Hybrid heatsinking providing improved thermal management

Abstract

The invention provides a luminaire (1000) comprising a housing part (600), an electrical component (7), a support (500), and a coating (700), wherein: (A) the housing part (600) comprises a first housing side (601) and a second housing side (602); wherein the housing part (600) comprises a housing part region (606) comprising a plurality of through-holes (630) from the first housing side (601) to the second housing side (602); (B) the support (500) comprises a first support side (501) and a second support side (502); wherein the support (500) is configured to support the electrical component (7); wherein the electrical component (7) is arranged at the second support side (502); wherein the first support side (501) faces at least part of the second housing side (602) at the housing part region (606); (C) the coating (700) comprises a thermally conductive material; wherein (a) the coating (700) covers at least part of the first housing side (601), and wherein (b) one or more of the following applies: (i) the coating (700) extends into the plurality of through-holes (630) and is in contact with the support (500) the plurality of through-holes (630), and (ii) the support (500) comprises a plurality of support protrusions (530), wherein the plurality of support protrusions (530) are at least partly protruding into the plurality of through-holes (630), and wherein the coating (700) is in contact with the plurality of support protrusions (530).

Description

[0001] 2024PF80238

[0002] 1

[0003] Hybrid heatsinking providing improved thermal management

[0004] FIELD OF THE INVENTION

[0005] The invention relates to a device, especially a luminaire, comprising a housing part, an electrical component, a support, and a coating. The invention further relates to a method for coating at least part of a device, especially for coating at least part of a luminaire.

[0006] BACKGROUND OF THE INVENTION

[0007] Devices comprising a heat conductive coating on a substrate are known in the art. For instance, US20240051280A1 describes systems and methods to form a metallized polymer substrate including the steps of forming a bond layer on a surface of a polymer substrate, the bond layer comprising a hybrid structure of a polymer film layer and a metal component; bonding the polymer film layer to the surface of a carbon fiber reinforced polymer substrate; and depositing, by low-temperature metal spray deposition, a plurality of metal particles onto the bond layer.

[0008] SUMMARY OF THE INVENTION

[0009] Heat sinking of a LED luminaires, lighting arrangements, or other electrical arrangements, is becoming increasingly challenging. There appears to be a trend towards miniaturization of devices and arrangements such as luminaires, to make them unobtrusive or easier to incorporate in other devices or assemblies. At the same time, luminaires and lighting arrangements may be desired to have a large lumen output. Hence, it appears desirable that the heat preferably is spread to a larger surface so that heat from electronic components, such as the LEDs, can be more effectively dissipated.

[0010] In known luminaires, the light source may have been configured inside a polymeric housing. In such a luminaire, the light source is typically provided on a metal carrier or support for dissipating heat away from the light source when the luminaire is in operation. If the size of a luminaire decreases or the light output is increased, the heat dissipating capacity of such metal carrier may become insufficient. To improve the heat dissipation, efforts have been made to enlarge the effective heat dissipating area by thermally coupling additional thermally conductive areas to the metal carrier. This may result in in an 2024PF80238

[0011] 2 increased size of the luminaire. The present inventors have tried to solve this problem without increasing the size of the luminaire. Initially, they have tried to coat the polymeric surface of the housing by means of supersonic particle deposition. The inventors found that this may not work properly because of a lack of adherence of the coating to the polymeric surface. The inventors, however, further found that it also does not appear to work properly when metal parts are incorporated in the polymeric housing and then using the (in the surface of the polymeric housing) exposed metal parts as seed surfaces in the supersonic particle deposition process. Using that strategy the formed metal layer was no continuous metal layer but was made of many separate (isolated) layer parts, resulting in only a minimized increase of the size of the heat dissipating surface. It was observed that during the particle deposition, a metal layer grew on the surface of the metal part and then extended to the surface of the polymeric. However, gaps were formed in the metal layer, and the layer was divided into multiple areas that were not connected. It is assumed that this may be the result of a difference in thermal expansion of the metal and the polymeric material. As the polymeric material becomes hotter the polymeric material expands and as it is confined from sides it bends, and the metal deposited on it grows as a bent layer (instead as a flat continuous layer) and contact between different areas misses.

[0012] Hence, it is an aspect of the invention to provide an alternative device, such as a luminaire, which preferably further at least partly obviates one or more of above-described drawbacks. It is a further aspect of the invention to provide a method for coating at least part of a device, such as a luminaire, which preferably further at least partly obviates one or more of above-described drawbacks. The present invention may have as object to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

[0013] According to a first aspect, the invention provides a device comprising a housing part, an electrical component, a support, and a coating, wherein the housing part comprises a first housing side and a second housing side; wherein the housing part comprises a housing part region comprising a plurality of through-holes from the first housing side to the second housing side. Especially, the second housing side is configured opposite to the first housing side. The coating may in embodiments cover at least part of the first housing side. Further, especially, the support comprises a first support side and a second support side; wherein the support is configured to support the electrical component; wherein the electrical component is arranged at the second support side. Especially, the electrical component is arranged in (thermal) contact with the support (at the second support side). Further, especially, the first support side faces at least part of the second housing side at the housing 2024PF80238

[0014] 3 part region. The second support side is especially configured opposite to the first support side. Further, the coating may comprise a thermally conductive material. In embodiments the coating extends into the plurality of through-holes and (the coating) is in (thermal and especially physical) contact with the support via the plurality of through-holes. Additionally, or alternatively, the support may comprise a plurality of support protrusions, wherein the plurality of support protrusions may at least partly protrude into the plurality of through- holes, and wherein the coating is in (thermal) contact with the plurality of support protrusions. The device may especially comprise a device, that (especially the electric component of the device) may produce heat during. The device especially may comprise a device of which optional changes to prior art alternatives may be limited because of limited heat dissipation options. In specific embodiments, the device may comprise a luminaire.

[0015] Herein, the invention is especially explained based on a luminaire as an embodiment of the device. Yet, alternative embodiments of the device may comprise a lighting arrangement, or an (other) electrical arrangement, such as an electronic circuit which may require shielding (especially in relation to electromagnetic waves). Also prior art embodiments of these types of devices / arrangements may show drawbacks described above in relation to luminaires. These types of embodiments may advantageously be configured according to the invention, especially to improve the heat dissipating quality of the embodiments, especially at least partly via the coating. Hence, for specific embodiments, herein the term “luminaire” may also be replaced by “lighting arrangement” or “electrical arrangement”. Therefore, in embodiments, the invention provides (a device, especially) a luminaire comprising a housing part, an electrical component, a support, and a coating, wherein (i) the housing part comprises a first housing side and a second housing side; wherein the housing part comprises a housing part region comprising a plurality of through- holes from the first housing side to the second housing side; (ii) the support comprises a first support side and a second support side; wherein the support is configured to support the electrical component; wherein the electrical component is arranged at the second support side; wherein the first support side faces at least part of the second housing side at the housing part region; (iii) the coating comprises a thermally conductive material; wherein (a) the coating covers at least part of the first housing side, and wherein (b) one or more of the following applies: (iiia) the coating extends into the plurality of through-holes and (the coating) is in contact with the support via the plurality of through-holes, and (iiib) the support comprises a plurality of support protrusions, wherein the plurality of support protrusions are 2024PF80238

[0016] 4 at least partly protruding into the plurality of through-holes, and wherein the coating is in contact with the plurality of support protrusions.

[0017] Such device may have a continuous thermal coating (especially thermally coupled to the electrical component) providing an enlarged heat dissipating surface. The housing part and a coating may comprise different materials having different expansion coefficients, yet the coating may be provided using the method of the invention as a continuous coating. The coating may especially not be divided or broken down in separated unconnected or isolated parts when being provided. The coating may especially be a continuous coating. With such device, the heat dissipation may be improved relative to prior art solutions. Additionally, or alternatively, dimensions of the device may be reduced compared to prior art solutions while keeping a comparable or improved functionality from the electrical component (resulting in a comparable or increased heat generation by the electrical compound). For instance, with embodiments of the luminaire of the invention larger lumen output may be generated compared to comparable prior art luminaires with the same size. Furthermore, smaller luminaires may be configured compared to prior art solutions, while keeping the same lumen output or even increasing the lumen output. Additionally, in embodiments, the coating may improve the fire safety of the device. The coating may in embodiments shield the housing part from, and protect the housing part against, heat. The coating may in further embodiments (also) shield electro-magnetic waves.

[0018] Hence, in embodiments, the device, e.g. the luminaire, comprises an electrical component such as a light generating device (see below) arranged at the second support side. The electrical component may especially be (directly or indirectly) thermally connected to the support. The support (at the first support side) may further be configured in (direct or indirect) thermal contact with the housing part, especially via the second housing side. Further, especially, the (thermally conductive) coating may be configured at the first housing side. For instance, the housing part may comprise a lamp shade, and especially (the first housing side of) the lamp shade is at least partly covered by the coating. The coating is further especially configured in thermal contact with the support. In such embodiments a heat conductive path may be defined from the electrical component (at an upstream side of the heat conductive path) to the coating (at a downstream side of the heat conductive path). The coating is further especially be configured in (thermal) contact with the atmosphere surrounding the device. This way, heat generated by the electrical component (during use) may be released to external of the device, especially to the atmosphere surrounding the device via the coating (wherein the heat may travel via heat conductive path). 2024PF80238

[0019] 5

[0020] The term “heat conductive path” may refer to a plurality of (different) heat conductive paths. The heat connective paths may especially be configured through the plurality of through-holes. The heat conductive paths may in embodiments be comprised by the coating configured in the through-holes. In further embodiments, the heat conductive paths may (further) be comprised by the support protrusions protruding (at least partly) into and optionally through (see below) the through-holes (if the support comprises the support protrusions).

