WO2015011636A1

WO2015011636A1 - Carrier for led lamps

Info

Publication number: WO2015011636A1
Application number: PCT/IB2014/063296
Authority: WO
Inventors: Hongwu Wang
Original assignee: Koninklijke Philips N.V.
Priority date: 2013-07-24
Filing date: 2014-07-22
Publication date: 2015-01-29

Abstract

A carrier (100) and a tubular LED lamp with such a carrier (100) are provided. The carrier (100) is for connecting an end cap (10), a driver board (20) and a LED board (30) of a tubular LED lamp. The carrier (100) includes an insulated body (110) configured to hold the driver board (20),a first coupling member and a second coupling member. When the driver board (20) is mounted on the carrier (100), the driver board (20) is electrically connected with the first coupling member and the second coupling member. Also, when the carrier (100) is assembled into the tubular LED lamp, the first coupling member is electrically connected with pins (12) of the end cap (10) and the second coupling member is electrically connected with terminals (34) of the LED board (30).

Description

CARRIER FOR LED LAMPS

FIELD OF THE INVENTION

The present invention relates to carriers, in particular to carriers for tubular LED (Light Emitting Diode) lamps. The present invention further relates to a tubular LED lamp comprising the carrier and a luminaire comprising the carrier.

BACKGROUND OF THE INVENTION

Solid state lighting (SSL) is rapidly becoming the norm in many lighting applications. This is because SSL elements such as light emitting diodes (LEDs) can exhibit superior lifetime and energy consumption.

Typical LED lamps, such as tubular LED lamps (TLEDs), comprise an end cap, a driver board and a LED board. When the LED lamp is assembled, the end cap has to be electrically connected to the driver board and the driver board has to be electrically connected to the LED board.

Previously, the connections between the end cap and the driver board and the LED lamp and the driver board were made either by punched connections, manual soldering or through use of high cost connectors. Most production lines for LED lamps are manual lines. These factors together mean that productivity is relatively low and automatic assembly may not be realised or may be difficult to realise.

Providing these connections when manufacturing LED lamp has become a bottle neck for the LED industry. This problem also exists in the upcoming Tube LED (TLED) industry.

SUMMARY OF THE INVENTION

Accordingly, the present invention seeks to provide a lighting device that can be manufactured in a more cost-effective manner.

The present invention further seeks to provide a luminaire including such a lighting device.

The invention is defined by the claims. According to an aspect, there is provided a carrier for connecting an end cap, a driver board and a LED board of a tubular LED lamp, comprising:

an electrically insulated body configured to carry the driver board;

a plurality of first coupling members positioned at a first end portion of the insulated body; and

a plurality of second coupling members positioned at a second end portion of the insulated body opposite said first end portion,

wherein when the driver board is mounted on the carrier, the driver board is electrically connected with both the first coupling members and the second coupling members, and

wherein when the carrier is assembled into the tubular LED lamp, the first coupling members are electrically connected with pins of the end cap and the second coupling members are electrically connected with terminals of the LED board.

The carrier can be assembled into a tubular LED lamp in a simple manner.

In particular, manual soldering or use of high cost connectors is not necessary during assembly of the end cap, the driver board and the LED board. It may be possible to increase productivity of tubular LED lamps and automatic assembly of tubular LED lamps may be easier to realise.

The first end portion may comprise a first inner surface and first outer surface, and the first coupling member may comprise a first coupling element on the first inner surface for electrically engaging with the driver board and a second coupling element on the first outer surface for electrically engaging with the pins of the end cap.

This is a simple, economical, arrangement for providing the above mentioned advantages.

The second end portion may comprise a second inner surface and a second outer surface, and the second coupling member may comprise a first further coupling element on the second inner surface for electrically engaging with the driver board and a second further coupling element on the second outer surface for electrically engaging with the terminals of the LED board. This is a simple, economical, arrangement for providing the above mentioned advantages.

The coupling elements may be resilient elements.

This enables the coupling elements to make good electrical contact with the driver board, the pins of the end cap or terminals of the LED board, respectively.

The first coupling members and the second coupling members may comprise plate springs.

The plurality of first coupling members may be arranged to align with the pins on the end cap. This simplifies assembly, as intermediate electrical connections between the pins on the end cap and the first coupling members are not required.

The plurality of second coupling members may be arranged to align with the terminals of the LED board. This simplifies assembly, as intermediate electrical connections between the terminals of the LED board and the second coupling members are not required.

