Beacon light assembly and method for manufacturing the same

Abstract

The present disclosure relates to a beacon light assembly comprising a mounting board and a beacon light unit. The beacon light unit comprises a plurality of light emitting elements attached to the mounting board, and a light optic positioned on the mounting board. The light emitting elements are aligned along a first reference line and the light optic comprises a bottom side facing the mounting board. The beacon light assembly comprises at least one pin-hole connection between the light optic and the mounting board, and wherein each pin-hole connection is formed by a pin member and a hole member receiving the pin member. The pin member is attached to the mounting board and aligned along the first reference line or aligned along a second reference line parallel with the first reference line, and the bottom side of the light optic comprises the hole member. Alternatively, the hole member is formed in the mounting board and aligned along the first reference line, or aligned along a second reference line parallel with the first reference line, and the pin member is attached to the bottom side of the light optic. The present disclosure also relates to a manufacturing method for manufacturing such a beacon light assembly.

Description

[0001] Title: Beacon light assembly and method for manufacturing the same

[0002] Field of the disclosure

[0003] The present disclosure relates to a beacon light assembly, for example for marking obstructions that may present a hazard for aircraft or marine vessel navigation, or for providing specific information to an aircraft or marine vessel through light signs. The present disclosure also relates to a method for manufacturing such a beacon light assembly.

[0004] Background

[0005] Beacon lights assemblies are for example used for indicating a presence of obstacles such as towers, wind turbines, and any other object that can cause hazard to aviation. The beacon lights help for instance pilots to identify and navigate around potential obstacles Beacon lights are also commonly used as navigation and landing lights. For example, beacon lights can be used on a helideck to indicate helideck operational statuses to the helicopter pilots approaching the deck.

[0006] Generally, a beacon light assembly comprises a beacon light unit composed of an array of light emitting elements and a light optic having an entrance surface for receiving the light from the array and an exit surface for outputting the light from the array. In embodiments, in order to output light over a larger azimuthal angle, for example over an angle of 360°, the assembly can comprise multiple beacon light units arranged in for example a circular configuration. Typically, the beacon light assembly further comprises a mounting board supporting the beacon light units and a protecting cover for protecting the beacon light optics from environmental conditions.

[0007] For example, publication WO2015 / 099533, describes a beacon light assembly comprising one or more beacon light units and wherein each beacon light unit has an array of light emitting elements and a light optic for generating a light beam. In this publication, the light optic used, is a so- called total internal reflection, TIR, element comprising an entrance surface for receiving light from the array and at least one exit surface for outputting a light beam. In this example, the light entering the entrance surface is redirected to the exit surface by an angle of about 90°. As described, the entrance surface defines a recess in the light optic and the array is arranged in the recess such that a light emitting surface of each the light emitting elements is facing the entrance surface. In this way, a compact beacon light optic structure is obtained.

[0008] The beacon lights for informing aircraft or marine vessel navigation are subject to regulatory requirements which involve for instance requirements with respect to light characteristics such as light intensity and light uniformity. This generally results in severe accuracy requirements for building the components of the beacon light optic assemblies and in severe accuracy requirements for assembling the components. This is especially the case for compact beacon lights of the type described in publication WO20 15 / 099533 wherein the dimensions of the various components are small. The severe requirements in terms of the design of the components and the assembly in the factory, further results in an overall higher cost for manufacturing these type of compact beacon lights. With the current manufacturing methods used, as a result of the severe quality control and inspections to verify conformance with regulations, a relatively large number of beacon light assemblies produced in the factory are disapproved.

[0009] Hence, there is room for improving beacon light optic assemblies and improving the manufacturing method for producing these beacon light optic assemblies. Summary

[0010] It is an object of the present disclosure to provide a compact and robust beacon light assembly with improved light distribution characteristics, such as light uniformity. It is a further object to reduce the cost of manufacturing the beacon light assemblies when compared to prior art manufacturing processes.

[0011] The present disclosure is defined in the appended independent claims. The dependent claims define advantageous embodiments.

[0012] According to a first aspect of the present disclosure, a beacon light assembly is provided.

[0013] The beacon light assembly comprises a mounting board and a beacon light unit. The beacon light unit comprises: a) a plurality of light emitting elements attached to the mounting board, and wherein the light emitting elements are aligned along a first reference line, and b) a fight optic positioned on the mounting board and configured for receiving light from the light emitting elements and for outputting one or more fight beams, and wherein the light optic comprises a bottom side facing the mounting board. The beacon light assembly further comprises at least one pin-hole connection, preferably at least two pin-hole connections, between the light optic and the mounting board, wherein each pin-hole connection is formed by a pin member and a hole member receiving the pin member. The pin member is attached to the mounting board and aligned along the first reference line or aligned along a second reference line parallel with the first reference line, and wherein the bottom side of the light optic comprises the hole member, or alternatively, the hole member is formed in the mounting board and aligned along the first reference line or aligned along a second reference line parallel with the first reference line, and wherein the pin member is attached to the bottom side of the light optic.

[0014] Advantageously, by providing a pin member arranged along the same line that is used for aligning the light emitting elements or along a parallel line, and by providing a hole member in the light optic for receiving the pin member, a precise alignment between the light optic and the light emitting elements is obtained. Indeed, as the pin member and the hole member can be located with high accuracy on respectively the mounting board and the light emitting element, a precise alignment between the light optic and the light emitting elements can be obtained.

[0015] Advantageously, with the improved alignment between light optic and the light emitting elements, the light beam outputted by the light optic benefits from improved performances in terms of light intensity and light uniformity. Also, stray light can be reduced.

[0016] Advantageously, an auxiliary light emitting element or a dummy light emitting element can be selected as a pin member.

[0017] In embodiments, the auxiliary light emitting element is a LED or the dummy light emitting element is a dummy LED. In other embodiments, the pin member is formed by a geometrical body selected from any of: a cube, a cuboid, a triangular prism, a cylinder, or any other geometrical shape that is suitable for forming the pin-hole connection.

[0018] In some embodiments, the light assembly comprises one or more guiding pins coupled to the bottom side of the light optic and the guiding pins are inserted through corresponding guiding holes, preferably through- holes, located in the mounting board.

