Light emitting device

Abstract

A light emitting device (1; 100, 100; 101), the light emitting device (1; 100, 100; 101) comprises: an array (2a, 2b) of LED light sources (3a, 3b) adapted to emit LED light in operation, wherein each LED light source (3a, 3b) comprises an LED package; and an array (4a, 4b) of optical elements (5a, 4b) arranged such that each LED light source (3a, 3b) of the array (2a, 2b) of LED light sources (3a, 3b) is associated with an optical element (5a, 5b) of the array (4a, 4b) of optical elements (5a, 5b) wherein each optical element (5a, 5b) is configured to convert LED light of the associated LED light source (3a, 3b) into a light beam such that a combined LED light of the LED light sources (3a, 3b) of the array (2a, 2b) forming light of the light emitting device forms a pixelated array, and wherein the light-emitting device (1; 100, 100; 101) further comprises a flexible substrate (6a, 6b) on which the array (2a, 2b) of LED light sources (3a, 3b) is arranged, and the array (4a, 4b) of optical elements (5a, 5b) is arranged on the array (2a, 2b) of LED light sources (3a, 3b).

Description

Technical Field

[0001] The present invention relates to a light emitting device suitable for emitting light during operation, the light emitting device comprising an LED light source array and an optical element array, wherein each LED light source of the LED light source array is suitable for emitting LED light during operation, and wherein each LED light source of the LED light source array comprises an LED package, wherein the optical element array is arranged such that each LED light source of the LED light source array is associated with an optical element of the optical element array.

[0002] As used herein, the term "array of optical elements" is intended to encompass both an array of individual components and an array of integrally formed flexible components.

[0003] As used herein, the term "flexible substrate" is intended to refer to a substrate that is flexible until the point of being assembled with or mounted on a solid or rigid mounting surface, such as a rigid metal strip. Background Art

[0004] KR 2012 119729A discloses a light-emitting diode lamp for smoothly radiating heat generated by the lamp. The LED lamp is arranged in a track, with multiple LED devices arranged in a matrix on three sides of the LED lamp. A heat sink is provided on the bottom surface of the base plate. A lens cover covers each LED device, and a connection unit is provided in the housing. The connection unit couples the conduit.

[0005] A common approach to achieving a specific light distribution is to create a specific optical solution in the form of a lens or reflector combined with a specific light source (such as a COB LED or an assembly of multiple mid-power LEDs). To achieve a different light distribution, or if the number of LEDs is reduced due to improved luminous efficacy, a new set of optical components must be designed and molds must be produced, increasing costs and lead times, and maintaining inventory. This often leads to potential obsolescence of the luminaire and a lack of backward compatibility.

[0006] The invention is based on the recognition that, driven by advances in the TV backlight industry (where cost is key), a dominant architecture has begun to emerge for arranging LED components on MCPCB (Metal Core Printed Circuit Board) substrates or conventional printed circuit boards, with copper tracks on a PI substrate (also known as LED flex strip), adhered with double-sided tape to an aluminum carrier for heat dissipation, which contains an assembly of a group of medium-power LEDs, each equipped with a lens having a high beam spread angle of approximately 140 degrees. In this way, with a limited number of LEDs, a uniformly illuminated surface can be created.

[0007] However, even with this insight, it is still desirable to provide a light emitting device of the type mentioned in the introduction, by which supply chain complexity is reduced and by which better opportunities are created for customization, in particular customization of the shape of the light beam emitted by the light emitting device. Summary of the Invention

[0008] The object of the present invention is to overcome this problem and to provide a lighting device of the type mentioned in the introduction, by which the supply chain complexity can be reduced.

[0009] It is an object of the present invention to provide such a lighting device, by means of which also improved customization opportunities can be achieved, in particular customization of the shape of the light beam emitted by the lighting device.

[0010] According to a first aspect of the present invention, this object and other objects are achieved by a light-emitting device suitable for emitting light from the light-emitting device during operation, the light-emitting device comprising an LED light source array and an optical element array, wherein each LED light source of the LED light source array is suitable for emitting LED light during operation, and wherein each LED light source of the LED light source array comprises an LED package, wherein the optical element array is arranged so that each LED light source of the LED light source array is associated with an optical element of the optical element array, wherein each optical element of the optical element array is configured to convert the LED light of the associated LED light source into a light beam so that the combined LED light of the LED light sources of the LED light source array that forms the light of the light-emitting device forms a pixelated array, and wherein the light-emitting device further comprises a flexible substrate, the LED light source array is arranged on the flexible substrate, and the optical element array is arranged on the LED light source array.

[0011] By providing a light emitting device having an array of LED light sources and an array of optical elements placed on a semi-rigid or flexible substrate (for example, both of the SMD (surface mount device) type), it is possible to obtain a specific light distribution by mechanically rearranging each LED in the array in a manner that only requires changing the mechanical arrangement, thereby covering the entire range of light distributions for a specific product line. In addition, the use of dedicated optical elements (such as diffusers, reflectors or specific lens arrays) for specific applications is obsolete. This significantly reduces supply chain complexity and creates more opportunities for customization, especially customization of the shape of the light beam emitted by the light emitting device.

