Abstract:
A circuit board ( 10 ) for carrying at least one light source ( 16 ) of a lighting device and a method of manufacturing such a circuit board are provided. The circuit board comprises a substrate ( 1 ), wherein the substrate comprises at least one fold ( 9 ) forming a projecting portion and extending from a periphery ( 3 ) of the substrate up to an inner portion ( 2 ) of the substrate, whereby the substrate has a polygonal funnel shape. The present aspects use the concept of folding the substrate in order to obtain a polygonal funnel shape of the circuit board, whereby shaping of the substrate without requiring removal of material of the substrate is allowed.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention generally relates to the field of circuit boards for carrying at least one light source of a lighting device. 
       BACKGROUND OF THE INVENTION 
       [0002]    Conventional solid state based lighting devices normally comprise light sources coupled to a circuit board, a supporting structure for supporting and orienting the circuit board and the light sources as desired, a reflector for reflecting light emitted by the light sources and a heat sink for dissipating heat generated by the light sources. It may be advantageous to integrate two or more of the components of the lighting device into a single component, thereby reducing the number of components in the lighting device, which facilitates manufacturing and reduces costs. JP2011040510 shows a lighting device with a circuit board to which light emitting diodes (LEDs) are mounted. The circuit board comprises a reflective surface and has a rectangular shape, wherein two opposite long sides of the circuit board are bent so as to reflect light emitted by the LEDs. Further, the circuit board comprises metal for conducting heat generated by the LEDs. A drawback with the circuit board shown in JP2011040510 is that the configuration with the bent portions of the circuit board merely enables a linear shape (or trench-like shape) of the circuit board. 
       SUMMARY OF THE INVENTION 
       [0003]    It would be advantageous to achieve a circuit board overcoming, or at least alleviating, the above mentioned drawback. In particular, it would be desirable to enable other shapes of a circuit board for carrying at least one light source of a lighting device. 
         [0004]    To better address one or more of these concerns, a circuit board and a method of manufacturing a circuit board having the features defined in the independent claims are provided. Preferable embodiments are defined in the dependent claims. 
         [0005]    Hence, according to a first aspect, a circuit board for carrying at least one light source of a lighting device is provided. The circuit board comprises a substrate, wherein the substrate comprises at least one fold forming a projecting portion and extending from a periphery of the substrate up to an inner portion of the substrate, whereby the substrate has a polygonal funnel shape. 
         [0006]    According to a second aspect, a method of manufacturing a circuit board for carrying at least one light source of a lighting device is provided. The method comprises providing a substrate and folding the substrate so as to form at least one fold forming a projecting portion and extending from a periphery of the substrate up to an inner portion of the substrate, whereby the substrate obtains a polygonal funnel shape. 
         [0007]    A polygonal funnel shape (or in general a bowl- or funnel-like shape) of a substrate of a circuit board may be desirable for different reasons. For example, it may be desired to have a polygonal funnel shaped supporting structure for the light source (or light sources) and/or a polygonal funnel shaped reflecting surface at the circuit board for reflecting light from the light source. The present aspects use the concept of folding the substrate in order to obtain a polygonal funnel shape of the circuit board. The extension of the fold (which also may referred to as a pleat) from the periphery of the substrate up to (but not past) the inner portion of the substrate may turn an originally substantially planar shape of a substrate into a polygonal funnel shape. The present aspects allow shaping of the substrate without requiring removal of material of the substrate. Hence, the polygonal funnel shape of the substrate may be obtained by the fold instead of cutting away a piece of the substrate and joining of the edges of the cut out of the substrate. Thus, material loss may be reduced. 
         [0008]    In the present specification, the term “polygonal funnel shape” is to be widely interpreted and may include any polygonal funnel shape, such as any (at least partially) parabolic, funnel, cup, pyramid or cone shape, and also polygonal variations of these shapes. Further, the inner portion of the substrate may be any portion of the substrate separate from the periphery of the substrate. Preferably, the fold may reach from a portion of the periphery of the substrate up to the inner portion of the substrate, but not past the inner portion up to an opposite portion of the periphery of the substrate. 
         [0009]    The fold may project from the non-folded portions of the substrate, such as from the outside of the polygonal funnel shape, which may facilitate heat dissipation from the substrate. The projecting portion formed by the fold may e.g. act like a heat dissipating fin. 