[0019] Advantageously, the guiding pins can be used for performing a coarse alignment between the light optic and the mounting board.

[0020] In embodiments, the reference line is for example a linear line. In embodiments, the light optic comprises a longitudinal axis and the bottom side of the light optic has an entrance surface for receiving light emitted by the light emitting elements and the entrance surface of the light optic is elongating parallel with the longitudinal axis and the hole member, when formed in the bottom side of the light optic, is aligned with the longitudinal axis, or alternatively, wherein the pin member, when attached to the bottom side of the light optic, is aligned with the longitudinal axis, such that when the pin member is received in the hole member for forming the at least one pin-hole connection the longitudinal axis is parallel with the first reference line.

[0021] In embodiments, typically, besides the entrance surface, the light optic further comprises a collimator, an internal reflector and an exit surface, and wherein the internal reflector is forming part of a top side of the light optic, opposite the bottom side, and wherein the collimator is located between the bottom side and the top side, and wherein the entrance surface and collimator are configured for directing light from the light emitting elements to the internal reflector and wherein the internal reflector is configured for directing light to the exit surface.

[0022] In other embodiments, the light optic comprises a longitudinal axis and the light optic further comprises a reflector surface configured for receiving fight from the light emitting elements and for redirecting fight received, and wherein the first reference line is a linear line and separated from the second reference line, and wherein the reflector surface is elongating parallel with the longitudinal axis, and wherein the hole member, when formed in the bottom side of the light optic, is aligned with the longitudinal axis, or alternatively, wherein the pin member, when attached to the bottom side of the light optic, is aligned with the longitudinal axis, such that when the pin member is received in the hole member for forming the at least one pin-hole connection the longitudinal axis is parallel with the first reference fine .

[0023] In embodiments, the mounting board comprises a printed circuit board having solder pads aligned along the first reference line, and wherein the light emitting elements and the pin member are attached to the solder pads. Alternatively, when the pin member is attached to the light optic, the hole member is made through one of the solder pads aligned along the first reference line. In other embodiments, the mounting board comprises a printed circuit board having solder pads aligned along the first reference line and further solder pads aligned along the second reference line, and wherein the light emitting elements are attached to solder pads aligned along the first reference line and the pin member is attached to a solder pad aligned with the second reference line. Alternatively, when the pin member is attached to the light optic, the hole member is made through one of the solder pads aligned with the second reference line.

[0024] According to a second aspect of the present disclosure, a method for manufacturing a beacon light assembly is provided. The method comprises: providing a mounting board, attaching a plurality of light emitting elements on the mounting board such that the light emitting elements are aligned along a first reference line, attaching at least one pin member on the mounting board such that the at least one pin member is aligned along the first reference line or aligned along a second reference line parallel with the first reference line, or alternatively forming at least one hole member in the mounting board such that the at least one hole member is aligned along the first reference line or aligned along a second reference line parallel with the first reference line, producing a light optic for receiving light from the light emitting elements and outputting one or more light beams and wherein the light optic comprises a bottom side, and, if the at least one pin member is attached to the mounting board, forming a hole member in the bottom side of the light optic for receiving the pin member, or alternatively, if the at least one hole member is formed in the mounting board, attaching a pin member to the bottom side of the light optic, and wherein the pin member is receivable in the hole member.

[0025] Generally, the method further comprises: positioning the light optic on the mounting board such that the pin member is received within the hole member so as to form a pin-hole connection between the light optic and the mounting board. Advantageously, by providing one or more pin members in the mounting board along the reference line, being the same line the light emitting elements are mounted on, the pin members can be attached to the mounting board with the same process and precision as the light emitting elements are attached to the mounting board. In this way, an improved overall alignment between the light emitting elements and light optic is obtained.

[0026] Advantageously, by attaching the pin member to the mounting board, which can be attached as part of the accurate process of placing components on a mounting board, such as a standard process of mounting components on a PCB board, the manufacturing process can be accelerated and facilitated.

[0027] Advantageously, with the improved method of manufacturing, the number of beacon light assemblies that fail the quality control tests is reduced, and hence the overall production cost is reduced.

[0028] In embodiments, the method further comprises: providing one or more guiding pins to the bottom side of the light optic and making corresponding guiding holes in the mounting board such that when the light optic is positioned on the board, the one or more guiding pins are insertable in the corresponding guiding holes, preferably the guiding holes are through-holes.

[0029] In these embodiments comprising guiding pins, the positioning of the light optic on the mounting board typically comprises: moving the light optic towards the mounting board such that the guiding pins enter the corresponding guiding holes and moving the light optic further towards the mounting board until the pin member is received within the hole member so as to form at least one pin-hole connection. Short description of the drawings

[0030] These and further aspects of the present disclosure will be explained in greater detail by way of example and with reference to the accompanying drawings in which:

[0031] Fig.l schematically illustrates a perspective view of an exemplary embodiment of a beacon light assembly according to the present disclosure,

[0032] Fig.2 is a perspective view of an embodiment of a light optic according to the present disclosure,

[0033] Fig.3 is a perspective view of an embodiment of a mounting board with light emitting elements mounted on the mounting board,

[0034] Fig.4 to Fig.8 show views of the bottom side of various embodiments of light optics according to the present disclosure,

[0035] Fig.9 shows a cross-sectional view of a further embodiment of a beacon light assembly according to the present disclosure.

[0036] The drawings of the figures are neither drawn to scale nor proportioned. Generally, identical components are denoted by the same reference numerals in the figures.

[0037] Detailed description of embodiments

[0038] The present disclosure will be described in terms of specific embodiments, which are illustrative of the disclosure and not to be construed as limiting. It will be appreciated by persons skilled in the art that the present disclosure is not limited by what has been particularly shown and / or described and that alternatives or modified embodiments could be developed in the light of the overall teaching of this disclosure. The drawings described are only schematic and are non-limiting.

[0039] Use of the verb "to comprise", as well as the respective conjugations, does not exclude the presence of elements other than those stated. Use of the article "a", "an" or "the" preceding an element does not exclude the presence of a plurality of such elements.

