Luminaire and method for manufacturing a luminaire

Abstract

The luminaire 101 comprises a cable assembly 1 for connecting a lighting device 103 to a power source. The cable assembly includes multistranded wire with an insulation sheath and an exposed portion bonded (e.g., using solder) into a solid section to block fluid flow. A sealing member 123 formed onto the cable overlies the sheath and solid section to block fluid flow between them. The lighting device emits light out of a first end 109b of a tubular casing 109 having first and second ends. The sealing member engages an internal surface of the casing, sealing the second end 109c. An end cap 121 is releasably attachable to the first end. An electrical connector device 126 including a resiliently compressible connector 130 connects the lighting device to the multistranded wire when the end cap is attached to the casing. The resiliently compressible connector may be mounted on a connector device PCB 128 to electrically connect with a lighting device PCB 107.

Description

The present invention relates to a luminaire and a method for manufacturing a luminaire. Luminaires frequently use multi-stranded electrical cables to connect the appliance to a power source since multi-stranded cables are very flexible and robust. The flexibility enables the cables to follow non-linear paths and enables frequent repositioning and bending of the cable without appreciably work hardening the cable. However when a luminaire, such as a sealed luminaire, is turned on heat given off by the light source, and sometimes other electrical components, causes the air inside the luminaire to expand, thereby increasing the pressure within the unit. The increased pressure causes air to be forced out of the unit via the multi-stranded electrical cable. The air flows through gaps located between strands of copper wire within an inner insulation sheath and via gaps between the inner insulation sheath and an outer sheath. When the light is turned off the air inside the unit cools and contracts causing a reduction in pressure within the unit. This causes air to be drawn into the unit through the same gaps. Frequently luminaires are used in damp environments such as outdoor applications, and in submersed conditions such as swimming pools and ponds. When air is drawn along cables in moist or wet conditions, moisture is also drawn into the luminaire. This can be fatal to the luminaire, for example by corroding electrical contacts or short circuiting the device. At best, moisture drawn into the unit causes water droplets to form inside the casing, which can reduce the operating effectiveness of the light and look unsightly. Accordingly, for luminaires used in damp environments, it is desirable to have a means of addressing moisture ingress into the luminaire. Furthermore, with today’s environmental concerns, there is a strong desire to minimise waste. With traditional luminaries used in damp environments the luminaries are sealed in a fashion which makes it very difficult, if not impossible to repair the luminaire, for example to replace a damaged light source, therefore it is necessary to replace the entire luminaire should the light source, or any other component, fail. This generates a lot of unnecessary waste and requires entire luminaries to be stocked rather than component parts or sub-assemblies. Furthermore, it is generally not possible to update and modify a traditional sealed luminaire, and therefore benefits of changing an old light source for a new light source, for example to benefit from efficiency gains, improved luminosity, etc, cannot be realised with the traditional luminaire. Of course, having a water resistant luminaire with an accessible interior can cause problems with water or moisture ingress. A further issue with these types of luminaires is the ease with which they can be manufactured and assembled. It is desirable to have a luminaire that can be manufactured and assembled more easily than prior art devices, without compromising the quality of the electrical connections between components. Accordingly the invention seeks to provide a luminaire mitigates at least one of the above-mentioned problems or at least provides an alternative solution thereto, and a method for manufacturing a luminaire. According to one aspect of the invention, there is provided a luminaire according to claim 1. Having a resiliently compressible electrical connector ensures that there is a good electrical connection between the lighting device and the electrical wire when the luminaire has been assembled. In particular, there is no need to provide flexible connecting wires between the multistranded electrical wire and the lighting device, which can be difficult to connect within the tubular casing. The invention helps to improve manufacture and assembly of the luminaire without compromising the effectiveness of the electrical connection. For example, it is possible to insert the lighting device and the seal member into the tubular casing from different ends. When luminaire is assembled, the resiliently compressible electrical connector is compressed between the sealing member and the lighting device in a longitudinal axial direction of the tubular casing. A reaction force from the resiliently compressible electrical connector urges the lighting device to move away from the sealing member in the longitudinal axial direction, however the lighting device is held fixed in position by other components, such as the end cap, and thus the resiliently compressible electrical connector remains in a compressed state which ensures a good electrical connection with the lighting device. Thus the invention provides a water resistant luminaire having a modular construction that is easy to assembly and manufacture without compromising the efficacy of the electrical connection. Having a modular construction, enables the casing to be opened so that it is possible to replace the lighting device, lens and / or any other accessories, such as reflectors, low glare devices, diffusers, etc, used within the luminaire, without compromising the ability to seal the interior of the casing. The invention also enables the lighting unit to be modified during its useful life to accommodate different lighting needs. Having a generic casing arrangement with replacement options, means that less stock of complete luminaires has to be stocked. According to another aspect there is provided a luminaire. The luminaire can include a lighting device. The luminaire can include a cable assembly including an electrical cable for electrically connecting the lighting device to a power source. The electrical cable can include a multi-stranded electrical wire, for example a first multi-stranded electrical wire, having an insulation sheath. An exposed section of the multi-stranded wire can include strands of wire that are bonded together with a bonding agent, thereby forming a substantially solid wire section which substantially blocks the flow of fluids along the multi-stranded wire. The electrical cable can include a sealing member pre-formed onto the electrical cable. The sealing member can overlie at least part of the substantially solid wire section and at least part of the insulating sheath. The sealing member can be arranged to substantially block the flow of fluids along gaps between the insulating sheath and wire. The luminaire can include a tubular casing. The lighting device can be located within the tubular casing. The lighting device can be arranged to emit light out of a first end of the tubular casing. At least a part of the cable assembly can be located within the casing. At least part of the sealing member pre-formed onto the electrical cable can be located within the casing. The sealing member can engage at least one internal surface of the tubular casing and seals against the at least one internal surface to close a second end of the tubular casing. The luminaire can include an end cap. The end cap can be releasably attachable to the first end of the tubular casing. The luminaire can include an electrical connector device. The electrical connector device can be arranged to electrically connect the multi-stranded wire to the lighting device. The electrical connector device can include a resiliently compressible electrical connector, for example a first resiliently compressible electrical connector. The resiliently compressible