WO2013132383A1 - Lighting device - Google Patents

Lighting device Download PDF

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Publication number
WO2013132383A1
WO2013132383A1 PCT/IB2013/051511 IB2013051511W WO2013132383A1 WO 2013132383 A1 WO2013132383 A1 WO 2013132383A1 IB 2013051511 W IB2013051511 W IB 2013051511W WO 2013132383 A1 WO2013132383 A1 WO 2013132383A1
Authority
WO
WIPO (PCT)
Prior art keywords
heat sink
lighting device
tubular member
tube
wall
Prior art date
Application number
PCT/IB2013/051511
Other languages
French (fr)
Inventor
Xuefei YANG
Yongsi Bi
Hongwu Wang
Original Assignee
Koninklijke Philips N.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Koninklijke Philips N.V. filed Critical Koninklijke Philips N.V.
Publication of WO2013132383A1 publication Critical patent/WO2013132383A1/en

Links

Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21KNON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20Light sources comprising attachment means
    • F21K9/27Retrofit light sources for lighting devices with two fittings for each light source, e.g. for substitution of fluorescent tubes
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S4/00Lighting devices or systems using a string or strip of light sources
    • F21S4/20Lighting devices or systems using a string or strip of light sources with light sources held by or within elongate supports
    • F21S4/28Lighting devices or systems using a string or strip of light sources with light sources held by or within elongate supports rigid, e.g. LED bars
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V13/00Producing particular characteristics or distribution of the light emitted by means of a combination of elements specified in two or more of main groups F21V1/00 - F21V11/00
    • F21V13/02Combinations of only two kinds of elements
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V17/00Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages
    • F21V17/10Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening
    • F21V17/104Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening using feather joints, e.g. tongues and grooves, with or without friction
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V17/00Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages
    • F21V17/10Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening
    • F21V17/16Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening by deformation of parts; Snap action mounting
    • F21V17/164Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening by deformation of parts; Snap action mounting the parts being subjected to bending, e.g. snap joints
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50Cooling arrangements
    • F21V29/502Cooling arrangements characterised by the adaptation for cooling of specific components
    • F21V29/505Cooling arrangements characterised by the adaptation for cooling of specific components of reflectors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50Cooling arrangements
    • F21V29/502Cooling arrangements characterised by the adaptation for cooling of specific components
    • F21V29/506Cooling arrangements characterised by the adaptation for cooling of specific components of globes, bowls or cover glasses
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21KNON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/60Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
    • F21K9/64Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50Cooling arrangements
    • F21V29/70Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V3/00Globes; Bowls; Cover glasses
    • F21V3/04Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings
    • F21V3/06Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings characterised by the material
    • F21V3/061Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings characterised by the material the material being glass
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V3/00Globes; Bowls; Cover glasses
    • F21V3/04Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings
    • F21V3/10Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings characterised by coatings
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00Reflectors for light sources
    • F21V7/0058Reflectors for light sources adapted to cooperate with light sources of shapes different from point-like or linear, e.g. circular light sources
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21YINDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2103/00Elongate light sources, e.g. fluorescent tubes
    • F21Y2103/10Elongate light sources, e.g. fluorescent tubes comprising a linear array of point-like light-generating elements
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21YINDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00Light-generating elements of semiconductor light sources
    • F21Y2115/10Light-emitting diodes [LED]

Definitions

  • the invention relates generally to lighting devices, and more specifically to a lighting device comprising at least one light source for providing light arranged in an elongated hollow, tubular member.
  • Lighting devices comprising light emitting diodes (LEDs) are used as replacement of traditional lighting devices such as conventional light bulbs. Recently they are also targeted at application of fluorescent tubes.
  • US Patent Application No. 2010 / 0033964 Al discloses such a LED light tube, which is formed by a semi-circular plastic housing and a semi-circular heat sink comprises an elongated hollow rigid tube into which a plurality of LEDs are inserted. A plurality of LEDs is inserted on the PCB mounted in the middle of the tube. To achieve uniformity and stability of light output, lots of LEDs are used. However, these LEDs account for a large percentage of the bill of material. It's difficult to decrease the number of LED substantially to obtain the same light performance, for the spottiness of light output will be a big issue by doing this.
  • the diametral clearance will increase when the rised temperature causes miss-matching deformations of the tube and the heat sink. This further leads to low thermal efficiency under operational conditions of the lighting devices.
  • a lighting device comprises an elongated hollow tubular member has a light exit window; a heat sink; and at least one light emitting element for providing light, which is thermally coupled to the heat sink.
  • the heat sink and the at least one light emitting element are located in the tubular member; and at least a portion of a first surface of the heat sink is geometrically matched with an inner wall of the tubular member, in order to have sufficient contact area between the first surface and the inner wall for effective heat transfer.
  • the tubular member comprises at least one connecting element to accommodate the heat sink. This allows the first surface of the heat sink to have a minimum distance to the inner wall of the tubular member under various operation conditions of the lighting device.
  • the connecting element keeps the heat sink attached to the inner wall within the tubular member under various operational conditions, e.g., when the heat sink is heated up and extended in size during operation, and allows good heat dissipation.
  • the lighting device preferably comprises multiple light emitting elements.
