阅读说明：本技术 灯具组件 (Lamp assembly ) 是由 英戈·施派尔 于 2015-05-28 设计创作，主要内容包括：本申请涉及灯具组件。一种灯具组件包括：基底,其沿着第一方向延伸,所述基底包含具有第一热膨胀系数的第一材料；多个发光元件(LEE),其紧固到所述基底并且沿着所述第一方向布置；光导,其由具有第二热膨胀系数的材料组成,所述第二热膨胀系数在工作温度范围内不同；多个光学元件,其沿着所述第一方向布置,每个光学元件被定位来接收从所述LEE中对应的一个或多个发射的光并且将所述光引导至所述光导的边缘；外壳；以及热耦合层,其布置在所述基底与所述外壳之间。所述基底和所述热耦合层被构造成使得所述多个LEE中的每一个虽然被紧固到所述基底,但是在所述工作温度范围内保持与其对应的光学元件配准。(The present application relates to a light fixture assembly. A light fixture assembly comprising: a substrate extending along a first direction, the substrate comprising a first material having a first coefficient of thermal expansion; a plurality of Light Emitting Elements (LEEs) secured to the substrate and arranged along the first direction; a light guide composed of a material having a second coefficient of thermal expansion that differs over an operating temperature range; a plurality of optical elements arranged along the first direction, each optical element positioned to receive light emitted from a corresponding one or more of the LEEs and to direct the light to an edge of the light guide; a housing; and a thermal coupling layer disposed between the substrate and the housing. The substrate and the thermal coupling layer are configured such that each of the plurality of LEEs, while secured to the substrate, remains in registration with its corresponding optical element over the operating temperature range.)

1. A light fixture assembly, comprising:

a substrate extending along a first direction and having a first coefficient of thermal expansion in the first direction;

a plurality of light emitting elements secured to the substrate, the light emitting elements arranged along the first direction;

a light guide having a second coefficient of thermal expansion in the first direction that is different from the first coefficient of thermal expansion over an operating temperature range;

a plurality of optical elements arranged along the first direction, each optical element positioned to receive light emitted from a corresponding one or more of the light-emitting elements and direct the light to an edge of the light guide;

a housing; and

a heat coupling layer disposed between the substrate and the housing,

wherein the substrate and the thermal coupling layer are configured such that each of the plurality of light-emitting elements, while secured to the substrate, remains in registration with its corresponding optical element over the operating temperature range.

2. The luminaire assembly of claim 1, further comprising a plurality of fastening features, each fastening feature attaching the light guide to the housing at a corresponding location along the first direction.

3. The luminaire assembly of claim 2, wherein one or more of the fastening features are configured to provide a sliding coupling that allows sliding along a portion of the first direction.

4. The luminaire assembly of claim 3, wherein one of the fastening features is configured to provide a tight coupling without mechanical play at the corresponding location along the first direction.

5. The luminaire assembly of claim 4, wherein one of the fastening features that provides a tight coupling is disposed between two fastening features that provide a sliding coupling.

6. The luminaire assembly of claim 5, wherein the substrate comprises a plurality of separate portions, and further comprising a plurality of registration features configured to register the optical elements with corresponding separate portions of the substrate at corresponding locations along the first direction, each separate portion of the substrate having one of the registration features arranged between adjacent fastening features and configured to provide a tight coupling with the respective optical element.

7. A light fixture assembly, comprising:

a substrate extending along a first direction, the substrate comprising a first material having a first coefficient of thermal expansion;

a plurality of light emitting elements secured to the substrate, the light emitting elements arranged along the first direction;

a light guide comprising a material having a second coefficient of thermal expansion that is different from the first coefficient of thermal expansion over an operating temperature range;

a plurality of optical elements arranged along the first direction, each optical element positioned to receive light emitted from a corresponding one of the light-emitting elements and direct the light to an edge of the light guide;

a housing; and

a heat coupling layer disposed between the substrate and the housing,

wherein the thermal coupling layer comprises spaced apart portions of thermal coupling material, and a discontinuity in the spaced apart portions of the thermal coupling material is located at the same location as the light emitting element in the first direction.

8. A light fixture assembly, comprising:

a substrate extending along a first direction, the substrate comprising spaced apart portions of a substrate material;

a plurality of light emitting elements secured to the substrate, the light emitting elements arranged along the first direction with breaks in the spaced apart portions of the substrate material located between adjacent light emitting elements in the first direction;

a light guide;

a plurality of optical elements arranged along the first direction, each optical element positioned to receive light emitted from a corresponding one of the light-emitting elements and direct the light to an edge of the light guide;

a housing; and

a heat coupling layer disposed between the substrate and the housing.