electrical connector can be arranged to electrically connect the lighting device to the multi-stranded wire, at least in a condition wherein the end cap is attached to tubular casing. The lighting device can comprise a solid state lighting device. For example, the solid state lighting device can include at least one LED and / or at least one LED chip. The lighting device can include a printed circuit board (PCB), and preferably a metal core printed circuit board (MCPCB). The at least one LED and / or the at least one LED chip can be electrically connected to the lighting device PCB. The resiliently compressible electrical connector can be located between the sealing member pre-formed onto the electrical cable and the lighting device PCB. The resiliently compressible electrical connector can be arranged to electrically connect with the lighting device PCB. The lighting device PCB can include an electrical contact that is arranged to engage with the resiliently compressible electrical connector. For example, the electrical contact can be located on a side of the lighting device PCB that is opposite to a side of the lighting device PCB on which the at least one LED and / or LED chip is located. The electrical connector device can be mounted on the sealing member pre-formed onto the electrical cable. The resiliently compressible electrical connector can be mounted on a base, such as a board, for example a printed circuit board (PCB). The base can be mounted on the sealing member pre-formed onto the electrical cable, for example on an end face of the sealing member pre-formed onto the electrical cable. The electrical connector device can include a printed circuit board (PCB). The multistranded wire can be electrically connected to the electrical connector device PCB. The resiliently compressible electrical connector can be electrically connected to the electrical connector device PCB. When the resiliently compressible electrical connector contacts the lighting device PCB, the lighting device PCB can be electrically connected to electrical connector device PCB. Thus electricity can be conducted from an electrical source to the LED and / or LED chip via the multistranded wire, the electrical connector device PCB, the resiliently compressible electrical connector, and the lighting device PCB. The resiliently compressible electrical connector can be mounted on the electrical connector device PCB. The electrical connector device PCB provides a firm base for the resiliently compressible electrical connector, and therefore helps to ensure that there is a good electrical connection with the lighting device PCB. The resilient compressible electrical connector can protrude perpendicular outwards form the electrical connector device PCB. The electrical connector device PCB can be attached to the sealing member preformed onto the electrical cable. The PCB can be mounted on an end face of the sealing member pre-formed onto the electrical cable. The resiliently compressible electrical connector can comprise a retractable pin. The retractable pin can include a first part fixed to the electrical connector device PCB. The retractable pin can include a second part arranged for limited movement with respect to the first part. The retractable pin can include a resilient element, such as spring, and preferably a helical spring, arranged to bias the second part into an extended position. The second part can be moved to a compressed position by applying an axial load to the second part. This can be achieved, for example by attaching the end cap to the tubular casing. This causes the second part to move relative the first part into the compressed position, thereby causing the pin to retract. In some embodiments, the resiliently compressible electrical connector can be attached to the lighting device PCB. For example, the resiliently compressible electrical connector can be mounted on an opposite side of the lighting device PCB from the LED(s) and / or LED chip(s). The resiliently compressible electrical connector can be arranged to electrically connect with the electrical connector device PCB. The electrical cable can include a second multistranded electrical wire. The second multistranded electrical wire can have a second insulation sheath, wherein an exposed section of the second multi-stranded wire can include strands that are bonded together with a bonding agent, thereby forming a substantially solid wire section which substantially blocks the flow of fluids along the second multistranded wire. The sealing member pre-formed onto the electrical cable can overlie at least part of the substantially solid wire section and at least part of the second insulating sheath, and can be arranged to substantially block the flow of fluids along gaps between the second insulating sheath and the second wire. The electrical conductor device can include a second resiliently compressible electrical connector that is arranged to electrically connect the second multistranded electrical wire to the lighting device. The second resiliently compressible electrical connector can be similar to the resiliently compressible electrical connector. The second resiliently compressible electrical connector can be arranged according to any configuration of the first resiliently compressible electrical connector described herein. The second resiliently compressible electrical connector is arranged to electrically connect with the lighting device PCB. The lighting device PCB can include a second electrical contact that is arranged to engage with the second resiliently compressible electrical connector. For example, the second electrical contact can be located on the side of the lighting device PCB that is opposite to the side of the lighting device PCB on which the at least one LED and / or LED chip is located. The end cap can include a first screw thread. The tubular member can include a second screw thread. The end cap can be releasably attachable to the tubular casing by engaging the first and second screw threads and screwing the end cap onto the casing. The end cap can be removed from the tubular casing by unscrewing the end cap. One of the first and second screw threads can be an internal screw thread and the other of the first and second screw threads can be an external screw thread. The end cap can include a flange, which protrudes perpendicularly outwards from an end cap tubular body. Optionally, the end cap include an optically transparent window, for example in the form of a panel, to allow light to be emitted from the luminaire. The transparent window can be made from glass or a plastics material. In other embodiments, the lens can be integrated into the end cap, and the lens can provide the optically transparent window. The sealing member can be moulded from: a plastics material, natural rubber or synthetic materials having rubber like-properties. The plastics material can include thermoplastic such as a polyamide. The plastics material can include silicone. Other suitable materials, including suitable mixtures, can be used, such as natural rubber and synthetic materials having rubber like-properties, such as resiliency. The tubular casing can include a first opening located at a first end of the tubular casing. The first opening can be a front opening. The tubular casing can include a second opening at the second end of the tubular casing. The second opening can be a rear opening. The electrical cable can protrude out of the second opening. The tubular casing can include a lip located adjacent the second opening. The lip can be arranged to prevent the sealing member from exiting the second end of the tubular casing via the second opening by providing axial resistance to movement of the seal member in a direction away from the lighting device. The external diameter of at least part of the sealing member can be greater than an internal diameter of the lip. The tubular casing can include a first part for housing the lighting device. The lighting device PCB can be arranged transversely to a longitudinal axis of the luminaire. The lighting device PCB can be seated on an internal shoulder of the tubular casing. The solid state lighting device can be mounted in thermal contact with the casing, and the casing can act as a heat sink for the lighting device. For example, lighting device MCPCB can be in thermal contact with the casing. The arrangement can be such