WO2015144118A1 - Led conversion kit for exterior lights - Google Patents

Abstract

The invention relates to an LED conversion kit for exterior lights. The problem addressed by the invention is that of disclosing such an LED conversion kit that provides a multivalently usable retrofit kit for a wide variety of exterior light geometries while maintaining the structural design of almost all individual components, and which merely requires that the service personnel retrofitting the conversion kit establish the electrical connection to a mast connection cable and a purely mechanical mounting of the conversion kit by means of a mounting plate. This problem is solved in that an LED module assembly (1) is placed on a heat-conductive mounting plate (2) wherein the base plate (11) of the LED module assembly (1) sits on the heat-conductive mounting plate (2) in a planar and flush manner, and is connected to the mounting plate (2) via a thermally conductive pad (12) encompassing the base plate (11) and an electrical insulation layer (13). The power connection of the LED module assembly (1) is guided through the mounting plate (2) on the opposite plane (22) thereof, wherein the mounting plate (2) has a mechanical carrier element (3) on the plane (22) located opposite the LED module assembly (1), on which mechanical carrier element (3), spaced apart from the mounting plate (2), conventional network operating devices (4) and lighting connectors (51) for a direct connection to a mast connection cable are provided. All electrical connections from the LED module assembly (1) to the network operation and control device (4) and to the lighting connectors (51) are completely wired in the LED conversion kit, and the entire assembly is sealed by way of interior or exterior insulation means (71, 73, 75) to satisfy at least protection requirement code IP65.

Description

 LED conversion kit for outdoor lighting

The invention relates to an LED conversion kit for outdoor lighting, especially for post-top luminaires such as lanterns, umbrella or

Bell lights and technical street lights. Furthermore, the LED conversion kit proposed here should also be used for the conversion of gas lanterns to electrical operation.

There has been an increasing need lately to provide existing lights with less power-consuming modern lighting means for the purpose of power saving. At the same time, there is also the need to preserve cityscapes, for example, which are characterized by gas lanterns, but to an electric lighting, the

Total lighting character gets to re-equip.

Since the existing lights on the one hand have a very different design, one is forced by the hitherto known retrofit solutions to develop a different conversion kit for each type of light, which is quite expensive and expensive. On the other hand, however, the state of preservation of existing existing lights

very different and requires z.T. the complete

Disassembly of existing electrical lighting.

However, since outdoor lighting has to meet certain specified degrees of protection with regard to moisture, condensation, dust density, generally at least IP65, at least partial replacement of lighting components, network operating and control units on site is difficult or impossible.

According to the known state of the art are different

Conversion variants known, which initially all have the disadvantage that they are tailored to special designs of existing lights and their use is thus only possible there.

For example, BRAUN Lighting Solutions e.K. Solutions after

different designs, which offer a cone LED installation kit, a BeeLED installation kit, a so-called LURA LED kit and as an alternative to gas light a so-called Hislux and LED GASIight kit, all different design principles subject to (see www.braun-lighting.com). This represents on the one hand enormous constructive and financial expenditure, on the other hand these designs require special heatsinks, which also

run differently and are expensive. Apart from the fact that some of the designs presented there do not have the degree of protection IP65

correspond.

The company RZB Rudolf Zimmermann Bamberg GmbH (see www.rzb.de) offers LED conversion kits, which are designed in their geometry on lights of this company and are to operate directly on the grid. Since there is no galvanic isolation from the network, such conversions can only be carried out by the manufacturer or specialist companies.

Also pure PCB modules, without galvanic power separation and thus afflicted with the disadvantages described above, offers the company TURCK duotec GmbH (www.truck-duotec.com).

The company MARK-TRONIK GmbH (www.flame-light.com) knows LED replacement bulbs with E27 / E40 connection for horizontally installed and downwardly directed lamps. These allow a quick replacement with conventional lamps with said sockets. The disadvantage here is that existing operating devices must be switched ineffective, i. a change in the internal wiring of the lamp is necessary, which can be performed only by qualified personnel. The LED bulbs offered there are compact with integrated operating devices, i. no thermal decoupling between LED and electronics is guaranteed.

