Method for manufacturing a linear lighting device

Patent metadata

Field	Value
Publication number	US-9746161-B2
Application number	US-201515306947-A
Country	US
Kind code	B2
Filing date	Apr 30, 2015
Priority date	May 9, 2014
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

Abstract

A method for manufacturing a linear lighting device, the method comprising the steps of providing a sheet of optically transmissive material, a sheet of thermally conductive material, and a plurality of light sources, arranging the light sources on the sheet of thermally conductive material, roll forming the sheet of thermally conductive material into a supporting heat spreader profile, roll forming the sheet of optically transmissive material into a first shape to cover the light sources and define an optical chamber, attaching end portions of the sheet of optically. The method enables the use of a lower amount of material and provides an efficient method for mass manufacturing linear lighting devices.

First claim

The invention claimed is:

1. A method for manufacturing a linear lighting device, said method comprising the steps of:
providing a sheet of optically transmissive material, a sheet of thermally conductive material, and a plurality of light sources,
arranging the light sources on the sheet of thermally conductive material,
roll forming the sheet of thermally conductive material into a supporting heat spreader profile,
roll forming the sheet of optically transmissive material into a first shape to cover said light sources and define an optical chamber, and
attaching end portions of said sheet of optically transmissive material to said supporting heat spreader profile.

2. The method of claim 1 , wherein said step of attaching comprises clamping said end portions in clamping portions formed as longitudinal slots roll formed in said supporting heat spreader profile.

3. The method of claim 1 , wherein said step of attaching comprises forming said sheet of optically transmissive material into a second shape.

4. The method of claim 1 , wherein said step of attaching comprises crimping portions of said supporting heat spreader profile to fixate said end portions.

5. The method of claim 4 , wherein crimping said portions is performed by roll forming.

6. The method of claim 4 , further comprising the step of:
roll forming, after said step of attaching, the supporting heat spreader profile, such that said sheet of optically transmissive material is formed into a second shape which covers said light sources and defines an optical chamber.

7. The method of claim 1 , wherein roll forming said supporting heat spreader profile comprises forming at least four longitudinal slots, said longitudinal slots being arranged in pairs either forming two slots having substantially parallel planes in a longitudinal extension or two slots forming the bottom half of an ‘X’, whereby said supporting heat spreader profile allows at least two possible first shapes for attaching said sheet of optically transmissive material.

8. The method of claim 1 , further comprising providing at least a second sheet of optically transmissive material, roll forming said second sheet of optically transmissive material into a first shape to cover said first sheet of optically transmissive material thereby forming a second optical chamber, and attaching said second sheet to said supporting heat spreader profile.

9. The method of claim 1 , further comprising the step of:
providing mounting levers connected to said linear lighting device, said mounting levers being configured to allow a user to elastically deform said supporting heat spreader profile for mounting said linear lighting device to a linear lighting device holder.

10. The method of claim 1 , wherein said supporting heat spreader profile comprises a plurality of parallel linear longitudinal portions, each linear longitudinal portion being configured for attaching a sheet of optically transmissive material, and wherein the method further comprises: arranging the light sources on each linear longitudinal portion, providing a plurality of sheets of optically transmissive material, roll forming the plurality of sheets of optically transmissive material into a plurality of parallel optical chambers covering and defining an optical chamber for each linear longitudinal portion, and attaching the plurality of sheets of optically transmissive material to said heat spreader profile.

11. The method of claim 10 , further comprising the step of:
separating each linear longitudinal portion of said heat spreader profile into an individual linear lighting device.

12. The method of claim 1 , wherein said supporting heat spreader profile comprises a plurality of parallel linear longitudinal portions, each linear longitudinal portion being configured for attaching a sheet of optically transmissive material, and wherein the method further comprises: arranging the light sources on each linear longitudinal portion, roll forming the sheet of optically transmissive material into a plurality of parallel optical chambers covering and defining an optical chamber for each linear longitudinal portion, and attaching the sheet of optically transmissive material to said heat spreader profile.

Assignees

• Philips Lighting Holding Bv

Inventors

• Gielen Vincent Stefan David
• Den Boer Reinier Imre Anton
• Vissenberg Michel Cornelis Josephus Marie

Classifications

• F21V3/02

  characterised by the shape · CPC title

• F21Y2103/10

  comprising a linear array of point-like light-generating elements · CPC title

• F21S4/28

  rigid, e.g. LED bars · CPC title

• F21V15/01

  Housings, e.g. material or assembling of housing parts (F21V15/02 takes precedence {housings forming signs or letters G09F13/04}) · CPC title

• B21D53/00

  Making other particular articles (making wire fabrics B21F; making chains or chain parts B21L) · CPC title