that heat generated by the lighting device can be conducted into the casing, and can be then transferred to the environment by conduction and / or convection. The tubular casing can include a material that is thermally conductive, such as aluminium or copper. This helps to dissipate heat from the solid state lighting device quickly and efficiently. Alternatively the casing can be made from steel, which has good fire resistance qualities, and preferably stainless steel, which resists water corrosion. Other components, such as optical components, can be located in the first part of the tubular casing. For example, a lens can be located in the first part of the tubular casing. The lens can be located between the lighting device and the end cap. A reflector can be located in the first part of the tubular casing. The reflector can be located between the lighting device and the end cap, and can be preferably located between the lens and the end cap. Some reflectors can be mounted around the lens, and can sit between the lens and an internal surface of the wall of the tubular container. A diffuser can be located in the first part of the tubular casing. A low glare device can be located in the first part of the tubular casing. The first part can be located in a front part of the luminaire. The tubular casing can include a second part for housing at least part of the cable assembly and at least part of the sealing member. The sealing member can be sized and shaped to fill a substantial part of the second part of the casing. The internal diameter of the tubular casing for the first part can be greater than the internal diameter of the tubular casing for the second part. The second part can be located in a rear part of the luminaire. The sealing member can be in the form of a bung. The sealing member can include an intermediate sealing element to form a seal between the sealing member and the internal wall of the tubular casing. The intermediate sealing element can comprise an O-ring. A recess can be formed in at least one of the tubular casing and the sealing member. The intermediate sealing element can be seated in the recess. The recess can comprise a circumferential groove. A plurality of recesses can be provided. A plurality of intermediate sealing elements can be provided. Each intermediate sealing element can be located in a respective one of the recess. The intermediate sealing elements can be spaced apart axially along the sealing member. The strands of wire can be bonded together using a metallic material, such as a solder. Molten solder has a low viscosity and therefore effectively fills the gaps between the strands. The solder solidifies to bond the wires together to form a substantially solid wire section. Of course other low viscosity materials can be used. It is not necessary for the material to be metallic or electrically conducting. According to another aspect, there is provided a method according to claim 24. The method forms a luminaire having the advantages of the luminaire of claim 1. Since the mould can be separate from the tubular casing, the sealing member can be formed on the electrical cable as a separate step, that can be, no liquid sealant can be poured into the rear of the luminaire. Forming the sealing member onto the electrical cable, provides a much better controlled sealing process, and allows the sealing member to have a shape that is not limited to the internal shape of the casing. Since no liquid is poured into the casing the process can be much cleaner at the place of assembling the luminaire. The sealing member comprises a solid body, for example in the form of a bung, which can be assembled together with the casing. According to another aspect there is provided a method for manufacturing a luminaire. The method can include providing a lighting device, an electrical cable having a multistranded electrical wire, for example a first multistranded electrical wire. The method can include providing a tubular casing. The method can include providing an end cap. The method can include forming a cable assembly by exposing a section of the multistranded electrical wire, bonding the exposed strands together with a bonding agent, thereby forming a substantially solid wire section which substantially blocks the flow of fluids along the multistranded wire. The method can include placing at least part of the electrical cable into a mould, and moulding at least one sealing member onto the electrical cable over at least a part of the exposed wire and at least a part of the insulating sheath, thereby sealing the substantially solid wire section to the insulation sheath. The method can include removing the cable assembly from the mould. The method can include providing an electrical connector device having a resiliently compressible electrical connector, for example a first resiliently compressible electrical connector. The method can include electrically connecting a resiliently compressible electrical connector to the multistranded electrical wire. The method can include inserting the lighting device into the tubular casing. The method can include inserting at least part of the sealing member into the tubular casing such that the sealing member engages and seals with at least one internal wall of the tubular casing. The method can include locating the resiliently compressible electrical connector between the sealing member and the lighting device. The method can include mounting the end cap on to a first end of the tubular casing, thereby compressing the resilient resiliently compressible electrical connector between the sealing member and the lighting device and forming an electrical connection between the multistranded wire and the lighting device. In preferred embodiments the method can include forming the sealing member from heated material. For example, the method can include forming the sealing member from melted material. This can be achieved, for example by melting solid material in the mould, or by inserting material into the mould in a liquid state. The melted material can be allowed to solidify. The solidified material conforms to the shape of the mould. The sealing member can be formed by an injection moulding process. Advantageously the method can include the step of treating at least some of the surfaces to be over moulded with a primer. This improves the bond between the sealing member and the surfaces on which the sealing member can be moulded. The primer can be selected according to the moulding material. The electrical connector device can include a printed circuit board (PCB). The method can include electrically connecting the electrical connector device PCB to the multistranded electrical wire. The method can include electrically connecting the resiliently compressible electrical connector to the electrical connector device PCB such that the resiliently compressible electrical connector is electrically connected to the multistranded electrical wire via the electrical connector device PCB. The method can include mounting the electrical connector device PCB on to the sealing member. The method can include mounting the electrical connector device PCB on to a leading end face of the sealing member. The electrical cable can include an outer sheath. The method can include the sealing member sealing the outer sheath to at least one of: the first solid wire section; the second solid wire section; the first insulation sheath; and the second insulation sheath. For example, the sealing member can be moulded over at least part of the first and second solid wire sections, at least part of the first and second insulating sheaths and at least part of the outer sheath. The electrical cable can include a second multistranded electrical wire having a second insulation sheath. The method can include exposing a second section of the second multistranded wire. The method can include bonding the exposed strands together with a bonding agent, thereby forming a second substantially solid wire section which substantially blocks the flow of fluids along the second multistranded wire. The method can include moulding the sealing member onto the electrical cable to seal the second substantially solid wire section to the second insulating sheath. The electrical connector device can include a second resiliently compressible electrical connector. The method can include electrically connecting the second resiliently