[0021] The terms “upstream” and “downstream” relate to an arrangement of items or features relative to the propagation of an physical element (e.g. a particle) or of a kind of energy (e.g. heat or light) in a channel or along a (flow) path, wherein relative to a first position within the channel or at the (flow) path, a second position in the channel or at the (flow) path closer to an inlet of the element or closer to a means generating the energy is “upstream”, and a third position within the channel or at the (flow) path further away from the inlet of the element or further away from the means generating the energy is “downstream”.

[0022] The coating may especially be configured for transferring heat away from the device (luminaire). The coating may be a thermally conductive coating. The coating may comprise or consist of a thermally conductive (coating) material. The thermally conductive material may in embodiments comprise thermally conductive particles, such as metal particles and / or carbon particles (thermally) contacting each other and / or fused to each other. It is noted that in embodiments, individual metal particles may not be noticeable in the coating, even if the coating originates from metal particles. In specific embodiments, the thermally conductive material may comprise (a) metal. The thermally conductive material may in further embodiments (further) comprise carbon and / or a thermally conductive ceramic material.

[0023] The term “thermally conductive” used herein, such as in a “thermally conductive element”, e.g., a thermally conductive coating, may relate to being able to conduct heat. The thermally conductive element especially comprises or is made of thermally conductive material. The thermally conductive material may e.g., have a thermal conductivity of at least 10 W m’1K’1, such as at least 50 W m’1K’1, especially at least 100 W m’1K’1. The thermally conductive material may comprise a metal, such as copper, aluminum, steel, iron, silver, lead, or an alloy of one or more (of these) metals. The thermally conductive element may in embodiments comprise a layer or a coating arranged configured at, or being part of, the element comprising the respective thermally conductive element. In further 2024PF80238

[0024] 6 embodiments, the element comprising the thermally conductive element may be configured thermally conductive, and especially may at least partly be made of the thermally conductive material. Herein “W m’^K’1” may also be written as “W / m K”, “W / m K”, or “W / mK”.

[0025] The term “thermal contact” between a first and a second elements indicates that the first element can exchange thermal energy (“heat”) through the process of heat transfer with the second element. The first element may e.g., comprise the electrical component and the second element may comprise the support. Based on a thermal contact between the two elements heat may be transferred between the electrical component and the support. Furthermore, the support may in embodiments transfer heat to the coating via the thermal contact between the support and the coating. In embodiments, thermal contact can be achieved by physical contact. In embodiments, thermal contact may be achieved via a thermally conductive material, such as a thermally conductive glue (or thermally conductive adhesive). The term “thermal contact” and comparable terms may refer to a direct thermal (and especially also physical) contact in embodiments. It may further refer to an indirect thermal contact. Thermal contact may also be achieved between two elements when the two elements are arranged relative to each other at a distance of equal to or less than about 10 pm, though larger distances, such as up to 100 pm may be possible. The shorter the distance, the better the thermal contact. Especially, the distance between the two elements is configured to be 10 pm or less, such as 5 pm or less. The distance may be the distance between two respective surfaces of the respective elements. The distance may be an average distance. For instance, the two elements may be in physical contact at one or more, such as a plurality of positions, but at one or more, especially a plurality of other positions, the elements are not in physical contact. For instance, this may be the case when one or both elements have a rough surface. Hence, in embodiments an average distance between the two elements (being in direct thermal contact with each other) may be 10 pm or less (though larger average distances may be possible, such as up to 100 pm).

[0026] The coating may especially comprise or consist of a thermally conductive material. In embodiments, the thermally conductive material comprises a metal-comprising material. The thermally conductive material may in further embodiments comprise a metal. The coating may comprise a metal-comprising coating. In further embodiments, the coating may comprise a metal coating. A metal coating may in embodiments consist substantially only of metal. In embodiments, the metal coating may consist of at least 95 wt.%, such as of at least 99 wt.% metal. 2024PF80238

[0027] 7

[0028] Herein the term “metal” may refer to any kind of, especially thermally conductive, metal element. The term metal may refer in embodiments to a plurality of different metals and / or e.g. a metal alloy. The metal may in embodiments for example comprise tin (Sn) and / or aluminum (Al). In further embodiments, the metal may be titanium (Ti), cupper (Cu), silver (Ag), and / or e.g. lead (Pb). In yet further embodiments, the metal may (further) comprise one or more of bismuth (Bi), and indium (In). Metal (in the coating) may facilitate a desired transfer.

[0029] The coating, especially a composition of the coating, may further be selected for its processability, i.e. the way it may be provided on the housing part and / or in the through-holes. The (composition of the) coating may especially be selected for its capacity to conduct heat.

[0030] In specific embodiments, the coating may be provided by using supersonic particle deposition or “cold spraying”, see further below. The coating may in embodiments be a cold spray spayed coating (or “cold spray coating”). Hence, in embodiments, the coating comprises a cold spray (sprayed) coating, wherein the coating comprises one or more of Sn, Al, Ti, Bi, Cu, In, Ag, and Pb. In specific embodiments the thermal conductivity of the coating is at least 50 W / m K, such as at least 100 W / m K, even more especially at least 150 W / m K.

[0031] The metal in the coating may be selected based on (a combination of) different criteria. The metal may for instance be selected to provide a desired thermal conductivity. The metal may further be selected to provide a desired processability or, e.g., hardness to the coating. Furthermore, the metal may be selected based on a price of the metal (to provide an economic coating). In embodiments, the metal may comprise aluminum. Aluminum may have a thermal conductivity of about 237 W / m K, which may be more than desired. Furthermore, aluminum may provide a hard coating and aluminum may be cost efficient. In further embodiments, the metal (in the coating) may (further) comprise tin. Tin may have a lower thermal conductivity than aluminum (of about 63 W / m K), may also be cost efficient, and may provide a softer coating. It will be understood that by combining tin with aluminum in the coating (optionally with further metals) the properties of the coating may further be set based on predetermined criteria.

[0032] The term “housing part” may in embodiments refer to an element that may house (especially at least partially enclose) the electrical component. For instance in embodiments of a luminaire, the housing part may comprise a lamp shade and especially the electrical component may comprise an LED (or a plurality of LEDs) at least partly enclosed 2024PF80238

[0033] 8 by the housing part. In further embodiments, the housing part may at least partly shield or protect the electrical component. It is noted that although the element is referred to a “housing part”, that also embodiments may be part of the invention in which the electronic component extends from (the housing part region of) the housing part without being enclosed by the housing part. The housing part may especially comprise a part of the device defining at least part of an outside (or “exterior”) of the device. The housing part, especially the first housing part side, (optionally covered by the coating) may in embodiments at least define part of the exterior of the device.

[0034] The housing part may provide a (predetermined) function to the device. In embodiments, the housing part comprising the coating may provide the (predetermined) function. The housing part may in embodiments be configured to provide the (predetermined) function. The housing part (optionally in combination with the coating) may e.g., comprise a lamp shade as described above. Additionally, or alternatively, the housing part (optionally in combination with the coating) may in embodiments comprise a collimator (for collimating a beam of light). In yet further embodiments, the housing part (optionally in combination with the coating) may comprise a reflector. For instance, in embodiments, the housing part may be transparent, and especially the coating may be configured to reflect light. As the coating may be configured to reflect light, the housing part may also be used as collimator or reflector. In further embodiments, the housing part may comprise a driver housing. In embodiments, the housing part may comprise one or more of a lamp shade, a collimator, a reflector, and a driver housing. In further embodiments, the housing part comprising the coating may comprise one or more of a lamp shade, a collimator, a reflector, and a driver housing.

[0035] As a result of different functions and different configurations, the housing part (and therefore also the first housing side and the second housing side) may essentially comprise any arbitrary shape. The housing part may in embodiments have a (hollow) cylindrical shape. In yet further embodiments, the housing part may further comprise a spherical shape, or e.g. a rectangular shape. The first housing part side and / or the second housing part side may be planar in embodiments. The first housing side and / or the second housing side may be curved in further embodiments. Especially, in embodiments at least the housing part region may comprise a plate-like shape. The plate-like shape may be flat in embodiments. In further embodiments, the plate-like shape may be curved. The housing part region may in embodiments comprise a (local) thickness. The first housing side and the second side may define the thickness of the housing part. Especially a shortest distance from the first housing side to the second housing side (at a given location) may define the (local) 2024PF80238

[0036] 9 thickness at the given location. The housing part region is further especially elongated in directions perpendicular to the thickness. Dimensions of a surface of the housing part region defined at the first housing side are especially larger than the thickness of the of the housing part. For instance, a first dimension, e.g., a width of the surface of the housing part region may at least be ten times as large as the thickness of the housing part. Furthermore, also a second dimension of the surface of the housing part, e.g., perpendicular to the first dimension, for instance a length, may also be at least ten times as large as the thickness of the housing part. The surface of the housing part region may be flat in embodiments.

[0037] Alternatively, the surface of the housing part region may be curved in one or more of the first and the second dimension and / or the surface may comprise more than one level.

