Lamp assembly and clamping element for lamp assembly

Abstract

A clamping element for clamping a luminaire assembly includes an inner section, a peripheral section, and an annular flexure section bridging the inner section and the peripheral section. The annular flexure structure permits elastic displacement of the inner section such that the flexure section, when extended, generates a clamping force between the inner section and the peripheral section. Thus, the clamping element may be manufactured as a flat element and, in use, extended to a desired height, creating a biasing spring force. Thus, one single clamping element can be used in different stacks with different clamping heights.

Description

Technical Field

[0001] The present invention relates to a clamping element for a lamp assembly, in particular for a reflector assembly such as a downlight. Background Art

[0002] Many luminaires, such as downlights, consist of a stack of components, such as heat sinks, diffusers, reflectors, and front edges. The stack is held together by rigid clamping elements. The clamping height of the stack can be different for different types of luminaires, such as different downlights. For example, a particular downlight can be manufactured in several different variants with different reflector heights. Each clamping height requires a different clamping element. Furthermore, even for the same variant, manufacturing tolerances of the components in the stack can result in slightly different stack heights. Consequently, the clamping element may not fit the stack perfectly. Summary of the Invention

[0003] It is an object of the present invention to overcome or alleviate the challenges discussed. The invention is set out in the accompanying claims. In particular, it is an object to provide a lamp assembly and a clamping element capable of clamping lamp assemblies having different clamping heights.

[0004] This object and other objects are achieved by a lamp assembly, which includes a group of components arranged in a stack along a central axis; a clamping element for clamping the stack of components in the lamp assembly, the clamping element including an inner section, a peripheral section coplanar with the inner section and surrounding the inner section, and an annular flexure structure bridging the inner section and the peripheral section, the annular flexure structure allowing elastic displacement of the inner section relative to the peripheral section in a direction extending perpendicular to the plane of the peripheral section, so that when the inner section is separated from the peripheral section in this direction, the flexure section generates a clamping force between the inner section and the peripheral section.

[0005] Thus, the clamping element can be manufactured as a flat element with the annular flexure segment in an unexpanded state. During use, the flexure segment extends to the desired height, thereby generating a biasing spring force (clamping force). Thus, a single clamping element can be used for a range of different stacks with different clamping heights. This reduces the number of components required for a given luminaire product portfolio, thereby reducing tooling and storage capacity. Furthermore, embodiments of the present invention can absorb variations in stack height due to manufacturing tolerances.

[0006] The unexpanded (flat) clamping element can be placed on the upper surface of the stack of luminaire assemblies and the peripheral segment is then pushed down onto the stack while simultaneously extending / expanding the annular flexure segment to the expanded state. The peripheral segment is then attached to the outer element of the stack, thereby ensuring a clamping force across the assembly.

[0007] The annular segment may be circular, which is convenient for many luminaire assembly geometries. However, the annular segment may alternatively have any other shape, such as elongated, oval or rectangular.

[0008] The flexure segment can include a set of helically arranged flexible elements such that the flexure segment in its expanded state resembles a helix. Alternatively, the flexure segment can include a set of zigzag elements, i.e., zigzag flexure elements, each of which includes two oppositely oriented legs arranged adjacent to each other around the circumference of the annular flexure segment. As the flexure segment expands, each zigzag segment will expand into an extended zigzag shape such that if both legs are extended, the rotational effects of the legs will cancel each other out.

[0009] The inner section has an outer perimeter that matches the inner boundary of the annular section, but can also have any other shape. For example, it can completely fill the area within the annular flexure section. Alternatively, it can have one or more openings, for example to match the design of the light fixture assembly.

[0010] In one embodiment, the inner section is annular with a central opening. The ring typically has a shape that matches the shape of the annular flexure section. Thus, for example, in the case of a circular annular flexure section, it is a circular ring.

[0011] The peripheral segment may also be annular and have an inner perimeter that matches the outer boundary of the annular segment.

[0012] The clamping element can advantageously be formed as a flat element fabricated as a single, integral part. For example, the flat element can be formed from a sheet material, such as sheet metal or plastic, using any suitable technique, including punching, stamping, laser cutting, or water jet cutting. Alternatively, the flat element can be formed by etching, injection molding, vacuum casting, or the like.