[0012] Furthermore, because the optical element array in this configuration is smaller and positioned above and close to the LED light source array, the overall volume of the light-emitting device is significantly smaller than architectures with conventional reflectors or larger lenses. This results in a smaller and lighter product. In other words, generating the desired light distribution near the LEDs allows for miniaturization of the entire light-emitting device, significantly reducing the size, cost, and environmental impact of the housing, and easing the logistical burden of shipping. This results in reduced material usage and lower application costs.

[0013] By further configuring the light-emitting device to include a flexible substrate, on which the LED light source array is arranged, and on which the optical element array is arranged, the flexibility of the substrate enables the LED light source array to be mechanically arranged in a variety of shapes. Furthermore, because the LED light source has a limited beam angle determined by the optical element array, each shape of the LED light source array is used to provide a different light distribution. This provides a light-emitting device that also enables improved customization opportunities.

[0014] The LED light sources of the LED light source array can be mechanically redirected by bending the LED light sources in a predetermined direction through a flexible substrate, by orienting one or more subsets of the LED light sources of the LED light source array in a predetermined direction, or by a combination of the two to provide a light emitting device light having a predetermined light pattern.

[0015] Thus, the LED light sources of the LED light source array can be rearranged in a particularly simple and straightforward manner by simple mechanical redirection.This results in a luminaire with which different light distributions can be generated in a particularly simple manner.

[0016] One or more of the bending of the shape of the flexible substrate in a predetermined direction and the orientation of the LED light sources of the LED light source array in a predetermined direction can be fixed by any one of the following items: providing a foil fixation of a sealing structure, and providing a solid holding device configured to hold the substrate, the LED light source array and the optical element array.

[0017] Thus, during the manufacture of individual luminaires, the selected orientation of the LED light sources of the LED light source array and thus the selected light distribution can be fixed in a particularly simple and durable manner. This further reduces supply chain complexity, as fewer components are required for fixing.

[0018] In addition, the construction of the sealing structure also makes the lighting device waterproof and particularly suitable for outdoor applications, and also reduces the cost of lens installation.

[0019] The sealing structure or solid retention device may further include one or more of the following: at least one first track configured to receive a flexible substrate having an array of LED light sources disposed thereon, and a second track configured to receive a driver.

[0020] Thereby, a lighting device comprising a simple and robust construction is provided.In particular, if a first track and a second track are provided, the lighting device can have a minimalist design or construction, which further reduces manufacturing costs.

[0021] The sealing structure or solid retaining device may also include at least one first track and a second track, wherein the at least one first track is configured to receive a flexible substrate on which an LED light source array is arranged, and the second track is configured to receive a driver, wherein the first track and the second track are arranged on opposite sides of the sealing structure or solid retaining device.

[0022] Thus, a lighting device is provided by which, when the driver is arranged in the second track, the driver is both hidden from view, such as not visible to an observer, and does not affect the light of the lighting device.

[0023] The sealing structure or solid retention device may further include one or more air channels configured to provide cooling air to the LED light sources of the LED light source array.

[0024] The sealing structure or solid retention device may further include one or more heat sink elements configured to provide cooling air to the LED light sources of the LED light source array.

[0025] Thus, enhanced cooling is provided for the LED light sources of the LED light source array, which in turn prolongs the life of the LED light sources of the LED light source array.

[0026] Furthermore, in the case of additional heat sink elements, such elements can be provided in a simple and straightforward manner by laser cutting of metal sheets.

[0027] The sealing structure or the solid retaining device may further include a support structure, wherein the flexible substrate is placed on the support structure in such a manner that the flexible substrate is in full surface contact with the support structure.

[0028] Thereby, a lighting device comprising a particularly simple and robust construction is provided.

[0029] The foil fixation providing the sealing structure may be provided by any one of sealing, foil sealing, vacuum forming and moulding.

[0030] The sealing arrangement can thus be provided in a particularly simple, quick and cost-effective manner.

[0031] The solid retention device may be provided by any of machining, moulding, 3D printing and a pen device attached to a different part of the base plate.

[0032] Thus, the solids retaining device can be provided in a particularly simple, quick and cost-effective manner.

[0033] The sealing structure may comprise a reflective first foil and a transparent second foil, the first foil and the second foil each comprising a thickness of less than 0.5 mm.

[0034] Thus, a particularly compact sealing structure can be provided while still achieving the desired optical properties, in particular the light distribution.

[0035] The sealing arrangement may comprise a reflective first foil and a transparent second foil, wherein the first foil is provided with holes arranged in a predetermined pattern, the holes being provided before or during fixing of the foils to provide the sealing arrangement.

[0036] Hereby it is ensured that when the second foil is applied during foil fixing, the second foil will be sucked into all edges of the structure to provide a smooth and even surface.

[0037] The optical element array may be a lens array.

[0038] Thus, a particularly simple array of optical elements is provided.

[0039] The lens may be, for example, a narrow beam generating lens.Each lens of the lens array may comprise a beam angle in the range of 30 degrees to 60 degrees FWHM.