[0038] In specific embodiments, the housing part may have a (housing part) thickness (shortest distance from the first housing side to the second housing side) that is approximately constant over the housing part. In embodiments, for instance, over at least 80% of a surface of the first housing side, the housing part thickness may be in the range of an average housing part thickness ((averaged over the at least 80% of the surface of the first housing side) ±10%. Yet, in embodiments, the thickness may vary over the housing part. In embodiments, the thickness may at least be approximately constant at the housing part region.

[0039] The housing part may in further specific embodiments comprise protrusions, e.g. pillars or posts extending from (part of) the first housing part side. The pillars or posts may especially be configured at locations of the housing part away from the housing part region. These protrusions may further support an adherence of the coating to the first housing side.

[0040] The through-holes are especially configured along straight lines connecting the first housing side to the second housing side. A (total) length of each through-hole may equal the thickness of the housing part (region) at (a location of) the through-hole.

[0041] Herein the term “plurality” such as in “the plurality of through-holes” and in “the plurality of support protrusions” may refer to two or more. The term may refer to at least three, such as at least four, and in embodiments at least five. In further embodiments, the term “plurality” may refer to at least nine, especially at least ten, such as at least 25, and in embodiments at least 100. The plurality of through-holes may especially comprise n (optionally different) through-holes. In specific embodiments device may compromise a total of protrusion that is equal or less than a total of through-holes. In embodiments, the plurality of protrusions may be equal to or lower than n. The number n may in embodiments, be at 2024PF80238

[0042] 10 least two, such as at least three, especially at least four, such as at least nine, and in embodiments at least ten. In specific embodiments, n may be 1000 at maximum, such as 500 at maximum in embodiments, and 200 at maximum in further embodiments. In embodiments, the plurality of through-holes refers to 6-100 through-holes. In further embodiments, the plurality of support protrusions refers to 6-100 support protrusions.

[0043] The housing part region especially comprises the through-holes. Moreover, the through-holes may define the housing part region. The plurality of trough-holes may comprise outer through-holes especially arranged at a perimeter of the plurality of through- holes. Hence, the most remote through-holes in an array of through-holes may be indicated as outer through-holes. For instance, in a 3*3 rectangular array, there are eight outer through- holes and one non-outer through-holes. The outer through-holes may (geometrically) enclose the other (non-outer) through-holes (if present). For instance in embodiments, three through- holes may define a triangle, and any other through-hole may be configured in the triangle. Likewise, in further embodiments, four outer through-holes may define a four-sided shape, and especially any other through-hole may be configured in the four-sided shape. Moreover, in embodiments the plurality of through-holes may be distributed randomly over the housing part region. The plurality of through-hole may be enclosed by a convex hull (or “convex envelope” or “convex closure”), i.e. a shape defining a smallest continuous area enclosing all through-holes. The outer through-holes are especially arranged at the perimeter of the convex hull. In embodiments, all through-holes may be outer through-holes. In embodiments, especially at least a subset of the through-holes, especially the outer through-holes define the housing part region. It is noted that in embodiments no other through-holes may be present and the term “outer” in “outer through-hole” may then be removed. The housing part region may thus especially be defined by outer through-holes. Moreover, in further embodiments, the housing part region may enclose the plurality of through-holes. A perimeter of the housing part region part may comprise (or coincide with) part of the edges of the outer through-holes.

[0044] The housing part region may comprise a cross-sectional area (especially defined by the outer through-holes) or “housing part region cross-sectional area AHPR”. Further, a total cross-sectional area of the through-holes may be indicated with “total through-hole cross-sectional area (ATH)”. In embodiments, ATH / AHPR is equal to or less than 0.75. In further embodiments ATH / AHPR is no more than 0.5, such as equal to or less than 0.35, and in embodiments, equal to or less than 0.25. Further, ATH / AHPR may at least be 0.025, such as at least 0.05, especially at least 0.075 and in embodiments at least 0.1. 2024PF80238

[0045] 11

[0046] Especially, 0.025<ATH / AHPR<0.75, such as 0.05<ATH / AHPR<0.5, and especially 0.05<ATH / AHPR<0.35. In these ranges, the heat conductive paths through the through-holes may allow the desired heat transfer. Moreover at lower ratios, the strength of the housing part may in embodiments be improved and at higher ratios thermal conductivity may be larger.

[0047] Hence, in embodiments, the housing part region, defined by outer through- holes, comprises a housing part region cross-sectional area AHPR, wherein the through-holes have wherein 0.05<ATH / AHPR<0.35.

[0048] In embodiments, the housing part region may comprise at least 2%, such as at least 3%, especially at least 5%, and in embodiments at least 10%, of a total surface area of the second housing side of the housing part. In further embodiments, the housing part region cross-sectional area AHPR is (or defines) no more than 90%, such as no more than 75%, especially no more than 50%, and even more especially no more than 30%, such as no more than 25% of a total surface area (at one of the first housing part side and the second housing part side) of the housing part. In specific embodiments, the housing part region cross- sectional area AHPR relative to the total surface area of the housing part is in a range from 2 to 50%, especially in the range of 3 to 30%. In embodiments, the housing part region is configured centrally in the housing part. Especially, the housing part region may in embodiments comprise less than two (including zero) edges of the housing part. The housing part region may in further embodiments be configured at a side of the luminaire where during operation of the luminaire essentially no light escapes from the luminaire (this can e.g. be a side opposite to an opening or light transmissive part of the luminaire).

[0049] In embodiments, the plurality of through-holes may be distributed over the housing part region according to a pattern. Alternatively in embodiments, the plurality of through-holes may be distributed randomly over the housing part region. The plurality of trough-holes may especially be distributed evenly over the housing part region. In embodiments a shortest distance between neighboring through-holes may at least 0.3 mm, such as at least 0.5 mm and in embodiments at least 1 mm. Said shortest distance may in further embodiments be 20 mm at maximum, such as 10 mm at maximum, and in specific embodiments 5 mm at maximum. It is noted that the shortest distance between neighboring through-holes in a first dimension of the housing part region (e.g., perpendicular to a third dimension aligned with the through-hole) may differ from the shortest distance between neighboring through-holes in a second dimension (e.g., perpendicular to the first dimension and to the third dimension). 2024PF80238

[0050] 12

[0051] The shortest distance between neighboring through-holes may herein also be indicated with the term “shortest through-hole distance” and may be indicated with the reference DH. The shortest distance DH between neighboring through-holes may especially correspond to a shortest length of a straight line connecting the neighboring through-holes. Further, the shortest distance between neighboring through-holes in the first dimension (or “shortest through-hole distance in the first dimension”) may herein be indicated as DHL The shortest distance between neighboring through-holes in the second dimension (or “shortest through-hole distance in the second dimension”) may herein be indicated as DH2. Because a direction of the straight line not necessarily is configured parallel to the first direction or the second direction, in embodiments, the shortest distance DHI between neighboring through- holes in the first dimension may be larger than the shortest distance DH between neighboring through-holes and the shortest distance DH2 between neighboring through-holes in the second dimension may be larger than the shortest distance DH between neighboring through-holes. In specific embodiments, DHI and Dintmay substantially be the same and may in further embodiment’s correspond to DH. In other embodiments, the values of DHI and DH2 may be substantially different. For instance, in specific embodiments, DHI may be in the range of 0.5 to 1 mm and DH2 may be in the range of 3-20 mm. Further, DH may is such embodiment be equal to or smaller than DHI .

[0052] In further specific embodiments, the plurality of through-holes have shortest through-hole distances (DH) selected from the range of 0.3-20 mm, especially from the range of 0.5-10 mm or from the range of 0.3 to 5 mm in further embodiments. In further embodiments, the plurality of through-holes may have shortest through-hole distances DHI in eth first dimension and / or shortest through-hole distances DH2 in the second dimensions selected from the range of 0.3-20 mm, especially from the range of 0.5-10 mm or from the range of 0.3 to 5 mm in further embodiments.

[0053] The housing part may especially comprise or be made of a thermally insulating material. In embodiments, the housing part may for instance comprise a polymeric material. In specific embodiments the housing parts may consists of a polymeric material. A polymeric material may bring the advantages that is may easily be configured in the desired shape, e.g. using injection molding techniques, extrusion techniques, pressing techniques, or 3D printing techniques. In embodiments, for instance, the housing part comprises (or consists) of a 3D printed housing part. The term “polymeric material” may in embodiments refer to a “plastic (material)”. 2024PF80238

[0054] 13

[0055] Examples of the polymeric material include ABS (acrylonitrile butadiene styrene), Nylon (or polyamide), Acetate (or cellulose), PLA (poly lactic acid), terephthalate (such as PET polyethylene terephthalate), Acrylic (polymethylacrylate, Perspex, polymethylmethacrylate, PMMA), Polypropylene (or polypropene), Polycarbonate (PC), Polystyrene (PS), PE (such as expanded- high impact-Polythene (or polyethene), Low density (LDPE) High density (HDPE)), PVC (polyvinyl chloride) Polychloroethene, such as thermoplastic elastomer based on copolyester elastomers, polyurethane elastomers, polyamide elastomers polyolefine based elastomers, styrene based elastomers, etc.. The housing part may in embodiments comprise a polymeric material listed above. The housing part may in embodiments comprise a thermoplastic material having a glass-transition or melting temperature of at least 100 °C, such as in embodiments of at least 140 °C. This way, softening or melting of the housing part during the coating process as a result of the generation of a little heat may be prevented. In further embodiments, the housing part may in embodiments comprise a thermoplastic material having a glass-transition or melting temperature of at maximum 250 °C.