         [0010]    According to an embodiment, the fold comprises at least one folding line and two portions of the substrate located on opposite sides of the folding line. Thus, the folding line may extend from the periphery of the substrate up to the inner portion of the substrate. For example, the two portions of the substrate may be interconnected at the folding line. The folding line may form an (outer) edge (or ridge) of the fold. Further, the angle between the two portions of the substrate (on opposite sides of the folding line) may be comprised within an interval of 0 to 90°, preferably within an interval of 0 to 45°, and most preferably within an interval of 0 to 10°. The smaller the angle is between the two portions of the substrate, the deeper (or more distinct) is the polygonal funnel shape of the substrate. In an embodiment, the two portions may at least partially abut each other, whereby the angle between the two portions may be, at least at the abutment of the two portions, around 0. 
         [0011]    According to an embodiment, the fold comprises at least two folding lines extending from separate points of the periphery of the substrate towards a common point. Hence, the fold may be formed by the substrate being folded along at least two folding lines extending towards the same point. It will be appreciated that the common point may be an imaginary point, and thus not necessarily a point of the substrate, which e.g. may be the case if a piece of the substrate is removed (or not present) at the location of the common point. Further, the previously described two portions of the substrate may be located on opposite sides of one of the folding lines, and the other one of the folding lines may delimit one of the two portions from an adjacent non-folded portion of the substrate. If the fold comprises no more than two folding lines, the transition between the other one of the two portions of the substrate (not delimited by both, but merely by one of the folding lines) and an adjacent non-folded portion of the substrate may not comprise any folding line. Hence, the substrate may be straight (or planar), at the interface (or limit) between the fold and the portion of the substrate adjacent to the fold. Optionally, the fold may comprise a further folding line (i.e. three folding lines in total extending from separate points of the periphery of the substrate towards a common point), which may delimit the other one of the two portions from an adjacent non-folded portion of the substrate. Alternatively, the fold may comprise no more than one folding line, and the interface between the fold and the portions of the substrate adjacent to the fold may be curved instead of comprising a folding line. 
         [0012]    In an embodiment, the depth of the fold increases in direction from the inner portion of the substrate towards the periphery of the substrate. In the present specification, the depth of the fold is the distance from the edge (or ridge) of the fold (e.g. the outermost folding line) to a non-folded portion of the substrate adjacent to the fold. The increased depth of the fold in direction towards the periphery of the substrate contributes to obtain the polygonal funnel shape of the substrate. Further, the width of the fold may increase in direction from the inner portion of the substrate towards the periphery of the substrate. In this context, the width of the fold is the distance between the two portions of the substrate located on opposite sides of the folding line, where the fold interfaces the adjacent non-folded portions of the substrate. 
         [0013]    According to an embodiment, the substrate has a polygonal shape, and the at least one fold may extend from a corner of the polygonal shape and up to the inner portion of the substrate. Hence, the substrate may have polygonal periphery (or circumference). 
         [0014]    According to an embodiment, the at least one fold projects inwards in the polygonal funnel shape. Alternatively, the at least one fold may project outwards such as from the outside of the polygonal funnel shape. In case two or more folds are provided, both inwards and/or outwards projected portions may be provided. 
         [0015]    According to an embodiment, the fold is arranged to dissipate heat generated by the at least one light source, which increases the life-time of the light source. The fold may e.g. act as a fin for heat dissipation from the substrate and form (at least a part of) a heat sink of the lighting device. Thus, the heat sink and the circuit board may be integrated in the same component, thereby reducing the number of components of the lighting device, which facilitates manufacturing. In an embodiment, the substrate may comprise a material having a thermal conductivity of at least 1 W/(mK), such as metal, which enhances heat dissipation from the light source. The substrate may comprise any material with relatively high heat conductivity, such as any metal (e.g. aluminum or copper) or thermally conductive polymer. Using a material with a lower thermal conductivity may be compensated by having a larger thickness of the substrate. However, a smaller thickness of the substrate facilitates forming of the fold. 
         [0016]    According to an embodiment, the circuit board further comprises a reflective surface arranged at the substrate so as to reflect light emitted by the at least one light source, whereby the circuit board may act as a reflector of the lighting device. Thus, the reflector and circuit board may be integrated in the same component, thereby reducing the number of components of the lighting device, which facilitates manufacturing. The reflective surface may e.g. be diffuse, specular or a combination thereof (that is, partially diffuse and partially specular). The circuit board may have a reflective layer applied on the substrate providing the reflective surface. In an embodiment, the circuit board may further comprise a reflective solder resist arranged so as to reflect light emitted by the at least one light source. The solder resist may provide the reflective surface of the circuit board. Alternatively, or as a complement, the substrate may be made of a material with light reflecting properties, such as metal, whereby (at least a portion of) the reflective surface may be provided by the substrate itself. Hence, at least a portion of the substrate may act as a reflector of the lighting device. 