For purely round lights, such. B. road, park (nostalgia and

Mushroom lights), for pedestrian zone, parking and tunnel lighting, the company Endres Lighting GmbH with "LED technology WITHOUT

ALUMINUM COOLING RIBS "a round LED module with

different diameters. This LED module is arranged horizontally in the luminaire and radiates freely downwards. This module is only suitable for round designs and has only a degree of protection according to IP44 (www.endres-lighting.de). Special LED conversion kits for gas lanterns with system outputs of 20-40W, which have a high degree of protection of IP64 / IP66, are offered by STK-Technik GmbH (www.stk-technik.de).

Immediately the LED bulbs there is associated with a complex heat sink. Another disadvantage of these solutions is that no separate Leuchtenkiemmstelle is provided for the mast connection, ie. the existing, possibly dilapidated terminal point is to be used further. The customer must make the mechanical adjustment to the existing light itself in these designs, which requires a considerable effort and specialist staff. The same applies to the installation of the operating device and the new wiring to be made. Thus, the customer inevitably assumes the responsibility of a luminaire manufacturer in the sense of the CE certificate of conformity. Comparable designs are also offered by other manufacturers, but have nothing in common with proposed inventive solution.

Finally, the company offers OS RAM GmbH

(http://www.osram.com/osram_de/news-und-wissen/oem-news/2012/led-modul-dsl-fuer-nachruestung-von-street-lights) LED retrofit modules for street lighting. These kits of LED module and mounting plate are basically adaptable to any lights. An advantage of these kits is a more targeted steering of the light, by multiple LED modules in a different arrangement, whereby by omitting one or more boards of the module targeted areas of light distribution can be hidden. The kit is already adapted by the manufacturer specifically to the lamp. For example, a public utility employee can then simply install the module on site. The main disadvantage of this solution, however, is that the LED modules are not in a hermetically protected against moisture and dust space and that each LED module requires its own heat sink, which requires a high material and a high design and manufacturing effort. The invention has for its object to provide a LED conversion kit for outdoor lighting, while maintaining the design of almost all individual components represents a multivalent retrofit kit for a variety of exterior luminaire geometries and the retrofit retrofitting staff only the production of electrical connection with a mast connection and a purely mechanical attachment of the conversion kit requires a mounting plate.

 Only the latter proviso makes it possible that no special technical personnel or the manufacturer itself are required for the Umrüstmontage, but the desired exchange can be done inexpensively by authorized urban staff, who must of course have appropriate professional qualifications for the electrical work. This is the main advantage of the present invention, since the invention

proposed LED conversion kit represents a completely prefabricated module, which independently already all safety-relevant

Requirements according to the valid standards for outdoor lighting met. The LED conversion kit, with its own degree of protection of at least IP65, already offers the requirement for an outdoor lamp itself. Approval and type tests for the suitability of intended

Conversions can therefore already from the manufacturer of the

LED conversion kit according to the invention are offered and made.

The object is solved by the characterizing features of claim 1. Advantageous embodiments are the subject of

subordinate claims.

The essence of the present invention is that a complete LED conversion kit for outdoor lights is proposed, which includes a LED module assembly, the flat and flush with its bottom plate placed on a heat-conducting mounting plate and a heat conducting pad and an electrical sensing their bottom plate

Insulation layer is connected to the mounting plate and the

Power connector of the LED module assembly is guided through the mounting plate on the opposite plane, wherein the mounting plate at the, the LED module assembly opposite plane with a is provided on the mechanical support element, on which, of the

Spaced apart mounting plate, per se conventional network equipment and light terminals are provided for direct connection to a mast connection, all electrical connections from the LED module assembly to the network operating and control unit and to the

Lamp terminals in the LED conversion kit are completely wired and already manufactured by the manufacturer and the entire assembly is sealed by internal or external insulation means, at least to IP65 degree of protection. When retrofitting existing luminaires so shows the first major advantage of the present invention, which is that the existing light is completely corroded by all existing wiring elements and possibly existing electrical control gear and the fitter only an electrical connection from the existing (or in the case of gas lamps to create) Mastanschlussleitung produce and the conversion kit according to the invention on his

Mounting plate is mechanically connected to the housing of the existing lamp. As you can easily see, only the mounting plate is subject in its outer contour and / or profiling, according to the given installation geometry of the existing light of a variability, which can be made very cost-effective as a purely mechanical component to be produced. All other components of the proposed LED conversion kit can be used independently

Reception room of the existing light fitted to these adapted and used unchanged for any designs. The particular other claimed embodiment of the mounting plate also ensures that only by them, i. without complex and specially adapted heatsink, the cooling of the LED module assembly is effected. If the special installation conditions such that the mounting plate is also directly connectable to the luminaire housing of the existing lamp, additional heat dissipation via selbiges done, but this is not a prerequisite for the functionality of the present invention.