[0040] Thus, the resulting light emitting device light is provided as a pixelated array having substantially the same number of spotlights as the number of LED light sources in the LED light source array. By selecting the number of LED light sources in the LED light source array, the total lumens of the resulting light emitting device light can be customized. For example, if a light emitting device light of 3000 lm is desired, approximately 20-30 LEDs are required.

[0041] The optical element array may be a micro-collimator array.

[0042] Thus, the resulting light emitting device light is provided as a pixelated array having substantially as many spotlights as the number of LED light sources in the LED light source array. Furthermore, an advantage of using a microcollimator array is that the low profile advantages associated with lenses can be maintained while achieving additional advantageous properties such as versatile off-axis emission beam shaping, good cutoff (and UGR) opportunities, and very easy assembly since no optical contact with the LED package is required.

[0043] Each micro-collimator of the micro-collimator array may include a single micro-collimator, or a combination of two or more micro-collimators.

[0044] Even after mounting the LDS and microcollimator on a flexible structure, using a single microcollimator for each LED package results in a high degree of flexibility. The combined collimator allows for a larger rigid area on the light-emitting device.

[0045] The LED light source array may include one or more of mid-power LEDs and COB LEDs.

[0046] The array of LED light sources may be configured to form an LED bar.

[0047] The LED light source array may include more than 6 LED light sources, more than 12 LED light sources, more than 20 LED light sources, or between 20 and 30 LED light sources.

[0048] The present invention also relates to a luminaire comprising at least one light emitting device according to the present invention, wherein the LED light sources of the LED light source array of the at least one light emitting device are mechanically redirected to provide light emitting device light having a predetermined light pattern by one or both of the following items: the flexible substrate is bent in a predetermined direction, and one or more subsets of the LED light sources of the LED light source array are oriented in a predetermined direction.

[0049] The present invention also relates to a luminaire comprising at least two light emitting devices according to the present invention, wherein the LED light sources of the LED light source array of at least one of the at least two light emitting devices are mechanically redirected to provide light emitting device light having a predetermined light pattern and a track drive arranged centrally between the at least two light emitting devices by one or both of the following items: the flexible substrate is bent in a predetermined direction, and one or more subsets of the LED light sources of the LED light source array are oriented in a predetermined direction.

[0050] The luminaire according to the invention may be configured for indoor or outdoor applications.

[0051] The luminaire according to the invention can be configured for lighting applications requiring a specific light distribution.

[0052] Luminaires according to the present invention may be low profile / low height ceiling luminaires, downlights, linear luminaires, troffers, and outdoor luminaires.

[0053] It is noted that the invention relates to all possible combinations of features recited in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing embodiment(s) of the invention.

[0055] Figure 1 An exploded view of a light emitting device according to the present invention is shown, which includes an LED light source array, an optical element array, a flexible substrate, and a solid holding device configured to hold the substrate, the LED light source array, and the optical element array.

[0056] Figure 2 A perspective view of a lighting device according to claim 1 is shown in the assembled state.

[0057] Figure 3 An exploded view of another lighting device according to the present invention is shown.

[0058] Figure 4 A- Figure 4 F shows the method of manufacturing the invention by means of foil fixing and Figure 3 The steps of the method of the light emitting device are shown.

[0059] Figure 5 A- Figure 5 B shows the Figure 4 A- Figure 4 Additional steps of the method of F.

[0060] Figure 6 A perspective view showing another solid state holding device of a light emitting device according to the present invention is shown.

[0061] Figure 7 and Figure 8 Another perspective view of a solid holding device according to the present invention is shown without and with an array of LED light sources and an array of optical elements mounted thereon.

[0062] Figure 9 A cross-sectional side view of another light emitting device according to the present invention is shown.

[0063] Figure 10 and Figure 11 Shown respectively according to Figure 9 A top view and a perspective view of a light emitting device.

[0064] Figure 12 and Figure 13 Shown are cross-sectional side views of two different luminaires comprising a light emitting device according to the invention.

[0065] Figure 14 Shown is a cross-sectional side view of another luminaire comprising a light emitting device according to the invention and further comprising a central track drive.

[0066] As shown in the figures, the sizes of layers and regions are exaggerated for illustrative purposes and, therefore, are provided to illustrate the general structure of embodiments of the present invention. Like reference numerals refer to like elements throughout. DETAILED DESCRIPTION

[0067] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which presently preferred embodiments of the invention are shown. However, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments described herein; rather, these embodiments are provided to be thorough and complete and to fully convey the scope of the invention to those skilled in the art.

[0068] Figure 1 An exploded view of a light emitting device 1 according to the invention is shown. Figure 2 The light emitting device 1 is shown in an assembled state. Generally, regardless of the embodiment, the light emitting device 1 comprises an array 2a, 2b of LED light sources 3a, 3b and an array 4a, 4b of optical elements 5a, 5b arranged on a flexible substrate 6a, 6b. For simplicity, the array 4a, 4b of optical elements 5a, 5b is only shown. Figure 1 Generally, regardless of the embodiment, the light emitting device 1 is adapted to emit light emitting device light in operation.