         [0017]    According to an embodiment, the circuit board further comprises a spring extending at least partially around the circumference of the polygonal funnel shape of the substrate so as to support the substrate in the funnel shape. The spring may e.g. comprise an at least slightly resilient ring, such as a metal ring, holding the substrate in the folded position. Hence, the spring may extend around the outside of the polygonal funnel shape and maintain the substrate in the folded position. The spring may not necessarily extend around the entire circumference of the substrate, but preferably at least around a major portion of the circumference of the substrate. The present embodiment is advantageous in that the substrate is secured in the funnel shaped position reducing the risk of the substrate getting unfolded during packaging and transportation. 
         [0018]    According to an embodiment, a lighting device is provided. The lighting device comprises a circuit board as defined in any one of the preceding embodiments and at least one light source coupled to the circuit board. Thus, a lighting device with a polygonal funnel shaped circuit board is provided. 
         [0019]    According to an embodiment, the lighting device further comprises a driver configured to drive the at least one light source, the driver being coupled to the circuit board. Thus, the circuit board may be used for carrying the driver of the lighting device. Further, the driver and the at least one light source may be arranged on opposite sides of the circuit board. For example, the at least one light source may be arranged on a reflective side of the circuit board and the driver on a side of the circuit board opposite to the reflective side. Alternatively, the driver may not be coupled (i.e. external) to the circuit board. 
         [0020]    It is noted that the invention relates to all possible combinations of features recited in the claims. Further, it will be appreciated that the various embodiments described for the circuit board are all combinable with the method as defined in accordance with the second aspect of the present invention. 
         [0021]    Further objectives of, features of, and advantages with, the present aspects will become apparent when studying the following detailed disclosure, the drawings and the appended claims. Those skilled in the art realize that different features of the present invention can be combined to create embodiments other than those described in the following. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    These and other aspects will now be described in more detail, with reference to the appended drawings showing embodiments. 
           [0023]      FIG. 1  shows a substrate of a circuit board during a manufacturing stage according to an embodiment. 
           [0024]      FIG. 2  shows the substrate of the circuit board during another manufacturing stage according to an embodiment. 
           [0025]      FIG. 3  shows another view of the substrate shown in  FIG. 2 . 
           [0026]      FIG. 4  shows yet another view the substrate shown in  FIG. 2 . 
           [0027]      FIG. 5  shows the circuit board comprising the substrate according to an embodiment. 
           [0028]      FIG. 6  shows a circuit board during a manufacturing stage according to an embodiment. 
           [0029]      FIG. 7  shows a lighting device according to an embodiment. 
           [0030]      FIG. 8  is an exploded view of the lighting device shown in  FIG. 7 . 
           [0031]      FIG. 9  shows a circuit board according to another embodiment. 
           [0032]      FIG. 10  shows a fold of a circuit board according to an embodiment. 
           [0033]      FIG. 11  shows a fold of a circuit board according to another embodiment. 
       
    
    
       [0034]    All the figures are schematic, not necessarily to scale, and generally only show parts which are necessary in order to elucidate the invention, wherein other parts may be omitted or merely suggested. 
       DETAILED DESCRIPTION 
       [0035]    A circuit board for a lighting device and a method of manufacturing such circuit board according to embodiments will be described with reference to  FIGS. 1 to 5 . 
         [0036]    The method of manufacturing the circuit board comprises providing a substrate  1 , as illustrated in  FIG. 1 . The substrate  1  may at a manufacturing stage be substantially planar. The substrate  1  may comprise metal (such as aluminum or copper) or any material with relatively high thermal conductivity, such as thermally conductive polymer. For example, the substrate  1  may comprise a metal sheet. The substrate  1  may have any desired shape, such as a polygonal shape having multiple corners  4 . The method further comprises folding the substrate  1  so as to form one or more folds  9  (in the present example, six folds  9 ) extending from a periphery  3  of the substrate  1  up to an inner portion  2  of the substrate, as illustrated in  FIGS. 1 and 2 .  FIG. 1  shows the substrate  1  being unfolded but with folding lines  5 ,  6 ,  7  of the folds  9  illustrated and  FIG. 2  shows the substrate  1  when the folds  9  have been formed. Optionally, a mid portion of the substrate  1  may be removed (such as cut out) prior to the folding so as to facilitate forming the folds  9  of the substrate  1 . The cut out may be used for electronic connections (such as wires) of the circuit board. 
