Explosion-proof LED module

Abstract

Explosion-proof LED module (1) with a plurality of light-emitting diodes (2) (LEDs), a heat sink (3) connected thereto and an LED cover (5) covering the LED at least in the radiation direction (4), wherein the LED cover (5) extends into a plug-in recess (6) of the heat sink (3) and is surrounded in this plug-in recess (6) by a potting compound (7) sealing the LED relative to an external and possibly explosive atmosphere, wherein the plurality of LEDs (2) are arranged on an LED board (8), in particular in the board longitudinal direction (9) next to one another and spaced from one another, and a one-part or multi-part LED cover (5) is formed for all LEDs of the LED board (8), characterized in that the LED cover (5) has LED domes (23) which are convexly curved away from the LEDs, wherein each LED dome (23) is assigned to an LED and the LED dome is designed as a lens system for the LED or comprises such a lens system.

Description

[0001] For explosion-proof areas, various luminaires are available that are designed according to corresponding types of protection. Light-emitting diodes (LEDs), for example, are known to operate in Ex-i protection. This means that the LED is supplied via a safety barrier that limits the current / voltage to such an extent that neither the ignition energy nor the ignition temperature required for an explosive mixture are reached. This usually also limits the maximum surface temperature of the corresponding component.

[0002] Furthermore, LEDs are known that are designed according to the Ex-m "encapsulation" type of protection. This means that at least parts of the LED that could be ignition sources for a corresponding explosive mixture are embedded in a potting compound. This prevents a corresponding arc from passing through to the explosive mixture outside the encapsulation.

[0003] Document GB 2 428 467 A discloses an explosion-proof lighting assembly comprising a cooling element, LEDs in thermal contact with the cooling element, a transparent cover, and a lens for deflecting and concentrating the light at an angle using two internal reflective surfaces. The power LEDs comprise a substrate for generating light and are arranged in a mounting plane such that the diode substrates are substantially parallel to an inner surface of the cooling element and the longitudinal axes of the diodes are transverse to the substrates and have substantially the same orientation.

[0004] Document DE 10 2009 016 629 A1 relates to a detachable lamp tube for light-emitting diodes, consisting of a tube, a light module, a drive module, and a power connection module. The light module and the drive module are arranged in the tube. The light module comprises a first circuit board and a plurality of light-emitting diodes. The drive module comprises at least a second circuit board and a drive circuit. The power connection module connects the first and second circuit boards to each other. The drive module and the light module are detachable and can be replaced if damaged.

[0005] The document DE 10 2005 020 908 A1 relates to a lighting device comprising an optoelectronic component having a housing body and at least one semiconductor chip provided for generating radiation, and a separate optical element which is provided for attachment to the optoelectronic component and has an optical axis, wherein the optical element has a radiation exit surface and the radiation exit surface has a concavely curved partial region and a convexly curved partial region which at least partially surrounds the concavely curved partial region at a distance from the optical axis, wherein the optical axis runs through the concavely curved partial region.

[0006] Document US 2005 / 0 265 019 A1 relates to a lighting assembly for illuminating a display case with an LED that illuminates objects placed in the display case. The lighting assembly can be attached to a door, door frame, or other structure of the display case.

[0007] Document EP 2 309 168 A1 relates to an incandescent-type light source using a light-emitting element such as an LED.

[0008] The document DE 20 2008 010 175 U1 relates to an electrical signal light for use in potentially explosive atmospheres with at least one electrical light source arranged on a circuit board made of a heat-conducting material.

[0009] Document GB 2458 345 A discloses a sealed lighting unit with an array of LEDs. The LEDs are mounted on a printed circuit board. Each LED is covered by a lens that is attached to the circuit board and surrounds the LED. The surface of the circuit board between the lens elements can be coated with a potting compound. The sealed lighting unit is particularly suitable for use in areas with potentially explosive atmospheres.

[0010] Document WO 2006 / 021620 A1 relates to a luminaire for potentially explosive atmospheres in Zone 0. The luminaire comprises a lighting device and a cable for supplying electrical energy for illuminating the lighting device. The luminaire further comprises a lighting unit with a housing to which the lighting device is attached and a protective cover mounted over the lighting device to protect the lighting device. The free space of the housing is filled with a filling material to make the lighting unit substantially gas-tight.