[0040] Furthermore, the terms first, second and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the disclosure described herein are capable of operation in other sequences than described or illustrated herein.

[0041] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiments is included in one or more embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one ordinary skill in the art from this disclosure, in one or more embodiments.

[0042] According to a first aspect of the disclosure, a beacon light assembly is provided.

[0043] With reference to Fig.l, a perspective view of an exemplary embodiment of a beacon light assembly 1 is shown.

[0044] The beacon light assembly 1 according to the present disclosure comprises a mounting board 4 and a beacon light unit.

[0045] A beacon light unit comprises a plurality of light emitting elements 2 attached to the mounting board 4, and a light optic 3 positioned on the mounting board. Hence a beacon light unit has to be construed as a combination of light emitting elements 2 and a light optic 3 associated to the light emitting elements. The light optic 3 is configured for receiving light from the light emitting elements and for forming and outputting one or more light beams. Typically, the light beams outputted by the light optic have a characteristic angular light distribution, specified by regulations, e.g. from aviation regulatory bodies.

[0046] The present disclosure is not limited to a specific type or specific geometry of the light optic 3. A first type of light optic 3 is a lens-type of device. This light optic can also be named light transmitting element. A second type of light optic 3 is a reflector-type of device. Embodiments of beacon light assemblies using the first type of light optic will first be discussed with reference to figures 1 to 8, and embodiments of beacon light assemblies comprising a light optic of the second type will be discussed thereafter with reference to Fig.9.

[0047] In embodiments, the light optic 3 of the first type is a solid body made of a transparent material, for example made of, or at least partly made of, glass or a suitable plastic material, such as polycarbonate, PC, or polymethyl methacrylate, PMMA.

[0048] In embodiments, the light optic 3 is manufactured by injection moulding. In this way, the light optic 3 can preferably be made as a singlepiece solid body.

[0049] In other embodiments, the light optic 3 can be composed out of multiple sub-elements which are attached together for forming the light optic.

[0050] In embodiments, the light optic 3 of the first type is TIR-type light optic, i.e. a light optic comprising at least an entrance surface 11 for receiving the light from the light emitting elements 2 and an exit surface 12 for outputting the one or more light beams, and one or more total internal reflection, TIR, surfaces for directing the light towards the exit surface. The light optic 3 shown on Fig.2 is an exemplary embodiment of a light optic of the first type. Typically, the entrance surface 11 is located in a bottom side 15 of the light optic 3 and an internal reflector 21 configured for redirecting the light to the exit surface is located in a top side of the light optic, opposite the bottom side. Generally, a collimator 13 is located between the bottom side and the top side, and the entrance surface 11 and the collimator 13 are configured for directing light from the light emitting elements to the top internal reflector, which further redirects the light to the exit surface 12.

[0051] In embodiments, the beacon light assembly 1 comprises one beacon light unit. In other embodiments, the beacon light unit can comprise a plurality of beacon light units, i.e. the mounting board can for example be a common mounting board for the plurality of beacon light units. Typically, a beacon light unit emits a light beam within a given azimuthal angle. In embodiments comprising a plurality of beacon light units, the units can for example be positioned in a circular geometry. This allows to cover a larger azimuthal angle, for example an angle of 360°. The embodiment shown on Fig.l is an example of a beacon light assembly wherein multiple beacon light units can be mounted on the mounting board 4. However, on Fig.l, for ease of presentation only a portion of the beacon light assembly is shown to clearly illustrate one beacon light unit having one light optic 3 and a plurality of light emitting elements 2.

[0052] The alignment of the light emitting elements 2a, 2b, 2c, 2d, 2e on the mounting board 4 is illustrated on Fig.3, which is a perspective view of a portion of the mounting board 4 shown on Fig.l. As schematically shown on Fig.l and Fig.3, the light emitting elements 2a, 2b, 2c, 2d, 2e are aligned along a reference line R. In the example shown, five light emitting elements, 2a, 2b, 2c, 2d and 2e are aligned along the reference line R. The light emitting elements aligned on the reference line R can also be named an array 2 of light emitting elements. As the light emitting elements 2a, 2b, 2c, 2d, 2e are attached to the mounting board, the reference line R can be construed as a reference line associated to the mounting board.

[0053] In embodiments, the light emitting element is for example a lightemitting diode, LED. In other embodiments, the light emitting element can be any type of light source suitable for producing light beams with the light optic.

[0054] In Fig.2 a perspective view is shown of the light optic 3 shown on Fig.l. In Fig.2, the light optic 3 is shown upside down to illustrate the bottom side 15 of the light optic 3. The bottom side 15 is the side of the light optic 3 that is facing the mounting board 4 when the light optic 3 is positioned on the mounting board.

[0055] In the embodiment shown on Fig.2, the entrance surface 11 is defining a recess 14 for receiving the light emitting elements. More precisely, the entrance surface defines the walls of the recess 14.

[0056] The beacon light assembly according to the present disclosure is characterized in that it comprises at least one pin-hole connection between the light optic and the mounting board. Each of the pin-hole connections is formed by a pin member and a mating hole member receiving the pin member. In other words, the hole member is mating with the pin member such that when the light optic 3 is positioned on the mounting board, the pin member can enter the hole member so as to form a pin-hole connection.

[0057] In the exemplary embodiment shown on Figi, Fig.2 and Fig.3, there are two pin-hole connections and the bottom side of the light optic 3 comprises a first hole member 6a and a second hole member 6b for receiving respectively a first 5a and second 5b pin member. As shown on Fig.3, the first pin member 5a and a second pin member 5b are positioned on the mounting board 4, and both, the first and second pin members are aligned along the reference line R. As illustrated on Fig.l, when the light optic 3 is positioned on the mounting board 4, the first pin member 5a is received within the first hole member 6a and the second pin member 5b is received within the second hole member 6b.

[0058] Advantageously by using pin-hole connections for coupling the light optic to the mounting board, the light optic can precisely be aligned with respect to the light emitting elements. Remark that a misalignment of the light emitting elements with respect to the entrance surface of the light optic can result in optical aberrations resulting in reduced beam quality in terms for instance of light intensity and / or beam uniformity.

