210 on which twelve LED elements 220 are mounted. The PCB 210 has a base plate (100 shown in FIG. 9) on which the PCB 210 is fixed or mounted. The PCB 210 also includes ten mounting holes 230 through which mounting screws (described below with reference to Figures 5 to 9) are inserted to mount an LED module whose PCBA 200 forms a portion of the luminaire housing. In addition, the PCB 210 includes terminals 240, 250 at one end of the terminal side thereof to which wires (not shown) are connected to supply power to the PCBA 200. The bearers 240, 250 include female connectors 245, 255 for yarns as will be described in more detail below with reference to FIGS. 3 and 4.

It will be readily appreciated that each terminal block 240, 250 includes a connection for supplying power to the LED elements 220 on the PCB 210.

Although only twelve LED elements 210 are shown, it will be readily appreciated that any appropriate number of LED elements may be provided depending on the particular implementation. In addition, the set of LED elements should not be configured according to the pattern shown in Figure 2 but any other pattern is also possible.

The PCB 210 has an edge 260 which extends around its periphery and against which the secondary lens array 300 forms a seal as will be described in more detail below with reference to FIGS. base 100 (as shown in FIG. 9) preferably extends beyond edge 260 of PCB 210 and has a surface 110 which is configured to engage corresponding portions of a peripheral lip of a network secondary lenses as will be described in more detail below with reference to FIG. 9.

Fig. 2 illustrates a secondary lens array 300 according to the present invention that can be mounted on the PCBA 200 shown in Fig. 1. The secondary lens array 300 comprises a body portion 310 in which twelve secondary lens elements 320 are formed, a lens element for each LED element 210. Ten mounting holes 330 which correspond to mounting holes 230 of the PCBA 200 are shown, the mounting screws being inserted through the two sets of holes as will be described in more detail below. with reference to Figures 6 and 9.

Covering portions 340, 350 are provided at one terminal end of the secondary lens array 300 and are aligned with and cover each of the terminals 240, 250 provided at the terminal end of the PCB 210 to prevent the ingress of water. Each cover portion 340, 350 has an associated sheath portion 345, 355 extending from one end thereof to the end of the body portion 310 of the secondary lens array 300.

According to the present invention, the body portion 310 has a peripheral lip 360 which forms a static seal or a watertight edge for the PCBA 200 when assembled as will be described in more detail below. In addition, a sheath portion forms a gasket or watertight seal around a wire inserted therein as will be described in more detail below.

Each mounting hole 330 formed in the body portion 310 has a boss portion (as shown in Figure 9) that extends into a corresponding hole 230 in the PCBA 200 and acts as a watertight gasket for each screw. assembly (FIGS. 5 to 9) to prevent the penetration of water, through the screw holes, between the secondary lens array 300 and the PCBA 200 as will be described in more detail below with reference to FIG. 9 .

Three short ribs 370 are formed at the center of each group of four secondary lens elements 320, and two long ribs 375 are formed between each group of four secondary lens elements. These ribs provide positioning points for a lens holder as will be described in more detail below.

An alignment pin 380 is also formed at one end of the secondary lens array 300 which is remote from the terminal block portions 340, 350. The functionality of the ribs and the alignment pin will be described in more detail below.

In the illustrated embodiment of the secondary lens array 300, light shields 325 are provided for each of the secondary lens elements 320 so that light passing through the secondary lens element 320 is locked in a particular direction. However, it will be appreciated that these light shields are not essential.

It will be readily appreciated that the number of secondary lens elements 320 in the secondary lens array 300 is chosen to correspond to the number of LED elements 220 in the PCBA 200. In addition, the alignment and / or orientation of secondary lens elements 320 in the secondary lens array 210 is not limited to the alignment and orientation shown in FIG. 2 and described herein and may be any other alignment and / or orientation appropriate to the application particular lighting.

It will be readily appreciated that the base plate 100 (FIG. 9) on which the PCBA 200 is mounted and with which the secondary lens array 300 forms a seal around its peripheral edge when assembled is not shown on FIG. Figures 3 to 6 for reasons of clarity.

Figure 3 illustrates an enlarged view of the terminal end of a secondary lens array 300 and a PCBA 200 assembled but not shown in the figure. As shown, wires 440, 450 of a power supply (not shown) are inserted into cylindrical holes 445, 455 (as shown in FIG. 4) of the sleeve portions 345, 355 and in the cover portions 340, 350 to plug into the female connectors 245, 255 of the terminal blocks 240, 250 (as shown in Figure 9). The cylindrical holes 445, 455 of the sheath portions 345, 355 act as static seals preventing the penetration of water along the wires 440, 450.