[0011] The present invention is based on the object of providing an explosion-proof LED module that can be manufactured relatively easily and cost-effectively from prefabricated parts in a short time. At the same time, the explosion-proof LED module is further characterized by the fact that it provides sufficient cooling in accordance with the "intrinsic safety" type of protection and that the component is encapsulated in accordance with the "encapsulation" type of protection.

[0012] This problem is solved by the subject matter of the independent patent claim.

[0013] The solution according to the invention is characterized in that the explosion-proof LED module has a plurality of light-emitting diodes (LEDs), a heat sink connected to the latter, and an LED cover covering the LED at least in the direction of radiation, wherein this LED cover extends into a plug-in recess of the heat sink and is surrounded in this plug-in recess by a potting compound, sealing the LED relative to an external and possibly explosive atmosphere.

[0014] Such an explosion-proof LED module is easy to manufacture and has various advantages that are otherwise only known for the implementation of various types of ignition protection, see the above explanations.

[0015] Directly sealed LEDs are not required, and at the same time, the use of encapsulant, a heat sink with a recessed mounting, and LED sealing ensures that the space surrounding the LED is relatively small. Adequate cooling of the LED is ensured, and the passage of an arc to the outside into a potentially explosive mixture is reliably prevented.

[0016] A corresponding explosion-proof LED module can be designed with just one light-emitting diode, if necessary on an LED board and the corresponding components. To combine multiple LEDs in a modular fashion, a corresponding LED board is used on which a plurality of LEDs are arranged next to one another and spaced apart, for example, in the longitudinal direction of the board. Such LED boards are known per se and can be manufactured in various lengths and widths as required. It is also possible to produce RGB boards or flexible boards, which can be optimally adapted to the respective conditions thanks to their flexibility. Another advantage of such flexible boards is that they can be processed easily and cost-effectively.

[0017] A single-piece or multi-piece LED cover is provided for all LEDs on such an LED board. This eliminates the need to seal each LED with a separate LED cover and appropriate encapsulation compound.

[0018] The implementation of such an explosion-proof LED module with a plurality of LEDs is further simplified if the heat sink is also designed for all LEDs on the LED board. This means that only one heat sink is used, on which, for example, the board with the LEDs is directly mounted. The heat sink can also be formed from multiple, particularly identical, body segments.

[0019] To enable simple and secure mounting of the circuit board on the heat sink, particularly with regard to encapsulation with the encapsulating compound, the heat sink can have at least one insertion recess running along its longitudinal direction, in which the LED circuit board is placed on a cooling surface. The cooling surface can have dimensions corresponding to those of the circuit board (see length and width).

[0020] It is of course also possible that the circuit board or cooling surface each have larger dimensions in length or width compared to the other part.

[0021] For better heat transfer between the cooling surface and thus the heat sink and the LED board, a corresponding thermally conductive foil can be applied either to the cooling surface or to the board.

[0022] In order to enable the LED cover to be attached in a simple manner, particularly in the case of its one-piece design for a plurality of LEDs, the cooling surface can be bordered on both sides in the longitudinal direction of the heat sink by the insertion recess, at least in places.

[0023] In one embodiment, for example, it is possible for the insertion recesses to extend at least along the cooling surface on both sides. It is also possible for the insertion recess to be present at the longitudinal ends of the cooling surface, so that it essentially completely surrounds the cooling surface.

[0024] It is conceivable to attach the LED cover simply by inserting or plugging it into the insertion recess and then encapsulating it with the encapsulating compound, ensuring that all LEDs are designed to meet the required ignition protection type. However, to ensure that the LED cover is at least temporarily secured to the heat sink during encapsulation with the encapsulating compound, the LED cover can have a number of plug-in elements protruding toward the insertion recess for attachment to the heat sink.

[0025] A conceivable embodiment for such plug-in elements can be seen in their design with locking elements that engage with counter-locking elements within the plug-in recess. In this way, after the LED board has been positioned and the board's electrical supply has been established, the LED cover can be snapped onto the heat sink. The potting compound is then poured into the plug-in recess to, on the one hand, secure the LED cover and, on the other hand, seal the LEDs from the surrounding atmosphere.