compressible electrical connector to the second multistranded electrical wire. The method can include electrically connecting the electrical connector device PCB to the second multistranded electrical wire. The method can include electrically connecting the second resiliently compressible electrical connector to the electrical connector device PCB such that the second resiliently compressible electrical connector is electrically connected to the second multistranded electrical wire via the electrical connector device PCB. The electrical cable can include an outer sheath. The method can include the sealing member sealing the outer sheath to at least one of: the first substantially solid wire section; the second substantially solid wire section; the first insulation sheath; and the second insulation sheath. The lighting device can include a printed circuit board (PCB). The method can include mounting the lighting device in the tubular casing such that the lighting device PCB is arranged perpendicularly to the longitudinal axis of the tubular casing. Thus the lighting device PCB extends transversely across the tubular casing. The tubular casing can include a first part and a second part. The method can include inserting the lighting device into the first part of the tubular casing. The method can include inserting at least a part of the sealing member into the second part of the tubular casing. The sealing member can be inserted into the second part of the casing in a manner such that, at least when the end cap can be fitted, the or each resiliently compressible electrical connector is electrically connected to the lighting device PCB. Typically, the sealing member is sized and shaped to fill a substantial part of the second part of the tubular casing. The tubular casing can include a first opening arranged to provide access the first part of the tubular casing. The method can include inserting the lighting device into the first part of the tubular casing through the first opening. The method can include inserting a lens device into the first part of the tubular casing. Typically, the lens is located between the lighting device and the end cap. The tubular casing can include a second opening arranged to provide access the second part of the tubular casing. The method can include inserting the sealing member into the second part of the tubular casing through the second opening. Typically, the sealing member forms a seal with at least one internal surface of the tubular casing, thereby closing the second opening. The sealing member can be in the form of a bung. The method can include providing at least one intermediate sealing element, and using the or each intermediate sealing element to form a seal between the sealing member and the tubular casing. Each intermediate sealing element can comprise an O-ring. The method can include forming a recess in at least one of the casing and the sealing member, and locating the intermediate sealing element in the recess. The recess can comprise a circumferential groove. The circumferential groove can be formed in an outer surface of the sealing member. The circumferential groove can be formed in an inner surface of the of the tubular casing, for example in the second part of the tubular casing. The bonding agent can include a metallic material; and preferably the bonding agent can include solder. The sealing member can be moulded from: a plastics material and / or natural rubber and / or synthetic materials having rubber like-properties. Embodiments of the invention will now be described by way of example only with reference to the drawings, wherein: Figure 1 is an isometric view of a luminaire in accordance with the invention; Figure 2a is a longitudinal cross sectional view of the luminaire of Figure 1; Figure 2b is an enlarged view of part of Figure 2a; and Figure 3 is a diagrammatic end view of an electric cable including two multistranded copper wires, which is used in the luminaire of Figure 1. A first embodiment of the invention is shown in Figures 1 to 3. Figure 1 shows a luminaire 101, including: a solid state lighting device 103, which includes at least one Light Emitting Diode (LED) chip and / or at least one LED mounted on a Printed Circuit Board (PCB) 107; a tubular casing 109 for housing part of an electrical the cable 1; a lens; an end cap 121; and a sealing member in the form of a bung 123. The tubular casing 109 can have a first part 111 for housing the solid state lighting device 103. The first part can be located on a front side of the tubular casing, that is, a side from which light is emitted. Hereinafter, the first part Illis referred to as the “light source part 111”. The tubular casing 109 can have second part 113 for housing part of the electrical the cable 1 and at least part of the bung 123. The second part is hereinafter referred to as the “cable receiving part 113”. In some embodiments, the tubular casing 109 has a circular transverse crosssection, however it will be appreciated that other embodiments may have a different transverse cross-section, for example a rectangular transverse crosssection. The light source part Illis defined by the side wall(s) 109a of the casing, the end cap 121, and the lighting device PCB 107. The tubular body 109 has a first opening located a first (front) end 109b of the tubular casing 109. The solid state lighting device 103is located within the light source part 111. The solid state lighting device 103 is mounted on a shoulder 125 formed in the side wall(s) 109a of the tubular casing. The light device PCB 107 extends transversely across the tubular casing, the arrangement being such that the at least one LED and / or at least one LED chip is oriented towards the first opening. Typically, the lighting device PCB 107 comprises a metal core printed circuit board (MCPCB), which helps to conduct heat generated by the at least one LED and / or at least one LED chip into the tubular casing 109. The casing 109, is preferably made from a material that has good thermal conductivity properties, such as aluminium, thereby enabling the casing 109 to act as a heat sink for the solid state lighting device 103. Thus heat generated, in use, by the solid state lighting device 103 is transferred by conduction through the partition 125 into the side wall(s) of the casing 109a. Alternatively, the tubular casing can be made from other materials such as steel and preferably stainless steel. Optionally, other optical components such as a lens 117 and reflector 118 can be located int the light source part 111. The lens 117 can be mounted on the lighting device PCB 107. The end cap 121 can have a transparent window 119. The end cap 121 has an internal screw thread 121a that is arranged to mate with an external screw thread 109d on the tubular casing 109. The end cap 121 and transparent window 119 substantially seal the front part of the casing 109 by closing the first opening, when the end cap is screwed on to the tubular body 109. Typically, an annular seal 110 is provided between at least one of the end cap 121 and the transparent window 119; the end cap 121 and the side wall 109a of the casing; and the transparent window 119 and the side wall of the casing 109a. The end cap 121 can include a flange 121b, which protrudes outwards from a tubular end cap body 121c. The cable receiving part 113 is located at the rear side of the tubular casing 109. Typically, a short section of the cable 1 is housed within the cable receiving part 113. The bung 123 fills a substantial part of the volume of the cable receiving part 113, and seals a second (rear) opening at the rear end of the cable receiving part 113. A lip 114 is located adjacent the second opening of the tubular container 109 and is arranged to engage the bung 123 to prevent the bung 123 from exiting the tubular casing 109 via the second opening. A preferred type of electrical cable 1 is shown in Figure 3. It includes a flexible outer sheath 5, two multistranded wires 7a,7b, each wire 7a,7b having multiple strands 9 of copper wire and a flexible insulating sheath Ila,lib. It can be seen from Figure 3 that there are gaps 13 between the strands 9 of copper wire, and gaps 15 between the insulating sheaths Ila, 11b and the flexible outer sheath 5. Each wire 7a,7b has been treated by removing a section of the insulating sheath Ila, 11b at one end and applying a filling material, such as a