Lighting unit for a lamp and lamp

Abstract

The invention relates to a lighting unit (100) for a lamp (200), in particular for a portable lamp (2001), comprising a housing (10), a circuit board (11) and a light source element (12), which are preferably arranged along a common longitudinal axis (A). According to the invention, the housing (10) has a contact element (13) which is at least indirectly in contact with the light source element (12) on a front contact surface (14) and at least indirectly in contact with the circuit board (11) on a rear contact surface (15), the housing (10) and the circuit board (11) each have at least two recesses (201, 202) which are aligned at least partially with each other, wherein the recesses (201, 202) are preferably spaced laterally from the contact element (13) of the housing (10) with respect to the longitudinal axis (A), and the circuit board (11) has at least two electrical contact surfaces (211, 212).which are facing away from the mounting element (13), and the light source element (12) has at least two contact springs (221, 222), each of which has a locking element (241, 242) and which extend through and engage behind the recesses (201, 202) of the housing (10) and the circuit board (11) in such a way that the light source element (12) is positively locked and is connected to the contact surfaces (211, 212) of the circuit board (11) in a contact-closing manner. The invention further relates to a lamp (200) with such a lamp unit (100).

Description

[0001] The invention relates to a lighting unit for a lamp, in particular for a portable lamp, comprising a housing, a circuit board and a light source element, which are preferably arranged along a common longitudinal axis.

[0002] The invention further relates to a lamp, in particular a portable lamp, preferably a flashlight or a headlamp, with such a lighting unit.

[0003] Luminaires of the type discussed here can initially be designed as static luminaires, particularly as streetlights, exterior building lights, or interior building lights. Such luminaires are often mounted in relatively inaccessible locations and / or exposed to constantly changing weather conditions with significant temperature fluctuations. To ensure the long-term functionality of the luminaire while minimizing maintenance requirements, particularly stringent demands are placed on the mountings of the light source elements within the luminaire units.

[0004] Furthermore, lights of the type discussed here can also be designed as portable lights, particularly as flashlights or headlamps. Such portable lights are versatile light sources with a flexible range of applications, used in various situations such as camping, hiking, cycling, and police, fire, and military operations. The mounting of the light source elements within the light unit is crucial for the long-term functionality and durability of the lights, especially since installation space is limited in portable lights and they are subject to frequent vibrations.

[0005] According to the current state of the art, various methods are known for mounting a light source element within the housing of a luminaire. In particular, mounting using screws and adhesives is known. With screw mounting, the light source element is attached directly to the housing with screws. This requires precise preparation of holes and threads in the housing to ensure the screws are held securely. The assembly effort for such a mounting is therefore comparatively high. Luminaires are also known in which the light source element is fixed by means of a plastic holder, which is itself screwed in place, resulting in similar disadvantages. With adhesive mounting, the light source element is glued to a substrate inside the housing.This option is relatively simple and quick, which reduces installation effort. However, precisely aligning the glued light source element is comparatively difficult, which is why such luminaires often have insufficient light output. In both options, the problem is compounded by the fact that a loosening fastening can only be fixed with considerable effort. Such luminaires therefore require significant maintenance.

[0006] From DE 20 2011 051 338 U1, a clip-on lamp with a housing is known, which has two housing parts separated by a plug-in gap, wherein at least in one housing part a light source, in particular an LED, is arranged, wherein the plug-in gap is formed by the legs of a U-shaped spring clip, on which a housing part is each attached.

[0007] DE 10 2017 128 583 A1 describes a flashlight with a housing in which at least one LED mounted on a carrier body and an attachment optic are arranged, which can be moved relative to each other to focus the emitted light cone, wherein a seal consisting of a membrane closes the space between the LED and the attachment optic in a dustproof and waterproof manner.

[0008] DE 103 38 771 A1 discloses a fastening device for light sources in vehicle lights, comprising a socket body that receives the light source. The socket body has contacting means for contacting the light source and a lamp holder, as well as retaining means for holding the light source within the socket body, and is connectable to the lamp holder. The socket body is formed by a number of socket body segments corresponding to the number of contact terminals of the light source. These segments are positively and / or frictionally and / or materially bonded to a base of the light source. The contact terminals are each electrically conductive and held in recesses of the socket body segments.

[0009] Starting from this premise, the object of the present invention is to provide a lighting unit that can be easily mounted and that has a consistently precise light emission, thus requiring minimal installation and maintenance. Furthermore, the object of the present invention is to provide a luminaire incorporating such a lighting unit.

[0010] This problem is solved by the lighting unit according to claim 1 and by the luminaire with such a lighting unit according to claim 10.