[0026] Various alternative mounting options are conceivable. For example, the LED board can be screwed to the heat sink. The protective cover or LED cover is then placed on top, held in place, and potted. After the potting has cured, the corresponding retaining device for the cover is removed, and the cover is then held in place solely by the potting.

[0027] In order to be able to easily assign the corresponding locking elements to the counter-locking elements, in one embodiment a locking recess can be formed that projects essentially perpendicular to the longitudinal direction of the body and extends along the insertion recess. This means that no precise assignment between the locking element and the counter-locking element is necessary and even the LED cover can be moved after the locking elements have engaged in the locking recess. However, in order to enable a specific assignment of LEDs and LED cover, if necessary, a corresponding counter-locking element can be provided for each locking element, each of which is formed by only one corresponding locking recess that is formed essentially perpendicular to the longitudinal direction of the body within the insertion recess.

[0028] In this context, it is possible for the locking elements to engage outward from the cooling surface or inward toward the cooling surface. Furthermore, it is possible for the locking elements to be arranged in pairs on both sides of the cooling surface or offset from one another.

[0029] In order to prevent the casting compound from being pulled out together with the LED cover after it has hardened by applying appropriate force to the LED cover, the insertion recess can have a varying cross-section and / or a direction-changing course in the direction of the counter-locking element.

[0030] This means that the insertion recess increases in cross-section, for example, toward the locking recess. Another possibility is for the locking recess to have a profile that is, for example, wave-shaped, zigzag-shaped, or similar toward the counter-locking element.

[0031] To also seal the LED cover at the ends of the LED board by applying appropriate potting compound, a potting recess can be formed at each of the longitudinal ends of the LED board in the heat sink. This potting recess can be the same depth as the insertion recess, but can also be designed with a different depth. For example, the corresponding insertion elements can no longer be arranged in the potting recess area, so that they no longer need to be placed in the potting compound, allowing a shallower potting recess than the insertion recess.

[0032] To ensure secure sealing of the LED cover by the encapsulation compound on the heat sink, the LED cover can have a peripheral edge, particularly a circumferential edge, that protrudes toward the insertion recess or encapsulation recess. When the LED cover is mounted on the heat sink, this edge is positioned in the encapsulation compound, so that the sealing of the LEDs from the outside atmosphere is essentially achieved by immersing this peripheral edge in the encapsulation compound.

[0033] It is possible for the insertion elements to be formed separately from the peripheral edge and protrude from the rest of the LED cover toward the insertion recess. In a simple embodiment, the insertion elements can protrude from the peripheral edge.

[0034] It is conceivable for the LED cover to have a uniform curvature in its longitudinal direction to accommodate all LEDs. According to the invention, the LED cover has convexly curved LED domes extending from the LEDs, with each LED dome being assigned to a single LED.

[0035] The individual LED domes are designed as a lens system for the LED or include one.

[0036] With this assignment of LED dome to LED, the corresponding dome can also be designed as an optical element that, for example, determines the radiation direction of the LED, which makes the radiation of all LEDs more continuous so that the LEDs do not appear as point light sources, etc.

[0037] Reflection devices can be provided within the LED cover or domes, which also serve to direct the light, or the cover or domes can have surface structures on the inside or outside that also influence the light output or light intensity.

[0038] The length of such an LED module with LED circuit board can be approximately equivalent to that of a tubular fluorescent lamp, allowing these lamps to be replaced by the LED module. With corresponding fluorescent lamps, it is also known for several lamps, for example two, to be arranged side by side. This is also possible with the LED module according to the present invention, in that the heat sink has two lateral ends extending transversely to the body's longitudinal axis and inclined relative to a vertical. An LED circuit board with an LED cover and encapsulation compound is arranged at each of these side ends, i.e., each of these side ends essentially forms a lamp similar to a fluorescent lamp.

[0039] The LED module can be manufactured in any length, even significantly shorter than the length of a tubular fluorescent lamp. The length of a fluorescent lamp (18, 36, & 58W, or their equivalents in other countries) can be achieved by assembling multiple modules. Luminaires can also be built that deviate significantly from these standard lengths.