[0069] exist Figure 1 In the embodiment shown, the light emitting device 1 further comprises a solid holding device 8 configured to hold and secure in place the flexible substrates 6a, 6b, the arrays 2a, 2b of LED light sources 3a, 3b and the arrays 4a, 4b of optical elements 5a, 5b.

[0070] In general, regardless of the embodiment, as used herein, the term "flexible substrate" is intended to refer to a substrate that is flexible until the moment of assembly with or mounting on a solid or rigid mounting surface (such as a rigid metal strip). More specifically, on the solid or rigid mounting surface, the flexible substrates 6a, 6b and, therefore, the light emitting device 1 are bendable prior to mounting, but need not be flexible, stretchable or foldable after mounting. This enables mechanical redirection of the LED light sources 3a, 3b of the LED light source arrays 2a, 2b by bending the flexible substrates 6a, 6b in a predetermined direction and / or orienting one or more subsets of the LED light sources 3a, 3b of the LED light source arrays 2a, 2b in a predetermined direction, thereby providing light emitting device light emitted by the light emitting device 1 with a predetermined light pattern.

[0071] Generally, regardless of the embodiment, each LED light source 3a, 3b of the LED light source array 2a, 2b is adapted to emit LED light in operation. Each LED light source 3a, 3b of the LED light source array comprises a LED package.

[0072] The LED light sources 3a, 3b can be any suitable type of LED light source. For example, the LED light sources 3a, 3b can be medium-power LEDs (e.g., each LED package emitting approximately 100-150 lm). Alternatively, the LED light sources 3a, 3b can be COB LEDs. The arrays 2a, 2b of LED light sources 3a, 3b can be configured to form any suitable or desired shape. For example, the arrays 2a, 2b of LED light sources 3a, 3b can be configured to form an LED bar.

[0073] The combined LED light source light of all LED light sources 3a, 3b forms the luminaire light. The total lumens of luminaire light emitted by the luminaire 1 can be customized by adding (or removing) the corresponding number of LED light sources 3a, 3b. For example, for a luminaire 1 emitting 3000 lm of luminaire light, an array 2a, 2b having approximately 20-30 LED light sources 3a, 3b would be required.

[0074] Typically, regardless of the embodiment, the arrays 4a, 4b of optical elements 5a, 5b are arranged such that each LED light source 3a, 3b of the LED light source arrays 2a, 2b is associated with an optical element 5a, 5b of the optical element arrays 4a, 4b. Each optical element 5a, 5b of the optical element arrays 4a, 4b is further configured to convert the LED light of the associated LED light source 3a, 3b into a light beam such that the combined LED light of the LED light sources 3a, 3b of the LED arrays 2a, 2b forming the light of the light emitting device forms a pixelated array. Figure 1 and Figure 2 In the embodiment shown, the arrays 4a, 4b of optical elements 5a, 5b are connected by a flexible connecting portion 11, such as a foil. In other embodiments, the connecting portion 11 may be omitted.

[0075] Therefore, each LED light source 3a, 3b is equipped with an optical element 5a, 5b. The optical element 5a, 5b can generally be a lens, such as Figure 1 and Figure 2 As shown in the embodiment of , it can also be a micro-collimator, such as Figures 9-11 The optical elements 5a, 5b may be, for example, lenses each having a limited beam angle of approximately 30-60 degrees FWHM.

[0076] In an alternative embodiment, the arrays 4a, 4b of optical elements 5a, 5b are arranged such that each subset of LED light sources 3a, 3b in the arrays 2a, 2b of LED light sources is associated with an optical element 5a, 5b in the arrays 4a, 4b of optical elements. In this case, the number of optical elements 5a, 5b in the arrays 4a, 4b of optical elements 5a, 5b is less than the number of LED light sources 3a, 3b in the arrays 2a, 2b of LED light sources 3a, 3b. For example, subsets of two, three, or four LED light sources 3a, 3b can be associated with each optical element 5a, 5b in the arrays 4a, 4b of optical elements 4a, 4b. Furthermore, different numbers of LED light sources 3a, 3b can be associated with different optical elements 5a, 5b in the arrays 4a, 4b of optical elements 4a, 4b.

[0077] The arrays 2a, 2b of LED light sources 3a, 3b are arranged on flexible substrates 6a, 6b, and the arrays 4a, 4b of optical elements 5a, 5b are arranged on the arrays 2a, 2b of LED light sources 3a, 3b.

[0078] It should be noted that in Figure 1 and Figure 2 In the embodiment shown, two arrays 2a, 2b of LED light sources 3a, 3b and two arrays 4a, 4b of optical elements 5a, 5b are provided. In other embodiments, the number of arrays 2a, 2b of LED light sources and arrays 4a, 4b of optical elements may be different from two, such as one, three, or more than three.

[0079] exist Figure 1 and Figure 2 In the illustrated embodiment, the light emitting device 1 further comprises a solid holding device 8 for holding and securing the flexible substrates 6a, 6b, the arrays 4a, 4b of optical elements 5a, 5b, and the arrays 2a, 2b of LED light sources 3a, 3b in place. The holding device 8 comprises two slots 9a, 9b configured to receive respective heat sink elements 10a, 10b on which the respective substrates 6a, 6b are disposed.