For a more detailed explanation of the invention, the following

Exemplary embodiments and figures serve. Show it: Fig. 1 shows a first embodiment of the invention with all

 essential individual elements in exploded view;

 1a is a perspective plan view of the top of a

 Embodiment of Figure 1 in the installed state of delivery. Fig. 2 shows a second embodiment of the invention with all

 essential individual elements in an exploded view and Fig. 3 shows a special installation situation of an inventive

 LED conversion kit in a bell light.

To be emphasized in advance, if in the following and the claims of an LED module assembly and a

Net operating device is spoken that under the solution of the invention, of course, the use of several subdivided and possibly separately controllable LED module assemblies and network equipment should fall, as long as they follow the basic structure principle according to the claims.

Figures 1 and 1a show a first embodiment of the invention with all the essential individual elements in an exploded view. In this example, on the one hand, on the one hand, on the one hand, a mounting plate 2, which is substantially continuous in itself, is formed

Wärmeleitpad 12 is provided, the mounting plate 2 towards a

electrical insulation layer 13, which corresponds in terms of area of the surface of the bottom plate 11 of the LED module assembly 1 used. The electrical connections, not shown in FIG. 1, of the LED module assembly 1 are sealed by a cable feedthrough 73 to the opposite plane 22 of the mounting plate 2.

Furthermore, in the months plate to the LED interior a

Pressure compensation valve 74 is provided. This causes at

Heating or cooling of the LED interior in the whole

mounted state during operation always a pressure equalization is brought about. On the Wärmeleitpad 12, the actual LED module assembly 1 is placed, which are bolted together in the example with a screen 15 against the mounting plate 2. In this example, it is further apparent that the LED module assembly 1 and o.g.

Cable bushing 73 and the pressure compensating valve 74 surrounding the first sealing ring 71 is provided. On this seal 71 is a the LED module assembly 1 comprehensive housing ring 16 placed, which projects beyond the height and which is advantageously made of an optically transparent or translucent material. On the

Housing ring 16 is followed by another sealing ring 71, on the one

Light exit ensuring cover plate 17 is placed, which leaves all components of the additional housing 7 with the mounting plate 2 screwed sealingly via a clamping ring 18. If this is done, the entire additional housing interior is sufficient at least

Degree of protection IP65.

It is also within the scope of the invention that the LED module assembly 1 is carried out completely potted in itself.

On the opposite side of the LED module assembly 1 level 22 of the mounting plate 2, a support member 3 is initially provided, which is also connected to the mounting plate 2, preferably by Versch robbery. As in other examples, this support member 3 is preferably formed as an angle such that the angle executed to the mounting plate 2 and fitting in the installed state has at least a first small-scale leg 31, wherein the repellent from the mounting plate 2 second larger-area leg 32 is executed in that he has different mounting positions of

Network operating devices 4, depending on the specified external

Luminaire housing form, allows. In this particular example, a network operating device 4 is transversely screwed to the leg 32. In one provided on the other surface of the thigh

Terminal box 5 can be seen in the illustration of FIG. 1 lamp terminals 51, to which the direct connection to the indicated in Fig. 1a mast connection 6 takes place. All the aforementioned modules in

Mains operating device 4, the junction box 5 and the respective interconnections, not shown here below each other are designed according to the standard sealed at least IP65.

Named support element 3 is also made of aluminum in the example and the intended spacing of the network operating device ensures even with such a good heat conducting material no inadmissible heating by the heat emitted by the LED module assembly 1 during operation. It is of course within the scope of Invention, the carrier element of a poor heat-conducting

To produce material. The special design of the mounting plate 2 ensures only the required heat dissipation, if the condition is met that the heat contact surface formed by the bottom plate 1 of the LED module assembly 1 a surface of the

Mounting plate 2 detected, which is set in the order of less than half the total area of the mounting plate 2. Preferably, the mounting plate 2 is given a thickness of at least 3 mm in the example, if it is made of aluminum.