[0011] The invention relates to a lighting unit for a lamp, in particular for a portable lamp, comprising a housing, a circuit board and a light source element, which are preferably arranged along a common longitudinal axis.

[0012] Furthermore, the invention relates to a lamp, in particular a portable lamp, preferably a flashlight or a headlamp, with such a lighting unit.

[0013] According to the invention, the housing has a contact element that is at least indirectly in contact with the light source element at a front contact surface and at least indirectly in contact with the printed circuit board at a rear contact surface. The housing and the printed circuit board each have at least two recesses that are at least partially aligned with each other, the recesses preferably being spaced laterally from the contact element of the housing with respect to the longitudinal axis. The printed circuit board has at least two electrical contact surfaces facing away from the contact element. The light source element has at least two contact springs, each with a locking element, which extend through and engage behind the recesses of the housing and the printed circuit board in such a way that the light source element is positively locked and is connected to the contact surfaces of the printed circuit board.

[0014] The invention enables simple and quick assembly of the lighting unit by inserting the unit, with its contact springs, into the recesses. This ensures that the light source element is positively locked in the assembled state and simultaneously connected to the contact surfaces of the circuit board. The positioning of the housing's mounting element between the light source element and the circuit board allows for efficient heat dissipation from the light source element to the housing. The recesses in the housing and the circuit board, which flank the housing's mounting element along its longitudinal axis, enable simple and permanently secure positioning of the light source element within the lighting unit.

[0015] The use of contact springs, which also serve as electrical contacts, ensures permanently precise alignment of the light source element, independent of changing weather and temperature conditions. This is particularly important for the exact positioning of the light source element, where precise positioning is crucial for accurate light shaping. The spring force of the contact springs ensures that the positioning is maintained even during thermal expansion. This improves the reliability and longevity of the connection. The contact springs that hold the light source element also serve as electrical contacts and enable good heat dissipation from the light source element, thus reducing the thermal stress on the components. This is because the precise alignment and tight fit of the components also minimize thermal contact resistance.This advantageously leads to more efficient heat transfer and thus a reduced temperature of the light source. The mounting ensures that the positioning of the components remains stable even under temperature fluctuations. This prevents thermal hotspots and ensures uniform heat distribution. This design also shortens assembly time, as fewer steps are required to achieve precise alignment of the light source element. This results in faster and more cost-effective manufacturing of the lighting unit and / or luminaire. Reducing the number of production steps also minimizes production costs. Furthermore, this special mounting helps to maintain a uniform luminous flux from the light source element, leading to better and more consistent light output.

[0016] Advantageous embodiments of the invention are specified below and in the dependent claims.

[0017] Preferably, the light is designed as a flashlight or headlamp. These portable lights require a compact and robust design, which is ensured by the light unit. Easy assembly and secure positioning of the light source element within the unit are particularly advantageous for these applications, as they guarantee high reliability and a long service life. Furthermore, efficient heat dissipation from the light source element to the housing enables efficient operation of the light, which is especially important for portable lights that are often powered by batteries or rechargeable batteries.

[0018] According to an advantageous embodiment of the invention, the housing is designed, at least in part, as a luminaire head that accommodates an attachment optic arranged coaxially to the luminaire unit. The attachment optic can, for example, be a lens or a reflector to direct and / or focus the light emitted by the light source element in a desired direction. The attachment optic can also be designed as a TIR collimator (Total Internal Reflection Collimator). The attachment optic can be fixedly mounted in the luminaire head or it can be longitudinally displaceable to adjust the luminaire's light beam. The attachment optic can also be interchangeable to allow for different lighting options.

[0019] Preferably, the mounting element is designed as a base whose front mounting surface is spaced longitudinally from a base surface of the housing. In addition to heat dissipation, this spacing from the base surface allows the light source element to be inserted into a rear cavity of the front optic, thus increasing the efficiency of the lighting unit.

[0020] The contact springs are preferably designed as curved leaf springs. This configuration enables a reliable and durable electrical connection between the light source element and the contact surfaces of the printed circuit board. The curved leaf springs can provide sufficient spring force to ensure good electrical contact while also exhibiting a degree of flexibility to allow for easy assembly and disassembly of the light source element. The curved leaf springs can be made of a conductive material, such as copper or a copper alloy. They can also have a surface treatment, such as gold plating or tin plating, to improve electrical conductivity and / or prevent corrosion.

[0021] The locking elements are preferably arranged at the ends of the contact springs and each has an electrical contact surface that makes contact with one of the electrical contact surfaces of the printed circuit board. The locking elements are preferably designed as flat profiles that are oriented at an angle to the longitudinal axis. The locking elements are preferably integrally (or integrally) connected to the contact springs. Furthermore, the contact springs preferably have a preload in the assembled state, and the locking elements preferably have a bearing surface on the side facing away from the light source of the light source element for proper mounting.

