• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Lighting cards and method for making lighting cards. The lighting board comprises a first group of light source components attached to a circuit board and connected to a circuit to produce lighting. The lighting board further comprises a second group of light source components having substantially the same color temperature as the light source components of the first group and which are attached to the circuit board electrically separated from said circuit.
    公开号:FI20175331A1
    申请号:FI20175331
    申请日:2017-04-10
    公开日:2018-10-11
    发明作者:Harri Mattila
    申请人:Teknoware Oy；
    IPC主号:
    专利说明:

    Lamp card and method of making the lamp card
    Field of the Invention
    The invention relates to lighting cards and in particular to lighting cards containing LED light sources.
    Background of the Invention
    Many lighting applications use LED components to produce light because of their associated benefits. The advantages of LED components are high luminous efficiency, energy saving, long service life and simple adjustability. In addition, compared to incandescent or fluorescent lamp solutions, LED-based luminaires are smaller in physical dimensions and therefore also light in weight. For example, in indoor public transport lighting, LED-based luminaires have become more widespread in use due to the above advantages.
    One way of implementing LED-based luminaires is to place the LED light sources and the circuitry needed to control them on a circuit board or similar. Such a circuit board is provided with the necessary connection and the LED components are attached as part of the connection. When the resulting luminaire board is connected to a power supply, the LED components produce light. The luminaire card is further used to form the luminaire, for example, by placing or closing the luminaire card between a separate body part and a dome part. One type of luminaire card can be used in many different luminaires. The problem with LED-based luminaires is the dispersion of the color temperature of the white light produced between the various LED components. One LED board has several LED components to produce lighting. For example, the LED components can be in 5 cm increments on a 50 cm long card and the purpose is to produce a uniform color temperature of each LED component. A luminaire does not look uniform if the color temperature of one or more of the light-producing components deviates significantly from the color temperature of the other components. LED manufacturers have tried to reduce the color temperature deviation between different batches (so-called color mapping), but the problem has not been completely eliminated. MacAdarm ellipses have been developed to capture noticeable color differences. With two LED components within one color temperature of MacAdarm, there is no noticeable difference in color temperature. When the color temperature of the light emitted by the components is between 2 and 3 MacAdam steps, there is hardly a noticeable difference in color temperature and when the difference is more than 3 MacAdam steps, a color difference is detectable.
    Component manufacturers are able to provide 3 color reductions inside MacAdarm. However, some people can also see the color difference between the 3 LED components inside MacAdarm. LED components are very reliable in operation and one LED component has an MTBF of about 10,000,000 h. Catastrophic component failure usually occurs early in life due to, for example, incorrect mechanical stress during the installation of the LED board. During operation, the color temperature of the LED component does not change significantly, although the luminous flux produced by the component decreases with time.
    In the event of a failure of the LED component on the luminaire board, that component may be replaced with a new equivalent component. While component manufacturers strive to produce components with no batch deviations of more than 3 MacAdarm at color temperatures, finding a new component with the same color rating is often problematic. This is due to the rapidly evolving manufacturing processes of LED components and the relatively short commercial availability of LED components. As a result, either the lighting card manufacturers or the lighting card users often have replacement spare parts in stock to replace faulty cards, rather than trying to find a LED component with a suitable color temperature for the faulty card. However, spare part cards unnecessarily tie up manufacturers' capital in terms of both storage and component costs.
    Brief Description of the Invention
    It is an object of the invention to provide a lighting card and a method of manufacturing a lighting card so that the above problem can be solved. The object of the invention is achieved by a lighting card and a method for making a lighting card, which is characterized in what is stated in the independent claims. Preferred embodiments of the invention are claimed in the dependent claims.
    The invention is based on the insertion of additional LED components which do not produce illumination in addition to the LED-producing components of the illumination board. In the event of a potential LED component failure, the LED component which is faulty may be replaced by an additional LED component on the luminaire board. The LED components used in the manufacture of the luminaire card can be selected with certainty from the same batch, so that the color temperature produced by the components is within one MacAdarm. When a defective component is replaced by an additional component attached to the luminaire board, all the LED components used in the luminaire board are still from the same batch and thus also as close as possible to their color temperature.