[0080] The solid holding device 8 is configured to ensure that the flexible substrates 6a, 6b bend in a predetermined direction and are fixed in this position when mounted on the solid holding device 8. This can be achieved by providing the holding device 8 with a Figure 1 The solid holding device 8 is further configured to ensure that one or more of the LED light sources 3a, 3b of the arrays 2a, 2b of LED light sources 3a, 3b are oriented in a predetermined direction and fixed in this orientation. This can also be achieved by providing the holding device 8 with a suitable surface curvature. Figure 1 and Figure 2As shown, this can also be achieved by arranging the slits 9a, 9b to extend in a direction V that is angled with the height direction H of the holding device 8. This will provide the assembled light emitting device 1 with a Figure 1 The surface curvature shown by arrow B in direction V can be selected so that an angle of -30°, -60°, 30° or 60° can be obtained between the planes of the flexible substrates 6a, 6b of adjacent LED light source arrays 3a, 3b 2a, 2b. The light distribution can be defined by (multiple) surface curvatures. In this example, the flexible substrates 6a, 6b are curved in only one direction. In most cases, a convex flexible substrate 6a, 6b and LED light source arrays 2a, 2b are suitable, although a concave configuration will result in a focal design configuration if desired. An example of a suitable radius in a convex configuration is 500 mm. Concave and convex systems can be designed in both directions A and B.

[0081] In this embodiment, the light emitting device 1 is assembled and the bending of the flexible substrates 6a, 6b in a predetermined direction and / or the orientation of the LED light sources 3a, 3b of the LED light source arrays 2a, 2b in a predetermined direction are fixed by the holding device 8 as follows.

[0082] First, heat dissipation elements 10a, 10b are placed in slots 9a, 9b of holding device 8, and then flexible substrates 6a, 6b, arrays 4a, 4b of optical elements 5a, 5b, and arrays 2a, 2b of LED light sources 3a, 3b are arranged on heat dissipation elements 10a, 10b. Alternatively, flexible substrates 6a, 6b, arrays 4a, 4b of optical elements 5a, 5b, and arrays 2a, 2b of LED light sources 3a, 3b may be arranged on heat dissipation elements 10a, 10b before heat dissipation elements 10a, 10b are arranged in slots 9a, 9b of holding device 8. Furthermore, an assembly including flexible substrates 6a, 6b, arrays 4a, 4b of optical elements 5a, 5b, and arrays 2a, 2b of LED light sources 3a, 3b may be formed first, and then this assembly may be arranged on the heat dissipation element before or after heat dissipation elements 10a, 10b are arranged in slots 9a, 9b of holding device 8. Alternatively, the assembly comprising the flexible substrate 6a, 6b, the array 4a, 4b of optical elements 5a, 5b and the array 2a, 2b of LED light sources 3a, 3b can be formed on the heat dissipating element before or after the heat dissipating element 10a, 10b is arranged in the slit 9a, 9b of the holding device 8.

[0083] For example, the heat dissipating elements 10a, 10b may be made from sheet metal, eg cut by laser cutting, and attached to the flexible substrates 6a, 6b.The holding device 8 may for example be 3D printed and configured to hold all components together.

[0084] Figure 3 FIG1 shows an exploded view of a light emitting device 100 according to another embodiment of the present invention. Figure 1 and Figure 2 The described light emitting devices differ in the following features.

[0085] The light emitting device 100 comprises a first foil 14 and a second foil 16 instead of the solid holding device 8. For simplicity, the second foil 16 is Figure 3 Not shown, see for example Figure 4 In the embodiment shown, the first foil 14 includes three parts 14a, 14b, and 14c. Parts 14a and 14b are adapted to receive respective substrates 6a and 6b. Part 14c is a connecting portion for connecting parts 14a and 14b. In addition, the arrays 4a and 4b of optical elements 5a and 5b include a connecting portion 11, so that the arrays 4a and 4b of optical elements 5a and 5b are integral.

[0086] In the assembled state of the light emitting device 100 (see Figure 4 F), the first foil is arranged below the flexible substrate 6a, 6b, while the second foil 16 is arranged on top of the array 4a, 4b of optical elements 5a, 5b.

[0087] In this way, the light emitting device 100 is adapted for assembly, and bending of the shape of the flexible substrates 6a, 6b in a predetermined direction and / or orientation of the LED light sources 3a, 3b of the LED light source arrays 2a, 2b in a predetermined direction are fixed by foil fixing.

[0088] Figure 4 A- Figure 4 F illustrates the manufacturing of a light emitting device (such as Figure 3 The steps of the method of the light emitting device 100).