         [0037]    Each fold  9  may comprise one or more folding lines, such as a first folding line  5 , a second folding line  6  and a third folding line  7 , extending from the periphery  3  of the substrate  1  towards a common point  8 . Optionally, the folding lines  5 ,  6 ,  7  may not extend all the way up to the common point  8 , but up to the inner portion  2  of the substrate  1 . The inner portion  2  of the substrate  1  may be any portion of the substrate  1  separate from the (outer) periphery  3  of the substrate  1 , such as a portion of the substrate  1  located substantially at (or proximate to) the center of the substrate  1 . Further, the common point  8  may be an imaginary point and may not necessarily be located at the substrate  1 . For example, the common point  8  may be located at the center of the circuit board, such as where the mid portion of the substrate  1  is cut out, as illustrated in  FIG. 1 . Each fold  9  may comprise a first portion  11  and a second portion  12  of the substrate  1  arranged on opposite sides of the second folding line  6 . Further, the first portion  1  may be delimited from a non-folded portion  13  of the substrate  1  by the first folding line  5  and the second portion  12  of the substrate  1  may be delimited from another non-folded portion  14  of the substrate  1  by the third folding line  7 . The fold  9  may be formed by the first and second portions  11 ,  12  of the substrate  1  being brought towards each other. In the present example, the first and second portions  11 ,  12  of the substrate  1  at least partially abut (thereby at least partially overlapping) each other, whereby an angle between the first and second portions  11 ,  12  is around 0. In other embodiments, the first and second portions  11 ,  12 , may form an angle comprised within an interval of 0 to 90°, preferably within an interval of 0 to 45°, and most preferably within an interval of 0 to 10°. 
         [0038]    As a consequence of the substrate  1  being folded as described above, it obtains a polygonal funnel shape (or in general a funnel shape). The funnel shape gets wider (is flared) in direction from the inner portion  2  of the substrate  1  towards the periphery  3  of the substrate  1 . The funnel shape of the substrate  1  may e.g. be an at least partially conical shape. In the present example, the substrate  1  has been folded so as to obtain a polygonal funnel shape. The depth D of the folds  9  may increase in direction from the inner portion  2  of the substrate  1  towards the periphery  3  of the substrate  1 , which contributes to a deeper (or more distinct) funnel shape. The folds  9  may project from the non-folded portions  13 ,  14  of the substrate  1 , such as from the outside of the polygonal funnel shape (as illustrated in  FIGS. 2 to 4 ) and/or inwards in the polygonal funnel shape (not shown), so as to form projecting portions of the substrate. Alternatively, one or more of the folds  9  may be arranged so as to abut one of the non-folded portions  13 ,  14  of the substrate  1 . 
         [0039]    Further, one or more light sources  16 , such as solid state based light sources (e.g. light emitting diodes, LEDs), may be coupled (such as soldered or glued) to the substrate  1 , as illustrated in  FIG. 5  showing the circuit board  10 . In case the substrate  1  is made of metal, the circuit board  10  may comprise a dielectric layer  15  for electric insulation between the components carried by the circuit board  10  and the substrate  1 . The circuit board  10  may further comprise metal (e.g. copper) tracks (not shown) for electrically interconnecting the components of the circuit board  10 . A solder resist (or solder mask) may be applied to the substrate  1 . The solder resist may preferably be reflective for reflecting light emitted by the light sources  16 . Hence, the solder resist may provide a reflective surface of the circuit board  10  for reflecting light emitted by the light sources. The metal surface of the substrate  1  and/or the dielectric layer  15  may also provide reflective surfaces for reflecting light emitted by the light sources  16 . The circuit board  10  may e.g. be a printed circuit board, PCB, optionally with a metal core (i.e. with a substrate made of metal). 
         [0040]    According to an example (not shown), merely a portion of the substrate may be covered with the dielectric layer, while another portion of the substrate is uncovered (or exposed). In the present example, a portion of the reflective surface of the circuit board may be provided by the solder resist at the dielectric layer (or any reflective surface of the dielectric layer), and another portion of the reflective surface may be provided by the uncovered portion of the substrate. Reflecting properties of the substrate may be provided by the substrate being of metal and/or a reflective coating applied on the substrate. 