  • the light emitting elements can comprise one or more light emitting diodes (LED) or LED dies.
  • the at least one connecting element comprises a protrusion from the inner wall.
  • the protrusion can be finger- shaped, dovetail-shaped, mushroom-shaped or T-shaped in cross-section.
  • the protrusion can be cost effectively manufactured with extrusion, injection, molding or other known techniques within the field. And it allows easy assembly of the lighting device or easy disassembly at the end-of-life, so that the tubular member can be recycled after removing the heat sink.
  • the tubular member can further comprise a second connecting element.
  • the heat sink is sized to be accommodated in the space defined by the connecting elements.
  • the connecting elements are configured inclined to the heat sink and formed wedge-shaped spaces between the connecting elements and the inner wall.
  • the connecting elements are deformable to open the wedge-shaped spaces upon a thermal expansion force of the heat sink. This allows the heat sink to keep good contact with the inner wall within the tubular member under various operational conditions, e.g., when the heat sink is heated up and extended in size during operation, and allows good heat dissipation.
  • the heat sink is rigid or has a thermal stable shape by using a carefully selected material. This allows the heat sink to be in good contact with the inner wall of the tubular member even when the heat sink is heated up during operation, and allows good heat dissipation.
  • a rigid heat sink can be slidely inserted into the tubular member easily. Therefore it provides an additional advantage of allowing easy assembly of the lighting device or easy disassembly at the end-of-life, as the tubular member can be recycled after removing the heat sink.
  • a first thickness of the heat sink between a position where the light emitting element is located and the first surface is relatively small compared to a second thickness of the heat sink being remote from the position of the light emitting element.
  • the thickness of the heat sink between a position where the light emitting element is located and the first surface is configured to be minimum, but is sufficient so that the heat sink has enough mechanical strength.
  • the tube shaped lighting device which has much less number of LEDs comparing to a known Tube Light Emitting Diode Lamp (TLED) for balanced performance of light distribution and thermal transfer.
  • TLED Tube Light Emitting Diode Lamp
  • the decreased number of LEDs together with the saved energy advantageously brings the benefit of cost saving while keeping the same light performance.
  • higher light output brightness can be achieved with a similar level of energy input as the known TLED by using fewer but higher power LEDs.
  • the lighting device further comprises a printed circuit board (PCB) arranged between the light emitting element(s) and the heat sink. This allows the electrical connection of driving circuits to the LEDs.
  • PCB printed circuit board
  • the lighting device wherein at least a portion of a second surface of the heat sink, which is opposite to the first surface, is reflective.
  • the surface can either be specular reflective or diffusive reflective.
  • the reflective or scattering surface portion further allows better light mixing and recycling, which lead to a good light output uniformity.
  • the heat sink can have two portions of the second surface extending oppositely from the position where the light emitting element is located. These two portions of the second surface can be symmetric or asymmetric with respect to the position where the light emitting element is located. This benefits the light distribution desired.
  • the heat sink further comprises at least one fin and/or at least one cavity.
  • the fin and/or cavity further enlarge the contact area between the heat sink and air. This is advantageous for increasing the heat dissipation capability of the heat sink.
  • the connecting element can be a protrusion from the inner wall of the tubular member.
  • the protrusion can extend along the generatrix direction on the inner wall of the tubular member.
  • the at least one connecting element of the tubular member comprises a recession in the inner wall of the tubular member. By matching the recession with a protrusion on the heat sink, the heat sink can also be accommodated along the inner wall of the tubular member.
  • the tubular member can be made of plastic.
  • the light exit window of the tubular member can further has one of a transparent layer, a diffusive layer, a semi-transparent layer, and a layer with reflective pattern, or comprises reflective or diffuse particles.
  • Plastic tubes with reflective or diffusive feature can be advantageous in cost and light output performance. It is noted that the invention relates to all possible combinations of features recited in the claims.
  • Fig. 1 shows a structure of an embodiment of a lighting device according to the present invention
  • Fig. 2 is a schematic cross-sectional side view of a lighting device of Fig 1;
  • Fig. 3 is a schematic cross-sectional side view of an alternative embodiment of heat sink of a lighting device according to the present invention.
  • Fig. 4 is a schematic cross-sectional side view of another alternative embodiment of heat sink of a lighting device according to the present invention.
  • Fig. 5 is a schematic cross-sectional side view of an alternative embodiment of a lighting device according to the present invention with one rail-type connecting element;
  • Fig. 6 is a schematic cross-sectional side view of a further alternative embodiment of a lighting device according to the present invention with one rail-type connecting element;
  • Fig. 7 is a schematic cross-sectional side view of another alternative embodiment of a lighting device according to the present invention.
  • Fig. 8 is a schematic cross-sectional side view of a further alternative embodiment of a lighting device according to the present invention.
  • Fig. 9 is a schematic cross-sectional side view of the embodiment of Fig. 8 when the lighting device is heated up during operation.
  • the lighting device comprises a tube 110, a heat sink 120 and a linear array of light emitting diodes (LED) 121 for light generation.
  • the LEDs 121 are mounted on the heat sink 120 for heat dissipation.