[0040] Various materials can be used for the heat sink, LED cover, or potting compound. The heat sink is preferably made of metal and, for example, has additional cooling fins. It is also possible for the heat sink to be constructed in several parts, thus comprising a metal cooling core with cooling fins and a surrounding plastic housing.

[0041] Like other cover hoods, the LED cover can be made of a corresponding transparent or at least translucent material, such as borosilicate, temperature-shock-resistant glass or even a plastic such as polycarbonate or the like.

[0042] The LED cover can be colored and / or coated in various colors if necessary.

[0043] The potting compound can also be made of a suitable material such as polyurethane resin, epoxy resin, silicone resin, or the like. Typically, the potting compound is a casting resin that solidifies through a chemical reaction, which is irreversible. Other casting resins besides those mentioned above are also possible.

[0044] In the following, an advantageous embodiment of the invention is explained with reference to the attached figures.

[0045] They show: Fig. 1 shows an embodiment of an LED module according to the invention in an exploded view; Fig. 2 a side view of an LED module according to Fig. 1; Fig. 3 a section along the line III-III Fig. 2 in exploded view; Fig. 4 a section along the line IV-IV Fig. 2; and Fig. 5 a section along the line VV Fig. 2

[0046] Fig. Figure 1 shows a side view of an exploded view of an LED module 1 according to the invention. The LED module 1 has a heat sink 3 extending in the longitudinal direction 10. At its two side ends 24, 25, see also Fig. 3, LEDs 2 are arranged, which are all arranged together on an LED board 8. This extends in the longitudinal direction 9 of the board essentially over the entire length of the heat sink 3. Between the side ends 24, 25, the heat sink has a number of cooling fins 28, see also Fig. 3-5. On the left side of the page 24 to Fig. 1, see also Fig. 3, the various individual parts of the LED module are shown exploded. For example, the LED board 8 with a plurality of LEDs 2 is visible, above which a corresponding LED cover 5 and a potting compound 7 are arranged. All of these parts extend essentially over the entire length of the heat sink 3; see also the other side end 25.

[0047] The LED board 8 is inserted into a recess 11 at the respective side end 24 or 25, and is provided with a corresponding cooling surface 12, see also Fig. 3, in the appendix. A heat-conducting foil (not shown) can also be arranged between the LED board 8 and the cooling surface. The cooling surface 12 extends along the insertion recess 11 and forms its lower end, see again. Fig. 3. Corresponding means can be provided on or associated with the cooling surface 11 to fix or at least position the LED board 8 in a specific relative position. Corresponding devices can also be provided only at the ends of the insertion recess 11 or the cooling surface 12.

[0048] At the ends of the cooling surface 12, see for example in Fig. 1 with longitudinal ends 20 and 21 of the LED board 8, the insertion recess 11 has corresponding ends in which end sections 26, 27 of the potting compound 7 are arranged.

[0049] With regard to Fig. 1, it should be noted that the potting compound 7 is not a separate part, but is usually formed from a casting resin that is poured into the insertion recess 11 and also a corresponding insertion recess 6, see the following embodiment. There, the potting compound 7 then hardens and solidifies in a mold according to Fig. 1, see reference number 7 there.

[0050] A corresponding cross-section of the cured casting compound is shown with reference number 7 in Fig. 3, whereby it is again pointed out that this part is not cured and inserted in this form, but only takes on this corresponding shape after the casting compound has been poured in and cured.

[0051] When the casting compound 7 is poured in, it forms a shape complementary to the insertion recess 6 or insertion recess 11 on its underside, see also Fig. 4 and Fig. 5, wherein the potting compound serves to seal the LED cover 5 relative to the heat sink 3 and thus to seal the LEDs of the LED board 8.

[0052] At the corresponding ends of the insertion recess 11, casting recesses 19 are formed, see Fig. 1, in which the end sections 26 and 27 of the casting compound 7 are arranged.

[0053] The LED cover 5 has on its insertion recess 6, see also Fig. 3, has a plurality of plug-in elements 13. These are inserted into the plug-in recess 6 when the LED cover 5 is arranged on the heat sink 3 and are locked there by means of locking elements 14 at the free ends of the plug-in elements 13 in corresponding locking recesses 16, see also Fig. 4 or 5. In addition to the plug-in elements 13, the LED cover 5 has a circumferential edge 22 which, when the LED cover 5 is attached to the heat sink 3, dips into the potting compound 7, see also Fig. 4. The corresponding insert elements 13 protrude from this peripheral edge 22, see Fig. 1.