[0013] In some embodiments, the clamping element is made of more than one separate component and / or more than one material. For example, the inner and outer segments can be made of one material, while the flexure segment is made of a second material. The different segments are then attached to each other using adhesives, welding, heat staking, overmolding, or other suitable techniques.

[0014] If the inner and outer segments need to be structurally strong while also requiring a relatively soft flex structure, using different parts / materials may be advantageous. For example, a plastic flex structure could be attached between two metal rings. Different materials can also be beneficial in preventing (or promoting) heat dissipation. For example, with a plastic flex segment between two metal segments, the inner segment can help dissipate heat without transferring heat to the outer segment.

[0015] As yet another alternative, the flat element may be 3D printed using one or more 3D printing materials.

[0016] In some embodiments, the annular flexure section includes a first annular flexure section and a second annular flexure section, and an intermediate section between the first and second annular flexure sections. The first annular flexure section is oriented oppositely to the second annular flexure section, so that if both the first and second annular flexure sections are expanded, the respective rotational effects of the first and second annular flexure sections will cancel each other out. The clamping element can then be expanded in two stages. This means that one clamping element can be used for different applications (multi-purpose clamping element). This also means that a single clamping element can apply clamping force at two stages (multi-stage clamping element). BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The invention will now be described in more detail with reference to the accompanying schematic drawings, which show currently preferred embodiments of the invention.

[0018] Figure 1 An exploded view of a lamp assembly with a clamping element according to the prior art is shown.

[0019] Figure 2 Shown Figure 1 A perspective view of the light fixture assembly.

[0020] Figure 3 A top view of a clamping element according to an embodiment of the present invention is shown.

[0021] Figure 4 An exploded view of a light fixture assembly with a clamping element according to an embodiment of the present invention is shown.

[0022] Figure 5 Shown Figure 4 A perspective view of the light fixture assembly.

[0023] Figure 6a A top view of a clamping element according to another embodiment of the present invention is shown.

[0024] Figure 6b Shown with Figure 6a Perspective view of the lamp assembly with the clamping elements in place.

[0025] Figure 7a A top view of a clamping element according to another embodiment of the present invention is shown.

[0026] Figure 7b Shown with Figure 7a Perspective view of the lamp assembly with the clamping elements in place.

[0027] Figures 8a to 8c Various shapes of clamping elements according to embodiments of the present invention are shown. DETAILED DESCRIPTION

[0028] Figures 1 to 2 The luminaire assembly 1 shown in FIG comprises a stack 2 of components held together by a heat sink serving as a rigid clamping element 3. The stack 2 here comprises a front edge 4, a reflector 5, a diffuser holder 6, a diffuser 7 and a light mixing box 8. The clamping element 3 is arranged on top of the stack so that the side 3 a of the clamping element rests on the front edge 4. A welding ring 9 is arranged above the clamping element 3 and welded to the front edge 4, thereby fixing the assembly 1 (see FIG. Figure 2 ).from Figures 1 to 2 It can be clearly seen that the rigid clamping element 3 must be precisely adapted to the specific height of the stack 2. If the side 3a of the clamping element is too short, the clamping element will not reach the front edge and cannot be welded to the front edge. If the side 3a of the clamping element is too long, the various components 3-8 of the stack 2 will not be fixed (clamped) by the clamping element 3.

[0029] Go to Figure 3 According to an embodiment of the present invention, a clamping element 10 comprises an inner section 11, a peripheral section 12 coplanar with the inner section 11 and surrounding the inner section 11, and an annular flexure section 13 bridging the inner section 11 and the peripheral section 12. The clamping element 10 here has a circular shape, so that the inner section 11, the outer section 13 and the annular flexure section 13 are all circular rings. Many other shapes are possible. However, it is preferred that the width D of the annular flexure section is relatively constant around the entire circumference of the clamping element 10, that is, the profile of the outer periphery 11a of the inner section 11 substantially matches the profile of the inner periphery 12a of the outer section 12. The annular flexure section 13 includes a plurality of flexures 14, which, in the illustrated example, are formed as spiral windings.