  • the LEDs 121 are mounted on a substrate or PCB 122 and the PCB 122 is mounted on the flat surface portion 124 of the heat sink 120 through mechanical connection, such as using adhesive layer or screws.
  • the PCB 122 is for an easy electrical connection between the driving circuits and the LEDs.
  • the linear array can be composed of a PCB with chip-board LEDs, or be a linear lead frame with LED-dies and wirebonds that in addition may be silicone overmoulded locally or over the full length.
  • the LEDs or LED-dies can be combined with wavelength conversion material.
  • the linear assembly may also be based on a foil with an electrically conductive surface.
  • LEDs in a linear array are suitable for the present inventive concept, but other arrangements are applicable as well.
  • the linear array is in embodiments of the invention equipped with separate lenses or a common linear lens.
  • the mounting method includes approaches to have good thermal engagement between the LEDs, the PCB and the heat sink.
  • the tube 110 has two protrusions or ribs 112 extending along the generatrix direction on the inner wall 116 of the tube 110.
  • the ribs 112 are finger- shaped in a cross-sectional view.
  • the heat sink 120 is arc-shaped in a cross-sectional view, with a curved surface 126 opposite to the flat surface portion 124.
  • the curved surface 126 is geometrically matched with the inner wall 116.
  • the heat sink 120 is sized to be
  • the arcuation distance between the two edges 128 of the heat sink 120 is a little smaller than the arcuation distance between the two protrusions 112, so that the heat sink 120 can be slidely inserted into the tube 110, and can be in good contact with the inner wall 116 of the tube 110, even when the heat sink is heated up during operation. This good contact under various conditions is advantageous for heat dissipation.
  • the tube 110 is made of plastic, and in alternative embodiments, the tube 110 is provided with wavelength conversion material, such as phosphorus material, or another additional optical layer, such as a diffusive layer, a semi-transparent layer, or a layer with reflective pattern, or comprises reflective or diffuse particles in the tube wall, etc., by means of deposition, lamination, extrusion or co-extrusion according to known techniques within the field.
  • wavelength conversion material such as phosphorus material
  • another additional optical layer such as a diffusive layer, a semi-transparent layer, or a layer with reflective pattern, or comprises reflective or diffuse particles in the tube wall, etc.
  • a number of different optical functionalities can advantageously be integrated in the tube 110, including the improvement of output light distribution and/or providing light recycling within the tube 110.
  • the plastic tube 110 with ribs 112 can be cost effectively manufactured with extrusion, injection, molding or other known techniques within the field.
  • the tube 110 can also formed with individual knobs on the inner wall 116 to act as the protrusions
  • the tube 110 can also be made of glass or other at least partly transparent, diffusive or translucent material.
  • the protrusions 112 can also be discrete knobs attached to the inner wall of the tube with glue, adhesive or by means of melting, or with other known mechanical methods, such as screws or bolts.
  • the tube 110 provides a light mixing chamber for light generated by the LEDs
  • the tube 110 can be transparent or translucent as a whole, or a transparent portion 111 is arranged on an opposite side of the tube with respect to the LEDs 121.
  • the transparent (or alternatively translucent) portion 111 provides a light exit window on the tube.
  • the thickness between the flat surface portion 124 and the curved surface 126 of the heat sink 120 is configured to minimum, as long as the heat sink 120 has enough mechanical strength, so as to allow the LEDs 121 be close to the inner wall 116 of the tube 110. This allows a maximum distance between the LEDs 121 and the light exit window on the tube 110, in turn allows a desired light recycling within the cavity of tube 110.
  • the light recycling can help to improve light mixing, which is advantageous for to prevent getting visible spots at the light exit window.
  • the second surface portions 125 there are two second surface portions 125, in addition to the flat surface portion 124 at the same side of the heat sink 120.
  • the second surface portions 125 can be reflective or scattering, or integrates a reflective or scattering functionality by coating, laminating, plating, polishing or other known techniques within the field.
  • the profile of the second surface portions 125 can be linear, parabolic or other configuration based on the optical consideration. Although it is shown in Fig. 2 that the two second surface portions 125 are symmetric, an asymmetric structure is also possible. In an alternative embodiment, only one second surface portion 125 is configured to meet the desired light output distribution. Since the LEDs 121 are positioned close to the inner wall 116 of the plastic tube 110, it will reduce spottiness if decreasing the number of LEDs 121 largely. In an experimental test with a commercial available 4 feet TLED, which has 256 pieces of LED, the output light distribution profile keeps the same, without issue of spottiness when the number of LED decrease to 64-80 with the structure according to the invention.
  • heat sink 220 and 320 are illustrated in Fig. 3 and Fig. 4, for better thermal dissipation, together with additional advantages on mechanical properties and/or optical properties.
  • the heat sink 220 is configured with two fins 223 which enlarge the volume of the heat sink 220 for improved heat transfer performance.
  • the heat sink 220 can be accommodated in the tube 110 by the two edges 228.
  • the curved surface 226 is geometrically matched with the inner wall 116 of the tube 110.
  • the LEDs are mounted in the flat surface portion 224, and the two second surface portions 225 are reflective.
  • the heat sink 320 is configured with two fins 323.
  • the heat sink 320 can be accommodated in the tube 110 by the two edges 328.