The insulated body may comprise a plurality of stop members for retaining the driver board. This enables the driver board to be easily retained within the insulated body of the carrier, such that a tubular LED lamp can be easily assembled and/or robustly constructed.

The carrier can comprise a push fit mount for the driver board. This enables the driver board to be easily assembled into the carrier and provides good electrical engagement between the first and/or second coupling members and the driver board.

The invention further provides a tubular LED lamp comprising:

an end cap with a plurality of pins;

a driver board;

a LED board; and

a carrier as described above configured to connect the end cap, the driver board and the LED board, wherein the driver board is electrically connected with both the first coupling members and the second coupling members, and

wherein the first coupling members are electrically connected with pins of the end cap and the second coupling members are electrically connected with the LED board.

This provides the advantages described above in relation to the carrier.

The tubular LED lamp may further comprise a transparent or translucent tube surrounding at least a part of the LED board. This provides protection of the components and/or a desired aesthetic.

The tubular LED lamp may further comprise a heat sink. This reduces the risk of components, e.g. the LED board and/or the driver board, overheating in use.

The heat sink may further comprise a track for receiving the LED board and the carrier. This enables easier assembly of the tubular LED lamp.

The heat sink may further comprise a channel for receiving a screw for affixing the end cap. This enables easier assembly of the tubular LED lamp.

The invention also provides a luminaire comprising the carrier or the tubular LED lamp. This provides the advantages described above in relation to the carrier and/or the tubular LED lamp.

The invention further provides a method of manufacturing a tubular LED lamp, comprising assembling a carrier, an end cap, a driver board and a LED board and into a tubular LED lamp. This provides the advantages described above in relation to the carrier and/or the tubular LED lamp. The invention also provides a carrier for connecting an end cap, a driver board and a LED board of a LED lamp, comprising: an insulated body configured to carry the driver board; a plurality of first springs positioned at one end of the insulated body; and a plurality of second springs positioned at the other end of the insulated body. When the driver board is mounted on the carrier, the driver board is electrically connected with both the first springs and the second springs, and when the carrier is assembled into the LED lamp, the first springs are electrically connected with pins of the end cap and the second springs are electrically connected with the LED board.

Preferably, the plurality of first springs includes two first springs.

Preferably, the plurality of second springs includes four first springs. Preferably, the insulated body is made of plastics.

Preferably, the first springs and the second springs are plate springs.

Preferably, the insulated body comprises a plurality of clamps.

The invention also provides a LED lamp comprising: an end cap with a plurality of pins; a driver board; a LED board; and a carrier configured to connect the end cap, the driver board and the LED board. The carrier includes an insulated body configured to carry the driver board, a plurality of first springs positioned at one end of the insulated body, and a plurality of second springs positioned at the other end of the insulated body. When the driver board is mounted on the carrier, the driver board is electrically connected with both the first springs and the second springs, and when the carrier is assembled into the LED lamp, the first springs are electrically connected with pins of the end cap and the second springs are electrically connected with the LED board.

Preferably, the plurality of first springs includes two first springs.

Preferably, the first springs and the second springs are plate springs.

Preferably, the insulated body comprises a plurality of clamps.

With the solution provided by the present disclosure, components of a LED lamp may be assembled automatically and quickly with low cost.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are described in more detail and by way of non-limiting examples with reference to the accompanying drawings, wherein:

Figures 1 , 2 and 3 illustrate an example end cap, an example driver board and an example LED board that are to be assembled into a LED lamp, respectively; Figures 4, 5, 6, 8 and 9 are perspective views of a carrier according to an embodiment of the present invention, viewed from different angles of view and Figure 7 is a sectional view of the same carrier;

Figures 10 and 1 1 are an enlarged view and a sectional view, respectively, of the first end of the insulated body where the first coupling members are positioned;

Figures 12, 13 and 14 are an enlarged view, a sectional view and a side view, respectively, of the second end of the insulated body where the second coupling members are positioned;

Figures 15, 16 and 17 illustrate a perspective view and two sectional views of the carrier with the driver board mounted on it, according to an

embodiment of the present invention;

Figures 18, 19, 20 and 21 illustrate two perspective views and two sectional views of the carrier with the driver board mounted on it, connected to a LED board and pins of an end cap, according to an embodiment of the present invention;

Figures 22 and 23 illustrate a sectional and a perspective view of a tube, a heat sink and a LED board for use with a carrier according to an embodiment of the present invention;