[0030] To achieve the desired properties, the clamping element provides several useful design parameters. The width D of the flexure section 13 will determine the maximum clamping height for a given flexure design. The larger width t of each flexure 14 (see Figure 5 ) will increase the clamping force and reduce the clamping range in a given width D. In addition, the thickness h of each flexure 14 (see Figure 5 ) will determine the clamping force (at a given clamping height).

[0031] exist Figure 3In the embodiment shown, the clamping element 10 is in a flat, non-expanded state, which is typically how clamping elements are manufactured. The material of the clamping element is selected so that the clamping element, and in particular the annular flexure section 13, is flexible, allowing elastic displacement of the inner section 11 relative to the outer section 12 in a direction extending perpendicular to the plane of the element 10. In this expanded (extended) state, the flexure section 13 generates an attractive (clamping) force between the inner section 11 and the outer section 12 when the inner section separates from the outer section.

[0032] The clamping element 10 can be stamped or pressed or cut (e.g., by laser or water jet) from a sheet of material (e.g., plastic or metal). As mentioned above, many other manufacturing methods can also be used, including assembling several independent parts or using several different materials. Alternatively, the clamping element can be 3D printed using plastic or metal printing materials. There are also 3D printing technologies that allow the use of several materials, so that some parts of the clamping element are printed in metal and other parts are printed in plastic.

[0033] Go to Figures 4 and 5 , shows a luminaire assembly 20 in which the clamping elements 10 are arranged into a stack 21 of clamping members. The members may be Figures 1 to 2 . In the example shown, a heat sink 22 in the form of a disk is arranged on top of the stack 21, the diameter of which is slightly larger than the opening in the inner section 11. The clamping element 10 in its flat, unexpanded state is then placed on top of the heat sink 22, and the peripheral section 12 is pushed down towards the front edge 23 and attached thereto. Figure 5 In this expanded state shown in FIG, the flexure sections 13 will provide a clamping force to secure the stack 21 .

[0034] It should be noted that the inner section 11 of the clamping element 10 may alternatively be filled so that the heat sink 22 is no longer required. However, it may be more cost effective to manufacture separate end plates, such as Figures 4 and 5 For example, while 3D printing a complex structure like the flexure section 13 may be beneficial, there may be a more cost-effective way to manufacture a simple structure like the heat sink 22.

[0035] like Figure 5 As shown in the enlarged view of FIG, the front edge 23 is provided with a snap-fit ​​structure 24 in which the peripheral section 12 can be snap-fitted. This snap-fit ​​can provide a temporary fixation of the clamping element before the clamping element is permanently fixed using, for example, welding.

[0036] exist Figures 6a to 6bIn the embodiment of FIG, the clamping element 100 again has an inner section 111, a peripheral section 112 and an intermediate flexure section 113 with a plurality of flexure elements 114. In this case, the flexure elements 114 are meander-shaped. Figure 6b In its expanded state as illustrated in FIG, each flexure element 114 will have a zigzag shape. Figures 6a to 6b The clamping device 100 in the reference Figures 4 and 5 Applied and fixed in a similar manner as discussed.

[0037] It should be noted that when the clamping element expands, Figure 3 The clamping element 10 (helical flexure 14) in will exhibit a slight rotation between the inner and outer segments. Figure 6a The clamping element 100 in FIG. 1 will not exhibit any such rotation because the meandering flexure element 114 has two oppositely oriented legs.

[0038] Figures 7a and 7b Another way to avoid rotation is shown in . Figure 7a The clamping element 200 in FIG. 1 also has an inner section 211, a peripheral section 212, and a first helical flexure section 213 with a flexure element 214. However, in this case, the clamping element 200 also has an intermediate section 215 and a second helical flexure section 216 with a flexure element 217. The two helical flexure sections 213 and 216 are oriented in opposite directions so that if they are both expanded, their rotational effects will cancel out. It should be noted that sections 213, 215, and 216 together form an intermediate flexure section that bridges the inner section 211 and the peripheral section 212.

[0039] Figure 7b Shown in expanded state Figure 7a As in Figure 5 In FIG, the outer section 212 is attached to the front edge 23, while the inner section presses on the heat sink 22. Between these sections are two spiral flexure sections 213, 216 (both in an expanded state) and an intermediate section 215.