[0056] It is an aspect of the invention to use the (extended) surface area of the first housing side of housing part to support heat dissipation by covering at least part of the first housing side with the coating. In embodiments at least 10 %, such as at least 20%, especially at least 30%, and in embodiments at least 50%, of a total first housing side may be covered by the coating, such as up to about 60%, though higher values may also be possible. Having such coverage may already provide the desired heat dissipation. Moreover, parts of the first housing side not covered by the coating may in embodiments provide another function than the parts that is covered by the coating, see also below. In further embodiments substantially all of the total first housing is covered by the coating, such as at least 95 %, and especially at least 99 % of the total first housing side. The coating is further especially configured as a continuous coating. In the coating any part of the coating may be thermally connected to further parts of the coating (to be considered as an effective part of the coating).\

[0057] A selected part of the first housing side that is covered may depend on different requirements, such as esthetic requirements, heat dissipating requirements, and further functional requirements. In embodiments, it may e.g. be of esthetic relevance to cover the entire first housing side with the coating, or providing a specific pattern in the coating, although less covering may be sufficient for heat dissipating reasons. In further embodiments, the housing part may for instance comprise a collimator and to collimate a beam of light a specific (collimating) part of the first housing side is preferably not be covered with the 2024PF80238

[0058] 14 coating. Likewise, if the housing part comprises a reflector, specific parts of the first housing side may advantageously be covered with a light reflecting coating, whereas other parts may not require a coating to reflect light (yet they may in embodiments be coated to further increase the heat dissipation). In yet further embodiments, the non-covered part may, e.g., provide a transparent or translucent window for light exiting the device.

[0059] Furthermore, the coating may in embodiments comprise a (continuous) singlelayer coating. In alternative embodiments, the coating may comprise a multi-layer coating. Layers of the multi-layer coating may especially comprise different coating materials (including different compositions). By using a multilayer coating different functionalities may be combined in the coating. A first material of a first coating layer may for instance be selected for facilitating a desired contact between the housing part and the coating. Material of a further coating layer may be selected having a high thermal conductivity. Yet, material of yet another coating layer may e.g. be selected for providing a good adherence with material of the protrusions, etc. In embodiments, the coating may comprise a first layer (contacting the housing part) comprising a first material and a second layer (on top of the first layer) comprising a second material including a composition of the second material). For instance, in embodiments the first layer may comprise a combination of tin and aluminum and the second layer comprises aluminum but no tin This may result in a first layer that is softer and that may better adhere to the housing part than the second layer, whereas the second layer may have a higher thermal conductivity than the first layer.

[0060] In specific embodiments, the coating comprises a multi-layer coating comprising (i) a first layer in contact with at least part of the housing part and (ii) a second layer, wherein the first layer is configured between the housing part and the second layer; wherein the first layer comprises a first material, wherein the second layer comprises a second material, wherein the housing part comprises a housing part material; wherein the first material has a higher adhesion to the housing part material than the second material, and wherein the second material has a higher thermal conductivity than the first material.

[0061] In embodiments, the second layer may substantially completely cover the first layer. In further embodiments, the first layer may only partly be covered by the second layer.

[0062] Herein the term “material” such as in “first material” and “second material” may refer to components / compounds of the material. The term may further refer to a composition of the material.

[0063] The coating may especially cover at least part of the first housing side. 2024PF80238

[0064] 15

[0065] In embodiments, wherein the support protrusions extend from the first support side, the coating may at least partially surround the support protrusions (extending from the first support side). Further, the coating may in embodiments also cover the (tops of the) support protrusions.

[0066] Would the support protrusions essentially be at the same level as the first housing side, the coating may cover at least part of the first housing side and may also cover the (tops of the) support protrusions. Dependent upon the shape of the support protrusions, the coating may also extend into the through-holes.

[0067] Would the support protrusions extend into the through-holes, but be lower in height than the through-holes, the coating may cover at least part of the first housing side and may also cover the (tops of the) support protrusions. Hence, the coating may also extend into the through-holes.

[0068] In embodiments, wherein there are no support protrusions, the coating may cover at least part of the first housing side and may extend into the through-holes and cover the (exposed) surface of the support behind the through-holes. Hence, the coating may in embodiments extend with coating extensions into the plurality of through-holes and may especially be in contact with the support via the coating extensions in the plurality of through-holes.

[0069] The contact of the coating with the support may thus be contact with the protrusions and / or contact with a part of the support from which the protrusions extend, and / or contact with the support as such when the support does not comprise protrusions. Hence, in some embodiments, as described amongst others above, the coating may extend into the through-holes. Parts of the coating that extend into the through-holes may be indicated as “coating extensions”. Hence, the coating may in embodiments extend with coating extensions into the plurality of through-holes and may especially be in contact with the support via the coating extensions in the plurality of through-holes.

[0070] The contact with the support may especially be physical contact (thereby also allowing thermal contact).

[0071] The support is especially configured for supporting the electrical component. In embodiments, the electrical component may be carried by the support. Additionally, or alternatively, the electrical component may be suspended on the support. The support may in embodiments function as a heatsink for heat being generated by the electrical component during use / operation. The electrical component may therefore be thermally coupled to the support. In embodiments, the electrical component may (further) be physically coupled to the 2024PF80238

[0072] 16 support. The electrical component may e.g. be connected to the support, especially to the second support side, using fasteners, such as screws, pins, rivets, etc. or e.g. using a (thermally conductive) glue. This may facilitate heat transfer to the support. Yet, in alternative embodiment, having the electrical component arranged at a small distance from the electrical component may (already) provide the desired heat transfer. The support may further especially be configured for conducting heat. In embodiments, the support may in have a heat conductivity of 50 W / K m or more, especially at least in a direction from the second support side to the first support side. The support may comprise or consist of a thermally conductive material as described herein e.g. in relation to the coating. In embodiments, the support may e.g. comprise, or be made of, a metal. The support may in embodiments, e.g., comprise aluminum or e.g. iron. The support is especially configured thermally conductive.

[0073] In further embodiments, the support may also be configured for comprising further electrical components. The support may in embodiments for instance comprise a printed circuit board (“PCB”), especially configured for functionally coupling to the electrical component / being functionally coupled to the electrical component. In specific embodiments, the electrical component may for instance comprise a light generating device. Such light generating device may in embodiments comprise a solid-state lighting (SSL) type of light source. The light generating device may for instance comprise one or more lightemitting diodes (LEDs). The light generating device may in embodiments comprise one or more electronic elements, such as a driver to control the light generating device. The light generating device may be arranged at, especially (thermally) coupled to, a heat sink. Additionally or alternatively, the light generating device, especially comprising one or more SSL types of light sources, may be arranged at, especially connected to, a printed circuit board. The PCB may comprise (part of) the one or more electronic elements or may comprise further electronic elements. The PCB may further function as heat sink. The PCB may especially comprise a metal core (“MC”) PCB. The metal core may further facilitate heat transfer / heat dissipation.

[0074] In specific embodiments, the support comprises the heat sink. Additionally, or alternatively, the support comprises the PCB.

[0075] Hence, in specific embodiments, the housing part comprises or consists of a polymeric material, wherein the electrical component comprises a light generating device, wherein the coating comprises a metal coating, wherein the support comprises one or more of 2024PF80238

[0076] 17 printed circuit board and a heatsink; and wherein the plurality of through-holes comprises n through-holes, wherein n>4.

[0077] As discussed above, in embodiments the support may comprise the plurality of support protrusions, especially at least partly protruding the plurality of through-holes. The plurality of support protrusions may therefore in embodiments be configured corresponding to the plurality of the through-holes (and vice versa). The plurality of support protrusion may be configured to fit in the plurality of through-holes. Hence, especially a value of a shortest distance between neighboring support protrusions may approximate the value of the shortest distance between neighboring through-holes.

[0078] It is noted that the shortest distance between neighboring support protrusions may especially correspond to a shortest length of a straight line connecting the neighboring through support protrusions The shortest distance between neighboring support protrusions may herein also be indicated with the term “shortest protrusion distance” and may be indicated with the reference Ds. In analogy with the configuration of the shortest through- hole distance, may also a shortest distance between neighboring support protrusions in the first dimension be defined, and may a shortest distance between neighboring support protrusions in the second dimension be defined.

[0079] The shortest distance between neighboring support protrusions may herein also be referred to as “shortest protrusion distances” and may be indicated with the reference Ds. Furthermore the shortest distance between neighboring support protrusions in the first dimension (or “shortest protrusion distance in the first dimension”) may herein be indicated as Dsi. The shortest distance between neighboring support protrusions in the second dimension (or “shortest protrusion distance in the second dimension”) may herein be indicated as Ds2. As is explained in relation to the shortest through-hole distances DH, DHI, and DH2, it will be understood that also the values for Ds, Dsi, and Ds2 may differ from each other in embodiments.

[0080] In specific embodiments, Dsi and Ds2 may substantially be the same and may in further embodiment’s correspond to Ds. In other embodiments, the values of Dsi and Ds2 may be substantially different. For instance, in specific embodiments, Dsi may be in the range of 0.5 to 1 mm and Ds2 may be in the range of 3-20 mm. Further, Ds may in such embodiment be equal to or smaller than Dsi.