Figure 24 illustrates a perspective view of a carrier, a driver board, a heat sink and a LED board according to an embodiment of the present invention;

Figure 25 illustrates a perspective view of a carrier, a driver board, a heat sink and a tube according to an embodiment of the present invention;

Figure 26 illustrates an exploded perspective view of an end cap, a driver board, a carrier, a heat sink, a LED board and a tube according to an embodiment of the present invention; and

Figure 27 illustrates a sectional view of a LED lamp with a carrier assembled in it, according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

Figures 1 , 2 and 3 illustrate an example end cap 10, an example driver board 20 and an example LED board 30 that are to be assembled into an LED lamp 1.

As shown in Figure 1 , the end cap 10 may include two pins 12 that are to be connected to power source.

The driver board 20 may be used to receive power supply from the end cap 10 and adapt the received power supply to power the LED board 30. In an example, the driver board 20 has two input terminals to receive power supply from respective pins 12 of the end cap 10, and has four output terminals to power the LED board 30.

The LED board 30 may have deployed on it many LEDs that generate a luminous output when powered by the driver board 20.

Figures 4, 5, 6, 8 and 9 are perspective views of the carrier 100 according to an embodiment of the present invention, viewed from different angles of view. Figure 7 is a sectional view of the same carrier.

As shown, the carrier 100 is for connecting the end cap 10, the driver board 20 and the LED board 30 of a LED lamp. The carrier 100 comprises an electrically insulated body 1 10 configured to carry the driver board 20 and a plurality of first coupling members 120 positioned at a first end portion of the insulated body; and a plurality of second coupling members 130 positioned at a second end portion of the insulated body opposite said first end portion.

When the driver board 20 is mounted on the carrier 100, the driver board 20 is electrically connected with both the first coupling members 120 and the second coupling members 130.

When the carrier 100 is assembled into an LED lamp, the first coupling members 120 are electrically connected with pins 12 of the end cap 10 and the second coupling members 130 are electrically connected with terminals 34 of the LED board 30.

This carrier 100 enables simple assembly of LED lamps. In particular, manual soldering or use of high cost connectors is not necessary during assembly of the end cap 10, the driver board 20 and the LED board 30. It may be possible to increase productivity of LED lamps and automatic assembly of LED lamps may be easier to realise.

The coupling elements 120, 130 may be e.g. springs.

The first coupling members 120 may be a plurality of first springs and the second coupling members 130 may be a plurality of second springs.

The insulated body 1 10 may be made of plastics, for example.

The insulated body 1 10 may be configured to carry the driver board 20.

The first end portion may comprise a first inner surface and first outer surface, and the first coupling member 120 may comprise a first coupling element on the first inner surface for electrically engaging with the driver board 20 and a second coupling element on the first outer surface for electrically engaging with the pins 12 of the end cap 10. This is a simple, economical, arrangement for providing the above mentioned advantages.

The second end portion may also comprise a second inner surface and a second outer surface, and wherein the second coupling member 130 may comprise a first further coupling element on the second inner surface for electrically engaging with the driver board 20 and a second further coupling element on the second outer surface for electrically engaging with the terminals 34 of the LED board 30. This is a simple, economical, arrangement for providing the above mentioned advantages.

The coupling elements 120, 130 may be resilient elements, such as, for example springs. This can enable the coupling elements 120, 130 to make good electrical contact with the driver board 20, the pins 12 of the end cap 10 or terminals 34 of the LED board 30, respectively.

The first coupling members 120 and the second coupling members 130 may comprise plate springs, and each may have two ends.

The plurality of first coupling members 120 may be arranged to align with the pins 12 on the end cap 10. This can simplify assembly, as intermediate electrical connections between the pins 12 on the end cap 10 and the first coupling members 120 may not be required. The plurality of second coupling members 130 may be arranged to align with the terminals 34 of the LED board 30. This can simplify assembly, as intermediate electrical connections between the terminals 34 of the LED board 30 and the second coupling members 130 may not be required.

Figures 10 and 1 1 are an enlarged view and a sectional view, respectively, of the first end portion of the insulated body 1 10 where the first coupling members 120 are positioned.

As illustrated in Figures 10 and 1 1 in particular, the first end portion may comprise a first inner surface and first outer surface, and the first coupling member 120 may comprise a first coupling element 122 on the first inner surface for electrically engaging with the driver board 20 and a second coupling element 124 on the first outer surface for electrically engaging with the pins 12 of the end cap 10.