[0089] In the first step, a hollow fixture 12 or template is prepared. Figure 4 In A, a schematic cross section of an example of such a fixture 12 is shown. In the undercut region, holes 13 are made in the fixture 12 in order to enable the first foil 14 layer to be sucked into the edge. In the next step, as Figure 4 As shown in FIG. 2B , a first foil 14 layer is vacuum formed onto the fixture 12 by applying vacuum from below (arrow 29). The first foil 14 may consist of layers of material, where for example the top layer is a glue (sticky) and / or colored layer. In the next step, as shown in FIG. Figure 4 As shown in C, holes 15 are made in the edge of the first foil 14 so that they correspond to the holes 13 in the fixture 12. In the next step, as shown in FIG. Figure 4As shown in FIG. 3 , a light emitting device in the form of a flexible substrate 6a, 6b, an array of LED light sources 3a, 3b 2a, 2b and an array of optical elements 5a, 5b 4a, 4b is placed on the first foil 14 and the fixture 12. The light emitting device may be secured in place with temporary glue or other fixing means to hold the assembly together for the remainder of the process. Figure 4 In the next step shown in E, vacuum is applied from below (arrow 29). Figure 4 A second foil 16 is vacuum formed over the obtained assembly shown in D. This will seal all the components attached in the above steps, such as Figure 4 D. Finally, as Figure 4 As shown at G, the fixture 12 is removed to leave the sealing structure 30 and thereby the final assembled light emitting device 100. The fixture 12 can be used in a continuous production cycle.

[0090] Note that the first foil 14 may be reflective, such as white, and the second foil 16 may be transparent.

[0091] like Figure 4 As shown in FIG. 5 , the final sealing structure 30 may further be provided with at least one (here two) first track 25 and a second track 26. The first track is configured to receive the flexible substrates 6a and 6b on which the LED light sources 3a and 3b arrays 2a and 2b are arranged. The second track is configured as follows: Figure 14 The manner of receiving the driver is further described.

[0092] Figure 5 A- Figure 5 B shows the Figure 4 A- Figure 4 Additional steps of the method of F. Figure 5 A- Figure 5 B illustrates that additional elements, namely air channels 18, may be added to enhance the cooling performance of the array(s) of LED light sources 3a, 3b. Figure 5 As shown in Figure A, air channels are first obtained by forming the jig 12 with additional slots 17. The slots 17 are provided with holes at the bottom corners of the slots 17. Thus, when the first foil 14 is vacuum formed onto the jig 12, the first foil 14 will be sucked into the slots 17 in the jig 12, thereby forming air channels 18. Now, when placed on the first foil 14, the array of LED light sources 3a, 3b, or more specifically the substrates 6a, 6b, close these channels 18 and prevent the second foil 16 from being sucked into the channels 18. When subsequently Figure 5When the clamp 12 is removed as shown in B, a channel 18 is left, which is formed by the first foil 14 and is covered with the array of LED light sources 3a, 3b or more specifically with the substrates 6a, 6b. The channel 18 can be open at both ends to allow free flow of air under the array of LED light sources 3a, 3b, which will enhance the cooling effect.

[0093] Now go to Figure 6-Figure 8 , two different solid holding devices 81 and 82 will be described, each having a structure similar to that described above. Figure 1 and Figure 2 The holding devices 8 described are designed differently.

[0094] Figure 6 A perspective view of a solid holding device 81 for a light emitting device according to the present invention is shown. In this embodiment, the solid holding device 81 is configured so that one or more light emitting devices in the form of flexible substrates 6a, 6b, arrays 2a, 2b of LED light sources 3a, 3b, and arrays 4a, 4b of optical elements 5a, 5b can be slid into place in the holding device 81, thereby forming the above-mentioned solid holding device 81. Figure 1 A light emitting device 1 of the type described is provided. To this end, the holding device 81 comprises one or more channels, in the embodiment shown two channels 811 and 812, formed in a solid body 810. The channels 811 and 812 are configured to receive substrates 6a, 6b on which arrays 2a, 2b of LED light sources 3a, 3b and arrays 4a, 4b of optical elements 5a, 5b are arranged. Thus, the channels 811, 812 correspond to the channels described above in conjunction with Figure 4 F. In this embodiment, the solid body 810 is a molded, 3D-printed, or cut component. Each channel 811, 812 includes an upwardly extending opening 813, 814 to enable emission of light from the light-emitting device. Each channel 811, 812 also includes a bottom surface or support structure 815, 816 that is configured to abut the substrate 6a, 6b of the light-emitting device in the assembled state. Thus, the flexible substrate 6a, 6b can be placed on the support structure 815, 816 in a manner that allows the flexible substrate 6a, 6b to make full surface contact with the support structure 815, 816.

[0095] Figure 7 and Figure 8 Perspective views of another solid holding device 82 of a lighting device according to the present invention are shown without and with an array 2 of LED light sources 3 and an array 4 of optical elements 5 mounted, respectively.

[0096] In this embodiment, the solid holding device 82 is configured to enable a light emitting device in the form of a flexible substrate 6a, 6b, an array 2a, 2b of LED light sources 3a, 3b and an array 4a, 4b of optical elements 5a, 5b to be able to Figure 8The position shown slides into place in the holding device 82 to form the above-mentioned Figure 1 A light emitting device 1 of the type described. To this end, the holding device 82 comprises one or more channels, in the embodiment shown two channels 821 and 822, formed in a solid body 820. In this embodiment, the solid body 820 can be made of a formed, machined, molded or bent material or sheet. Each channel 821, 822 comprises an opening 823, 824 extending upwardly to enable emission of light emitting device light. Each channel 821, 822 also comprises a surface or support structure 825, 826, which is configured to abut a portion of the substrate 6a, 6b of the light emitting device in the assembled state. Thus, the flexible substrate 6a, 6b can be placed on the support structure 825, 826 in such a way that the flexible substrate 6a, 6b is in partial surface contact with the support structure 825, 826, as shown. Figure 8 shown.