         [0041]    The light sources  16  may be mounted to the substrate  1  after the substrate  1  has been folded. Alternatively, the light sources  16  may be mounted prior to folding the substrate  1 , as illustrated in  FIG. 6 . Further, a driver configured to drive the light sources  16  may be mounted to the circuit board  10  (not shown), either on the same side of the substrate  1  as the light sources  16  or on the side of the substrate  1  opposite to the side at which the light sources  16  are mounted. 
         [0042]    The circuit board  10  carrying the light sources  16  may be mounted in a lighting device  30 , as illustrated in  FIG. 7  showing a perspective view of the lighting device  30  and  FIG. 8  showing an exploded view of the lighting device  30 . The lighting device  30  may comprise a housing (or frame)  31 , in which the circuit board  10  may be supported, a driver  34  coupled to the circuit board  10 , such as on the side of the circuit board  10  opposite to the side to which the light sources  16  are coupled. The lighting device  30  may further comprise contact pins  32  for connecting the lighting device  30  to a power supply and a transparent (or translucent) cover  33  (e.g. made of glass) for protecting the light sources  16 . Optionally, the cover may comprise an optical element, such as a diffusing element. 
         [0043]    The circuit board  10  may act as a funnel shaped reflector of the lighting device  30  and a, preferably rigid, funnel shaped support structure for the light sources  16 . A drawback with the circuit board shown in JP2011040510 is that the bent portions of the circuit board merely enable reflection of light emitted from the LEDs in directions towards the long sides of the circuit board, while light emitted in directions towards the short sides of the circuit board is not reflected. With the present embodiment, the circuit board  10  provides reflection of light emitted by the light sources  16  in more directions. 
         [0044]    Further, the circuit board  10  may act as a heat sink for the components carried by the circuit board  10 , such as the light sources  16 . The heat conductive material (e.g. metal) of the circuit board  10  dissipates heat generated by the light sources  16 . Moreover, the folds  9  may act as heat dissipating fins further enhancing heat dissipation from the light sources  16 . Since the polygonal funnel shape of the circuit board is obtained by the folds  9 , material spillage is reduced in manufacturing of the circuit board  10 . The excessive material (i.e. the folds  9 ) resulting from forming the polygonal funnel shape of the originally planar substrate may, instead of being cut away, be used as heat dissipating fins. A hexagonal shape of the substrate is advantageous in that material spillage is further reduced since the hexagonal shape allows cutting several hexagonal substrates out of a single (metal) sheet (at least almost) without wasting material. 
         [0045]    According to an embodiment illustrated in  FIG. 9 , the circuit board  10  may further comprise a spring  20  extending around the circumference of the funnel-like shape of the substrate so as to support the substrate in the funnel-like shape. The spring  20  may e.g. comprise a slightly resilient ring-like element, such as a metal ring holding the substrate in the folded position. Hence, the spring  20  may extend around the outside of the funnel shape and maintain the substrate  1  in the folded position. The spring  20  may be supported by grooves  21  in the folds  9 . 
         [0046]    According to embodiments, the fold may comprise no more than one folding line (as illustrated in  FIG. 10 ) or no more than two folding lines (as illustrated in  FIG. 11 ).  FIG. 10  is a cross-section of a fold  91  having one folding line  61  separating the first and second portions  111 ,  121  of the substrate. The fold  91  is delimited from the adjacent non-folded portions  141 ,  131  of the substrate by curved portions  151 ,  161  of the substrate.  FIG. 11  is a cross-section of a fold  92  having a first folding line  61  separating the first and second portions  111 ,  121  of the substrate and a second folding line  72  separating the second portion  122  of the substrate from the adjacent non-folded portion  142  of the substrate. The transition between the first portion of the substrate  112  and the adjacent non-folded portion  132  of the substrate may be straight or curved (or at least not defined by a folding line). 
         [0047]    For the sake of clarity, only one of multiples of a certain feature (such as the light sources, the corners of the polygonal shape of the substrate and the first, second and third folding lines) is denoted with a reference sign in the drawings (with the folds, which are all denoted with reference number  9 , as an exception). 
         [0048]    While embodiments have been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. 
         [0049]    For example, each fold may comprise more than three folding lines. Further, the folds may project from different sides of the substrate. The circuit board may have more than six or less than six folds. The at least one light source and/or the driver may be mounted on either side of the funnel-like substrate. 
         [0050]    Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. 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. Any reference signs in the claims should not be construed as limiting the scope.