Figures 12, 13 and 14 are an enlarged view, a sectional view and a side view, respectively, of the second end portion of the insulated body 1 10 where the second coupling members 130 are positioned.

As illustrated in Figures 12, 13 and 14 in particular, the second end portion may also comprise a second inner surface and a second outer surface, and the second coupling member 130 may comprise a first further coupling element 132 on the second inner surface for electrically engaging with the driver board 20 and a second further coupling element 134 on the second outer surface for electrically engaging with the terminals 34 of the LED board 30.

Figures 15, 16 and 17 illustrate a perspective view and two sectional views of the carrier 100 with the driver board 20 mounted on it, according to an embodiment of the present invention.

As shown, when the driver board 20 is mounted on the carrier 100, the driver board 20 is electrically engaged with, and thus establishes an electrical connection with, both the first coupling members 120 and the second coupling members 130. In other words, the driver board 20 is automatically touched by both the first coupling members 120 and the second coupling members 130. As shown in Figure 16 and 17 in particular, the insulated body 1 10 may comprise a plurality of stop members 140 for retaining the driver board 20. This enables the driver board 20 to be easily retained within the insulated body 1 10 of the carrier 100, such that a LED lamp could be easily assembled and/or robustly constructed.

The carrier 100 may comprise a push fit mount for the driver board 20, which may be provided by the stop members 140. This enables the driver board 20 to be easily assembled into the carrier 100. This also provides good electrical engagement between the first and/or second coupling members 120, 130 and the driver board 20.

The stop members 140 may form clamps to hold the driver board 20 when the driver board 20 is mounted into the insulated body 1 10.

Figures 18, 19, 20, 21 , 22, 23, 24 and 25 show a partially assembled LED lamp comprising the carrier 100, according to an embodiment of the present invention; Figure 26 shows an exploded view of the LED lamp and Figure 27 shows a sectional view of the LED lamp.

The LED lamp comprises an end cap 10 with a plurality of pins 12, a driver board 20, a LED board 30 and a carrier 100 as described above. The carrier 100 is configured to connect the end cap 10, the driver board 20 and the LED board 30.

The driver board 20 is electrically connected with both the first coupling members 120 and the second coupling members 130. The first coupling members 120 are also electrically connected with pins 12 of the end cap 10 and the second coupling members 130 are also electrically connected with the LED board 30.

This provides the advantages described above in relation to the carrier

100.

When the carrier 100 is assembled into the LED lamp, the first coupling members 120 (first springs) will electrically engage with (automatically touch) and thus establishes an electrical connection with the pins 12 of the end cap 10, and the second coupling members 130 (second springs) will electrically engage with (automatically touch) and thus established an electrical connection with the LED board 30.

The LED lamp may further comprise a transparent or translucent tube 50 surrounding at least a part of the LED board 30. This provides protection of the components and/or a desired aesthetic.

The transparent or translucent tube 50 may surround substantially all or all of the internal components of the LED lamp. The tube 50 may be of glass.

The LED lamp may further comprise a heat sink 40. This reduces the risk of components, e.g. the LED board 30 and/or the driver board 20, overheating in use.

The heat sink may further comprise a track 42 for receiving the LED board 30 and the carrier 100. This enables easier assembly of the LED lamp.

The heat sink may also comprise a channel 44 for receiving a screw 14 for affixing the end cap 10. The end cap 10 may also comprise a corresponding hole 16 for receiving the screw 14. These features enable easier assembly of the LED lamp.

The LED board 30 may have its own internal cover 32.

There is also provided a luminaire comprising the carrier 100 or the LED lamp as described above. This provides the advantages described above in relation to the carrier and/or the LED lamp.

There is further provided method of manufacturing a LED lamp as described above, comprising assembling a carrier 100 as described above, an end cap 10, a driver board 20 and a LED board 30 and into a LED lamp. This can provide the advantages described above in relation to the carrier and/or the LED lamp.

In summary, the invention provides a carrier 100 and a LED lamp with such a carrier 100. The carrier 100 is for connecting an end cap 10, a driver board 20 and a LED board 30 of a LED lamp. The carrier 100 includes an insulated body 1 10 configured to hold the driver board 20, a first coupling member 120 and a second coupling member 130. When the driver board 20 is mounted on the carrier 100, the driver board 20 is electrically connected with the first coupling member 120 and the second coupling member 130. Also, when the carrier 100 is assembled into the LED lamp, the first coupling member 120 is electrically connected with pins 12 of the end cap 10 and the second coupling member 130 is electrically connected with terminals 34 of the LED board 30.