  • the curved surface 326 is geometrically matched with the inner wall 116 of the tube 110.
  • the LEDs are mounted in the flat surface portion 324, and the two second surface portions 325 are reflective.
  • the fins are thinned and extended to form two cavities 327 which further enlarge the contact area between the heat sink 320 and air for better heat transfer performance.
  • Embodiments of various modifications to the connecting element between the tube 510, 610, 710 and 810 and the heat sink 520, 620, 720 and 810 are exemplarily illustrated in Fig. 5 to Fig. 9 for improvements to keep the tube and heat sink in good contact.
  • the tube 510 has a protrusion or rail 519, which is dovetail- shaped in cross sectional view, extending along the generatrix direction on the inner wall 516.
  • the heat sink 520 has a curved surface 526 which is geometrically matched with the inner wall 516. Accordingly, the heat sink 520 is configured with a dovetail groove 529.
  • the heat sink 520 can be easily slided into the tube 510 with the rail-groove engagement. During the lamp operation, the rail-groove engagement attaches the heat sink 520 to the inner wall 516 of the tube 510, regardless the thermal expansion of the heat sink 520, and allows a good heat transfer. As shown in Fig.
  • the protrusion or rail 619 of tube 610 is mushroom-shaped in cross sectional view, which engages with the mushroom-shaped groove 629 in heat sink 620 to allow the curved surface 626 of the heat sink 620 keep good contact with the inner wall 616 of the tube 610.
  • the protrusion or rail 719 of tube 710 is T-shaped in cross sectional view, which engages with the T-shaped groove 729 in heat sink 720 to allow the curved surface 726 of the heat sink 720 keep good contact with the inner wall 716 of the tube 710.
  • the tube 710 is further configured with two protrusions 712 defining the space to accommodate the heat sink 720 by the two edges 728.
  • Fig. 5 to Fig. 7 show protrusions from the tube to the heat sink
  • the connecting element of alternative embodiments can be at reversed way, in other words, the grooves can be in the tube while the rails are configured on the curved surface of the heat sink.
  • the shapes of the rail-groove engagement can be revised according to known techniques within the field.
  • the protrusions 112, 712 on the inner wall in Fig 1, 2 and 7 can also be reversed to recessions in the inner wall and engage with protrusions or ribs on the heat sink.
  • the tube 810 has two protrusions or ribs 812 extending along the generatrix direction on the inner wall 816 of the tube 810.
  • the ribs 812 are configured inclined to the heat sink 820 and formed wedge-shaped space 818 between the ribs 812 and the inner wall 816.
  • Fig. 8 and the dash line in Fig. 9 shows the initial state of the lighting device when the cool heat sink 820 is accommodated by the two ribs 812 and has the curved surface 826 attached to the inner wall 816.
  • the edges 828 are forced into the wedge-shaped space 818, as the solid line shown in Fig. 9.
  • the plastic material of the tube 810 has certain elasticity which enables the ribs 812 to deform slightly and open the wedge-shaped space 818 upon the thermal expansion force of the heat sink 820. Therefore, this allows good contact between the curved surface 826 and the inner wall 816 during the life time of the lighting device.
  • the matched shape of the surfaces, the contacting area and the close connection therebetween leads to the good thermal transfer. Therefore, it would be advantageous to have a substantial portion of the first surface (shown as 126, 226, 326, 526, 626, 726 and 826 in the figures) of the heat sink in good contact with the inner wall of the tube, to achieve a good thermal efficiency. In other words, a sufficient contact area between the heat sink and the tube will help the heat dissipation.
  • the tube material can be a thermal conductive plastic which brings more advantage in heat transfer.
  • the lighting device cavity can be evacuated or filled with a gas and sealed.
  • the lighting device cavity can be filled with a liquid or a solidifying material like silicones.

Abstract

There is provided a lighting device comprising an elongated hollow tubular member (110) which has a light exit window; a heat sink (120); and at least one light emitting element (121) for providing light, which is thermally coupled to the heat sink. The heat sink and the at least one light emitting element are located in the tubular member; and at least a portion of a first surface of the heat sink is geometrically matched with an inner wall of the tubular member. The tubular member comprises at least one connecting element (112) to accommodate the heat sink.

Description

LIGHTING DEVICE
FIELD OF THE INVENTION
The invention relates generally to lighting devices, and more specifically to a lighting device comprising at least one light source for providing light arranged in an elongated hollow, tubular member.
BACKGROUND OF THE INVENTION
Lighting devices comprising light emitting diodes (LEDs) are used as replacement of traditional lighting devices such as conventional light bulbs. Recently they are also targeted at application of fluorescent tubes. US Patent Application No. 2010 / 0033964 Al discloses such a LED light tube, which is formed by a semi-circular plastic housing and a semi-circular heat sink comprises an elongated hollow rigid tube into which a plurality of LEDs are inserted. A plurality of LEDs is inserted on the PCB mounted in the middle of the tube. To achieve uniformity and stability of light output, lots of LEDs are used. However, these LEDs account for a large percentage of the bill of material. It's difficult to decrease the number of LED substantially to obtain the same light performance, for the spottiness of light output will be a big issue by doing this.