[0054] In Fig. 2 is a side view of the LED module 1 after Fig. 1. In particular, some sections are marked that correspond to the following Fig. 3-5, see section lines III-III, IV-IV and VV. In Fig. 2 it is particularly evident that the LED cover 5 has a number of LED domes 23, see also Fig. 1, each of which is assigned to an LED 2 of the LED board 8. In the illustrated embodiment, corresponding LED domes 23 are arranged, for example, at longitudinal ends 20 and 21 of the LED board 8, in order to cover LEDs 2 still located there. The LED cover 5 is surrounded by the potting compound 7 along its entire circumference, see end sections 26 and 27 and the potting compound 7 poured into the insertion recess 6 according to Fig. 3-5.

[0055] Fig. 3 corresponds to a section along the line III-III of Fig. 2 in the exploded view according to Fig. 1. In this embodiment, the heat sink 3 comprises mirror-image halves 29, 30, which are detachably connected to one another at their adjacent sides. Each of these halves has a metal inner body with cooling fins 28 projecting therefrom. These are arranged in a housing made, for example, of plastic.

[0056] On each of the side ends 24, 25 of the entire heat sink 3, an LED board 8, an LED cover 5, and corresponding potting compound 7 are arranged. The LED board 8 is arranged on the cooling surface 12 within the insertion recess 11. The cooling surface 12 is limited along its long sides by the insertion recess 6, which extends into the heat sink 3 and is used in particular to receive the insertion elements 13, see Fig. 5, and serves at least to partially absorb the casting compound 7.

[0057] The insertion recess 6 has a changing cross-section, see also reference numeral 17 in Fig. 4, whereby the cross-section generally increases from the insertion side, ie from the cooling surface 12. However, the cross-section can later decrease again and the insertion recess 6 can have a profile 18, see again Fig. 4, which changes its direction.

[0058] Lower ends of the insertion recess 6 have lateral locking recesses 16, which serve as counter-locking elements 15 for locking elements 14 arranged at free ends of the insertion elements 13, see also Fig. 5. In the area between the plug-in elements 13, see for example Fig. 4, the peripheral edge 22 of the LED cover 5 extends into the potting compound 7, which essentially completely fills the insertion recess 6 and essentially leaves only the LED domes 23 free.

[0059] Otherwise, the LED cover is completely arranged with its peripheral edge 22 and the plug-in elements 13 in the potting compound 7.

[0060] After Fig. 3, the corresponding LEDs 2 have a specific radiation area or a radiation direction 4, which is essentially determined by the corresponding LED domes 23.

[0061] It is further pointed out that the casting compound 7, see for example Fig. 3, can also leave areas between the LED domes 23 uncovered, and in such a case extends only in the circumferential direction around the LED cover 5, see in particular insertion recess 6 and insertion recess 11 with edge-side potting recesses 19, see again Fig. 1 or Fig. 2.

[0062] In Fig. 3 also shows an electrical supply line 31, which is inserted into the insertion recess 6 in the region of one longitudinal end of the LED board 8 for electrically contacting the LED board 8. This is also sealed by the potting compound 7, similar to the LED cover 5.

[0063] Fig. 4 and Fig. 5 show further cross sections along lines IV-IV and VV to Fig. 2, see also Fig. 1.

[0064] In Fig. 4, in particular, the LED cover 5 is shown in section between corresponding plug-in elements 13, wherein the peripheral edge 22 dips into the potting compound 7.

[0065] In Fig. 5, the LED cover 5 is shown in the region of a plug-in element 13 with a locking element 14, which extends essentially to the bottom of the plug-in recess 6 and there engages with a counter-locking element 15 in the form of a locking recess 16.

[0066] The assembly of the LED module is described below.