It should be understood that the Figures are merely schematic and are not drawn to scale. It should also be understood that the same reference numerals are used throughout the Figures to indicate the same or similar parts.

The end cap 10, the driver board 20 and the LED board 30 are

substantially the same with those currently used in the art, and thus detailed description for them is omitted.

It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. For example, although LED elements have been described above any solid state lighting (SSL) element could be used. Furthermore, it may be understood by those skilled in the art that the end cap 10 may have any other applicable number of pins 12 and the driver board 20 may have any other applicable number of input terminals and output terminals, without departing from the scope of the present disclosure. Further, the pins 12 of the end cap may be any kind of electrical terminal and are not necessarily limited in their shape. The push fit mount for retaining the driver board described above comprises stop members 140, however the push fit mount could alternatively or additionally comprise formations in or on the first and/or second coupling members 120, 130 or some other arrangement. The heat sink 40 has a track 42 and a channel 44, it will however be realised that the advantages of the track 42 and/or the channel 44 could be obtained by their formation in a component other than a heat sink 40, e.g. in a structural member.

In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word "comprising" does not exclude the presence of elements or steps other than those listed in a claim. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The invention can be implemented by means of hardware comprising several distinct elements. In the device claim enumerating several means, several of these means can be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

Claims

1 . A carrier (100) for connecting an end cap (10), a driver board (20) and a LED board (30) of a tubular LED lamp, comprising:

an electrically insulated body (1 10) configured to carry the driver board; a plurality of first coupling members (120) positioned at a first end portion of the insulated body, wherein the first end portion comprises a first inner surface and first outer surface, and wherein the first coupling member comprises a first coupling element on the first inner surface for electrically engaging with the driver board and a second coupling element on the first outer surface for electrically engaging with the pins of the end cap; and

a plurality of second coupling members (130) positioned at a second end portion of the insulated body opposite said first end portion, wherein the second end portion comprises a second inner surface and a second outer surface, and wherein the second coupling member comprises a first further coupling element on the second inner surface for electrically engaging with the driver board and a second further coupling element on the second outer surface for electrically engaging with the terminals of the LED board;

wherein the coupling elements are resilient elements,

wherein when the carrier is assembled into the tubular LED lamp, the first coupling members are electrically connected with pins (12) of the end cap and the second coupling members are electrically connected with terminals (34) of the LED board.

2. The carrier of any one of claim 1 , wherein the first coupling members and the second coupling members comprises plate springs.

3. The carrier of any one of claims 1 -2, wherein the plurality of first coupling members are arranged to align with the pins on the end cap.

4. The carrier of any one of claims 1-3, wherein the plurality of second 5 coupling members are arranged to align with the terminals of the LED board.

5. The carrier of any one of claims 1 -4, wherein the insulated body comprises a plurality of stop members (140) for retaining the driver board. o 6. The carrier of any one of claims 1 -5, wherein the carrier comprises a push fit mount for the driver board.

7. A tubular LED lamp comprising:

an end cap (10) with a plurality of pins (12);

5 a driver board (20);

a LED board (30); and

a carrier (100) according to any one of claims 1 -6 configured to connect the end cap, the driver board and the LED board,

wherein the driver board is electrically connected with both the first0 coupling members and the second coupling members, and

wherein the first coupling members are electrically connected with pins (12) of the end cap and the second coupling members are electrically connected with the LED board. 5 8. The tubular LED lamp of claim 7, further comprising a transparent or translucent tube (50) surrounding at least a part of the LED board.

9. The tubular LED lamp of claim 7 or 8, further comprising a heat sink

(40).

0

10. The tubular LED lamp of claim 9, wherein the heat sink further comprises a track (42) for receiving the LED board and the carrier and/or a channel (44) for receiving a screw (14) for affixing the end cap.

1 1. A luminaire comprising the carrier of any one of claims 1 -6 or the tubular LED lamp of any one of claims 7-10.

12. A method of manufacturing a tubular LED lamp according to any one of claims 7-10, comprising assembling a carrier according to any one of claims 1 -6, an end cap, a driver board and a LED board and into a tubular LED lamp.