9. A light fixture assembly, comprising:

a substrate extending along a first direction, the substrate comprising a first material having a first coefficient of thermal expansion;

a plurality of light emitting elements secured to the substrate, the light emitting elements arranged along the first direction;

a light guide comprising a material having a second coefficient of thermal expansion that is different from the first coefficient of thermal expansion over an operating temperature range;

a plurality of optical elements arranged along the first direction, each optical element positioned to receive light emitted from a corresponding one or more of the light-emitting elements and direct the light to an edge of the light guide;

a housing; and

a heat coupling layer disposed between the substrate and the housing,

wherein the heat coupling layer comprises a layer of flexible material extending continuously in the first direction adjacent a plurality of light emitting elements.

Technical Field

The present technology relates to lamp assemblies, and more particularly to lamp assemblies having a robust thermo-mechanical design.

Background

Light sources are used in a variety of applications, such as to provide general illumination and to provide light for electronic displays (e.g., LCDs). Historically, incandescent light sources have been widely used for general lighting purposes. Incandescent light sources produce light by heating a filament to a high temperature until it emits light. The hot filament is protected from oxidation in air by an inert gas filled or evacuated glass envelope. Incandescent light sources are being gradually replaced in many applications by other types of electro-optics, such as fluorescent lamps, Compact Fluorescent Lamps (CFLs), Cold Cathode Fluorescent Lamps (CCFLs), high intensity discharge lamps, and solid state light sources, such as Light Emitting Diodes (LEDs).

Disclosure of Invention

Solid state Light Emitting Elements (LEEs), such as light emitting diodes, can experience substantial heating during their operation. Accordingly, luminaire assemblies incorporating such elements are often characterized as components that facilitate the dissipation of heat generated by the LEEs. In particular, solid state light fixtures often feature a heat sink to which heat from the LEEs is dissipated and dispersed. Nevertheless, heating the components in the lamp assembly may present lamp durability issues. For example, when an assembly is made up of components having different Coefficients of Thermal Expansion (CTE), heating the assembly may damage the assembly due to, for example, differential thermal expansion, hygroscopic expansion, or other expansion of the different components. In a luminaire assembly featuring LEEs in registration with corresponding optical elements, differential thermal expansion between the optical elements and the substrate supporting the LEEs can cause misalignment between the LEEs and their corresponding optical elements, which can affect optical performance, for example. These problems can become severe in embodiments featuring components that extend in one or two directions, such as, for example, components featuring an array of LEEs that extend one foot or more in one direction. Accordingly, embodiments are disclosed that feature designs for mitigating such effects. For example, embodiments having an array of LEEs extending in one direction include one or more features designed to accommodate differential expansion or contraction between the substrate and the optical coupling element arrangement. These areas (also referred to as seams) provide a buffer to accommodate expansion of the substrate along the length of the lamp assembly, thereby relieving catastrophic tension on the components of the assembly that can expand different amounts relative to the substrate material.

Various aspects of the invention are summarized below.

In general, in a first aspect, the invention features a luminaire assembly comprising: a substrate extending along a first direction, the substrate comprising a first material having a first coefficient of thermal expansion; a plurality of light emitting elements secured to the substrate, the light emitting elements arranged along the first direction; a light guide comprised of a material having a second coefficient of thermal expansion that is different from the first coefficient of thermal expansion over an operating temperature range; a plurality of optical elements arranged along the first direction, each optical element positioned to receive light emitted from a corresponding one or more of the light-emitting elements and direct the light to an edge of the light guide; a housing; and a thermal coupling layer disposed between the substrate and the housing. The substrate and the thermal coupling layer are configured such that each of the plurality of light-emitting elements, while secured to the substrate, remains in registration with its corresponding optical element over the operating temperature range.

Embodiments of the lamp assembly may include one or more of the following features and/or features of other aspects. For example, the housing may include a heat sink.

The thermal coupling layer may comprise spaced apart portions of thermal coupling material. The discontinuities in the spaced apart portions of the thermal coupling material may be located at the same locations as the light emitting elements in the first direction. The spaced apart portions of the heat coupling layer may extend continuously in the first direction adjacent to the at least two or more light emitting elements. The discontinuities in the spaced apart portions of the thermal coupling material may be offset from the location of the light emitting element in the first direction.

In some embodiments, the spaced apart portions of the thermal coupling material and the portions of the substrate located between the LEEs are more rigid than the portions of the substrate located adjacent the LEEs.

The heat coupling layer may include a layer of flexible material extending continuously in the first direction adjacent the plurality of light emitting elements. The heat coupling layer may adhere the substrate to the housing. In some embodiments, the heat coupling layer comprises a silicone foam. In certain embodiments, the thermal coupling layer comprises thermal glue and/or thermal tape.

The thermal coupling layer can accommodate differential thermal expansion between the light guide and optical element and the heat sink over the operating temperature range.

In some embodiments, the luminaire assembly comprises a plurality of registration features, each registration feature affixing a corresponding one or more optical elements to the substrate at one location along the first direction. Each registration feature may extend into a corresponding optical element at a corresponding location and to the substrate. Each registration feature may include a male portion and a female portion shaped to receive the male portion. The substrate may include a convex portion of each registration feature and the optical element includes a concave portion. In some embodiments, the registration features are periodically positioned in the first direction. At least two light-emitting elements may be located between adjacent registration features.