[0081] In further specific embodiments, the plurality of through-holes may have shortest through-hole distances (DH) selected from the range of 0.3-20 mm, especially from the range of 0.5-10 mm or from the range of 0.3 to 5 mm in further embodiments. In further 2024PF80238

[0082] 18 embodiments, the plurality of through-holes may have shortest through-hole distances DHI in eth first dimension and / or shortest through-hole distances DH2 in the second dimensions selected from the range of 0.3-20 mm, especially from the range of 0.5-10 mm or from the range of 0.3 to 5 mm in further embodiments.

[0083] Further, in embodiments a shape or cross-section of the support protrusions may correspond to a shape of the through-holes. The through-holes may e.g. have a circular cross-section and the support protrusions may have a circular cross-section, see also further below. As a result of a clearance between the support protrusion and the through-hole, the value of the shortest distance Ds between neighboring support protrusions may be a little larger than the respective shortest distance between neighboring through-holes. Moreover, also the value of the shortest distance Dsi between neighboring support protrusions in the first dimension and / or the shortest distance Ds2 between neighboring support protrusions in the in the second dimension may be a little larger than the respective shortest distances between neighboring through-holes.

[0084] In embodiments a shortest distance Ds between neighboring support protrusions may at least 0.3 mm, such as at least 0.5 mm, especially at least 0.6 mm, such as at least 1 mm, and in embodiments at least 2 mm. Said shortest distance may in further embodiments be 25, mm at maximum, especially 20 mm at maximum, such as 10 mm at maximum. Such maximum distance may allow bridging the distance with coating material during providing the coating and may and may provide effective heat sinking. In embodiment, the shortest distance between neighboring support protrusions may e.g. be at least 10%, such as at least 25%, and in embodiments at least 50%, larger than the shortest distance between neighboring through-holes. In specific embodiments, neighboring support protrusions of the plurality of support protrusions have shortest protrusion distances as described above in relation to the shortest through-hole distances.

[0085] In specific embodiments, neighboring support protrusions of the plurality of support protrusions have shortest protrusion distances selected from the range of 0.3-20 mm, especially from the range of 0.5-10 mm or from the range of 0.3 to 5 mm in further embodiments.

[0086] The support protrusions may in embodiments protrude through the through- holes. The support protrusions may in specific embodiments extend beyond the first housing side, for instance at least 0.1 mm, such as at least 1 mm. In further embodiments, the support protrusions may extend beyond the first housing side up to 7.5 mm, such as up to 5 mm, or up to 2 mm in further embodiments. In embodiments, the support protrusions extend in the 2024PF80238

[0087] 19 range of 0.1-5 mm beyond the first housing side. In further embodiments, the support protrusions do not extend beyond the first housing side. Further, a (total) height of the support protrusion may especially be at least 0.5 mm, such as at least 1 mm, and in embodiments at least 2 mm. Depending on the cross-sectional area of support protrusions such length may provide an effective heat conduction and may also provide a mechanically reliable connection. The height of the support protrusion may in embodiments equal to a total of a height of the through-hole and a total length that the support protrusion extends beyond the first housing side. Hence, in further embodiments, the height of the support protrusion may be larger than 7.5 mm, such as up to 10 mm in embodiments, or even larger than 10 mm in embodiments.

[0088] Moreover, the through-holes may have a (first) height of the through-holes (“first height” or “through-hole height”) (in a direction from the first housing side to the second housing side). Further, the support protrusions may have a (second) height of the support protrusions (“second height” or “support protrusion height”) configured protruding into the through-holes. In embodiments, the first height may be larger than the second height. In other embodiments, the second height may be larger than the first height. A ratio of the second height to the first height, H2 / H1 may in embodiments be at least 0.25, such as at least 0.5, and in embodiments at least 1, such as at least 1.5, and especially 2 at maximum.

[0089] A characteristic size, especially a cross-sectional dimension, such as diameter or width, of the support protrusion may in embodiments be at least 0.5 mm, especially at least 1 mm, such as at least 1.5 mm, and especially at least 2 mm. The cross-sectional dimension may in further dimensions be at least 1 cm, such as at least 2 cm, or at least 2.5 cm. The cross-sectional dimension may further especially be no more than 75 mm, even more especially no more than 50 mm, and in embodiments no more than 10 mm. Such characteristic sizes may facilitate effective heat conduction to the coating.

[0090] The support protrusions are especially thermally conductive. The support protrusion may comprise or consist of thermally conductive material described above in relation to the coating. In specific embodiments, the support protrusions comprise a metal. The support protrusions may further be configured for facilitating a physical connection between the coating and the support. Moreover, in embodiments, the support protrusions in combination with the through-holes may be configured for facilitating connecting the housing part to the support.

[0091] The plurality of support protrusion may further have a shape for facilitating one or more of these functions. The plurality of support protrusions may in embodiments 2024PF80238

[0092] 20 comprise (solid) pillars (or “rods”). The pillars may have a circular or e.g. have a triangular cross-section. The pillar may comprise a cylinder. Herein, the cross-section of the support protrusion may especially be defined perpendicular to a direction of protruding into the through-hole. A (solid) cylinder may essentially comprise a circular cross-section. Additionally, or alternatively, the pillars may comprise a rectangular (including squared) cross-section. The pillars may in further embodiments have a star-like cross-section (increasing a contact area between the pillar and the coating (extensions)). Additionally, or alternatively, the support protrusions may comprise a plate or fin-like shape, especially having an elongated cross-section. In embodiments, such elongated shape may be flat. In further embodiments, the elongated shape of the plate may be curved. In a plate-like support protrusion a first cross sectional dimension may be substantially larger than a second cross- sectional area. For instance, a ratio of the first cross-sectional area to the second cross- sectional dimension may be equal to or larger than 10, such as equal to or larger than 20 in embodiments. In further embodiments a surface area for contacting the coating (extensions) may be roughened, e.g. abraded or scratched. A rough surface may facilitate adhering of the coating to the surface of the support protrusions.

[0093] The cross-section of the support protrusions may be constant along the height of the support protrusions. Alternatively, the cross-section may change along the height of the support protrusions. In embodiments, for instance the cross-sectional area may gradually decrease in a direction in which the support protrusion extends, i.e. in a direction towards a top of the support protrusion. The top of the support protrusion may in embodiments be truncated. In embodiments, the support protrusion may have a planar top (or “flat” top). In embodiments, the tops of the support protrusions may have been configured planar to facilitate an improved (thermal and / or physical) contact between the support and the coating. The (planar) tops of the support protrusions may further comprise a rough surface, which may further facilitate adhering of the coating to the support protrusions. Furthermore, in embodiments, during providing the coating in the through-holes and / or at the support protrusions, the shape of the top may have been changed affecting the cross sectional area at the top of the support protrusion. In embodiments, the cross sectional area of the support protrusion gradually decreases in a direction of the top. In further embodiments, the cross- sectional area is substantially constant between a base of the support protrusion up to a specific height of the support protrusion, and is only changed over part of the height of the support protrusions. In further embodiments the support protrusions may have cross-sectional areas having a constant value over at least 50%, such as at least 80% of the second height 2024PF80238

[0094] 21

[0095] (H2) of the support protrusions. Likewise, the through-holes may have cross-sectional areas that may have a changing value along the first height, In embodiments, for instance the cross- sectional area of the through-holes may have a constant value over at least 50%, such as at least 80% of the first height (Hl) of the through-holes.

[0096] In embodiments the term “constant” in “constant value” in relation with the cross-sectional area of the through-holes and / or of the support protrusions may refer to a constant value ±10%.

[0097] Hence, it will be understood that the plurality of support protrusions may essentially comprise any kind of shape, and in embodiments a combination of different shapes. The plurality of support protrusions may for instance comprise a combination of plate-type (or fin-like shaped) support protrusions and pillar-shaped support protrusions. In embodiments, the support protrusions may especially have planar protrusion tops.

[0098] The plurality of through-holes may especially be configured corresponding to the plurality of support protrusions. Hence, in embodiments, also the plurality of through- holes may comprise a combination of different shapes. The plurality of through-holes may in embodiments for instance comprise a combination of cylindrical openings (e.g. for receiving pillars or rods) and slits (for receiving plate-type support protrusions).

[0099] The support may thus in specific embodiments comprise a protrusion region.

[0100] The protrusion region especially encloses the plurality of support protrusions. The protrusion region may be defined by outer support protrusions. The protrusion region may be defined by outer support protrusions in a comparable way that the housing part region may be defined by outer through-holes. Hence, i.e. part of edges of the outer support protrusions may form a part of a perimeter of the protrusion region. The protrusion region may further comprise a protrusion region cross-sectional area APR. Further, the support protrusions may have a total support protrusion cross-sectional area Ap. The total support protrusion cross-sectional area may especially be defined at a base of the support protrusions. Further, especially a value of a ratio of the total support protrusion cross-sectional area to the protrusion region cross- sectional area, AP / APR, may approximate the value of ATH / AHPR, described above. In embodiments, for instance, 0.025<AP / APR<0.75, such as 0.05<AP / APR<0.5, and especially 0.05<Ap / ApR<0.35.In further embodiments, the ration may be in the range 0.025<AP / APR<0.25. In specific embodiments, 0.05<AP / APR<0.35.

[0101] Hence, in specific embodiments, the support comprises a protrusion region, defined by outer support protrusions, comprising a protrusion region cross-sectional area APR, wherein the support protrusions have a total support protrusion cross-sectional area Ap, 2024PF80238

[0102] 22 wherein 0.05<AP / APR<0.35; and especially wherein the support protrusions have cross- sectional dimensions selected from the range of 0.5-50 mm.