[0097] The channels 821, 822 are configured to receive substrates 6a, 6b on which are arranged arrays 2 of LED light sources 3a, 3b and arrays 4 of optical elements 5a, 5b. Figure 4 F. The solids retaining device 82 may also include a second track 26 configured as follows: Figure 14 The manner of receiving the driver is further described.

[0098] The solid holding device 82 further comprises an air channel 819 formed below the respective support structures 825, 826. In the assembled state, the air channel 819 will thus be arranged below the flexible substrates 6a, 6b and thus the array of LED light sources 3a, 3b, arranged in the channels 821, 822 of the holding device 82. Thus, the air channel 819 forms an element configured to enhance the cooling of the LED light sources 3a, 3b of the lighting device.

[0099] Typically, the holding devices 8, 81, 81 and the support structures 815, 816, 825, 826 may be provided by any of machining, moulding, 3D printing, forming, bending, or attaching the pen device to different parts of the base. Figure 1 In the embodiment shown, the support structure may be formed by an upper surface of the holding device 8 or by a surface of the heat sink elements 10a, 10b, to which surface the base plates 6a, 6b are attached.

[0100] In about Figure 3-Figure 5 In the case of the sealing construction described in B, the support structure may be formed by a portion of the first foil 14. In this case, the support structure is formed by the sealing construction (see Figure 4 A- Figure 4 F), or formed by combining a sealed construction with an additional heat sink element (see Figure 5 A- Figure 5 B).

[0101] Now go to Figures 9-11 , respectively showing a cross-sectional side view, a top view and a perspective view of another light emitting device 101 according to the present invention.

[0102] Figures 9-11 The light emitting device 101 is the same as the above Figure 1-Figure 5 The main difference between the light emitting devices of FIG. 2 and FIG. 3 is that the optical element array 5 is an array of micro-collimators 51-53. Thus, each LED light source 31-33 is associated with a micro-collimator 51-53. The micro-collimators 51-53 can be single collimators, with each LED package 31-33 having one collimator, or they can be combined collimators, in which case a larger rigid area is formed on the array 2 of LED light sources 31-33. In other words, each micro-collimator 51-53 of the micro-collimator array can include a single micro-collimator or a combination of two or more micro-collimators.

[0103] The use of micro-collimators 51-53 provides an additional effect in that further additional levels of beam shaping from individual LED packages or groups of LED light sources can be achieved. More specifically, as Figure 10 and Figure 11 As shown, multiple optical axes can be achieved without bending the array of LED light sources 31-33 2. Multiple optical axes can be obtained by configuring a micro-collimator with individual optical axes or emission angles α, β and γ.

[0104] Now go to Figure 12 and Figure 13 , shows a cross-sectional side view of two different luminaires 20 and 200 comprising a light emitting device according to the present invention. In this respect, the light emitting device may be any light emitting device 1, 100, 101 according to the present invention.

[0105] Generally, the luminaire 20, 200 may include a lighting device having one single LED light source array 2, or the luminaire 20, 200 may include a lighting device having multiple LED light source arrays 2a, 2b having different configurations.

[0106] Figure 12 An embodiment is shown in which a luminaire 20 comprises a mounting 21 on which three light emitting devices 1 are arranged, each emitting a light beam 19 .

[0107] Figure 13 An embodiment is shown, in which a luminaire 200 comprises a mounting base 21 on which five light emitting devices 1 are arranged, each emitting a light beam 19 .

[0108] at last, Figure 14 A cross-sectional side view of a further luminaire 201 comprising a light emitting device according to the invention is shown.

[0109] Here, the luminaire 201 comprises a light emitting device 100 and a track drive 22, which is arranged in a track 26 located at the center of the light emitting device 100 and thus at the center of the luminaire 201. The light emitting device 100 comprises an array 2a, 2b of LED light sources 3a, 3b arranged in a convex shape on both sides. The luminaire 201 can illuminate a specific area along the axis T of the track 26. This minimizes the build height below the track 26 by using the space inside the track 26. The light emitting device 100 of the luminaire 201 can comprise a double bubble (vacuum form) construction, in which the second foil 16 is transparent and the first foil 14 is reflective, for example white.

[0110] The light emitting devices 1, 100, 101 according to the present invention can be used in any suitable type of luminaire, including all lighting applications requiring a specific light distribution. Applications include, for example, creating low profile / low height ceiling luminaires and downlights, as well as linear luminaires, tripods and outdoor luminaires.

[0111] Those skilled in the art realize that the present invention is by no means limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims.