solder (a so called “tinning process”), to the multiple strands 9 in a molten state. The solder flows into the gaps 13 between the strands 9 and solidifies, thereby bonding the strands 9 together to produce a substantially solid wire along at least part of the exposed section of the wire. The purpose of soldering the strands 9 together is to block the flow of air and moisture along the gaps 13 between the strands 9 of wire. Thus overall the electrical cable 101 retains its flexibility, while at the same times includes means for blocking the flow of moisture into the luminaire 101. The bung 123 is resilient. It is made from a mouldable material that is capable of forming a seal with the casing 109 when the bung 123 is located at least partly within the cable receiving part 113. The bung 123 can be moulded from a plastics material, natural rubber or synthetic materials having rubber like-properties. The plastics material can include thermoplastic such as a polyamide. The plastics material can include silicone. Other suitable materials, including suitable mixtures, can be used, such as natural rubber and synthetic materials having rubber like-properties, such as resiliency. The bung 123 is formed on the cable 1 via a moulding process such that it overlies at least part of each bonded wire 7a,7b section and part of at least one of the insulating sheaths Ila,lib and the outer sheath 5. The bung 123 prevents air from entering the light source part 111 since it blocks air from travelling along the gaps 13,15 in the cable 1. Providing the bung 123 is this manner provides better control of the wires 7a,7b, which helps to ensure separation of the wires 7a,7b so that no short circuits can occur. The bung 123 comprises a body at least a part of which is arranged to substantially conform with at least part of the of the cable receiving part 113. The bung 123 is pushed into the cable receiving part 113 with cable 1, since the bung 123 is formed outside of the casing 109. The bung is pushed in through an opening at a rear end 109c of the casing. In the embodiment shown in the Figures, the body includes a substantially cylindrical portion 123a which substantially fills the cable receiving part 113, save for a gap adjacent the solid state lighting device PCB 107 to accommodate an electrical connection device 126. First and second circumferential grooves 150,152 are formed in an outer surface of the bung 123. A first O-ring 154 is seated in the first groove 150. A second O-ring 156 is seated in the second groove 152. The O-rings 152,154 sealingly engage with an internal surface of the casing 109 to seal the cable receiving part 113. Preferably each O-ring 154,156 is made from Nitrile Butadiene Rubber (NBR). The second O-ring 156 is spaced apart from the first O-ring 154 in a longitudinal axial direction X-X. The bung 123 also includes a tail portion 123b, which overlies a portion of the cable 1 that protrudes from the cable receiving part 113. The tail portion 123b is provided for mechanical purposes. The electrical connection device 126 includes a printed circuit board (PCB) 128 and a pair of resiliently compressible electrical connector pins 130. The multistranded electrical wires 7a,7b are electrically connected to the electrical connection device PCB 128. The resiliently compressible electrical connector pins 130 protrude perpendicular outwards from the electrical connection device PCB 128, in a direction away from the bunt 123. The electrical connection device 126 is mounted on to the bung 123 such that the electrical connection device PCB 128 is sat on a leading end face of the bung 123, i.e. the face of the bung 123 that is inserted furthest into the cable receiving part 113. When the bung 123 is inserted into the cable receiving part 113 the longitudinal axes of pins 130 are arranged generally parallel with the longitudinal axis X-X of the tubular casing 109, and they protrude from the electrical connection device PCB 128 towards the lighting device PCB 107. The lighting device PCB 107 includes electrical contacts that are arranged to engage the respective resiliently compressible electrical connector pins 130. One of the resiliently compressible electrical connectors 130 comprises a first part 130a, which is fixed to the electrical connection device PCB 128 and is electrically connected to one of the multistranded electrical wires 7a via the electrical connection device PCB 128. That resiliently compressible electrical connector 130 includes a second part 130b that is moveable axially with respect to the first part by a limited amount. A helical spring (not shown) is located within the retractable pin, and when compressed is arranged to urge the second part into engagement with the lighting device PCB 107. Thus the second part 130b is moveable between extended (non-compressed) and compressed positions. The other resiliently compressible electrical connector 130 comprises a first part 130a, which is fixed to the electrical connection device PCB 128 and is electrically connected to the other one of the multistranded electrical wires 7b via the electrical connection device PCB 128. That resiliently compressible electrical connector 130 includes a second part 130b that is moveable axially with respect to the first part by a limited amount. A helical spring (not shown) is located within the retractable pin, and when compressed is arranged to urge the second part into engagement with the lighting device PCB 107. Thus the second part 130b is moveable between extended (non-compressed) and compressed positions. The resiliently compressible electrical connectors 130 can be made from a metallic material, such as brass, copper, or aluminium. The resiliently compressible electrical connectors 130 are arranged to electrically connect with the lighting device PCB 107, at least in a condition when the end cap 121 is screwed on to the tubular casing 109. By applying the end cap 121, the lens 117 firmly holds the lighting device PCB 107 against the shoulder 125. This causes the pins to retract from the extended position to the compressed position, thereby loading the lighting device PCB 107 and ensuring a good electrical connection with the lighting device PCB 107. Since the at least one LED and / or the at least one LED chip are electrically connected to the lighting device PCB 107, when the resiliently compressible electrical connectors 130 electrically connect with the lighting device PCB 107, the at least one LED and / or the at least one LED chip are electrically connected to an electrical source (not shown) via the lighting device PCB 107, the resiliently compressible electrical connectors 130, the electrical connector device PCB 128 and the multistranded electrical wires 7a,7b. An advantage of the arrangement is that it is possible to electrically connect the lighting device PCB 107 to the multistranded electrical wires 7a,7b without the need for any intervening joining wires that have to be connected to the lighting device PCB 107 within the tubular casing 109, which makes assembly easier. Also, it enables the bung 123 to be inserted into the tubular casing 109 from an opposite an end of the tubular casing 109 from the lighting device 103, which eases the assembly process. Two mounting wings 136 are attached to an outer surface of the casing 109. The wings 136 are used to fix the luminaire to a body, such as a wall, ceiling, or floor. The process for manufacturing the luminaire 101, includes at least some of the following steps: A. Removing a section of the outer sheath 5 of the electrical cable 1 to expose sections of the two multistranded wires 7a,7b; B. For each multistranded wire 7a,7b, removing a section of insulating sheath Ila,lib to expose the copper strands 9; C. For each multistranded wire 7a,7b, over a relatively short length of wire, filling the gaps between the strands 9 by bonding the exposed strands together to form a substantially solid section of wire. The filler material is typically a low viscosity material that can easily flow into the gaps 13 between the strands and solidifies in-situ. For example, a solder can be used; D. Optionally, applying a primer 137, such as a silicone primer, to part of electrical cable 1 which is to be over moulded, which typically includes parts of the wires 7a,7b, insulating sheaths Ila, 11b and outer sheath 5; E. Inserting a part of the cable 1, which is to be over moulded into