The inside diameter of the cylindrical holes 445, 455 and the outer diameter of the wires 440, 450 can be chosen to provide a tight fit or interference fit. Due to the flexible nature of the silicone material, the sheath portions 345, 355 may stretch slightly to accommodate the outer diameter of the wires when the wires are inserted into the female connectors 245, 255 and then resume their shape and size. normal thereafter.

In one embodiment, the outer diameter of each cylindrical hole 445, 455 is formed to create a release angle of the demolding tool used to mold the secondary lens array into one piece. One embodiment of the inside diameter of the cylindrical holes 445, 455 is described in more detail with reference to FIG.

FIG. 4 illustrates a side view of the terminal-side end of the assembly shown in FIG. 3. As before, the PCBA 200 is not visible except for the female connectors 245, 255 of the sliders 240, 250.

According to the present invention, a lens holder is provided for mounting the secondary lens array relative to the PCBA. The lens holder includes a simple frame for surrounding and retaining the secondary lens elements as will be described in more detail below with reference to Fig. 5.

Turning now to FIG. 5, a perspective top view of an assembly 500 of a PCBA (not shown), a secondary lens array 300 and a lens holder 510 according to the present invention. The lens holder 510 comprises a frame 515 having twelve openings 520 formed to each receive one of the secondary lens elements 320 and the associated light shield 325 when assembled.

Ten holes 530 corresponding to the ten holes 230 formed in the PCB 200 and the ten holes 330 formed in the secondary lens array 300 are formed in the frame 515. Each hole 530 includes a boss portion (as shown in Fig. 9) configured to extend through a corresponding boss portion of the secondary lens array 300 as will be described in more detail below with reference to Fig. 9. Mounting screws 590 are used to secure the frame 515 of the lens holder to the PCBA 200 by sandwiching the secondary lens array 300 therebetween and to secure the assembly to a mounting plate or other surface. on which the LED module will be mounted (not shown).

Cut-outs 540, 550 are provided at the end of the frame 515 to house the cover portions 340, 350 for the abutments 240, 250 (Figure 1).

A skirt 560 extending from the frame 515 engages, when the assembly is made, with the peripheral lip 360 of the secondary lens array 300 to form a seal with the base plate 100 (FIG. this will be described in more detail below. The skirt 560 of the frame 515 is sized to stick against the peripheral lip 360 of the secondary lens array 300 and to cause the peripheral lip 360 to stick against the peripheral edge 260 of the PCB 210 and against the surface 110 of the plate. base 100.

Five transverse ribs 570 are formed in the frame 515 and are configured to engage the three short ribs 370 at the center of each group of four secondary lens elements 320 and with the long ribs 375 between each group formed on the secondary lens array. 300 during assembly.

The frame 515 also includes an aperture or hole 580 in which the alignment pin 380 of the secondary lens array 300 engages during assembly. This opening or hole 580 together with the transverse ribs 570 ensure proper latching of the secondary lenses 300 on the lens holder 510 so that the secondary lens elements 320 and their associated shields 325 are located in the apertures 520 of FIG. lens holder 510.

Non-limiting examples of materials in which the lens holder 510 may be made include thermoplastic materials, for example polycarbonate (PC), polyphenylene sulfide (PPS), polybutylene terephthalate (PBT and polyamide (PA).

For the construction of the LED module assembly 500, the secondary lens array 300 (FIGS. 2 to 5) is positioned on the PCBA 200 (FIG. 2) with the peripheral lip 360 extending on the edges of the PCBA 200 so that that only the base plate 100 (FIG. 10) on which the PCB 210 is mounted is surrounded by the secondary lens array 300. The surface on which the PCBA 200 is mounted forms a surface against which the peripheral lip 360 of the secondary lens network 300 may stick as will be described in more detail below with reference to FIG. 9.

In addition, the boss portions 330a (as shown in FIG. 9) associated with the mounting holes 330 of the secondary lens array 300 passing through corresponding holes 230 formed in the PCBA 200. The end cutouts 540, 550 are provided at the end. on the terminal side of the frame 515 are located around the cover portions 340, 350 and associated sheath portions 345, 355 so that the respective cylindrical holes 445, 455 are accessible for wire connections.

The skirt 560 of the lens holder 510 has additional cutouts 640, 650, as shown more clearly in FIG. 6, to give access to the cylindrical holes 445, 455. Each of these cutouts 640, 650 generally forms a rim. in U which provides both a centering for each of the wires 440, 450 when they are inserted in the sheath portions 345, 355 associated with a support for each wire when it is fully inserted in its own terminal block 240,250.

The lens holder 510 is placed on the secondary lens array 300 with the transverse ribs 570 of the lens holder 510 engaging the short ribs 370 and the long ribs 375 of the secondary lens array 300. Screws 590 are inserted into the lens array 300. the holes 530 in the frame 515 of the lens holder 510, pass through the boss portions associated with the holes 330 formed in the secondary lens array 300 and extending through the holes 230 in the PCBA 200 and enter the holes 130 formed in the base plate (Figure 9).