When lots of LEDs are used to replace fluorescent tubes, there is severe thermal issue to be solved. The heat generated by LEDs should be dissipated as quick as possible, otherwise the lighting devices will be failure when the temperature rises to a certain level. Many attemptions are presently available, such as the exposed heat sink in the above mentioned patent application. However, there can be potential safety risk as the user may access the electrical circuits within the tube. Simply putting the heat sink in the tube can solve the safety issue, but can not have good heat dissipation, because the diametral clearance between the heat sink and the inner wall of the tube forms a thermal barrier. As there is difference on coefficient of thermal expansion between the materials of the tube and the heat sink, the diametral clearance will increase when the rised temperature causes miss-matching deformations of the tube and the heat sink. This further leads to low thermal efficiency under operational conditions of the lighting devices.
SUMMARY OF THE INVENTION
It is an objective of the invention, among others, to achieve a lighting device which can replace fluorescent tubes with good thermal efficiency.
To better address one or more of these concerns, in a first aspect of the invention, a lighting device comprises an elongated hollow tubular member has a light exit window; a heat sink; and at least one light emitting element for providing light, which is thermally coupled to the heat sink. The heat sink and the at least one light emitting element are located in the tubular member; and at least a portion of a first surface of the heat sink is geometrically matched with an inner wall of the tubular member, in order to have sufficient contact area between the first surface and the inner wall for effective heat transfer. The tubular member comprises at least one connecting element to accommodate the heat sink. This allows the first surface of the heat sink to have a minimum distance to the inner wall of the tubular member under various operation conditions of the lighting device. The connecting element keeps the heat sink attached to the inner wall within the tubular member under various operational conditions, e.g., when the heat sink is heated up and extended in size during operation, and allows good heat dissipation.
The lighting device preferably comprises multiple light emitting elements. The light emitting elements can comprise one or more light emitting diodes (LED) or LED dies.
According to an embodiment of the lighting device, the at least one connecting element comprises a protrusion from the inner wall. Preferably, the protrusion can be finger- shaped, dovetail-shaped, mushroom-shaped or T-shaped in cross-section. The protrusion can be cost effectively manufactured with extrusion, injection, molding or other known techniques within the field. And it allows easy assembly of the lighting device or easy disassembly at the end-of-life, so that the tubular member can be recycled after removing the heat sink.
According to an embodiment of the lighting device, the tubular member can further comprise a second connecting element. Preferably, the heat sink is sized to be accommodated in the space defined by the connecting elements. Alternatively, the connecting elements are configured inclined to the heat sink and formed wedge-shaped spaces between the connecting elements and the inner wall. Preferably, the connecting elements are deformable to open the wedge-shaped spaces upon a thermal expansion force of the heat sink. This allows the heat sink to keep good contact with the inner wall within the tubular member under various operational conditions, e.g., when the heat sink is heated up and extended in size during operation, and allows good heat dissipation.
According to an embodiment of the lighting device, the heat sink is rigid or has a thermal stable shape by using a carefully selected material. This allows the heat sink to be in good contact with the inner wall of the tubular member even when the heat sink is heated up during operation, and allows good heat dissipation. A rigid heat sink can be slidely inserted into the tubular member easily. Therefore it provides an additional advantage of allowing easy assembly of the lighting device or easy disassembly at the end-of-life, as the tubular member can be recycled after removing the heat sink.
According to an embodiment of the lighting device, a first thickness of the heat sink between a position where the light emitting element is located and the first surface is relatively small compared to a second thickness of the heat sink being remote from the position of the light emitting element. In other words, the thickness of the heat sink between a position where the light emitting element is located and the first surface is configured to be minimum, but is sufficient so that the heat sink has enough mechanical strength. This allows the light emitting elements be located near the inner wall of the tubular member, and allows a maximum distance between the light emitting elements and the light exit window on the tubular member. A large distance between the light emitting elements and the light exit window allows better light mixing and recycling, which lead to a good light output uniformity. As a result, less LEDs can be used in the tube with similar optical performance. The optical performance includes brightness and light distribution uniformity. Thus there is provided a tube shaped lighting device which has much less number of LEDs comparing to a known Tube Light Emitting Diode Lamp (TLED) for balanced performance of light distribution and thermal transfer. The decreased number of LEDs together with the saved energy advantageously brings the benefit of cost saving while keeping the same light performance. Alternatively, in embodiments of the lighting device according to the present invention, higher light output brightness can be achieved with a similar level of energy input as the known TLED by using fewer but higher power LEDs.
According to an embodiment of the lighting device, the lighting device further comprises a printed circuit board (PCB) arranged between the light emitting element(s) and the heat sink. This allows the electrical connection of driving circuits to the LEDs.
According to an embodiment of the lighting device, wherein at least a portion of a second surface of the heat sink, which is opposite to the first surface, is reflective. The surface can either be specular reflective or diffusive reflective. The reflective or scattering surface portion further allows better light mixing and recycling, which lead to a good light output uniformity. In a further embodiment of the lighting device, the heat sink can have two portions of the second surface extending oppositely from the position where the light emitting element is located. These two portions of the second surface can be symmetric or asymmetric with respect to the position where the light emitting element is located. This benefits the light distribution desired.