a mould, this typically includes parts of the: bonded sections of the wires 7a,7b; insulating sheaths Ila,lib; and outer sheath 5. Inserting a material into the mould, such as silicone, in solid form and heating the mould to melt the material. Alternatively the material can be inserted into the mould in liquid form, for example by using an injection moulding process. Allowing the material to solidify by natural cooling, or by actively cooling the mould, to form the bung 123 around that part of the cable 1. The bung 123 forms a seal to prevent moisture ingress into the gaps 13,15. This provides a controlled and neat way of sealing around the cable 1. It is to be noted that the mould is separate from the casing 109. Thus the bung 123 is formed outside of the casing 109 prior to sealing the second opening; F. Electrically connecting the wires 7a,7b to the electrical connector device PCB 128, and mounting the electrical connector device PCB 128 on an end face of the bung 128, such that the resiliently compressible electrical connectors protrude outwards from a leading end of the bung; G. Optionally, inserting O-rings into groves formed in an outer surface of the bung; H. Inserting at least part of the bung 123 into the second opening at the rear of the cable receiving part 113 in a manner such that, the resiliently compressible electrical connects are oriented towards and extend into the light source part 111 in a non-compressed state, thereby sealing the part 113; I. Inserting the solid state lighting device 103 into the light source part 111, so that the lighting device PCB 107 sits transversely across the tubular container 109, adjacent the shoulder; J. Optionally, inserting a lens and any other required optical components into the light source part 111; K. Attaching the end cap 121 to the tubular casing 109, to seal the front of the luminaire. As the end cap 121 is attached, the lighting device PCB 107 is forced into it seating position on shoulder 125 causing the lighting device PCB 107 to engage the resiliently compressible electrical connectors 130, and compresses them, thereby electrically connecting the lighting device PCB 107 to the multistranded electrical wires 7a,7b. It will be appreciated by the skilled person that strict adherence to the order of these steps is not required for at least some luminaires. When it is necessary to disassemble the luminaire 101 for repair or modification, the end cap 121 can be unscrewed to remove and replace the lighting device 103 and / or any of the optical components such as the lens 117 and reflector. The parts to be repaired or modified can be replaced with the new equivalent parts and the end cap can be screwed on to the tubular casing 109 again. It will be appreciated by the skilled person that modifications can be made to the above embodiments that fall within the scope of the invention, for example the transparent window is not strictly necessary. The lens device can be arranged in a manner that enables a front part of the lens device to form a seal with the trim element. The bung can be moulded to any required shape. For example, the bung may include a substantially cuboid portion, or any other polygonal form required. The bung can also be moulded to fit irregular shapes, according to the form of cable receiving part. The cable can include any suitable number of wires required for the application. The electrical cable 1 may not include an outer sheath 5, in which case seals are formed between the exposed section of wire and the insulating sheath Ila,11b. Light sources other than LED type lights can be used in the invention. Other materials can be used to manufacture the bung. The main characteristic is that an effective seal has to be made with the cable and the casing. Mouldable materials having rubber like properties are most preferable. These can be natural materials such as natural rubber or synthetic materials such as an elastomer. An inner surface of the casing can include circumferential grooves to receive the circumferential ridges formed in the sealing member. If a non-cylindrical casing is provided, for example one having a square cross-section, the inner walls of the casing includes peripheral grooves that extend around the four walls. In some embodiments, the sealing member is releasably attachable to the casing so that the sealing member can be removed. Additionally, or alternatively, grooves can be formed in the casing to receive the O-rings, and preferably an inner face of the casing. The bung can be formed by a plurality of moulding processes, which produces a bung having at least first and second parts. The first part can seal the solid sections of wire 7a,7b to the insulation sheaths Ila,11b and outer sheath 5. The second part can be formed such that it lies over at least a section of the first part of the bung, and parts of the multistranded wires 7a,7b. The first part can be made from a first material, such as nylon, and the second part can be made from a second material, such as silicone. In the embodiment shown in the Figures, the end cap 121 has an internal screw thread 121a that is arranged to mate with an external screw thread 109d on the tubular casing 109. In other embodiments, the end cap 121 can have an external screw thread and the tubular casing can have an internal screw thread. In some embodiments, the resiliently compressible electrical connectors 130 can be attached to the lighting device PCB 107. For example, the resiliently compressible electrical connector 130 can be mounted on an opposite side of the lighting device PCB from the LED(s) and / or LED chip(s). The resiliently compressible electrical connectors 130 can be arranged to electrically connect with the electrical connector device PCB 128. The electrical connector device PCB 128 can include suitable electrical contacts to engage with the resiliently compressible electrical connectors 130. The description presents exemplary embodiments and, together with the drawings, serves to explain principles of the invention. However, the scope of the invention is not intended to be limited to the precise details of the embodiments or exact adherence with all method installation steps, since variations will be apparent to a skilled person and are deemed also to be covered by the claims. Terms for components used herein should be given a broad interpretation that also encompasses equivalent functions and features. In some cases, several alternative terms (synonyms) for structural features have been provided but such terms are not intended to be exhaustive. Descriptive terms should also be given the broadest possible interpretation; e.g. the term "comprising" as used in this specification means "including" such that interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. Directional terms such as “vertical”, “horizontal”, “up”, “down”, “front”, “rear”, “upper” and “lower” may be used for convenience of explanation usually with reference to the illustrations and are not intended to be ultimately limiting if an equivalent function can be achieved with an alternative dimension and / or direction. The description herein refers to embodiments with particular combinations of configuration steps or features, however, it is envisaged that further combinations and cross-combinations of compatible steps or features between embodiments will be possible. Indeed, isolated features may function independently as an invention from other features and not necessarily require implementation as a complete combination. Any feature from an embodiment can be isolated from that embodiment and included in any other embodiment. The term “at least one of’ is to be interpreted in the sense of “and / or”. For example, the term “at least one of the tubular casing and the sealing member” is to be interpreted as meaning any one of the following: the tubular casing alone; the voltage alone; or the combination of the tubular casing and sealing member. As another example, the term “at least one of the tubular casing, the sealing member and the lens” is to be interpreted as meaning any one of the following: the tubular casing alone; the sealing member alone; the lens alone; the combination of the tubular casing and the sealing member; the combination of the tubular 5 casing and the lens; the combination of the sealing member and the lens; or the combination of the tubular casing, the sealing member and lens.