[0059] In embodiments, the first 5a and / or second 5b pin member are auxiliary light emitting elements or dummy light emitting elements. A dummy light emitting element is an element that has the same shape as a light emitting element but the dummy light emitting element cannot operate, i.e. emit light. A standard light emitting element can also be used as pin member, and in that case, in some embodiments, the light emitting element is not electrically connected such that the light emitting element remains inactive. In further embodiments, a standard light emitting element, such as for example an LED, can be used that is electrically connected and hence can emit light. In this way, the light emitting elements that is used as part of the pin-hole connector, can also be used to provide for some additional light when required and hence have a double function.

[0060] In other embodiments, the pin members 5a, 5b are geometrical bodies which do not necessarily have the shape of a light emitting element. The geometrical bodies can for example be: a cube, a cuboid, a triangular prism or a cylinder, or any other geometrical shape that is suitable for forming a pin. Hence, a cross-section with a plane parallel with the mounting board can have any shape selected from for example: a circular shape, an oval shape, a rectangular shape, a triangular shape, or any other polygon shape suitable for forming a pin member.

[0061] In embodiments, a reference point of each of the light emitting elements, preferably a centroid or a centre of the light emitting elements, and a reference point of the first and / or second pin member, preferably a centroid or centre of the first and / or second pin member, are located on the reference line R.

[0062] As will be discussed in more detail below, in preferred embodiments, the light emitting elements 2a, 2b, 2c, 2d, 2e and the first 5a and / or second 5b pin member are attached to the mounting board by a soldering process.

[0063] In embodiments as illustrated on Fig.l and Fig.3, the reference line R is a linear line, i.e. a straight line. The beacon light assembly according to the present disclosure is however not limited to a reference line that is linear . More generally, the reference line can be selected from any of: a linear line, a circular line and an arc-shaped line. The type of line is determined by the type light array is used, if the light emitting elements are forming a linear array, the reference line is a straight line, if the array of light emitting elements are forming an arc-shaped array, the reference line is following an arc.

[0064] In the embodiment shown on Fig.l and Fig.2, the bottom side of the light optic 3 has a first 16 and a second 17 planar surface portion facing the mounting board, and the first 6a and second 6b hole member is formed in respectively the first 16 and second 17 planar surface portion. In this example, the first and second planar surface portion are located adjacently to respectively a first end and a second end, opposite the first end, of the plurality of light emitting elements 2.

[0065] In the example shown on Fig.2, the first 16 and second 17 planar surface portion of the bottom side of the light optic 3 are provided on respectively a first 18 and second 19 flange of the light optic. In embodiments wherein injection moulding is used for manufacturing the light optic 3, the flanges 18,19 are for example formed as part of the injection moulding process so as to form a single piece light optic 3 comprising the flanges.

[0066] In embodiments, in order to facilitate the installation of the light optic on the mounting board during the production process of the light optic assembly, as discussed below in more detail, the beacon light assembly further comprises one or more guiding pins and corresponding guiding holes. The guiding pins are coupled to the bottom side of the light optic and the corresponding guiding holes are located in the mounting board. The holes are preferably through-holes, made in the mounting board. The guiding pins are however optional features of the beacon light assembly.

[0067] In the embodiment shown on Fig.l to Fig.3, guiding pins are provided and in this example, the mounting board 4 comprises four holes 7a to 7d, configured for receiving the four guiding pins 8a to 8d shown on Fig.2.

[0068] As mentioned above, the guiding pins are optional features and serve to guide the light optic 3 during the mounting process when the light optic 3 is being positioned on the mounting board 4. The corresponding holes in the mounting board receiving the guiding pins have dimensions sufficiently large such that the guiding pins can easily be inserted in the corresponding holes. Hence, these guiding pins support an initial coarse alignment, which is then followed by the precise alignment made with the pin-hole connection.

[0069] In embodiments, the beacon light assembly comprises one or more fixation members configured for maintaining the light optic 3 coupled to the mounting board 4, i.e. to maintain the light optic rigidly attached to the mounting board. Different options are possible to realize a fixation that maintains the light optic 3 rigidly attached to the mounting board 4.

[0070] In the embodiment shown on Fig.l to Fig.3, a fixation plate 10 is coupled to the first 18 and second 19 flange. In this example, the fixation plate 10 is attached to the mounting board 4 using a first 9a and second 9b fixation member. The first 9a and second 9b fixation member comprise a bolt and a nut. In other embodiments, screws could be used to attach the fixation plate 10 to the mounting board.

[0071] In embodiments comprising multiple light optic units, for instance positioned on a circle, the same fixation plate can be used in combination with two flanges of adjacent light optic units.

[0072] In other embodiments, no fixation plate is used. In these embodiments, fixation openings can for example be made in the first 18 and / or second 19 flange of the light optic and bolts or screws can be inserted through the fixation openings for fixing the light optic to the mounting board.

[0073] The embodiment shown on Fig.l to Fig.3 is an exemplary embodiment of a beacon light assembly. The present invention is however not limited to a specific number of pin-hole connections or the presence of guiding pins or not. Generally, the beacon light assembly comprises at least one pin-hole connection. The guiding pins are optional features and hence in some embodiments, no guiding pins are provided.

[0074] To further illustrate the present disclosure, Fig.4 to Fig. 8 show views of the bottom side 15 of various embodiments of light optics 3 according to the present disclosure.

[0075] In Fig.4, a bottom side 15 of an embodiment of a light optic 3 is shown comprising a first 6a and a second 6b hole member located on respectively a first 16 and second 17 surface portion of the bottom side 15. The first and second surface portion are located on each of the ends of the entrance surface 11. A first 8a and second 8b guiding pin is coupled to respectively the first 16 and second 17 surface portion. As schematically illustrated on Fig.4, in this example, the entrance surface 11 is elongating along a longitudinal axis L and the two hole members are aligned with the longitudinal axis L. On Fig.4, the entrance surface 11 is illustrated with a dotted pattern and the entrance surface 11 defines a recess 14 for receiving the light emitting elements. In this example, the hole members have a rectangular cross section.