[0022] This configuration enables a reliable and durable electrical connection between the light source element and the contact pads of the printed circuit board. The angled orientation of the flat profiles ensures good electrical contact while also providing a degree of flexibility to allow for easy assembly and disassembly of the light source element. The flat profiles can be made of a conductive material, such as copper or a copper alloy. They can also have a surface treatment, such as gold plating or tin plating, to improve electrical conductivity and / or prevent corrosion.The one-piece connection means that the locking elements and contact springs are formed as a single component, simplifying the assembly of the lighting unit and improving the reliability of the electrical connection between the light source element and the contact pads on the circuit board. This one-piece design of the locking elements and contact springs can be achieved through various manufacturing processes, such as stamping, bending, or embossing. The preload ensures that the contact springs maintain a firm and reliable contact with the circuit board contact pads at all times, even when forces act on the light source element due to vibrations and / or temperature fluctuations. The preload can be determined by the shape and material of the contact springs, as well as by the method of their assembly.For example, the contact springs can be shaped and mounted so that, in their relaxed state, they have a greater length along their longitudinal axis than in their mounted state, thus compressing them in the mounted position and thereby creating or maintaining a preload. The ramp surface enables quick and easy mounting of the light source element in the lighting unit. When the light source element is inserted into the lighting unit, the ramp surfaces of the contact springs slide down the side faces of the mounting element until they engage the recesses and snap into place on the back of the circuit board. The ramp surface can have a smooth or textured surface to facilitate the sliding of the contact springs. The ramp surface can also have a specific shape or contour to facilitate the positioning and alignment of the light source element in the lighting unit.

[0023] Specific embodiments of the invention are explained below with reference to the figures. These show: Fig. 1 a cross-sectional view of a luminaire with one lighting unit; Fig. 2a-c different cross-sectional views of the lighting unit; Fig. 3a, b Cross-sectional views of the lighting unit during intended installation; Fig. 4a, b perspective views of a light source element of the lighting unit; Fig. 4c a perspective view of the light source element in combination with a circuit board.

[0024] The Fig. Figure 1 shows a cross-sectional view of a lighting unit 100, which is installed inside a luminaire 200. In the illustrated embodiment, the luminaire 200 is designed as a portable luminaire 2001, namely as a pocket light 2002. Fig. Figures 2a-c show different cross-sectional views of this 100-unit light fixture.

[0025] The luminaire 100 comprises a housing 10, a circuit board 11, and a light source element 12, which are arranged along a common longitudinal axis A. This longitudinal axis A coincides with an optical axis of the luminaire 200. Directional terms used in this application, such as left, right, front, or rear, refer to this longitudinal axis A or to this optical axis.

[0026] The housing 10 has a mounting element 13 which is at least indirectly in contact with the light source element 12 at a front mounting surface 14 and at least indirectly in contact with the circuit board 11 at a rear mounting surface 15. The housing 10 is designed as a luminaire head 16, which accommodates a front optic 17 arranged coaxially with the luminaire unit 100, wherein the front optic 17, in the illustrated embodiment, is designed as a so-called TIR collimator 171 with a rear cavity 18. The mounting element 13 is designed as a base 131, the front mounting surface 14 of which is spaced longitudinally from a base surface 19 of the housing 10, so that the light source element 12 engages in the rear cavity 18 of the front optic 17.

[0027] The housing 10 and the circuit board 11 each have at least two recesses 201, 202 which are aligned section by section and flank the mounting element 13 of the housing 10 on the right and left sides with respect to the longitudinal axis A.

[0028] The circuit board 11 has two electrical contact surfaces 211, 212, which are facing away from the system element 13.

[0029] The light source element 12 has two contact springs 221, 222 mounted on a common plate 23, each possessing a locking element 241, 242, which extend through and engage behind the recesses 201, 202 of the housing 10 and the circuit board 11 such that the light source element 12 is positively locked and connected to the contact surfaces 211, 212 of the circuit board 11. The contact springs 221, 222 are designed as curved leaf springs 2211, 2221. The locking elements 241, 242 are arranged at the ends of the contact springs 221, 222 and are designed as flat profiles 2411, 2421. The flat profiles 2411, 2421 are oriented at an oblique angle with respect to the longitudinal axis A and each has an electrical contact surface 25 which contacts one of the electrical contact surfaces 211, 212 of the printed circuit board 11. The locking elements 241, 242 are integrally formed (or...(in one piece or by means of a material bond) connected to the contact springs 221, 222 and the contact springs 221, 222 have a preload in the assembled state so that the light source unit 100 is mounted in a vibration-stable manner.