From the above-described provisos it is readily apparent that the mounting plate 2 can be given an arbitrary external contour, which corresponds to the mounting geometry of the light housing receiving it and can be screwed or mounted directly or via further mechanical connection means. Due to the intended variability of the attachment of the network equipment 4 and junction boxes 5 an adaptation to the possible installation depths is given easily. If special lighting geometries make it necessary, can be given to increase the surface of the mounting plate 2 and / or the formation of connection flanges on the outer lamp housing of the mounting plate 2 angled edge regions.

If, without limiting the invention to it, all at the

Mounting plate 2 mounted assemblies are detachably connected to this, it is possible only by adjusting the outer contour and / or profiling of the mounting plate 2 a corresponding to the

Installation geometry of different outer luminaire housing forms variable design of the proposed LED conversion kit

to maintain, with otherwise identical other components. This represents the known, on each special

Luminaire versions parked solutions of the prior art, another significant economic advantage of the present invention.

FIG. 1a shows the upper assemblies of the LED conversion kit according to FIG. 1 in the completely wired state for better illustration of the main advantage of the present invention with the visible there

Wirings 72. All mentioned above in the description of FIG. 1 assemblies are as a unitary and after The LED conversion kit has been made available to the refurbisher at least to the degree of protection IP65. This only has a complete gutting of the existing lights up to the

Make the connection cable 6. Then he needs only to open the junction box 5, there connect the mast connection 6 with the light terminals 51 to close the junction box 5 again and to connect the mounting plate 2 at the intended locations with the existing light. Furthermore, it can be seen from FIG. 1 a how the power connection 14 of the LED module assembly 1 (see FIG. 1) is hermetically sealed in accordance with the degree of protection IP65 by the mounting plate 2 on its opposite plane 22 and within the housing ring 16 (see FIG. 1) surface is arranged in the mounting plate 2 together with a pressure compensating valve 74.

Figure 2 shows a second embodiment of the invention with all the essential individual elements in an exploded view in a design which is referred to as a technical street lamp and which are, for example, in whip lighters according to the prior art to be found. While retaining all the essential features already described with reference to FIG. 1, a lower luminaire housing part 8 can initially be seen in FIG. 2, in which, as usual in the prior art, a

Cover 9 is sealed sealed from a safety glass. In a groove of the upper edge of this lamp housing part 8 is a

Insulation 71, here in the form of a sealing cord inserted, against which engages a top, not shown, the lamp housing cover, which after tightening of the upper and lower parts of the lamp housing a complete seal is guaranteed to IP65, although the cable gland 82 sealed to the mast connection, not shown here as well is executed. In addition, that owns

Luminaire housing, as also common in the prior art, in a peripheral region of a pressure compensation valve 74. In this known housing design, the assemblies according to the invention are now introduced, which in turn consists of an LED module assembly 1, which is provided with an electrical insulation layer 13 Wärmeleitpad 12 is connected to a mounting plate 2. For reasons of more compact production of the LED module assembly 1 Terminals 52 are provided directly on the underside of the LED module assembly 1 through a recess in the

Wärmeleitpad 12 and in the mounting plate 2 for the electrical connection of the LEDs are provided with the operating device 4. As already stated for FIG. 1, the side of the mounting plate 2 facing away from the LED module subassembly 1 is also equipped with a carrier element 3 in the form of an angle. In the example, it can be seen that the angle with its small-area angle leg 31 is here designed in two parts, so that the total contact surface of this angle leg region is in turn fixed in the order of about 4 cm ² . Spaced from the mounting plate 2, a control gear 4 is provided on the larger angle leg 32. Likewise, not shown in Fig. 2 junction box with light terminals for connection to a

Mast connection line 6. All other specifications follow those, as already described in more detail in FIG. As with such

Luminaire types, as described in FIG. 2, the existing lights i.d.R. are not in a good condition, worth the replacement, as described in Fig. 1 usually not, but it is the complete luminaire housing incl. All electrical and lighting components changed. This simplifies for the manufacturer the guarantee of tightness according to IP65 and increases the scope for the specific design of the individual LED attachment on the LED module assembly 1. In the example, it is only indicated that here, for example, easily an assembly of optical elements (eg lenses ) 83 can be assigned to the light control LEDs.