[0076] In Fig.5, an embodiment of a light optic 3 is shown wherein the bottom side 15 of the light optic 3 comprises a single hole member 6a located on the first planar surface portion 16, and a first guiding pin 8a coupled to the first surface portion 16 and a second guiding pin 8b coupled to the second planar surface portion 17.

[0077] In Fig.6, an embodiment is shown wherein the bottom side 15 of the light optic 3 comprises a single hole member 6a located on the first planar surface portion 16 and a first guiding pin 8a located on the second planar surface portion 17.

[0078] In Fig.7, an embodiment of a light optic 3 is shown wherein the bottom side 15 of the light optic 3 comprises three entrance surfaces: a first entrance surface Ila, a second entrance surface 11b and a third entrance surface 11c, illustrated with dotted patterns. In this example, the first entrance Ila is longer than the other entrance surfaces and is aligned along the longitudinal axis L. The two hole members 6a, 6b are aligned with respect to the longitudinal axis L. The first planar surface portion 16 comprises a first hole member 6a and a first guiding pin 8a, and the second planar surface portion 17 comprises a second hole member 6b and a second guiding pin 8b. In this example the first Ila, second 11b and third 11c entrance surfaces define respectively a first 14a, a second 14b and a third 14c recess, and wherein each recess can receive one or more light emitting elements.

[0079] In Fig.8, an embodiment of a light optic 3 is shown wherein the bottom side 15 of the light optic 3 comprises two entrance surfaces: a first entrance surface Ila, and a second entrance surface 11b, illustrated with dotted patterns. In this example, three hole members 6a, 6b and 6c are aligned with respect to the longitudinal axis L. The first hole member 6a is located on the first planar surface portion adjacent to the first recess, and the second hole member 6b is located on the second planar surface portion 17 adjacent to the second recess. The third hole member 6c is located on a further planer surface portion 20 of the bottom side 15 of the light optic, and wherein the further planar surface portion 20 is located between the first Ila and the second 11b entrance surface.

[0080] In the embodiment shown on Fig.l to Fig.3, the entrance surface 11 of the light optic 3 is elongating along a longitudinal axis L In this embodiment, as illustrated on Fig.2, the hole members 6a, 6b are aligned with the longitudinal axis L. When the light optic is positioned on the mounting board, the longitudinal axis L associated to the light optic 3 is parallel with the reference line R associated to the mounting board 4.

[0081] In the embodiments illustrated in Fig.l to Fig.8, for each of the pin-hole connections, the pin member is attached to the mounting board and the hole member is located on the bottom side of the light optic. In other embodiments, as can be recognized by the person skilled in the art, the hole member can be formed on the mounting board and be aligned with the reference line R, and the pin member can be attached to the bottom side of the light optic.

[0082] In embodiments, the mounting board comprises a printed circuit board, PCB, comprising solder pads aligned along the reference line R, and the light emitting elements and the at least one pin member are attached to the solder pads. Typically, the light emitting elements and at least one pin member are attached to the mounting board by a soldering process using a solder paste.

[0083] With reference to Fig.9, a cross-sectional view of a further embodiment of a beacon light assembly according to the present disclosure is shown. In this example, the light optic 3 is of the second type discussed above, namely a reflector-type of light optic. Similarly as for the embodiments discussed with respect to Fig.l to Fig.8, the embodiment of a beacon light assembly illustrated on Fig.9 comprises a plurality of light emitting elements 2 attached to a mounting board 4, and the light emitting elements are aligned along a first reference line Rl. In the cross-sectional view shown on Fig.9, the first reference line R1 is perpendicular to the figure and indicated with a white dot. The light optic 3 is positioned on the mounting board 3, and the light optic comprises a bottom side 15 facing the mounting board 4.

[0084] In this example shown on Fig.9, the light optic is a reflector-type of light optic and the light optic 3 comprises a reflector surface 22 configured for receiving light from the light emitting elements and for redirecting light received. Typically, the reflector surface 22 is provided with a reflecting coating.

[0085] In the example shown on Fig.9, for each pin-hole connection, the pin member 5a is attached to the mounting board and aligned along a second reference line R2 parallel with the first reference line Rl, and the bottom side 15 of the light optic comprises the hole member 6a. The second reference line R2, that is separated from the first reference line Rl, is also indicated with a white dot on Fig.9. In this example the first and second reference lines are linear lines.

[0086] In other embodiments, instead of attaching the pin member to the mounting board, the pin member 5a is attached to the bottom side 15 of the light optic and the hole member 6a is formed in the mounting board and aligned along the second reference line R2.

[0087] Typically, the mounting board shown on Fig.9 is for example a PCB board.

[0088] In embodiments, the printed circuit board having solder pads aligned along the first reference line Rl and further solder pads aligned along the second reference line R2. The light emitting elements are then attached to solder pads aligned along the first reference line Rl and the pin member is attached to one of the further solder pads aligned with the second reference line R2. Alternatively, when the pin member 5a is attached to the bottom side of the light optic 3, the hole member 6a is made through one of the solder pads aligned with the second reference line R2.

[0089] According to a second aspect of the disclosure, a method is provided for manufacturing a beacon light assembly.

[0090] According to an embodiment of the present disclosure, the method of manufacturing a beacon light assembly comprises: providing a mounting board 4, attaching a plurality of light emitting elements 2a, 2b, 2c, 2d, 2e on the mounting board 4 such that the light emitting elements are aligned along a first reference line R, attaching at least one pin member 5a on the mounting board such that the at least one pin member is aligned along the first reference line R, R1 or aligned along a second reference line R2 parallel with the first reference line, producing a light optic 3 for receiving light from the light emitting elements and outputting one or more light beams, and wherein the light optic comprises a bottom side, and wherein the method further comprises: forming a hole member 6a in the bottom side 15 of the light optic for receiving the pin member 5a.

[0091] For attaching the light emitting elements and the at least one pin member to the mounting board, standard manufacturing techniques known in the art can be applied, e.g. manufacturing techniques used to place components on mounting board, such as a printed circuit board, can be used. These processes are known to be able to position and attach components on for example a printed circuit board, PCB, with great accuracy. Generally, a pick-and-place machine can be used to position those components on the mounting board. In embodiments, the method uses a PCB board as a mounting board.