[0030] The Fig. Figures 3a and 3b show two cross-sectional views of the lighting unit 100 during its intended assembly. For this purpose, the light source element 12 is guided along the longitudinal axis A in the direction of arrow P1 so that the locking elements 241 and 242 of the contact springs 221 and 222 come into contact with the mounting element 13. The locking elements 241 and 242 have a bearing surface 27 on the side facing away from a light source 26 of the light source element 12. By further adjusting the light source element 12 in the direction of arrow P2, the contact springs 221 and 222 are pivoted and can then be pushed over the mounting element 13 until the contact springs 221 and 222 engage (pass through) the recesses 201 and 202 of the circuit board 11. Due to the built-up spring force, the locking elements 241, 242 of the contact springs 221, 222 move in this position in the direction of arrow P3 and interlock the light source element 12 in such a way that it is mounted under preload and in a form-fitting manner.

[0031] The Fig. Figures 4a-b show different perspective views of the light source element 12 and Fig. Figure 4c shows a perspective view of a combination of the light source element 12 with the circuit board 11. Reference sign 100 light units 200 lights 2001 portable lamp 2002 Flashlight 10 cases 11 Circuit board 12 light source elements 13 Plant element 131 sockets 14 front mounting surface 15 rear installation area 16 Lamp head 17 Attachment optics 171 TIR collimator 18 cavities 19 Floor area 201 Exclusion 202 Exclusion 211 electrical contact surface 212 electrical contact surfaces 221 Contact spring 2211 Leaf spring 222 Contact spring 2221 Leaf spring 23 plate 241 Latching element 2411 Flat profile 242 Latching element 2421 Flat profile 25 electrical contact surfaces 26 Light source 27 Drainage area P(1-3) Arrow direction

Claims

[1] Lighting unit (100) for a luminaire (200), in particular for a portable luminaire (2001), comprising a housing (10), a circuit board (11) and a light source element (12), which are preferably arranged along a common longitudinal axis (A), characterized by , that • the housing (10) has a mounting element (13) which is at least indirectly in contact with the light source element (12) on a front mounting surface (14) and at least indirectly in contact with the circuit board (11) on a rear mounting surface (15), • the housing (10) and the circuit board (11) each have at least two recesses (201, 202) which are aligned at least partially with each other, wherein the recesses (201, 202) are preferably spaced laterally from the mounting element (13) of the housing (10) with respect to the longitudinal axis (A), • the circuit board (11) has at least two electrical contact surfaces (211, 212) which are facing away from the system element (13), and • the light source element (12) has at least two contact springs (221, 222), each of which has a locking element (241, 242) and extends through and engages behind the recesses (201, 202) of the housing (10) and the circuit board (11) in such a way that the light source element (12) is positively locked and is connected to the contact surfaces (211, 212) of the circuit board (11) in a contact-closing manner. [2] Lighting unit (100) according to claim 1, wherein the light (200) is a flashlight (2002) or headlamp. [3] Lighting unit (100) according to one of the preceding claims, wherein the housing (10) is at least partially designed as a lighting head (16) which accommodates a front optic (17) arranged coaxially to the lighting unit (100). [4] Lighting unit (100) according to one of the preceding claims, wherein the mounting element (13) is designed as a base (113) whose front mounting surface (14) is spaced apart in a longitudinal axial direction from a base surface (19) of the housing (10). [5] Lighting unit (100) according to one of the preceding claims, wherein the contact springs (221, 222) are designed as bent leaf springs (2211, 2221). [6] Lighting unit (100) according to one of the preceding claims, wherein the locking elements (241, 242) are arranged at the ends of the contact springs (221, 222) and each have an electrical contact surface (25) which contacts one of the electrical contact surfaces (211, 212) of the circuit board (11), wherein the locking elements are preferably designed as flat profiles (2411, 2421) which are oriented at an oblique angle with respect to the longitudinal axis (A). [7] Lighting unit (100) according to claim 6, wherein the locking elements (241, 242) are integrally connected with the contact springs (221, 222). [8] Lighting unit (100) according to one of claims 6 or 7, wherein the contact springs (221, 222) have a preload in the assembled state. [9] Lighting unit (100) according to one of claims 6 to 8, wherein the locking elements (241, 242) have a ramp surface (27) on the side facing away from a light source (26) of the light source element (12) for intended mounting. [10] Lamp (200), in particular portable lamp (2001), preferably flashlight (2002) or headlamp, with a lamp unit (100) comprising a housing (10), a circuit board (11) and a light source element (12), characterized by , that the lighting unit (100) is designed according to one of claims 1 to 9.

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