FIG. 6 illustrates an enlarged view of the terminal end of the assembly 500. The cutouts 640, 650 provide access to the abutments 240, 250 provided on the PCB 210 via the sheath portions 345, 355 and within the parts covers 340, 350 on the terminal blocks 240, 250. As shown, the wire 440 is inserted into the female connector (not shown in FIG. 6) in the terminal block 240 (FIG. 1) via the sheath portion 345 and the cover portion 340 of FIG. terminal.

The yarn 450 is not shown in FIG. 6 so that the cutout 650 can be seen more clearly. As shown, the cutout 650 forms a flange on which the yarn can be supported when it is inserted into the female connector concerned. in the terminal block as described above. It will be readily appreciated that the cutout 640 is substantially identical to the cutout 650.

Figure 7 illustrates a sectional view of the terminal end of the assembly 500, taken along the line VII-VII of Figure 4, which shows the terminal block 240 and its associated female connector 245. The female connector 245 is substantially aligned with the sheath portion 345 and the cylindrical hole 445 formed therein. The cutout 640 in the frame 515 is also substantially aligned with the female connector 245.

As shown in FIG. 7, the cylindrical hole 445 includes a plurality of shoulder portions of different diameters that decrease in the insertion direction of the wire 440 (FIG. 8). This decreasing diameter structure allows smooth insertion of the wire 440 while forming a plurality of static seal portions along the length of the wire in the cylindrical hole 445 which stick to the outer diameter of the wire.

FIG. 8 illustrates a sectional view of a terminal-end end of the assembly 500 taken along the line VIII-VIII of FIG. 3 and is similar to FIG. 7 but with a wire 440 inserted into the sheath portion 345 and adhering thereto and extending a conductor 440a of the wire 440 extending into and through the female connector 245. The wire 440, once inserted through the silicone material forming the sheath portion 345 and with its conductor 440a fully engaged in the female connector 245, is held in place due to the constriction of the sheath portion 345 to the outer diameter of the wire 440 to form a watertight connection as described above.

As described above with reference to Figure 6, the skirt 560 of the frame 515 has cutouts 640, 650 which are formed to support the wires 440, 450 and also to provide access to the terminal blocks 240, 250 and their female connectors 245. , 255 partners. These cutouts 640, 650 are configured to prevent excessive bending of the wires 440, 450 which could create undesirable stresses on the silicone material forming the wire covers 345, 355.

Fig. 9 is a sectional view taken along the lines IX-IX of Fig. 8. As can be readily seen, the secondary lens array 300 fits on the PCBA 200 with the lip 360 of the secondary lens array. extending around the periphery of the PCBA 200 and engaging a surface of the base plate 100 on which the PCB 210 is mounted. The PCBA 200 is in direct contact with the surface 110 of the base plate 100 as will be described in more detail below.

The base plate 100 is substantially flat and effectively comprises a block of material having a plurality of threaded holes formed therein for receiving the mounting screws 590 as will be described in more detail below and for mounting the mounting plate. base on a luminaire body (not shown). In one embodiment, the base plate 100 may comprise only a single mounting plate for the module 500. In another embodiment, the base plate 100 may include a heat sink for the module 500 so well. no additional heat sink is required. In a further embodiment, the base plate 100 is part of a heat sink in a luminaire body in which it is mounted (not shown).

The boss portion 330a associated with the hole 330 extends through the hole 230 in the PCBA 200. The lens holder 510 is also shown with lens holder boss portions 530a extending through respective boss portions 330a of the array. 300. When assembled, the mounting screws 590 extend through the respective holes 530 in the lens holder 510, through the associated lens holder boss portions 530a and into the base plate 100. on which the PCBA 200 is mounted. Each boss portion 530a of the lens holder may be slightly tapered so that the insertion of the mounting screw 590 expands the boss portion to compress the array boss portions 330a associated with the mounting holes 330 formed in the secondary lens array 300 against the holes 230 formed in the PCBA 200 and compresses the ends 330b of the grid boss portions 330a against the surface 110 of the base plate 100.

As shown, the secondary lens array 300 made of silicone forms a gasket between: the skirt 560 of the lens holder 510 and the peripheral edge 260 of the PCBA 200; and the boss portions 530a of the lens holder 510 and the holes 230 in the PCBA 200 with the ends 330b of the network boss portions 330a being compressed against the surface 110 of the base plate 100. In addition, the secondary lens array 300 also forms static gaskets around the wires 440, 450 (FIG. 3) in the sleeve portions 345, 355 as described above.