[0092] In an alternative embodiment, the method comprises providing a mounting board 4, attaching a plurality of light emitting elements 2a, 2b, 2c, 2d, 2e on the mounting board 4 such that the light emitting elements are aligned along a first reference line R, Rl, forming at least one hole member 6a on the mounting board such that the at least one hole member is aligned along the first reference line R, Rl, or aligned along a second reference line R2 parallel with the first reference line, producing a light optic 3 for receiving light from the light emitting elements and outputting one or more light beams and wherein the light optic comprises a bottom side, and attaching a pin member 5a to the bottom side of the light optic, and wherein the pin member is receivable in the hole member 6a. For this alternative embodiment, the at least one hole member can be formed by for example drilling a hole through the mounting board by positioning a drill on the first or second reference line such that the hole member is formed on the first or second reference line.

[0093] In embodiments, the method further comprises positioning the light optic on the mounting board such that the at least one pin member is received in the at least one hole member so as to form a pin-hole connection between the light optic and the mounting board.

[0094] The dimensions of the pin member and the pin hole are mating, i.e. the dimensions of the at least one hole member and the dimensions of the at least one pin member are made such that the pin member is receivable in the corresponding hole member but without leaving any space or only a minimum space between the hole member and the pin member after insertion, i.e. the pin members can glide in the hole members but after insertion a pin-hole connection is formed aligning the light optic 3 with the light emitting elements 2a, 2b, 2c, 2d and 2e.

[0095] In embodiments, the light optic 3 is produced by injection moulding. This allows to form the light optic as a single body.

[0096] For embodiments wherein the hole member of the pin-hole connection is located in the light optic, the hole member can for example be formed as part of an injection moulding process used to manufacture the light optic. In other embodiments, a body is made by an injection moulding process but without forming the hole members and the hole members 6a can be made afterwards in the body by for example a milling process.

[0097] As discussed above, in some embodiments guiding pins 8a, 8b, 8c, 8d are provided. For these embodiments, producing the light optic further comprises: providing one or more guiding pins 8a, 8b, 8c, 8d to the bottom side of the light optic, and making corresponding guiding holes 7a, 7b, 7c, 7d in the mounting board such that when the light optic is positioned on the board, the one or more guiding pins are insertable in the corresponding guiding holes. In embodiments, the guiding holes are through-holes.

[0098] In embodiments, positioning the light optic on the mounting board comprises: moving the light optic towards the mounting board such that the guiding pins enter the corresponding holes and continue moving the light optic further towards the mounting board until the pin member is received within the hole member so as to form at least one pin-hole connection.

[0099] In embodiments, as discussed above, the light optic comprises at least two pin members, e.g. a first 5a and a second 5b pin member. For these embodiments, the method comprises: attaching at least two pin members on the mounting board aligned along the first reference line R,R1, or aligned along the second reference line R2, and forming at least two hole members in the bottom side.

[0100] In alternative embodiments, when the pin members are not attached to the mounting board, the method comprises: forming at least two hole members in the mounting board aligned along the first reference line or aligned along the second reference line, and attaching at least two pin members to the bottom side of the light optic.

[0101] In embodiments comprising at least two pin-hole connections, the positioning of the light optic on the mounting board comprises: moving the light optic towards the mounting board such that the guiding pins enter the corresponding guiding holes and continue moving the light optic further towards the mounting board until the at least two pin members are received within the at least two hole members so as to form at least two pin-hole connections.

[0102] In embodiments, the method further comprises using one or more fixation members and / or a fixation plate for maintaining the light optic coupled to the mounting board. In embodiments, the fixation member comprises a bolt and a nut or alternatively a screw.

[0103] As discussed above, in embodiments, the method uses for the at least one pin member an auxiliary light emitting element or a dummy light emitting element. In other embodiments, the method uses for the at least one pin member a body having a suitable shape for acting as a pin member. The pin body is for example a geometrical body selected from any of: a cube, a cuboid, a triangular prism, a cylinder, or any other geometrical shape that is suitable for forming a pin member.

[0104] In embodiments, the mounting board is provided with soldering pads indicating where the components, in this case the light emitting elements and the at least one pin member are to be positioned. These soldering pads are aligned along the first reference line and / or second reference line.

[0105] In embodiments, the attaching of the plurality of light emitting elements to the mounting board comprises soldering the plurality of light emitting elements 2a, 2b, 2c, 2d, 2e to the mounting board by using a solder paste, and wherein attaching the at least one pin member 5a, or attaching the at least two pin members 5a, 5b, to the mounting board comprises soldering the at least one pin member, or the at least two pin members, to the mounting board 4 using the solder paste.

[0106] In embodiments wherein the light optic 3 is for example manufactured by injection moulding, the one or more guiding pins 8a, 8b, 8c, 8d can be made as part of the injection moulding process so as to form a single-piece light optic 3 including the one or more guiding pins. In other embodiments, the guiding pins can be manufactured separately and be coupled to the planar surface portions of the bottom side of the light optic, for example with a glue or with a tight-fit.

[0107] Preferably the holes 7a, 7b, 7c, 7d for receiving the guiding pins 8a, 8b, 8c, 8d are through-holes, which are for example holes drilled through the mounting board. As mentioned above, the holes for receiving the guiding pins can be sufficiently large such that the guiding pins can easily enter the holes when positioning the light optic on the mounting board. The guiding pins only serve a coarse alignment.

[0108] In embodiments wherein the light optic is of the lens-type, as discussed above, the method comprises producing a light optic comprising a bottom side having an entrance surface for receiving light from the plurality of light emitting elements. In embodiments, the light optic is produced such that the entrance surface is defining a recess for receiving the plurality of light emitting elements.

[0109] In embodiments the light optic comprises a longitudinal axis L and the first reference line is for example a linear line. In embodiments, the entrance surface of the light optic is elongating parallel with the longitudinal axis L and the at least one hole member, when formed in the bottom side of the light optic, is aligned with the longitudinal axis. Alternatively, when the at least one pin member is attached to the bottom side of the light optic, the at least one pin member is aligned with the longitudinal axis. In this way, when the pin member is received in the hole member for forming the at least one pin-hole connection the longitudinal axis of the light optic is parallel with the first reference line.