Claims

1. A luminaire, including: a lighting device; a cable assembly including an electrical cable for electrically connecting the lighting device to a power source, the electrical cable including a multistranded electrical wire having an insulation sheath, wherein an exposed section of the multistranded wire includes strands that are bonded together with a bonding agent, thereby forming a substantially solid wire section which substantially blocks the flow of fluids along the multistranded wire; a sealing member pre-formed onto the electrical cable, wherein the sealing member overlies at least part of the substantially solid wire section and at least part of the insulating sheath, and is arranged to substantially block the flow of fluids along gaps between the insulating sheath and wire; a tubular casing, wherein the lighting device is located within the tubular casing and is arranged to emit light out of a first end of the tubular casing, at least a part of the cable assembly is located within the tubular casing, and at least part of the sealing member pre-formed onto the electrical cable is located within the tubular casing and engages at least one internal surface of the tubular casing and seals against the at least one internal surface to close a second end of the tubular casing; an end cap releasably attachable to the first end of the tubular casing; and an electrical connector device including a resiliently compressible electrical connector arranged to electrically connect the lighting device to the multistranded wire at least in a condition wherein the end cap is attached to tubular casing.

2. The luminaire of any one of the preceding claims, wherein the lighting device comprises a solid state lighting device.

3. The luminaire of any one of the preceding claims, wherein the lighting device includes a printed circuit board (PCB), and preferably a metal core printed circuit board (MCPCB).

4. The luminaire of claim 3, wherein the resiliency compressible electrical connector is located between the sealing member pre-formed onto the electrical cable and the lighting device PCB, and the resiliency compressible electrical connector is arranged to electrically connect with the lighting device PCB.

5. The luminaire of any one of the preceding claims, wherein the electrical connector device is mounted on the sealing member pre-formed onto the electrical cable.

6. The luminaire of any one of the preceding claims, wherein the resiliently compressible electrical connector is mounted on a base, such as a board, for example a printed circuit board (PCB).

7. The luminaire of any one of the preceding claims, wherein the electrical connector device includes a printed circuit board (PCB), the multistranded wire is electrically connected to the electrical connector device PCB, and the resiliently compressible electrical connector is electrically connected to the electrical connector device PCB.

8. The luminaire of claim 7, wherein the resiliently compressible electrical connector is mounted on the electrical connector device PCB.

9. The luminaire of claim 7 or 8, wherein the electrical connector device PCB is attached to the sealing member pre-formed onto the electrical cable.

10. The luminaire of any one of the preceding claims, wherein the resiliently compressible electrical connector comprises a retractable pin.

11. The luminaire of claim 10 when dependent on claim 8, wherein the retractable pin includes a first part fixed to the electrical connector device PCB, a second part arranged for limited movement with respect to the first part, and a resilient element, such as spring, arranged to bias the second part into an extended position.

12. The luminaire of any one of the preceding claims, wherein the resiliency compressible electrical connector is attached to the lighting device PCB.

13. The luminaire of any one of the preceding claims, wherein the electrical cable includes a second multistranded electrical wire having a second insulation sheath, wherein an exposed section of the second multistranded wire includes strands that are bonded together with a bonding agent, thereby forming a substantially solid wire section which substantially blocks the flow of fluids along the second multistranded wire; the sealing member pre-formed onto the electrical cable, wherein the sealing member overlies at least part of the substantially solid wire section and at least part of the second insulating sheath, and is arranged to substantially block the flow of fluids along gaps between the second insulating sheath and the second wire; and the electrical connector device includes a second compressible electrical connector that is arranged to electrically connect the second multistranded wire to the lighting device.

14. The luminaire of any one of the preceding claims, wherein the end cap includes a first screw thread and the tubular member includes a second screw thread, and the end cap is releasably attachable to the tubular casing by engaging the first and second screw threads, and screwing the end cap onto the casing.

15. The luminaire of any one of the preceding claims, wherein the sealing member is moulded from: a plastics material, natural rubber or synthetic materials having rubber like-properties.