In one embodiment, the peripheral edge 360 of the secondary lens array 300 has a pair of peripheral lips 360a, 360b formed therein, which flattens when compressed by the lens holder 510 to be flush with the lens. surface 110 of the base plate 100 to form a pair of seals preventing the ingress of water as shown in FIG. 9. Although this is not shown in FIG. 9 (for the sake of clarity), it It is possible that the peripheral lips 360a, 360b lie totally flat against the surface 110 of the base plate 100.

It will be readily understood that the clamping of the peripheral edge 360 against the surface 110 of the base plate 100 can be implemented differently and is not limited to the pair of peripheral lips 360a, 360b as described above. More lips or other means may be provided to effect the seal between the peripheral edge 360 of the secondary lens array 300 and the surface 110 of the base plate 100.

Moreover, although only one LED module 500 mounted on the base plate 100 has been described above, it will be readily appreciated that more than one such LED module may be mounted on the base plate 100, each having a secondary lens array that forms a gasket therewith to prevent water from entering the LED module 500 and in particular between the secondary lens array and the PCBA 200.

It will be appreciated that while the invention described above includes a non-conductive lens holder, lens holders comprising conductive materials, for example metals, can also be used as a secondary silicone lens array having good electrical insulation properties that meet electrical safety regulations.

Although the present invention has been described with reference to the use of silicone as the material in which the secondary lens array 300 is made, it will be appreciated that the secondary lens array may comprise other materials or combinations of materials which are compatible with each other and offer the characteristics of being molded in one piece with optical grade lenses and compressible to form static seals at locations of the assembly as described above.

Claims (14)

CLAIMS: A waterproof light emitting diode module comprising: - a base plate; a printed circuit board mounted on the base plate; a plurality of light-emitting diodes mounted on the printed circuit board; at least two electrical connections mounted on the printed circuit board and electrically connected to supply current to each of the plurality of light emitting diodes; a secondary lens array on the plurality of light-emitting diodes on the printed circuit board, the secondary lens array comprising a plurality of secondary lens elements and being configured to provide a cover portion for each of the electrical connections and a sheath portion for each wires connected to each of the electrical connections; and a lens holder mounted on the secondary lens array, the lens holder comprising a plurality of apertures formed therein for accommodating one of the secondary lens elements and being configured to compress at least a portion of the secondary lens array to forming at least one gasket between the lens holder and the base plate to prevent ingress of water around the printed circuit board. The watertight light emitting diode module of claim 1, wherein the secondary lens array comprises a peripheral lip portion which extends over a surface of the base plate. The watertight light emitting diode module according to claim 1 or 2, wherein the base plate forms one of: a heat sink and a portion of a luminaire body on which the module will be mounted. A watertight light emitting diode module according to any one of claims 1 to 3, wherein the lens holder comprises a skirt portion arranged around its periphery, the skirt portion being configured to compress the peripheral lip portion of the secondary lens array against the surface of the base plate. The watertight light emitting diode module according to claim 4, wherein the skirt portion has at least two cut portions therein, each cut portion being configured to substantially align with a relevant sheath portion and to provide a accessing a connection in the corresponding cover part of the secondary lens network for a wire passing through the sheath portion. The watertight light emitting diode module of claim 5, wherein each sheath portion is configured to form a gasket around a wire inserted therethrough. The watertight light emitting diode module of any one of claims 1 to 6, wherein the secondary lens array comprises a plurality of network mounting holes formed therein, each network mounting hole. having a network boss portion associated therewith and configured to pass through a corresponding mounting hole formed in the printed circuit board. The watertight light emitting diode module according to claim 7, wherein the lens holder further comprises a plurality of lens holder mounting holes formed therein, each lens holder mounting hole having a lens holder boss portion associated therewith and configured to engage a corresponding network boss portion of the secondary lens array and to compress the array boss portion against the corresponding mounting hole formed in the lens array; printed circuit boards and against the surface of the base plate to form a seal therewith. The watertight light emitting diode module according to claim 8, further comprising a plurality of mounting screws for mounting the lens holder and the secondary lens array on the base plate on which the printed circuit board is mounting, each mounting screw passing through one of the lens holder mounting holes and its associated lens holder boss portion and entering an associated hole in the base plate. The light emitting diode module according to any one of claims 1 to 9, wherein the secondary lens array comprises an optical quality silicone material. The watertight light emitting diode module according to any one of claims 1 to 10, wherein the secondary lens array is integrally molded. 12. Water-tight light emitting diode module according to any of claims 1 to 11, wherein the lens holder is molded in one piece. The watertight light emitting diode module according to claim 12, wherein the lens holder comprises a polycarbonate, polyphenylene sulfide, polybutylene terephthalate and polyamide. 14. Luminaire comprising at least one watertight light-emitting diode module according to any one of claims 1 to 13.