[0110] In other embodiments the light optic is of the reflector type. In these embodiments, the light optic comprises a reflector surface configured for receiving light from the light emitting elements and for redirecting light received, and wherein the light optic comprises a longitudinal axis and wherein the reflector surface is elongating parallel with the longitudinal axis. Typically, the first reference line R1 is a linear line and separated from the second reference line R2. Further, the pin member is attached to the mounting board and aligned along the second reference line R2 and the at least one hole member is formed in the bottom side of the light optic and aligned with the longitudinal axis L. Alternatively, the hole member is formed in the mounting board and aligned along the second reference line R2 and the at least one pin member is attached to the bottom side of the light optic and is aligned with the longitudinal axis L. Hence, also for this embodiment comprising a light optic of the reflector type, when the pin member is received in the hole member for forming the at least one pin-hole connection, the longitudinal axis of the light optic is parallel with the first reference line.

[0111] Reference numbers

Claims

Claims1. A beacon light assembly comprising a mounting board and a beacon light unit, wherein the beacon light unit comprises: a) a plurality of light emitting elements attached to said mounting board, and wherein the light emitting elements are aligned along a first reference line (R, Rl), and b) a fight optic positioned on said mounting board and configured for receiving fight from the light emitting elements and for outputting one or more light beams, and wherein said light optic comprises a bottom side facing said mounting board, characterized in that said beacon light assembly further comprises at least one pin-hole connection, preferably at least two pin-hole connections, between the light optic and the mounting board, wherein each pin-hole connection is formed by a pin member and a hole member receiving the pin member, and in that said pin member is attached to the mounting board and aligned along said first reference line (R, Rl) or aligned along a second reference line (R2) parallel with said first reference line (Rl), and wherein the bottom side of the light optic comprises said hole member, or alternatively wherein said hole member is formed in the mounting board and aligned along the first reference line (R, Rl) or aligned along a second reference line (R2) parallel with the first reference line (Rl), and wherein said pin member is attached to the bottom side of the light optic.

2. The beacon fight assembly according to claim 1 wherein said pin member is attached to the mounting board, and wherein said pin member is an auxiliary light emitting element or a dummy fight emitting element.

3. The beacon light assembly according to claim 2 wherein said auxiliary light emitting element is a LED or said dummy light emitting element is a dummy LED.

4. The beacon light assembly according to claim 1 wherein said pin member is formed by a geometrical body selected from any of: a cube, a cuboid, a triangular prism, a cylinder, or any other geometrical shape that is suitable for forming the pin-hole connection.

5. The beacon light assembly according to any of previous claims wherein a reference point of each of the light emitting elements, preferably a centroid or a centre of the light emitting elements, is located on said first reference line (R, Rl), preferably the reference point is a centroid or centre.

6. The beacon light assembly according to claim 5 wherein a reference point of said pin member when attached to mounting board, or a reference point of the hole member when formed in the mounting board, is located on said first reference line (R, Rl) or on said second reference line (R2).

7. The beacon light assembly according to any of previous claims wherein said bottom side of said light optic comprises a first planar surface portion facing said mounting board, and wherein said hole member is formed in said first planar surface portion if said pin member is attached to the mounting board, or alternatively, wherein said pin member is attached to the first planar surface portion if said hole member is formed in said mounting board, preferably said first planar surface portion is provided on a first flange.

8. The beacon light assembly according to claim 7 wherein said bottom side of said light optic comprises a second planar surface portion facing said mounting board, and wherein said first and second planar surface portion are located adjacently to respectively a first end and a second end, opposite the first end, of the plurality of light emitting elements, preferably said second planar surface portion is provided on a second flange.

9. The beacon light assembly according to any of previous claims comprising one or more guiding pins coupled to the bottom side of the light optic and wherein the guiding pins are inserted through corresponding guiding holes, preferably through -holes, located in said mounting board.

10. The beacon light assembly according to claim 8 wherein said light optic comprises one or more guiding pins coupled to the first planar surface portion and / or wherein said light optic comprises one or more further guiding pins coupled to the second planar surface portion, and wherein the guiding pins coupled to the first and / or second planar surface portion are inserted through corresponding holes, preferably through -holes, located in said mounting board.

11. The beacon light assembly according to any of previous claims comprising one or more fixation members configured for maintaining the light optic coupled to the mounting board, preferably each fixation member comprises a bolt or a screw.

12. The beacon light assembly according claim 11 further comprising a fixation plate configured for maintaining the light optic coupled to the mounting board and wherein the fixation plate is attached to the mounting board with said one or more fixation members.

13. The beacon light assembly according to any of previous claims wherein said first reference line (R, Rl) is selected from any of: a linear line, a circular fine or an arc-shaped line.

14. The beacon light assembly according to any of previous claims wherein said light optic is a solid body, preferably a single-piece solid body.

15. The beacon light assembly according to any of previous claims wherein said mounting board comprises a printed circuit board having solder pads aligned along said first reference line, and wherein said light emitting elements and said pin member are attached to said solder pads, or alternatively, when said pin member is attached to the light optic, said hole member is made through one of said solder pads.

16. The beacon light assembly according to any of claims 1 to 14 wherein said mounting board comprises a printed circuit board having solder pads aligned along said first reference line and further solder pads aligned along said second reference line, and wherein said light emitting elements are attached to solder pads aligned along the first reference line and said pin member is attached to a solder pad aligned with the second reference line, or alternatively, when the pin member is attached to the light optic, the hole member is made through one of said solder pads aligned with the second reference line.

17. The beacon light assembly according to any of previous claims wherein said light emitting elements and said pin member are attached to the mounting board by a soldering process using a solder paste.

18. The beacon light assembly according to any of previous claims comprising a plurality of beacon light units and wherein each beacon lightunit comprises at least one pin-hole connection, preferably two pin-hole connections.

19. The beacon light assembly according to claim 18 wherein said plurality of beacon light units are arranged in a circular configuration.

20. The beacon light assembly according to any of previous claims wherein said light optic is a TIR-type light optic or a reflector-type light optic.