Preferably, the heat sink further comprises at least one fin and/or at least one cavity. The fin and/or cavity further enlarge the contact area between the heat sink and air. This is advantageous for increasing the heat dissipation capability of the heat sink.
As explained, the connecting element can be a protrusion from the inner wall of the tubular member. The protrusion can extend along the generatrix direction on the inner wall of the tubular member. There can be more than one protrusion on the inner wall of the tubular member for steadily accommodating the heat sink. In an alternative embodiment of the lighting device, the at least one connecting element of the tubular member comprises a recession in the inner wall of the tubular member. By matching the recession with a protrusion on the heat sink, the heat sink can also be accommodated along the inner wall of the tubular member.
According to an embodiment of the lighting device, the tubular member can be made of plastic. The light exit window of the tubular member can further has one of a transparent layer, a diffusive layer, a semi-transparent layer, and a layer with reflective pattern, or comprises reflective or diffuse particles. Plastic tubes with reflective or diffusive feature can be advantageous in cost and light output performance. It is noted that the invention relates to all possible combinations of features recited in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the lighting device, according to the invention will become apparent from and will be elucidated with respect to the implementations and embodiments described hereinafter and with reference to the accompanying drawings.
Fig. 1 shows a structure of an embodiment of a lighting device according to the present invention;
Fig. 2 is a schematic cross-sectional side view of a lighting device of Fig 1;
Fig. 3 is a schematic cross-sectional side view of an alternative embodiment of heat sink of a lighting device according to the present invention;
Fig. 4 is a schematic cross-sectional side view of another alternative embodiment of heat sink of a lighting device according to the present invention;
Fig. 5 is a schematic cross-sectional side view of an alternative embodiment of a lighting device according to the present invention with one rail-type connecting element;
Fig. 6 is a schematic cross-sectional side view of a further alternative embodiment of a lighting device according to the present invention with one rail-type connecting element;
Fig. 7 is a schematic cross-sectional side view of another alternative embodiment of a lighting device according to the present invention;
Fig. 8 is a schematic cross-sectional side view of a further alternative embodiment of a lighting device according to the present invention;
Fig. 9 is a schematic cross-sectional side view of the embodiment of Fig. 8 when the lighting device is heated up during operation.
DETAILED DESCRIPTION
A lighting device according to the present inventive concept is illustrated in Fig. 1. The lighting device comprises a tube 110, a heat sink 120 and a linear array of light emitting diodes (LED) 121 for light generation. The LEDs 121 are mounted on the heat sink 120 for heat dissipation.
Preferably, the LEDs 121 are mounted on a substrate or PCB 122 and the PCB 122 is mounted on the flat surface portion 124 of the heat sink 120 through mechanical connection, such as using adhesive layer or screws. The PCB 122 is for an easy electrical connection between the driving circuits and the LEDs. A person skilled of the art can understand that, there can be multiple PCBs for LED mounting, and the linear array can be composed of a PCB with chip-board LEDs, or be a linear lead frame with LED-dies and wirebonds that in addition may be silicone overmoulded locally or over the full length. The LEDs or LED-dies can be combined with wavelength conversion material. The linear assembly may also be based on a foil with an electrically conductive surface. LEDs in a linear array are suitable for the present inventive concept, but other arrangements are applicable as well. The linear array is in embodiments of the invention equipped with separate lenses or a common linear lens. The mounting method includes approaches to have good thermal engagement between the LEDs, the PCB and the heat sink.
As shown in Fig. 2, the tube 110 has two protrusions or ribs 112 extending along the generatrix direction on the inner wall 116 of the tube 110. The ribs 112 are finger- shaped in a cross-sectional view. The heat sink 120 is arc-shaped in a cross-sectional view, with a curved surface 126 opposite to the flat surface portion 124. The curved surface 126 is geometrically matched with the inner wall 116. The heat sink 120 is sized to be
accommodated in the space defined by the two protrusions 112. In other words, the arcuation distance between the two edges 128 of the heat sink 120 is a little smaller than the arcuation distance between the two protrusions 112, so that the heat sink 120 can be slidely inserted into the tube 110, and can be in good contact with the inner wall 116 of the tube 110, even when the heat sink is heated up during operation. This good contact under various conditions is advantageous for heat dissipation.
The tube 110 is made of plastic, and in alternative embodiments, the tube 110 is provided with wavelength conversion material, such as phosphorus material, or another additional optical layer, such as a diffusive layer, a semi-transparent layer, or a layer with reflective pattern, or comprises reflective or diffuse particles in the tube wall, etc., by means of deposition, lamination, extrusion or co-extrusion according to known techniques within the field. Thus, a number of different optical functionalities can advantageously be integrated in the tube 110, including the improvement of output light distribution and/or providing light recycling within the tube 110. The plastic tube 110 with ribs 112 can be cost effectively manufactured with extrusion, injection, molding or other known techniques within the field. A person skill in the art can understand that, the tube 110 can also formed with individual knobs on the inner wall 116 to act as the protrusions 112 defining the space for the heat sink
120. The tube 110 can also be made of glass or other at least partly transparent, diffusive or translucent material. The protrusions 112 can also be discrete knobs attached to the inner wall of the tube with glue, adhesive or by means of melting, or with other known mechanical methods, such as screws or bolts.