The substrate may include one or more seams each located between a pair of adjacent light-emitting elements. The substrate may comprise a layer of substrate material and each seam comprises an interruption in said layer of substrate material. In some embodiments, the substrate comprises a layer of substrate material, and each seam comprises a portion of the substrate material having a thickness in at least one dimension that is different from the thickness of the substrate material adjacent each light-emitting element in the dimension.

The substrate may include a layer of conductive material that is discontinuous at the seam. Portions of the flexible conductive material may electrically couple the layers of conductive material on opposite sides of the corresponding seam. The seam may be flexible enough to accommodate thermal expansion of the substrate over a range of operating temperatures.

In an embodiment, the light emitting element is a light emitting diode, such as a white light emitting diode.

The substrate may comprise a metal core printed circuit board, a glass epoxy laminate printed circuit board, a ceramic printed circuit board, or a flexible circuit board.

The housing may include a material having high thermal conductivity, such as a high thermal conductivity material formed of a metal (e.g., aluminum).

The light fixture assembly may extend about 6 inches or more in the first direction (e.g., about 12 inches or more, about 24 inches or more, about 48 inches or more in the first direction).

The substrate may comprise a printed circuit board.

The substrate may include a flexible portion between the LEEs and the spaced apart portions of the heat transfer material.

The optical element may be a compound parabolic reflector.

Each optical element may include a recess shaped to receive a corresponding one or more light-emitting elements. In some implementations, an air gap exists between the optical element and the corresponding one or more light-emitting elements in the recess. . In other implementations, one or more light-emitting elements can be optically coupled to a corresponding optical element through an optical coupling medium in the recess. In some other implementations, the luminaire component can further include a layer comprising a wavelength converting material disposed on a surface of the optical element in the recess. For example, the wavelength converting material includes a phosphor.

In general, in another aspect, the invention features a lamp assembly including: a substrate extending along a first direction, the substrate comprising a first material having a first coefficient of thermal expansion; a plurality of light emitting elements secured to the substrate, the light emitting elements arranged along a first direction; a light guide comprising a material having a second coefficient of thermal expansion that is different from the first coefficient of thermal expansion over an operating temperature range; a plurality of optical elements arranged along the first direction, each optical element positioned to receive light emitted from a corresponding one of the light-emitting elements and direct the light to an edge of a light guide; a housing; and a thermal coupling layer disposed between the substrate and the housing. The thermal coupling layer may include spaced apart portions of thermal coupling material, and a discontinuity in the spaced apart portions of thermal coupling material is located at the same position as the light emitting element in the first direction.

Drawings

Fig. 1A-1C illustrate aspects of an exemplary light fixture assembly.

FIG. 1D is an example of an optical coupling element for use in the luminaire assembly shown in FIGS. 1A-1C.

FIG. 1E is an example of an array of optical coupling elements similar to the optical coupling elements shown in FIG. 1D.

Fig. 2A is a perspective view of components of an embodiment of a light fixture assembly.

FIG. 2B is a perspective view of the components of the light fixture assembly shown in FIG. 2A with the housing removed.

FIG. 2C is a cross-sectional view of components of the light fixture assembly shown in FIG. 2A.

FIG. 2D is another cross-sectional view of the components of the lamp assembly shown in FIG. 2B.

FIG. 2E is a perspective view of the components of the lamp assembly shown in FIG. 2D with the heat transfer layer removed.

FIG. 3 is a cross-sectional view of components of another embodiment of a light fixture assembly.

Fig. 4A is a cross-sectional view of components of yet another embodiment of a light fixture assembly.

Fig. 4B is a cross-sectional view of a substrate having a flexible portion.

Fig. 4C is a top view of another substrate having a flexible portion.

FIG. 5A is a perspective view of another exemplary light fixture assembly.

Fig. 5B is a side view of the light fixture assembly of fig. 5A.

FIG. 5C is a front view of a portion of the light fixture assembly of FIG. 5A.

FIG. 6A is a perspective view of a portion of another exemplary light fixture assembly.

FIG. 6B is a side view of a portion of the lamp assembly of FIG. 6A.

FIG. 7 is a cross-sectional view of components of another embodiment of a light fixture assembly.

Like elements in different figures are identified with the same reference numerals.

Embodiments may include one or more of the features described in connection with other aspects of the invention.

In general, in another aspect, the invention features a lamp assembly that includes: a substrate extending along a first direction, the substrate comprising spaced apart portions of a substrate material; a plurality of light emitting elements secured to the substrate, the light emitting elements arranged along the first direction with breaks in spaced apart portions of the substrate material between adjacent light emitting elements in the first direction; a light guide; a plurality of optical elements arranged along the first direction, each optical element positioned to receive light emitted from a corresponding one of the light-emitting elements and direct the light to an edge of a light guide; a housing; and a thermal coupling layer disposed between the substrate and the housing.