21. The beacon light assembly according to any of previous claims wherein the bottom side of the light optic has an entrance surface for receiving light emitted by the light emitting elements.

22. The beacon light assembly according to claim 21 wherein said entrance surface is defining a recess for receiving said plurality of light emitting elements.

23. The beacon light assembly according to claim 21 or 22 wherein said first reference line is a linear line, and wherein said light optic comprises a longitudinal axis and wherein said entrance surface of the light optic is elongating parallel with the longitudinal axis (L) and wherein said hole member, when formed in the bottom side of the light optic, is aligned with said longitudinal axis, or alternatively, wherein said pin member, when attached to the bottom side of the light optic, is aligned with said longitudinal axis, such that when said pin member is received in the hole member for forming the at least one pin-hole connection the longitudinal axis is parallel with the first reference fine.

24. The beacon light assembly according to any of claims 21 to 23 wherein said light optic further comprises a collimator, an internal reflector and an exit surface, and wherein the internal reflector is forming part of a top side of the light optic, opposite the bottom side, and wherein the collimator is located between the bottom side and the top side, and wherein the entrance surface and collimator are configured for directing light from the light emitting elements to the internal reflector and wherein the internal reflector is configured for directing light to the exit surface.

25. The beacon light assembly according to any of claims 1 to 19 wherein said light optic comprises a reflector surface configured for receiving light from said light emitting elements and for redirecting light received, and wherein said first reference line is a linear line and separated from the second reference line, and wherein said pin member is attached to the mounting board and aligned along said second reference line (R2), or alternatively wherein said hole member formed in the mounting board is aligned along said second reference line (R2).

26. The beacon light assembly according to claim 25 wherein said light optic comprises a longitudinal axis and wherein said reflector surface is elongating parallel with the longitudinal axis, and wherein said hole member, when formed in the bottom side of the light optic, is aligned with said longitudinal axis, or alternatively, wherein said pin member, when attached to the bottom side of the light optic, is aligned with said longitudinal axis, such that when said pin member is received in the hole member for forming the at least one pin-hole connection the longitudinal axis is parallel with the first reference fine.

27. A method for manufacturing a beacon light assembly comprising: providing a mounting board,• attaching a plurality of light emitting elements on the mounting board such that the light emitting elements are aligned along a first reference line,• attaching at least one pin member on said mounting board such that the at least one pin member is aligned along said first reference line or aligned along a second reference line parallel with the first reference line, or alternatively forming at least one hole member in said mounting board such that the at least one hole member is aligned along said first reference line or aligned along a second reference line parallel with the first reference line,• producing a fight optic for receiving light from the light emitting elements and for outputting one or more fight beams, and wherein the fight optic comprises a bottom side , and, if the at least one pin member is attached to the mounting board, forming a hole member in the bottom side of the light optic for receiving the pin member, or alternatively, if the at least one hole member is formed in the mounting board, attaching a pin member to the bottom side of the light optic, and wherein the pin member is receivable in the hole member.

28. The method of claim 27 comprising positioning said light optic on the mounting board such that the pin member is received within the hole member so as to form a pin-hole connection between the light optic and the mounting board.

29. The method of claim 28 wherein producing the light optic comprises: providing one or more guiding pins to said bottom side of the light optic, and wherein the method further comprises: making corresponding guiding holes in said mounting board such that when the light optic is positioned on theboard, the one or more guiding pins are insertable in the corresponding guiding holes, preferably the guiding holes are through-holes.

30. The method of claim 29 wherein said positioning the light optic on the mounting board comprises: moving said light optic towards the mounting board such that the guiding pins enter the corresponding guiding holes and moving the light optic further towards the mounting board until the pin member is received within the hole member so as to form at least one pin-hole connection.

31. The method of claim 30 comprising: attaching at least two pin members on said mounting board aligned along said first reference line, or aligned along the second reference line, and forming at least two hole members in the bottom side, or alternatively, forming at least two hole members in said mounting board aligned along said first reference line, or aligned along the second reference line, and attaching at least two pin members to the bottom side, and wherein said positioning the light optic on the mounting board comprises: moving said light optic towards the mounting board such that the guiding pins enter the corresponding guiding holes and continue moving the light optic further towards the mounting board until the at least two pin members are received within the at least two hole members so as to form at least two pin-hole connections.

32. The method of any of claims 27 to 31 comprising: using one or more fixation members and / or a fixation plate for maintaining the light optic coupled to the mounting board, preferably the fixation member comprises a bolt or a screw.

33. The method of any of claims 27 to 32 wherein the mounting board is a printed circuit board.

34. The method according to any of claims 27 to 33 wherein said attaching the plurality of light emitting elements to the mounting board comprises soldering the plurality of light emitting elements to the mounting board using a solder paste, and wherein said attaching the at least one pin member on the mounting board comprises soldering the at least one pin member to the mounting board using the solder paste.

35. The method according to any of claims 27 to 34 wherein said bottom side has an entrance surface for receiving light from the plurality of light emitting elements.

36. The method according to claim 35 wherein said first reference line is a linear line, and wherein said light optic comprises a longitudinal axis (L) and wherein said entrance surface of the light optic is elongating parallel with said longitudinal axis (L), and said at least one hole member, when formed in the bottom side of the light optic, is aligned with said longitudinal axis (L), or alternatively, wherein said at least one pin member, when attached to the bottom side of the light optic, is aligned with said longitudinal axis (L).

37. The method according to any of claims 27 to 34 wherein said producing a light optic comprises producing a light optic having a reflector surface configured for receiving light from said light emitting elements and for redirecting light received, and wherein said light optic comprises a longitudinal axis and wherein said reflector surface is elongating parallel with the longitudinal axis, and wherein said first reference line is a linear line and separated from the second reference line,and wherein said pin member is attached to the mounting board and aligned along said second reference line (R2) and said at least one hole member is formed in the bottom side of the light optic and aligned with said longitudinal axis (L), or alternatively wherein said hole member is formed in the mounting board and aligned along said second reference line (R2) and said at least one pin member is attached to the bottom side of the light optic and is aligned with said longitudinal axis (L).

Images