The tube 110 provides a light mixing chamber for light generated by the LEDs
121. The tube 110 can be transparent or translucent as a whole, or a transparent portion 111 is arranged on an opposite side of the tube with respect to the LEDs 121. The transparent (or alternatively translucent) portion 111, provides a light exit window on the tube.
The thickness between the flat surface portion 124 and the curved surface 126 of the heat sink 120 is configured to minimum, as long as the heat sink 120 has enough mechanical strength, so as to allow the LEDs 121 be close to the inner wall 116 of the tube 110. This allows a maximum distance between the LEDs 121 and the light exit window on the tube 110, in turn allows a desired light recycling within the cavity of tube 110. The light recycling can help to improve light mixing, which is advantageous for to prevent getting visible spots at the light exit window.
In an embodiment of the invention as shown in Fig. 2, there are two second surface portions 125, in addition to the flat surface portion 124 at the same side of the heat sink 120. The second surface portions 125 can be reflective or scattering, or integrates a reflective or scattering functionality by coating, laminating, plating, polishing or other known techniques within the field.
The profile of the second surface portions 125 can be linear, parabolic or other configuration based on the optical consideration. Although it is shown in Fig. 2 that the two second surface portions 125 are symmetric, an asymmetric structure is also possible. In an alternative embodiment, only one second surface portion 125 is configured to meet the desired light output distribution. Since the LEDs 121 are positioned close to the inner wall 116 of the plastic tube 110, it will reduce spottiness if decreasing the number of LEDs 121 largely. In an experimental test with a commercial available 4 feet TLED, which has 256 pieces of LED, the output light distribution profile keeps the same, without issue of spottiness when the number of LED decrease to 64-80 with the structure according to the invention.
Various embodiments of heat sink 220 and 320 are illustrated in Fig. 3 and Fig. 4, for better thermal dissipation, together with additional advantages on mechanical properties and/or optical properties.
As shown in Fig. 3, the heat sink 220 is configured with two fins 223 which enlarge the volume of the heat sink 220 for improved heat transfer performance. The heat sink 220 can be accommodated in the tube 110 by the two edges 228. The curved surface 226 is geometrically matched with the inner wall 116 of the tube 110. The LEDs are mounted in the flat surface portion 224, and the two second surface portions 225 are reflective.
As shown in Fig. 4, the heat sink 320 is configured with two fins 323. The heat sink 320 can be accommodated in the tube 110 by the two edges 328. The curved surface 326 is geometrically matched with the inner wall 116 of the tube 110. The LEDs are mounted in the flat surface portion 324, and the two second surface portions 325 are reflective. The fins are thinned and extended to form two cavities 327 which further enlarge the contact area between the heat sink 320 and air for better heat transfer performance.
Embodiments of various modifications to the connecting element between the tube 510, 610, 710 and 810 and the heat sink 520, 620, 720 and 810 are exemplarily illustrated in Fig. 5 to Fig. 9 for improvements to keep the tube and heat sink in good contact.
As shown in Fig. 5, the tube 510 has a protrusion or rail 519, which is dovetail- shaped in cross sectional view, extending along the generatrix direction on the inner wall 516. The heat sink 520 has a curved surface 526 which is geometrically matched with the inner wall 516. Accordingly, the heat sink 520 is configured with a dovetail groove 529. The heat sink 520 can be easily slided into the tube 510 with the rail-groove engagement. During the lamp operation, the rail-groove engagement attaches the heat sink 520 to the inner wall 516 of the tube 510, regardless the thermal expansion of the heat sink 520, and allows a good heat transfer. As shown in Fig. 6, the protrusion or rail 619 of tube 610 is mushroom-shaped in cross sectional view, which engages with the mushroom-shaped groove 629 in heat sink 620 to allow the curved surface 626 of the heat sink 620 keep good contact with the inner wall 616 of the tube 610.
As shown in Fig. 7, the protrusion or rail 719 of tube 710 is T-shaped in cross sectional view, which engages with the T-shaped groove 729 in heat sink 720 to allow the curved surface 726 of the heat sink 720 keep good contact with the inner wall 716 of the tube 710. In addition to the rail 719, the tube 710 is further configured with two protrusions 712 defining the space to accommodate the heat sink 720 by the two edges 728.
Although Fig. 5 to Fig. 7 show protrusions from the tube to the heat sink, the connecting element of alternative embodiments can be at reversed way, in other words, the grooves can be in the tube while the rails are configured on the curved surface of the heat sink. And a person skill in the art can understand that, the shapes of the rail-groove engagement can be revised according to known techniques within the field. The protrusions 112, 712 on the inner wall in Fig 1, 2 and 7 can also be reversed to recessions in the inner wall and engage with protrusions or ribs on the heat sink.