 When replacing such a designed stock light, the installer has only the entire old luminaire housing of the

Disconnect the mast connection cable, open the new luminaire housing and connect it to the mast connecting cable, close the housing again and at the outer mechanical connections available

Fasten.

 However, if an existing luminaire of the type described above is in a technically flawless condition and only a conversion to a more energy-saving lighting system, the entire old indoor electrical system can be up to

Mast connection line to be gutted and against the LED conversion kit according to the invention are exchanged with the components to be placed under protection according to the claims.

In the case of the abovementioned specific embodiments, it is of course within the scope of the invention that the LED module assembly 1 is designed to be completely potted in itself, which may be advantageous for large-scale production.

Finally, FIG. 3 shows a concrete installation situation of an LED conversion kit for a bell light, with an LED conversion kit essentially being used according to FIG. Such

Bell light can also be a grandfather

Be gas lamp housing. Here then only an electrical pole connection line would be completely new to lay. In the left-hand illustration of FIG. 3 is a schematic external view of such

Bell light shown and in the right figure a section along a plane A-A. In addition to the individual components described in Figure 1 it can be seen here that the mounting plate 2 in addition with an angled support member 21 is providable in a simple manner, if only in the upper part of the lamp housing

mechanical connection options for the complete LED conversion kit should be available. At the basic principle of the complete replacement of a trained in itself IP65 degree of protection

Conversion kit according to the present invention, however, changes nothing. Basically, here too, only the outer boundary of the mounting plate 2 in its contour to the receiving possibility of

Existing light to be adjusted. All other modules are illustrated and arranged according to FIG. 1, which should be indicated in Fig. 3, that the network operating device 4 is installed in a rotated by 90 ° to FIG. 1 position, bringing it better to the given

Mounting space clings. It also applies here that the thermal contact surface of the LED module assembly detects a surface of the mounting plate 2, which is set in the order of less than half the total area of the mounting plate 2, wherein the heat-dissipating function of the mounting plate 2, if necessary by the surface of the support element 21 is increased. Should the installation geometry in the existing luminaire require that the mounting plate 2 be given angled edge regions, This is also easily possible manufacturing technology to maintain the above-mentioned measure of the surface design in relation to the LED contact surface. Such a measure is, compared to the special new production of separate heat sinks, as usual in the prior art, almost without concern and cost.

In the context of the described embodiments, the respective cable bushings are known per se known sealing sleeves 73 which, where occurring, as Zugentlastungsmuffen 75, 82 act in a conventional manner use, so that their description requires no detailed reduction.

All in the description, the embodiments and the

The following drawings discernible features can both individually, as well as in any combination with each other

be essential to the invention.