[0112] Moreover, variations to the disclosed embodiments may be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the present disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The 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 light emitting device (1; 100; 101) adapted to emit light emitting device light in operation, the light emitting device comprising: an array (2a, 2b) of LED light sources (3a, 3b), wherein each LED light source of the array of LED light sources is adapted to emit LED light in operation, and wherein each LED light source of the array of LED light sources comprises an LED package, and An array (4a, 4b) of optical elements (5a, 5b), wherein the array of optical elements is arranged so that each LED light source of the array of LED light sources is associated with an optical element of the array of optical elements, wherein Each optical element (5a, 5b) of the optical element array is configured to convert the LED light of the associated LED light source (3a, 3b) into a light beam such that the combined LED light of the LED light sources of the LED light source array forming the light of the light emitting device forms a pixelated array, and wherein The light emitting device further comprises a flexible substrate (6a, 6b), the LED light source array is arranged on the flexible substrate, and the optical element array is arranged on the LED light source array.

2. The lighting device according to claim 1 , wherein the LED light sources (3a, 3b) of the LED light source array (2a, 2b) are mechanically redirected to provide the lighting device light having a predetermined light pattern by one or both of the following: The flexible substrate (6a, 6b) is bent in a predetermined direction, and One or more subsets of the LED light sources (3a, 3b) of the LED light source array (2a, 2b) are oriented in a predetermined direction.

3. The light emitting device according to claim 2, wherein one or more of the shape of the flexible substrate (6a, 6b) bent in a predetermined direction and the orientation of the LED light sources (3a, 3b) of the LED light source array (2a, 2b) in the predetermined direction is fixed by any one of the following items: providing foil fixation of the sealing structure (30), and A solid holding device (8) is configured to hold the substrate, the LED light source array and the optical element array.

4. The light emitting device according to claim 3, wherein the sealing structure (30) or the solid holding device (8) further comprises one or more of the following: at least one first track (25) configured to receive the flexible substrate on which the LED light source array is arranged, and The second track (26) is configured to receive a driver.

5. The light-emitting device according to claim 3 or 4, wherein the sealing structure or the solid retaining device further comprises at least one first track and a second track, wherein the at least one first track is configured to receive the flexible substrate on which the LED light source array is arranged, and the second track is configured to receive a driver, and wherein the first track and the second track are arranged on opposite sides of the sealing structure or the solid retaining device.

6. The light emitting device according to any one of claims 3 to 5, wherein the sealing structure (30) or the solid retention device (8) further comprises one or more of the following: one or more air passages (18; 819), and One or more heat dissipation elements (9a, 9b) are configured to provide cooling air to the LED light sources of the LED light source array.

7. A light-emitting device according to any one of preceding claims 3 to 6, wherein the sealing structure (30) or the solid retaining device (8) further comprises a supporting structure (14a, 14b; 815, 816), and wherein the flexible substrate is placed on the supporting structure in such a manner that the flexible substrate is in full surface contact with the supporting structure.

8. A light emitting device according to any one of claims 3 to 7, wherein the foil fixation providing the sealing structure (30) is provided by any one of the following: seal, Foil seal, Vacuum forming, and Molding, or wherein the solids retaining device (8) is provided by any one of: Machining, Molding, 3D printing, and A pen device is connected to a different portion of the base plate.

9. Light emitting device according to any one of claims 3 to 8, wherein the sealing structure (30) comprises a reflective first foil (14) and a transparent second foil (16), and wherein: The first foil and the second foil each comprise a thickness of less than 0.5 mm, and / or The first foil (14) is provided with holes (13) arranged in a predetermined pattern, the holes being provided before or during sealing of the foil providing the sealing structure (30).

10. Light emitting device according to any of the preceding claims, wherein the array (4a, 4b) of optical elements (5a, 5b) is an array of lenses.

11. The lighting device according to claim 10, wherein each lens of the lens array (4a, 4b) comprises a beam angle in the range of 30 degrees to 60 degrees FWHM.

12. Light emitting device according to any one of claims 1 to 9, wherein the array (4a, 4b) of optical elements (5a, 5b) is an array of micro-collimators (51, 52, 53).

13. The light emitting device according to claim 12, wherein each micro-collimator (51, 52, 53) of the micro-collimator array comprises a single micro-collimator or a combination of two or more micro-collimators.

14. A luminaire (20) comprising at least one light emitting device (1; 100; 101) according to any one of the preceding claims, wherein the LED light sources (3a, 3b) of the LED light source array (2a, 2b) of the at least one light emitting device (1; 100; 101) are mechanically redirected so as to provide the light emitting device light having a predetermined light pattern by one or both of the following: The flexible substrate (6a, 6b) is bent in a predetermined direction, and One or more subsets of the LED light sources (3a, 3b) of the LED light source array (2a, 2b) are oriented in a predetermined direction.

15. A luminaire (20) comprising at least two light emitting devices (1; 100; 101) according to any one of the preceding claims 1 to 13, wherein the LED light sources (3a, 3b) of the LED light source array (2a, 2b) of at least one of the at least two light emitting devices are mechanically redirected to provide the light emitting device light having a predetermined light pattern and a track drive (22) arranged centrally between the at least two light emitting devices by one or both of the following: The flexible substrate (6a, 6b) is bent in a predetermined direction, and One or more subsets of the LED light sources (3a, 3b) of the LED light source array (2a, 2b) are oriented in a predetermined direction.

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