[0040] It should be noted that Figure 7a The clamping element in the embodiment of FIG. 2 may have additional advantages. For example, it allows only one of the flexure sections 213, 216 to be expanded. This means that a single clamping element can be used for different applications (e.g., different clamping heights). Furthermore, the intermediate section 215 can be used to apply a second clamping force, i.e., a single clamping element can provide multiple levels of clamping.

[0041] It should be noted that although Figure 3The clamping elements 10, 100, 200 in Figure 7 are all circular, but this is not an essential requirement. On the contrary, many other geometric shapes are possible, and Figures 8a to 8c Some of them are shown. Figure 8a In FIG, the clamping element 81 is rectangular and is configured to mate with an elongated rectangular stack of luminaires. Figure 8b In FIG, the clamping element 82 is oval and configured to mate with an oval stack of luminaires. Figure 8c In the example shown, the clamping element 83 is octagonal and is configured to cooperate with the octagonal stack of the lamp. In all examples, the annular flexure section has substantially the same width around the entire periphery to ensure equal or nearly equal clamping force around the entire periphery.

[0042] Those skilled in the art will recognize that the present invention is by no means limited to the preferred embodiments described above. On the contrary, numerous modifications and variations are possible within the scope of the appended claims. For example, the clamping element according to the present invention can, in principle, be formed by forming a flexure section in an existing (rigid) clamping element.

Claims

1. A lamp assembly comprising: a set of components arranged in a stack (21) along a central axis, and Clamping element (10; 100； 200), the clamping element is used to clamp the stack of components in the lamp assembly, the clamping element comprising: inner section (11; 111; 211); a peripheral section (12; 112; 212) coplanar with and surrounding the inner section; and an annular flexure section (13; 113; 213, 215, 216) bridging the inner section and the peripheral section, the annular flexure structure allowing elastic displacement of the inner section relative to the peripheral section in a direction extending perpendicular to a plane of the peripheral section, so that when the inner section is separated from the peripheral section in said direction, the flexure section generates a clamping force between the inner section and the peripheral section, wherein the inner segment (11; 111, 211) abuts an outer member (22) in the rear end of the stack and the outer segment is attached to an outer member (23) in the front end of the stack such that the members are clamped between the inner ring segment and the outer ring segment and clamped by the clamping force.

2. The light fixture assembly of claim 1, wherein the annular flexure section (13; 113; 213, 215, 216) is circular.

3. A lamp assembly according to claim 1 or 2, wherein the annular flexure section (13; 213, 215, 216) comprises a set of helically arranged flexible elements.

4. The lamp assembly according to claim 1 or 2, wherein the annular flexure section (113) comprises a set of zigzag flexure elements, each flexure element comprising two legs having opposite orientations.

5. A lamp assembly according to any one of the preceding claims, wherein: The inner section (11; 111, 211) is annular.

6. A lamp assembly according to any one of the preceding claims, wherein: The peripheral section (12; 112; 212) is annular.

7. A lighting assembly according to any one of the preceding claims, wherein: An outer edge of the peripheral segment is provided with a snap-fit ​​structure configured to snap-fit ​​to an outer member of a stack of members.

8. A lighting assembly according to any one of the preceding claims, wherein: The inner section, the peripheral section and the annular flexure section are all formed as separate components that have been assembled to form the clamping element.

9. A lamp assembly according to any one of the preceding claims, formed as a flat element made from one integral part.

10. The lamp assembly according to claim 9, wherein: The flat element has been formed from a sheet material such as sheet metal or plastic.

11. The lamp assembly according to claim 9, wherein The flat element has been 3D printed.

12. A lamp assembly according to any one of the preceding claims, wherein the annular flexure section includes a first annular flexure section (213) and a second annular flexure section (216) oriented opposite to the first annular flexure section, and an intermediate section (215) between the first and second annular flexure sections (213, 216).

13. A lamp assembly according to any one of the preceding claims, wherein the set of components comprises a heat sink (22), a reflector (24) and a front rim (23), and wherein the peripheral section (12; 112; 212) is attached to the front rim (23).

14. The light fixture assembly of claim 13, wherein the front rim includes a snap-fit ​​structure, and the peripheral segment snap-fits into the front rim.

15. A clamping element suitable for use in a lamp assembly according to claim 4 or 12.

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