    An advantage of the lighting board according to the invention is that the uniform color temperature of the LED components of the lighting board can be ensured even after the failure and replacement of one or more LED components. Removal of the additional LED components attached to the luminaire board for mounting on the electronic circuit can be accomplished by simple means. Further, the attachment of the component can also be accomplished in a simple manner. The lighting card according to the invention can eliminate the storage of spare parts cards, since a faulty lighting card can be repaired in a simpler way than before.
    BRIEF DESCRIPTION OF THE DRAWINGS
    The invention will now be further described in connection with preferred embodiments, with reference to the accompanying drawings, in which:
    Figure 1 illustrates an example of the placement of components on a circuit board; and
    Figure 2 shows a circuit diagram of an embodiment of the invention.
    DETAILED DESCRIPTION OF THE INVENTION
    Figure 1 illustrates, on a fundamental level, the positioning of the components of an illumination board of an embodiment of the invention on a circuit board. The lighting board comprises a first set of light source components, such as LED components D1 to D6, mounted on a circuit board 1 and connected to a circuit for providing illumination. When Fig. 1 illustrates the positioning of components on a circuit board, the circuit itself is not exposed. The first set of light source components are coupled to the circuit so that when power is applied to the circuit, the light source components begin to produce light. For example, the light source components are in series with one another or connected to two or more parallel series circuits. Since the luminous flux produced by the light source components is proportional to the current flowing through the component, the circuit is designed such that the desired current passes through the light source components in the circuit.
    The invention will now be described with the light source component used being an LED component. As shown in principle in the figure, the first set of LED components are located on the luminaire card at even intervals in the longitudinal direction of the card. However, it is clear that the LED components can also be spaced apart at varying distances over the entire card surface, as required by the lighting application. Correspondingly, the shape of the luminaire card is not limited to the rectangular shape shown, but the shape may vary according to the lighting application required.
    According to the invention, the luminaire card further comprises a second set of light source components, such as LED components D11 to D15, having substantially the same color temperature as the first set of light source components D1 to D6 and electrically mounted on the circuit board separated from said circuit. A second set of light source components, such as LED components D11 to D15, are mounted on the circuit board during the manufacture of the luminaire board, i.e. in the same process as the first set. Thus, the second set of LED components and the first set of LED components have substantially the same color temperature. As shown in Figure 1, a second set of LED components are arranged in one array at the edge of the luminaire board. The placement of one set is irrelevant to the operation of the luminaire board as the other set of LED components are not in active use.
    In the example of Figure 1, the first set has 6 LED components D1 to D6 and the second set has 5 LED components D1 to D15. As discussed above, a first set of LED components are actively used to provide light when power is applied to the circuit formed on the circuit board. The second set of LED components, in turn, are located outside the circuit electrically separated from the circuit. When the power supply is connected to the circuit board of the luminaire board of which the first set of LED components are part, the second set of LED components remain unpowered. Another set of LED components forms a repository of LED components from which the LED components can be removed and placed in the circuit if the LED component in the circuit ceases to function.
    When the first and second set of LED components are loaded onto the circuit board in the same manufacturing process or assembly process, the LED components are from the same manufacturing batch. Thus, the color temperature of the components is substantially the same between the first and second set. As stated above, the differences in color temperature between LED components within a single batch are minimized by the component manufacturer. By using LED components from the same batch, it can be ensured that the second set of LED components can be used to replace the first set of LED components. It has been stated above that the first and second set of LED components are from the same batch. It may also be possible for the component manufacturer to perform component color temperature matching between batches. Therefore, the LED components need not necessarily be of the same batch if their intermediate temperatures are otherwise matched.
    According to one embodiment of the invention, the circuit board comprises means for forming a bypass channel for one or more of the first plurality of light source components. Preferably, these means comprise attachment points for the bypass channel components such that the bypass channel component attached to the attachment points provides a parallel current path for the first set of light source components. The bypass component may for example be a resistive component such as a resistor.