Bezuaszeichenliste

1 - LED module assembly

 11 - Bottom plate of the LED module assembly

12 - thermal pad

 13 - electrical insulation layer

 14 - Power connection

 15 - screen

 16 - housing ring

 17 - Cover disc

 18 - clamping ring

 2 - Mounting plate

 21 - carrier element

 22 - plane of the mounting plate

 3 - carrier element / angle

 31 - small-scale leg

 32 - large leg

 4 - Mains power supply

 5 - junction box

 51 - Light terminals

 52 - Connection terminals

 6 - Mast connection cable

 7 - Additional housing

 71 - Insulation / sealing ring

 72 - Wiring

 73 - Cable entry

 74 - Pressure compensation valve

 75 - Strain relief and sealing sleeves

8 - Luminaire housing part

 82 - Cable entry

 83 - optical elements

 A-A - cutting plane

Claims

claims 1. LED conversion kit for outdoor lighting, in which  - An LED module assembly (1) with its bottom plate (11) flat and flush  - A heat-conducting mounting plate (2) and placed on a bottom plate (11) detecting the heat conducting pad (12) and an electrical insulation layer (13) with the mounting plate (2) is connected  - And the power connector (52; 72) of the LED module assembly (1) through the mounting plate (2) on the opposite plane (22) is guided, wherein  - The mounting plate (2) at the, the LED module assembly (1) opposite plane (22) is provided with a mechanical support member (3),  - At which, spaced from the mounting plate (2), per se usual network equipment (4) and light terminals (51) for direct connection to a mast connection (6) are mounted, all electrical connections (72) of the LED module assembly (1 ) to the network operating device (4) and to the  Luminaire terminals (51) in the LED conversion kit are completely wired and the entire assembly is sealed by internal or external insulation means (71; 73; 75; 82) according to at least degree of protection requirement IP65. 2. LED conversion kit according to claim 1, characterized in that the LED Moduibaugruppe (1) by an additional housing (7) and at least one of these with the mounting plate (2) sealingly connecting insulation means (71) is completely hermetically sealed to at least IP65 , 3. LED conversion kit according to claim 1, characterized in that the LED module assembly (1) relative to the outer  Luminaire housing (8) which accommodates and surrounds the mounting plate (2) and the assemblies (3; 4; 5) attached and connected thereto by means of insulating means (71) sealingly provided on the luminaire housing (8) and completely hermetically sealed to at least IP65 , 4. LED conversion kit according to claim 1, characterized in that the LED Moduibaugruppe (1) is carried out completely potted in itself. 5. LED conversion kit according to claim 1, characterized in that all provided in the LED conversion kit electrical wiring (72) are designed according to standard sealed to at least IP65. 6. LED conversion kit according to claim 1, characterized in that the carrier element (3) is designed as an angle to the  Mounting plate (2) has at least a first small-scale leg (31) and the repellent of the mounting plate second leg (32) is designed with a larger leg surface compared to the first leg with a smaller area, whereby different mounting positions of the network operating devices (4), depending on predetermined outer luminaire housing form, are feasible. 7. LED conversion kit according to claim 1, characterized in that the of the LED module assembly (1) covered area of  Bottom plate (11) and thus formed thermal contact surface to the mounting plate (2) detects a surface of the mounting plate (2), which is set in the order of less than half the total area of the mounting plate (2). 8. LED conversion kit according to claim 1 and 7, characterized in that the heat-conducting mounting plate (2) is given a thickness of the order of 3 mm, if it is made of aluminum. 9. LED conversion kit according to claim 1 and 2, characterized in that through the mounting plate (2) and within the auxiliary housing (7) is provided a per se conventional pressure compensating valve (74). 10. LED conversion kit according to claim 1 and 3, characterized in that in the outer lamp housing (8) is a conventional  Pressure compensation valve (74) is provided. 11. LED conversion kit according to claim 1, characterized in that the mounting plate (2) is given an outer contour, which corresponds to the mounting geometry of the female housing receiving them (8) and with this directly or via more  mechanical connection means can be screwed or mounted. 12. LED conversion kit according to claim 1, 7 and 11, characterized  characterized in that to increase the area of the  Mounting plate (2) and / or for the formation of connection flanges on the outer lamp housing, the mounting plate (2) with  Angled edge regions and / or support elements (21) is provided. 13. LED conversion kit according to claim 1, characterized in that all of the mounting plate (2) mounted assemblies are detachably connected thereto. 14. LED conversion kit according to claim 1 and 6, characterized in that the surface with which the carrier element (3), respectively, the first leg (31) with the mounting plate (2) is connected, set in the order of 4 cm ² is. 15. LED conversion kit according to claim 1 and 2, characterized in that the additional housing (7) by a LED module assembly (1) comprehensive and towering in height housing ring (16), with a further sealing ring (71) and a Cover (17) via a clamping ring (18) with the Mounting plate (2) is screwed sealingly, is formed. 16. LED conversion kit according to claim 16, characterized in that the housing ring (16) is made of an optically transparent or translucent material. 17. LED conversion kit according to claim 1 and 15, characterized  in that the power connection (14) of the LED module assembly (1) is hermetically sealed to the degree of protection IP65 by the mounting plate (2) on its opposite plane (22) and within the area enclosed by the housing ring (16) in the mounting plate (FIG. 2) together with one  Pressure equalization valve (74) is provided.