[0103] In further embodiments one or more of the following applies: (a) the through- holes have cross-sectional areas having a constant value over at least 80% of a first height (Hl) of the through-holes, and (b) the support protrusions have cross-sectional areas having a constant value over at least 80% of a second height (H2) of the support protrusions.

[0104] In further specific embodiments, the housing part may comprise one of a lamp shade, a collimator, a reflector, and a driver housing, wherein n is at least 9; wherein the luminaire comprises (also) n support protrusions; wherein the support protrusions have a shape selected from a plate and a (solid) cylinder; wherein the support protrusions comprise a metal.

[0105] In a further aspect, the invention provides a method for coating at least part of a device, especially the device described above. The device may in embodiments comprise the luminaire. In embodiments, the method comprises providing a coating comprising a thermally conductive material to at least part of the device such that: (a) the coating covers at least part of the first housing side. In further embodiments the coating is provided such that one or more of the following applies: (i) the coating (especially extending into the through- holes and) is in contact with the support via the through-holes, and (ii) the support comprises support protrusions, wherein the support protrusions are at least partly protruding into the through-holes, and wherein the coating is in contact with the support protrusions. In specific embodiments, the coating is provided by cold spraying.

[0106] The invention may in specific embodiments provide a method for coating at least part of a luminaire, wherein (I) the luminaire comprises a housing part, an electrical component, and a support; wherein the housing part comprises a first housing side and a second housing side; wherein the housing part comprises a housing part region comprising a plurality of through-holes; wherein the support comprises a first support side and a second support side; wherein the support is configured to support the electrical component; wherein the electrical component is arranged at the second support side; wherein the first support side faces at least part of the second housing side; (II) the method comprises providing a coating comprising a thermally conductive material to at least part of the luminaire by cold spray coating such that: (a) the coating covers at least part of the first housing side, and wherein (b) one or more of the following applies: (i) the coating is in contact with the support via the through-holes, and (ii) the support comprises support protrusions, wherein the support 2024PF80238

[0107] 23 protrusions are at least partly protruding into the through-holes, and wherein the coating is in contact with the support protrusions.

[0108] Especially, based on the contact that is provided with the method between the support (optionally at least partly via the support protrusions) and the coating, the method may provide a continuous coating at the first housing side. During providing the coating, the coating may start growing from the support / support protrusions at the location of the through-holes so that they are connected, and a continuous coating may be is formed covering at least part of the first housing side.

[0109] Cold spraying (also known as “Gas dynamic cold spraying” and, e.g., “supersonic particle deposition”) is a coating deposition method wherein solid powders are accelerated in a supersonic gas jet, especially to velocities up to ca. 1200 m / s. The powders typically comprise particles having a size, such as width or diameter in the range of 1 to 50 micrometers. During impact with the substrate, the particles may undergo plastic deformation and adhere to the surface. The powders may comprise one or more of metals, polymers, ceramics, composite materials and nanocrystalline particles to be deposited. The kinetic energy of the particles, supplied by the expansion of the gas, is converted to plastic deformation energy during bonding. The energy may further result in an optional deformation of the substrate. The powders may in embodiments also comprise silicate (sand) particles. The sand particles may facilitate the process, yet they may especially not end up in the coating. The sand particles may e.g. prevent clogging of the spray nozzle. In embodiments, e.g., a few wt.%, such as 1 to 2 wt.%, of the powder may consist of sand particles. Unlike thermal spraying techniques, the powders are typically not melted during the spraying process. A “cold spray sprayed coating” or also indicated as “cold sprayed coating” is especially provided using cold spraying.

[0110] Cold spraying may bring the advantage that heating of the substrate may be minimized, thereby maintaining the initial physical and chemical properties of the substrate in a larger extend than other coating techniques. Furthermore, using the method (high) thermal conductive may be provided; the coating may be provided at substrates having complex shapes; and the method may provide precise control over the deposition area based on the focused beam of particles.

[0111] In further embodiments, the method may comprise leveling the coating provided at the first housing side. The method may comprise sanding and / or polishing the provided coating. Leveling the coating may in embodiments comprise removing (extending) parts of the plurality of support protrusions that optionally extend from the coating. 2024PF80238

[0112] 24

[0113] With embodiments of the method of the invention embodiments of the device of the invention may be provided.

[0114] In specific embodiments, especially for lighting applications, the terms “light” and “radiation” refer to (at least) visible light.

[0115] BRIEF DESCRIPTION OF THE DRAWINGS

[0116] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts.

[0117] Figs, la to le schematically depict aspects of the invention.

[0118] Fig. 2 schematically depicts a configuration of a support.

[0119] Figs. 3a to 3b schematically depict some aspects of the support protrusions. Fig. 3c schematically depicts some further aspects of the coating.

[0120] The schematic drawings are not necessarily to scale.

[0121] DETAILED DESCRIPTION OF THE EMBODIMENTS

[0122] Figures la to le schematically depict some aspects of embodiments of the luminaire 1000. The luminaire 1000 is an example of an embodiment of the device of the invention. The luminaires 1000 depicted in these figures comprise a housing part 600, an electrical component 7 comprising a light generating device 100, a support 500 supporting the electrical component 7, and a coating 700. The housing part 600 comprises a first housing side 601 and a second housing side 602 opposite to the first housing side 601. Likewise, the support 500 comprises a first support side 501 and a second support side 502 at which the electrical component 7 is arranged. A part of the housing part 600 may be define a receipt region 605. The receipt region 605 is schematically indicated in Figure la having a size in one direction, e.g. a width, which is indicated with the reference Dx. The depicted size Dxmay further indicate a size, such as a width, of the support 500. The housing part 600 comprises a housing part region 606 comprising a plurality of through-holes 630. A first size, such as a width, of the housing part region 606 is indicated in the figure with reference Dm. The receipt region 605 comprises the housing part region 606 in the depicted embodiment. Figures la to le further schematically depict that the first support side 501 faces the second housing side 602 at the housing part region 606. In embodiments, there may be a small gap between the first support side 501 and the second housing side 602 (at the receipt region 605 and / or at the housing part region 606). In further embodiments, the first support side 501 and 2024PF80238

[0123] 25 the second housing side 602 may (directly) contact each other at the housing part region 606. The receipt region 605 and / or the housing part region 606 may in specific embodiments have a flat, plate-like, or planar configuration. Likewise, the support 500 may have such flat configuration. Such flat configurations are also schematically indicated in Figures la to le, 2, and 3b. Yet, also other configurations, such as curved, levelled or any further arbitrary configuration are not excluded from the invention.

[0124] In Fig la, coating 700 is omitted and schematically depicts the housing part 600 comprising open through-holes 630 with a size, or cross-sectional dimension, such as a width or diameter, indicated with reference DTH. Figure la may thus also depict an embodiment of the luminaire 1000 used in the method of the invention. The coating 700, especially comprising a thermally conductive material, is depicted in Figures lb to le. The coating 700 covers the first housing side 601. In embodiments the coating may cover almost the entire first housing side 601, see e.g. Figure le. Yet, alternatively, only a minor part of the first housing side 601 may be covered by the coating 700, such as depicted in Figures lb to Id. In embodiments, at least the receipt region may be covered by the coating 700.

[0125] In the embodiments depicted in Figures lb and le, the coating 700 extends into the plurality of through-holes 630 and is in (direct) contact with the support 500 via the plurality of through-holes 630. In the embodiments of Figures 1c to Id, the support 500 comprises a plurality of support protrusions 530 at least partly protruding into the plurality of through-holes 630 (compare Figure 1c to Figure Id showing different levels of the extend of protrusion of the support protrusions 530). In these embodiments the coating 700 is (also) in contact with the plurality of support protrusions 530. Moreover, referring to Figures lb to le it may also be described the coating 700 extends with coating extensions 730 into the plurality of through-holes 630 and that the coating 700 is in contact with the support 500 via the coating extensions 730 in the plurality of through-holes 630. The contact via the coating extensions 730 may include contact via the support protrusion 530.

[0126] Typically, the housing part 600 may comprises or consists of a polymeric material, such as polycarbonate or polystyrene. The housing part 600 may in embodiments comprise a 3D printed housing part 600. It is noted that the first housing side 601 may be configured with a rather smooth surface. Yet, in embodiments, the first housing side 601 may also comprise a texture, such as an embossing or e.g. protrusions. This texture may facilitate the adherence of the coating 700 to the first housing side 601. Such texture may especially be configured outside of the housing part region 606 and is schematically depicted in Figure le. 2024PF80238

[0127] 26

[0128] Preferably, the polymeric material is a thermoplastic material having a glasstransition or melting temperature of at least 100 °C. This may allow providing the coating with the method of the invention using cold spraying techniques, without softening or melting the housing part 600. Using a cold spray technique may in embodiments provide a metal coating 700. The coating 700 may be a metal coating. A cold spray (sprayed) coating 700 may e.g. comprise one or more metals selected from the group consisting of Sn, Al, Ti, Bi, Cu, In, Ag, and Pb. The coating 700 may in embodiments comprise at least aluminum As described above, in the depicted embodiments of Figures la to le, the electrical component 7 comprises a light generating device 100. The light generating device 100 especially comprises LEDs. The depicted support 500 comprises a printed circuit board (“PCB”) (connected to the LEDs). Additionally, or alternatively, the support 500 may comprise a heatsink. Moreover, the PCB may function as a heat sink. Light emitted by the LEDs is schematically depicted as with reference 101. Device light, generated by the light generated device 100 may be a combination of the light 101 of the LEDs and is indicated with reference 1001.