    In a known manner, the circuit conductors are formed on a circuit board by copper pairs to which electrical components are attached as part of the circuit. According to an embodiment, ready-made strokes are formed alongside the LED components which are part of the circuit, to which bypass channel components can be connected to form a bypass channel.
    The bypass channel components can be connected alongside the light source components when a second set of light source components is enabled and installed in the circuit to provide light. Many light source components, such as LED components, are characterized by a reduction in the light current they produce as a result of their use. When the LED component in use is replaced with another component stored in the second set, the luminous flux it produces may deviate from the luminous flux produced by the other components connected to the circuit, thereby producing a non-uniform effect. While replacing a faulty LED component with an unused component, a bypass component can be coupled alongside it, thereby reducing the current passing through the LED component and thus the luminous flux it produces. One or more bypass component components can thus account for the effects of aging and provide uniform illumination on the luminaire board.
    According to the embodiment, the luminaire board is provided with ready slots for bypass channel components. When a bypass component is coupled to such a location, it is electrically coupled to the light source component. Figure 1 shows the positions R1 through R6 of the bypass channel components located in the vicinity of the LED components.
    Fig. 2 shows, by way of example, three serially connected LED components D31 to D33, one of which is coupled with a resistor R31 as a bypass component to form a bypass channel. In connection with other LED components, switching locations for parallel resistors, which can provide a parallel current path for other LED components, are schematically shown.
    For example, if a damaged luminaire board has 10,000 operating hours such that the luminous flux of the LED components in the electronic circuit has dropped about 10% of its original, a portion of the current of the replacement LED component may be controlled through a parallel resistor. For example, if the current of the LED components is set to 100 mA, the resistance of the resistor to be connected in parallel must be approximately the overvoltage of the LED component divided by the parallel resistor current. The parallel resistor current is 10% of the LED component current, i.e. 10 mA, and assuming an over-voltage of 3V, the resistance of the switchable resistor is 300 Ohms. It should be noted that the value of the actual resistor need not be just calculated but close to that value.
    It is shown above how said bypass channel component is implemented by a resistive component such as a resistor. According to a preferred embodiment of the invention, the means for forming a bypass channel comprises a circuit adapted to be modified such that, when modifying the circuit, said current path is passed which bypasses the first set of light source components. Such modifications to the circuit may involve adding, removing or replacing the component with another electrical component. The parallel circuit of the light source component, i.e. the bypass channel, can also be implemented as a combination of several different electrical components or with semiconductor circuits designed for this purpose.
    According to a preferred embodiment of the invention, the second set of light source components are mounted on the luminaire board at only one attachment point. As noted above, a second set of light source components serve as spare parts and are thus not used to provide lighting. Therefore, it is advantageous to attach a second set of light source components from only one attachment point to the card so that their removal from the card for use as part of the circuit can be done simply and without damage to the component. Preferably, the first and second set of light source components are surface mount components that are mounted on the circuit board surface without holes drilled on the card. However, the invention is not limited to surface mount components, but all methods of attaching the components to the circuit board are possible within the scope of the invention.
    A second set of LED components, known as spare LEDs, are soldered or glued to the circuit board. In a typical circuit board manufacturing process, the electrical components are loaded onto the circuit board and soldered to the circuit. Since the second set of LED components are not part of the electrical circuit, they do not require the use of electrically conductive tin or other soldering material. If the PCB manufacturing process allows for the gluing of components or parts, the LED components used as spare parts can also be glued.
    Figure 1 shows a component layout of a lighting card showing only the locations of light source components such as LED components and said resistive components. It is understood, however, that the luminaire board also contains other electrical components such as connectors, capacitors, resistors, diodes, and switches to provide a functional assembly; (PWM) power.