[0067] In a first step, the heat sink 3 is assembled from two halves 29, 30, see Fig. 3, and these halves are connected to each other. Subsequently, the LED circuit board 8 is placed along the cooling surface 12 with the thermally conductive foil arranged between them. To temporarily fix the LED circuit board 8, the LED cover 5 is attached in a next step, with its plug-in elements 13 engaging in the plug-in recess 6.

[0068] By applying appropriate pressure to the LED cover 5, the latter is inserted with its insertion elements 13 into the insertion recess 6 until the locking elements 14 finally lock into the locking recess 16 as a counter-locking element 15, see also Fig. 5. The potting compound 7 is then poured into the insertion recess 6 and also into the corresponding potting recesses 19 of the insertion recess 11 at the longitudinal ends 20, 21 of the LED board 8 or the LED cover 5.

[0069] Due to the special arrangement of the LED board with LEDs and LED cover 5, a corresponding gap remains between the LEDs and the LED cover due to the diving bell principle. This creates a flood-proof cover for the LEDs.

[0070] After the potting compound 7 has hardened, the LED module 1 is ready for use, whereby all LEDs can be operated even in an explosive atmosphere due to the sealing via the potting compound and the corresponding cooling of each LED.

Claims

[1] Explosion-proof LED module (1) with a plurality of light-emitting diodes (2) (LEDs), a heat sink (3) connected thereto and an LED cover (5) covering the LED at least in the radiation direction (4), wherein the LED cover (5) extends into a plug-in recess (6) of the heat sink (3) and is surrounded in this plug-in recess (6) by a potting compound (7) sealing the LED relative to an external and possibly explosive atmosphere, wherein the plurality of LEDs (2) are arranged on an LED board (8), in particular in the board longitudinal direction (9) next to one another and spaced from one another, and a one-part or multi-part LED cover (5) is formed for all LEDs of the LED board (8), characterized by , that the LED cover (5) has LED domes (23) which are convexly curved away from the LEDs, wherein each LED dome (23) is assigned to an LED and the LED dome is designed as a lens system for the LED or comprises such a lens system. [2] Explosion-proof LED module according to claim 1, characterized by that the heat sink (3) is designed for all LEDs of the LED board (8) and is in particular formed in one piece or from several segments. [3] Explosion-proof LED module according to one of the preceding claims, characterized by that the heat sink (3) has at least one insertion recess (11) running in the longitudinal direction (10) of the body, in which the LED board (8) is placed on a cooling surface (12). [4] Explosion-proof LED module according to claim 3, characterized by that the cooling surface (12) is bordered on both sides in the longitudinal direction (10) of the body at least in places by the insertion recess (6). [5] Explosion-proof LED module according to one of the preceding claims, characterized by that the LED cover (5) has a number of plug-in elements (13) projecting in the direction of the plug-in recess (6) for fastening to the heat sink (3). [6] Explosion-proof LED module according to claim 5, characterized by that the insertion elements (13) are formed with locking elements (14) which engage with counter-locking elements (15) within the insertion recess (6). [7] Explosion-proof LED module according to claim 6, characterized by that the counter-locking elements (15) are formed by a corresponding number or at least one locking recess or locking recess projecting substantially perpendicular to the longitudinal direction (10) of the body. [8] Explosion-proof LED module according to one of the preceding claims 6 or 7, characterized bythat the insertion recess (6) has a varying cross-section (17) and / or a direction-changing course (18) in the direction of the counter-locking element (15). [9] Explosion-proof LED module according to one of the preceding claims, characterized by that a potting recess (19) is formed at both longitudinal ends (20, 21) of the LED board (8) in the heat sink (3). [10] Explosion-proof LED module according to one of the preceding claims, characterized by that the LED cover (5) has a circumferential edge (22) projecting in the direction of the insertion recess (6), in particular a circumferential edge. [11] Explosion-proof LED module according to claim 10, characterized by that the plug-in elements (13) protrude from the peripheral edge (22). [12] Explosion-proof LED module according to one of the preceding claims, characterized bythat the heat sink (3) has two lateral side ends (24, 25) extending transversely to the longitudinal direction (10) of the body and inclined relative to a vertical, wherein an LED board (8) with LED cover (5) and casting compound (7) is arranged at each side end (24, 25). [13] Explosion-proof LED module according to one of the preceding claims, characterized by that the heat sink is composed of two or more parts.

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