16. The luminaire of any one of the preceding claims, wherein the tubular casing includes a first opening located at a first end of the tubular casing.

17. The luminaire of any one of the preceding claims, wherein the tubular casing includes a second opening at the second end of the tubular casing, and the electrical cable protrudes out of the second opening.

18. The luminaire of claim 17, including a lip located adjacent the second opening, wherein the lip is arranged to prevent the sealing member from exiting thesecond end of the tubular casing via the second opening, by providing axial resistance to movement of the seal member in a direction away from the lighting device.

19. The luminaire of any one of the preceding claims, wherein the tubular casing includes a first part for housing the lighting device and a second part for housing at least part of the cable assembly and at least part of the sealing member.

20. The luminaire of any one of the preceding claims, wherein the sealing member is in the form of a bung.

21. The luminaire of any one of the preceding claims, wherein sealing member includes an intermediate sealing element to form a seal between the sealing member and the internal wall of the tubular casing; and preferably the intermediate sealing element comprises an O-ring.

22. The luminaire according to claim 21, including a recess in at least one of the tubular casing and the sealing member, wherein the intermediate sealing element is seated in the recess; and preferably the recess comprises a circumferential groove.

23. The luminaire of any one of the preceding claims, wherein the strands of wire are bonded together using a metallic material, such as a solder.

24. A method for manufacturing a luminaire, including: providing a lighting device, an electrical cable having a multistranded electrical wire, a tubular casing and an end cap; forming a cable assembly by exposing a section of the multistranded electrical wire, bonding the exposed strands together with a bonding agent, thereby forming a substantially solid wire section which substantially blocks the flow of fluids along the multistranded wire, placing at least part of the electrical cable into a mould, and moulding at least one sealing member onto the electrical cable over at least a part of the exposed wire and at least a part of the insulating sheath, thereby sealing the substantially solid wiresection to the insulation sheath; removing the cable assembly from the mould; and providing an electrical connector device having a resiliently compressible electrical connector and electrically connecting a resiliently compressible electrical connector to the multistranded electrical wire; inserting the lighting device into the tubular casing; inserting at least part of the sealing member into the tubular casing such that the sealing member engages and seals with at least one internal wall of the tubular casing and such that the resiliently compressible electrical connector is located between the sealing member and the lighting device; mounting the end cap on to a first end of the tubular casing, thereby compressing the resilient resiliently compressible electrical connector between the sealing member and the lighting device and forming an electrical connection between the multistranded wire and the lighting device.

25. The method according to claim 24, wherein electrical connector device includes a printed circuit board (PCB), electrically connecting the electrical connector device PCB to the multistranded electrical wire, and electrically connecting the resiliently compressible electrical connector to the electrical connector device PCB such that the resiliently compressible electrical connector is electrically connected to the multistranded electrical wire.

26. The method of claim 25, including mounting the electrical connector device PCB on to the sealing member, and preferably mounting the electrical connector device PCB on to a planar end face of the sealing member.

27. The method according to any one of claims 24 to 26, wherein the electrical cable includes an outer sheath, and the method can include the sealing member sealing the outer sheath to at least one of: the first solid wire section; the second solid wire section; the first insulation sheath; and the second insulation sheath.

28. The method according to any one of claims 25 to 27 when dependent on claim 25, wherein the electrical cable includes a second multistranded electrical wire having a second insulation sheath, and the method includes exposing a second section of the second multistranded wire; bonding the exposed strands togetherwith a bonding agent, thereby forming a second substantially solid wire section which substantially blocks the flow of fluids along the second multistranded wire; moulding the sealing member onto the electrical cable to seal the second substantially solid wire section to the second insulating sheath; and the electrical connector device having a second resiliently compressible electrical connector and electrically connecting the second resiliently compressible electrical connector to the second multistranded electrical wire.

29. The method according to claim 28, including electrically connecting the electrical connector device PCB to the second multistranded electrical wire, and electrically connecting the second resiliently compressible electrical connector to the electrical connector device PCB such that the second resiliently compressible electrical connector is electrically connected to the second multistranded electrical wire.

30. The method of claim 28 or 29, wherein the electrical cable includes an outer sheath, and the method includes the sealing member sealing the outer sheath to at least one of: the first substantially solid wire section; the second substantially solid wire section; the first insulation sheath; and the second insulation sheath.

31. The method according to any one of claims 24 to 30, wherein the lighting device includes a printed circuit board (PCB), and mounting the lighting device in the tubular casing such that the lighting device PCB is arranged perpendicularly to the longitudinal axis of the tubular casing.

32. The method according to any one of claims 24 to 31, wherein the tubular casing includes a first part and a second part, inserting the lighting device into the first part of the tubular casing and inserting at least a part of the sealing member into the second part of the tubular casing.

33. The method according to claim 32, wherein the tubular casing includes a first opening arranged to access the first part of the tubular casing, and inserting the lighting device into the first part of the tubular casing through the first opening.

34. The method according to claim 32 or 33, including inserting a lens device into the first part of the tubular casing.

35. The method according to any one of claims 32 to 34, wherein the tubular casing includes a second opening arranged to access the second part of the tubular casing, and inserting the sealing member into the second part of the tubular casing through the second opening.

36. The method according to any one of claims 24 to 35, wherein the sealing member is in the form of a bung.

37. The method according to any one of claims 24 to 36, including providing at least one intermediate sealing element, and using the or each intermediate sealing element to form a seal between the sealing member and the tubular casing.

38. The method according to claim 37, including forming a recess in at least one of the casing and the sealing member, and locating the intermediate sealing element in the recess; and preferably the recess comprises a circumferential groove.

39. The method according to any one of claims 24 to 38, wherein the bonding agent includes a metallic material; and preferably the bonding agent includes solder.

40. The method according to any one of claims 24 to 39, wherein the sealing member is moulded from: a plastics material, natural rubber or synthetic materials having rubber like-properties.

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