    The first set of light source components on the luminaire card comprises two or more light source components which provide illumination on the luminaire card. The second plurality of light source components on the illumination card comprises one or more light source components that may be used to replace one or more defective light source components of the first plurality of light source components producing the light. In pursuit of the long life of the luminaire card, the number of second component parts constituting the second set may be selected so that faulty luminaire components can be replaced several times.
    The luminaire card according to the invention is adapted to be mounted in connection with the luminaire dome and body, thereby providing a luminaire. In addition, the lighting board is adapted to be connected to a power supply. The power supply can be brought to the luminaire board directly by means of wires, connectors or wireless power supply connected to the luminaire, with a known voltage or current in the power supply, and a circuit fitted on the luminaire board provides power to the light source components.
    The structure and operation of the solution according to the invention are described above, mainly in that the light source components are LED components. In addition to the LED components, the light source components may be, for example, a laser component, an OLED component, or a field-induced polymer electroluminescent technology.
    It will be obvious to a person skilled in the art that as technology advances, the basic idea of the invention can be implemented in many different ways. The invention and its embodiments are thus not limited to the examples described above, but may vary within the scope of the claims.
    权利要求:
    Claims (15)
    [1]
    Luminaire card comprising a first plurality of light source components mounted on a circuit board and connected to a circuit for providing illumination, characterized in that the luminaire card further comprises a second plurality of light source components having substantially the same color temperature as the first plurality of light source components .
    [2]
    Luminaire card according to claim 1, characterized in that the color temperature of the first and second set of light source components is within 3 MacAdam steps.
    [3]
    Luminaire card according to claim 1 or 2, characterized in that the second set of light source components are mounted on the circuit board at one or more mounting points.
    [4]
    Luminaire card according to any one of claims 1 to 3, characterized in that the circuit board comprises means for forming a bypass channel for one or more of the first plurality of light source components.
    [5]
    Luminaire card according to claim 4, characterized in that the means for forming a bypass channel comprises anchor points for the bypass channel components such that the bypass channel component attached to the anchor point provides a parallel current path for the first set of light source component.
    [6]
    Luminaire card according to claim 4, characterized in that the means for forming a bypass channel comprises a circuit adapted to be modified such that, when modifying the circuit, a parallel current path is formed for the first set of light source components.
    [7]
    Luminaire card according to claim 4, characterized in that the circuit board is provided with attachment points for the bypass channel components so that a parallel current path can be formed for any of the first plurality of light source components and the bypass channel current is adjustable.
    [8]
    Lamp card according to Claim 5 or 7, characterized in that the bypass component is a resistive component.
    [9]
    Luminaire card according to any one of claims 1 to 8, characterized in that the second set of light source components are adapted to be removable and replace the defective first set of light source components.
    [10]
    Luminaire card according to any one of claims 1 to 9, characterized in that the first plurality of light source components comprises two or more light source components and the second plurality of light source components comprises one or more light source components.
    [11]
    Luminaire card according to any one of claims 1 to 10, characterized in that the luminaire card is adapted to be coupled to a power supply and is adapted to be mounted in connection with a luminaire body and a dome.
    [12]
    Luminaire card according to one of the preceding claims 1 to 11, characterized in that the first and second set of light source components are selected from the group consisting of an LED component, an OLED component, a laser component and a light producing film.
    [13]
    A method for manufacturing a lighting board, the method comprising the step of mounting a first plurality of light source components on a circuit board as part of a circuit for providing illumination, characterized in that the method further comprises the step of the second set of light source components having substantially the same color temperature as the first set of light source components.
    [14]
    Method according to claim 13, characterized in that the attachment of the second set of light source components comprises the step of attaching the light source components at one or more attachment points.
    [15]
    A method according to claim 13 or 14, characterized in that the method comprises the step of forming anchor points for the bypass channel components on the circuit board such that the bypass channel component attached to the attachment point provides a parallel current path for the first set of light source components.
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    法律状态:
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    优先权:
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    EP18166318.8A| EP3389341B1|2017-04-10|2018-04-09|Luminaire circuit board and method for manufacturing a luminaire circuit board|
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