[0129] In Figures la to le also the shortest distance between neighboring through- holes 630 is depicted as shortest trough-hole distance with reference DH. The shortest through-hole distances DH may in embodiments be selected from the range of 0.5-10 mm. In Figure 1c, the shortest distance between neighboring support protrusions 530 is depicted as shortest protrusion distance with reference Ds. The shortest protrusion distances Ds may in embodiments also be selected from the range of 0.5-10 mm. It is noted that Figures 1 a to le schematically depict a cross-section of the luminaire 1000 in one direction. It is assumed that the depicted shortest distances DH and Ds in the depicted direction are equal to or shorter than further distances between neighboring through-holes 630 and further distances between neighboring support protrusions 530 in other directions.

[0130] In Figure 1c, a size, such as a width or a diameter of the support protrusions is indicated with the reference Dp, and a protrusion-protrusion distance P is indicted. The protrusion-protrusion distance P is especially defined as the distance between a center of a first support protrusion 530 and a center of a second (neighboring) support protrusion 530. The protrusion-protrusion distance P may thus equal the sum of Ds and Dp (if the size Dp of the neighboring support protrusion is the same).

[0131] Further, in Figure Id, also the first height Hl of the through-holes 630 and the second height H2 of the support protrusions 530 are schematically depicted. In the embodiment, 2024PF80238

[0132] 27 the support protrusions 530 extend beyond the first housing side 601 (H2>HI). They 530 may e.g. extend 0.1 to 5 mm in embodiments. Yet, in further embodiments, they 530 may extend further than 5 mm.

[0133] Figure 2 schematically depicts a part of the housing part 600 connected to a support 500 comprising support protrusions 530. The depicted part may herein also be referred to as receiving region 605, see also Figure la. Here size Dxof the support 500 (and / or of the receiving region 605 of the housing part 600) is depicted in two dimensions (e.g., perpendicular to each other and perpendicular to the plurality of support protrusions 530) with references Dxiand DX2. It is noted that the cross-sectional views depicted in Figures la to le may in specific embodiments relate to a cross-section parallel to the first dimension, i.e. where Dxmay correspond to Dxior parallel to the second dimension (where Dxmay correspond to DX2). However, Figures la to le may also depict cross sectional views made in another direction. Hence values of Dxmay differ from values of Dxiand from Dx2.

[0134] Also sizes Dmof the housing part region 606 are depicted in two dimensions (e.g. perpendicular to each other and to the plurality of through-holes 630) with references Dmi and Dm2. The depicted through-holes 630 are all cylindrically shaped, having a circular cross sectional area. In the figure, the size of the through-holes 630 in first dimension is indicates with the reference DTHI and the size in a second dimension (e.g. perpendicular to the first dimension and to the direction of the through-holes 630) is indicated with the reference DTH2. Because the through-holes are cylindrical, DTHI= DTH2 and the cross- sectional area of each of the through-holes may be calculated as7t / 4 *DTHI * DTHI . In the embodiment, the plurality of through-holes 630 comprises n through-holes 630, wherein n =16. Of these 16 through-holes, 12 through-holes 630 are outer through-holes 630, especially enclosing the 4 other through-holes 630. In the figure, also the housing part region 606 is depicted. The housing part region 606 encloses the plurality of through-holes 630. The housing part region 606 may be defined by the outer through-holes 630. The housing part region 606 especially comprises a smallest continuous area enclosing all through-holes 630 (also known as “convex hull”). The housing part region 606 in the figure has a cross- sectional area AHPR having a size of Dmitimes Dm2. Furthermore, a total cross-sectional area of the through-holes 630, or total through-hole cross-sectional area ATH, may for the given embodiment (having 16 identical cylindrical through-holes 630) be calculated as 16 times 7t / 4 *DTHI * DTHI . In specific embodiments of the invention, the through-holes may be configured such that 0.05<ATH / AHPR<0.35. 2024PF80238

[0135] 28

[0136] The figure further depicts the protrusion region 607 enclosing the plurality of support protrusions 530. In the embodiment, the plurality of support protrusions 530 comprises sixteen support protrusions 530, thus as many as the n trough-holes 630. Of these sixteen support protrusions, twelve support protrusions 530 are configured as outer support protrusions 530 (enclosing the four other support protrusions 630). The protrusion region 607 may be defined by the outer support protrusions 530 (like the housing part region 606 may be defined by the outer through-holes 630). The protrusion region 607 in the figure has a protrusion region cross-sectional area APR having a size of DPRI * DPR2. Furthermore, a total cross-sectional area of the support protrusions 530, or a total support protrusion cross- sectional area Ap, may for the given embodiment having cylindrical pillars as support protrusions 530 be calculated as 16 times 7t / 4 *Dpi*Dpi(or 16 times 7t / 4 *DP2*DP2, since Dpiequals DP2 for the cylindrical pillar 530). In specific embodiments 0.05<AP / APR<0.35. For the cylindrical pillar 530 Dpiequals DP2. In other embodiments, this may be different. For instance, the plurality of support protrusions may also comprise plate-like support protrusions 530 (see e.g. Figure 3a) in which Dpi» DP2 or Dpi» Dp2. Dpiand DP2 may also be called cross-sectional dimensions and may especially have a values selected from the range of 0.5- 50 mm. Moreover, in the depicted embodiment, the through-holes 630 (and the support protrusions530) are evenly distributed (the shortest trough-hole distances DH in the first dimension DHI are especially equal to the shortest trough-hole distances DH in the second dimension Dm). In further embodiments, the through-holes 630 may be distributed in another way. As such may the shortest trough-hole distances DHI in the first dimension differ from the shortest trough-hole distances Dm in the second dimension in embodiments. Moreover, in embodiments the shortest trough-hole distances DH corresponding to the shortest length of a line connecting neighboring protrusion 530 may be smaller than any one of DHI and Dm. This would for instance be true if the first and second dimensions in Figure 2 would be selected at an angel of 45° relative to the present figure.

[0137] Figure 2 further also depicts the shortest distance Dsi between neighboring support protrusions 530 in the first dimension and the shortest distance Ds2 between neighboring support protrusions 530 in the second dimension. Based on the even and symmetrical distribution of protrusions, the shortest protrusion distances in the first dimension Dsi and the shortest protrusion distances in the second dimension Ds2 are approximately the same and may correspond to the shortest protrusion distances Ds. In the figure Ds is not depicted. However Ds may correspond to a shortest distance between neighboring protrusions 530 measured along a straight line connecting them. In Figure 2 this 2024PF80238

[0138] 29 corresponds to the indicated Dsi and Ds2. Based on a clearance between the protrusions 530 and the through-holes 630, DHI < Dsi and DH2 < Ds2 in the depicted embodiment.

[0139] The support protrusions 530 may essentially have any arbitrary shape. In Figure 3a (some examples of embodiments of the support protrusions 530 are depicted. Moreover, the figure may further depict cross-sections of the support protrusions 530. From the left to the right the next examples are given: a rod or (solid) cylindrical support protrusion, a flat or straight plate-like support protrusion, a curved plate-like support protrusion, a star shaped support protrusion, and a rectangular support protrusion.

[0140] In embodiments, the support protrusions 530 may have a constant cross- sectional area or cross-sectional dimensions DPI,DP2 along the height of the support protrusion 530. This is schematically depicted in the left embodiment of the support protrusion 530 in Figure 3b, showing a cylindrical or e.g., rectangular, or plate-like support protrusion 530 having a second height H2 of the support protrusion 530 and a cross-sectional dimension DPI,DP2, especially a width Wp, that is constant over the height of the support protrusion 530. As a result of the constant cross-sectional dimensions DPI,DP2, the support protrusion 530 has a planar protrusion top 531. In alternative embodiments, such as depicted at the right hand side of Figure 3b, the cross-sectional area changes (gradually). In that embodiment, at least the width Wpchanges along the height of the support protrusion 530. In the embodiment, the cross-sectional area starts changing from the base of the support protrusion 530. In further embodiments, a first part of the support protrusion 530 may have a constant cross-sectional area, and another part may have a changing cross-sectional area. The depicted configuration has a sharp top 531. Alternatively, a changing cross-sectional area may also result in a planar protrusion top 531. In specific embodiments, the support protrusions 530 have cross-sectional areas having a constant value over at least 80% of the second height H2 of the support protrusions 530. Additionally, or alternatively, the through- holes 630 have cross-sectional areas having a constant value over at least 80% of a first height Hl of the through-holes 630.

[0141] In Figure 3c, some further aspects of the coating 700 are depicted. To provide different functionalities to the coating 700, such as providing a high adherence of the coating 700 to the housing part 600, and providing a high thermal conductivity to the coating 700, it may be advantageous to provide the coating 700 in multiples layers. Figure 3c depicts an example of such coating 700. The coating 700 comprises a multi-layer coating comprising a first layer 710 comprising a first material (composition) and a second layer 720 comprising a second material (composition). The first layer 710 may be in contact with at least part of the 2024PF80238

[0142] 30 housing part 600 (not depicted in the figure) at the first side 701. Further the first layer 710 may then be configured between the housing part 600 and the second layer 720. The second side 702 of the coating is especially configured in contact with air surrounding the luminaire 1000 (where it may release heat to the air).