As shown in Fig. 8 and Fig. 9, the tube 810 has two protrusions or ribs 812 extending along the generatrix direction on the inner wall 816 of the tube 810. The ribs 812 are configured inclined to the heat sink 820 and formed wedge-shaped space 818 between the ribs 812 and the inner wall 816. Fig. 8 and the dash line in Fig. 9 shows the initial state of the lighting device when the cool heat sink 820 is accommodated by the two ribs 812 and has the curved surface 826 attached to the inner wall 816. When the lighting device is in operation state and the heat sink 820 is heated up, the edges 828 are forced into the wedge-shaped space 818, as the solid line shown in Fig. 9. The plastic material of the tube 810 has certain elasticity which enables the ribs 812 to deform slightly and open the wedge-shaped space 818 upon the thermal expansion force of the heat sink 820. Therefore, this allows good contact between the curved surface 826 and the inner wall 816 during the life time of the lighting device.
While the invention has been illustrated and described in detail in the drawings and foregoing description as one, two or three connecting elements for a better contact between the heat sink and the inner wall of the tube, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. A person skill in the art can understand that, more connecting elements can be implemented to achieve the contact for heat dissipation.
At the position(s) where the heat sink keeps contact with the tube, the matched shape of the surfaces, the contacting area and the close connection therebetween leads to the good thermal transfer. Therefore, it would be advantageous to have a substantial portion of the first surface (shown as 126, 226, 326, 526, 626, 726 and 826 in the figures) of the heat sink in good contact with the inner wall of the tube, to achieve a good thermal efficiency. In other words, a sufficient contact area between the heat sink and the tube will help the heat dissipation. The tube material can be a thermal conductive plastic which brings more advantage in heat transfer.
In embodiments, after assembly of the heat sink and the tube, the lighting device cavity can be evacuated or filled with a gas and sealed. Alternatively, the lighting device cavity can be filled with a liquid or a solidifying material like silicones.
A person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. 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 alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be constructed as limiting the claim. The word 'comprising' does not exclude the presence of elements or steps not listed in a claim. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The usage of the words first, second and third, etc., do not indicate any ordering. These words are to be interpreted as names. No specific sequence of acts is intended to be required unless specifically indicated.

Claims

CLAIMS:
1. A lighting device comprising:
an elongated hollow tubular member (110; 510; 610; 710; 810) which has a light exit window (11 1);
a heat sink (120; 220; 320; 520; 620; 720; 820); and
at least one light emitting element (121) for providing light, which is thermally coupled to the heat sink (120; 220; 320; 520; 620; 720; 820);
the heat sink (120; 220; 320; 520; 620; 720; 820) and the at least one light emitting element (121) being located in the tubular member (110; 510; 610; 710; 810); and at least a portion of a first surface (126; 226; 326; 526; 626; 726; 826) of the heat sink (120; 220; 320; 520; 620; 720; 820) being geometrically matched with an inner wall
(116; 516; 616; 716; 816) ofthe tubular member (110; 510; 610; 710; 810); wherein,
the tubular member (110; 510; 610; 710; 810) comprises at least one connecting element (112; 519; 619; 719, 712; 812) to accommodate the heat sink (120; 220; 320; 520; 620; 720; 820).
2. A lighting device according to claim 1, wherein the connecting element (112; 519; 619; 719, 712; 812) comprises a protrusion from the inner wall (116; 516; 616; 716; 816).
3. A lighting device according to claim 2, wherein the protrusion is finger-shaped, dovetail-shaped, mushroom-shaped or T-shaped, in cross-section.
4. A lighting device according to claim 1 , wherein the tubular member (110; 510;
610; 710; 810) further comprises a second connecting element (112; 712, 719; 812).
5. A lighting device according to claim 4, wherein the heat sink (120) is sized to be accommodated in the space defined by the connecting elements (112).
6. A lighting device according to claim 4, wherein the connecting elements (812) are configured inclined to the heat sink (820) and formed wedge-shaped spaces (818) between the connecting elements (812) and the inner wall (816).
7. A lighting device according to claim 6, wherein the connecting elements (812) are deformable to open the wedge-shaped spaces (818) upon a thermal expansion force of the heat sink (820).
8. A lighting device according to any of the preceding claims, wherein the heat sink (120; 220; 320; 520; 620; 720; 820) is rigid or has a thermal stable shape.
9. A lighting device according to any of the preceding claims, wherein a first thickness of the heat sink (120; 220; 320; 520; 620; 720; 820) between a position where the light emitting element (121) is located and the first surface (126; 226; 326; 526; 626; 726; 826) is relatively small compared to a second thickness of the heat sink (120; 220; 320; 520; 620; 720; 820) being remote from the position of the light emitting element (121).
10. A lighting device according to any of the preceding claims, further comprising a printed circuit board (122) arranged between the at least one light emitting element (121) and the heat sink (120; 220; 320; 520; 620; 720; 820).
11. A lighting device according to any of the preceding claims, wherein at least a portion of a second surface (125; 225; 325) of the heat sink (120; 220; 320; 520; 620; 720; 820), which is opposite to the first surface (126; 226; 326; 526; 626; 726; 826), is reflective.
12. A lighting device according to any of the preceding claims, wherein the heat sink (120; 220; 320; 520; 620; 720; 820) further comprises at least one fin (223; 323) and/or at least one cavity (327).
13. A lighting device according to any one of claims 1 - 12, wherein the light exit window (111) has one of a transparent layer, a diffusive layer, a semi-transparent layer, and a layer with reflective pattern, or comprises reflective or diffuse particles.
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