[0143] In embodiments, the housing part 600 may comprise a housing part material and the first material has a higher adhesion to the housing part material than the second material. Moreover, the second material may also have a higher thermal conductivity than the first material. |This way, the heat may best be released via the second side 702 with the coating 700 firmly connected to the housing part 600.

[0144] The coating 700 may especially be provided with the method of the invention. In embodiments of the method, the coating 700 (comprising a thermally conductive material) is provided to at least part of the luminaire 1000 by cold spraying such that the coating 700 covers at least part of the first housing side 601. Furthermore, the coating 700 may be provided such that the coating 700 is in contact with the support 500 via the through-holes 630. The coating may also be provided (if the support comprises support protrusions 530 at least partly protruding into the through-holes 630) such that the coating 700 is (also) in contact with the support protrusions 530.

[0145] Hence, it is also an aspect of the invention to facilitate that also miniaturized luminaires with a light source inside a polymeric housing may have sufficient heat dissipating capacity. The surface of the polymeric housing on which a thermally conductive support may have been mounted may have been configured having openings in embodiments to expose parts or support protrusion of the support. These exposed parts may for instance in embodiments serve as seed surfaces for the growth of a metal layer by means of supersonic particle deposition. A metal layer being deposited may start growing on the exposed parts of the support and then extend over the surface of the polymeric housing, thereby effectively increasing a total surface to sink heat. To ease the coating process, in advantageous embodiments, the exposed parts or support protrusions may especially extend through the openings in the surface of the polymeric housing, or are at least flush with the surface.

[0146] In specific embodiments LEDs may be arranged on the support comprising a plurality of conductive support protrusions e.g. thermally conductive rods and / or blades as shown in one or more of the accompanying figures. The housing part may be produced such that it comprises a plurality of openings or through-holes, e.g. holes and / or slits. The support with LEDs may be placed into the housing part so that the plurality of support protrusions go through the openings and optionally extend out of the holes to a level which is the same or 2024PF80238

[0147] 31 higher than the surface of the housing. Supported by the fact that the support protrusions extend out of the housing upon supersonic metal coating of the surface, a metal layer may start growing from these support protrusions so that they are totally connected, and a metallic layer is formed covering part of the surface or the whole surface. In this way the housing becomes sandwiched between the LED support and the metallic layer deposited by supersonic metal coating (cold spray)

[0148] The terms “substantially” or “essentially” herein, and similar terms, will be understood by the person skilled in the art. The terms “substantially” or “essentially” may also include embodiments with “entirely”, “completely”, “all”, etc. Hence, in embodiments the adjective substantially or essentially may also be removed. Where applicable, the term “substantially” or the term “essentially” may also relate to 90% or higher, such as 95% or higher, especially 99% or higher, even more especially 99.5% or higher, including 100%. The term “comprise” also includes embodiments wherein the term “comprises” means “consists of’. The term “and / or” especially relates to one or more of the items mentioned before and after “and / or”. For instance, a phrase “item 1 and / or item 2” and similar phrases may relate to one or more of item 1 and item 2. The term “comprising” may in an embodiment refer to “consisting of’ but may in another embodiment also refer to “containing at least the defined species and optionally one or more other species”. Use of the verb “to comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”. The article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements.

[0149] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[0150] The devices, or systems may herein amongst others be described during operation. As will be clear to the person skilled in the art, the invention is not limited to methods of operation, or devices, or systems in operation. It should be noted that the above- mentioned embodiments illustrate rather than limit the invention, and that those skilled in the 2024PF80238

[0151] 32 art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim.

[0152] The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In a system claim, enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. The invention also provides a control system that may control the device or system, or that may execute a mode of operation of the system. Yet further, the invention also provides a computer program product, when running on a computer which is functionally coupled to or comprised by the device, or system, controls one or more controllable elements of such device, or system. The invention further applies to a device, or system comprising one or more of the characterizing features described in the description and / or shown in the attached drawings. The invention further pertains to a method comprising one or more of the characterizing features described in the description and / or shown in the attached drawings.

[0153] The various aspects discussed in this patent can be combined in order to provide additional advantages. Further, the person skilled in the art will understand that embodiments can be combined, and that also more than two embodiments can be combined. Furthermore, some of the features can form the basis for one or more divisional applications.

Claims

2024PF8023833CLAIMS:

1. A luminaire (1000) comprising a housing part (600), an electrical component (7), a support (500), and a coating (700), wherein: the housing part (600) comprises or consists of a polymeric material, and further comprises a first housing side (601) and a second housing side (602); wherein the housing part (600) comprises a housing part region (606) comprising a plurality of through- holes (630) from the first housing side (601) to the second housing side (602); the support (500) comprises a first support side (501) and a second support side (502); wherein the support (500) is configured to support the electrical component (7); wherein the electrical component (7) is arranged at the second support side (502); wherein the first support side (501) faces at least part of the second housing side (602) at the housing part region (606); the coating (700) is a cold spray sprayed coating comprising one or more of Sn, Al, Ti, Bi, Cu, In, Ag, and Pb, and having a thermal conductivity of at least 50 W / m K; wherein the coating (700) covers at least part of the first housing side (601), wherein the support (500) comprises a plurality of support protrusions (530), wherein the plurality of support protrusions (530) are at least partly protruding into the plurality of through-holes (630), and wherein the coating (700) is in contact with the plurality of support protrusions (530).

2. The luminaire (1000) according to claim 1, wherein the electrical component (7) comprises a light generating device (100), wherein the support (500) comprises one or more of printed circuit board and a heatsink; and wherein the plurality of through-holes (630) comprises n through-holes (630), wherein n>4.

3. The luminaire (1000) according to any one of the preceding claims, wherein the housing part region (606), defined by outer through-holes (630), comprises a housing part region cross-sectional area AHPR, wherein the through-holes (630) have a total through-hole cross-sectional area ATH, wherein 0.05<ATH / AHPR<0.35.2024PF80238344. The luminaire (1000) according to any one of the preceding claims, wherein the plurality of through-holes (630) has shortest through-hole distances (DH) selected from the range of 0.5-10 mm.

5. The luminaire (1000) according to any one of the preceding claims, wherein neighboring support protrusions of the plurality of support protrusions (530) have shortest protrusion distances (Ds) selected from the range of 0.5-10 mm.

6. The luminaire (1000) according to any one of the preceding claims, wherein the support (500) comprises a protrusion region (607), defined by outer support protrusions (530), comprising a protrusion region cross-sectional area APR, wherein the support protrusions (530) have a total support protrusion cross-sectional area Ap, wherein 0.05<AP / APR<0.35; and wherein the support protrusions (530) have cross-sectional dimensions selected from the range of 0.5-50 mm.

7. The luminaire (1000) according to any one of the preceding claims, wherein one or more of the following applies: (a) the through-holes (630) have cross-sectional areas having a constant value over at least 80% of a first height (Hl) of the through-holes (630), and (b) the support protrusions (530) have cross-sectional areas having a constant value over at least 80% of a second height (H2) of the support protrusions (530).

8. The luminaire (1000) according to any one of the preceding claims, wherein the support protrusions (530) extend in the range of 0.1-5 mm beyond the first housing side (601).

9. The luminaire (1000) according to any one of the preceding claims, wherein the support protrusions (530) have planar protrusion tops (531).

10. The luminaire (1000) according to any one of the preceding claims, wherein the housing part (600) comprises or consists of a 3D printed housing part.

11. The luminaire (1000) according to any one of the preceding claims, wherein the housing part (600) comprises a thermoplastic material having a glass-transition or melting temperature of at least 100 °C.2024PF802383512. The luminaire (1000) according to any one of the preceding claims, wherein the coating (700) comprises a multi-layer coating comprising (i) a first layer (710) in contact with at least part of the housing part (600) and (ii) a second layer (720), wherein the first layer (710) is configured between the housing part (600) and the second layer (720); wherein the first layer (710) comprises a first material, wherein the second layer (720) comprises a second material, wherein the housing part (600) comprises a housing part material; wherein the first material has a higher adhesion to the housing part material than the second material, and wherein the second material has a higher thermal conductivity than the first material.

13. The luminaire (1000) according to any one of the preceding claims, wherein the housing part (600) comprises one of a lamp shade, a collimator, a reflector, and a driver housing, wherein n as defined in claim 2 is at least 9; wherein the luminaire comprises n support protrusions (530); wherein the support protrusions (530) have a shape selected from a plate and a cylinder; wherein the support protrusions (530) comprise a metal.

14. A method for coating at least part of a luminaire (1000), wherein: the luminaire (1000) comprises a housing part (600), an electrical component (7), and a support (500); the housing part (600) comprises or consists of a polymeric material, and further comprises a first housing side (601) and a second housing side (602); wherein the housing part (600) comprises a housing part region (606) comprising a plurality of through- holes (630); the support (500) comprises a first support side (501) and a second support side (502); wherein the support (500) is configured to support the electrical component (7); wherein the electrical component (7) is arranged at the second support side (502); wherein the first support side (501) faces at least part of the second housing side (602); the method comprises providing a coating (700) to at least part of the luminaire by cold spraying, the coating (700) comprising one or more of Sn, Al, Ti, Bi, Cu, In, Ag, and Pb, and having a thermal conductivity of at least 50 W / m K, such that the coating (700) covers at least part of the first housing side (601), wherein the support (500) comprises support protrusions (530), wherein the support protrusions (530) are at least partly protruding into the through-holes (630), and wherein the coating (700) is in contact with the support protrusions (530).

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