Disclosed herein is a downlight, which includes an optoelectronic module and a rim module. The optoelectronic module includes a light source driving board, a back housing, and a front housing. The light source driving board is disposed between the back housing and the front housing. The light source driving board includes a light-emitting diode unit and a driving circuit. The rim module has a central opening for accommodating the optoelectronic module. The rim module is not integrally formed with the optoelectronic module.

CROSS-REFERENCE TO RELATED APPLICATION

This application relates to and claims the benefit of Chinese Patent Application No. CN201710152124.5, filed Mar. 15, 2017, the content of which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure relates to a downlight; more particularly, to a downlight having a light-emitting diode.

2. Description of Related Art

With the advancement of the technology, many modern lighting apparatuses now use light-emitting diodes (LEDs) as the light source. The downlight is a lighting device that is installed in the ceiling of the building. The downlight has a tubular appearance and can be embedded within the ceiling so that the front surface of the light is level with the ceiling, thereby giving a flat and even look. By placing the LED unit within the downlight, it is feasible to enhance the light efficiency and the aesthetics. However, in the conventional downlight, the light source module and the driver are separately designed, and the two has to be assembled individually following specific steps and fixed with screws separately; the structure of such downlight is very complicated, and the terminals for making electric conduction between the driver and the light source module should be taken into account, too. Accordingly, for the conventional downlight, the manufacturing process is complicated, the production efficiency is low, the cost is high, and the driver is an inserting piece with higher manufacturing and material cost and inferior efficiency. For the conventional product, a complete light is obtained only after all the components are assembled together, while a single component cannot exhibit its function, thereby limiting the application of the product. In view of the foregoing, there is an urgent need in the industrial field of the LED lighting to provide a novel product design that simplifies the assembly process, improves the test efficiency, enhance the manufacturing efficiency and increases the adaptability of the product.

SUMMARY

In light of the foregoing technical problems, the present inventor proposes the following embodiments to respectively address some or all of the technical problems.

One purpose of the present invention is to provide a dual-modular downlight, in which each module may be manufactured and tested separately, thereby increasing the production efficiency. Another purpose of the present invention is to provide a dual-modular downlight, in which the optoelectronic module and the rim module may be combined with each other, thereby increasing the adaptability of the product and improving the competitiveness. Still another purpose of the present invention is to provide a dual-modular downlight, which is easy-to-assemble and requires only a minimal amount of screws.

According to one embodiment of the present invention, a downlight is provided. Said downlight comprises an optoelectronic module and a rim module. The optoelectronic module comprises a light source driving board, a back housing, and a front housing. The light source driving board is disposed between the back housing and the front housing. The light source driving board comprises a light-emitting diode unit and a driving circuit. The rim module has a central opening configured to accommodate the optoelectronic module. The rim module is not integrally formed with the optoelectronic module.

According to another embodiment of the present invention, a downlight is provided. The downlight comprises an optoelectronic module and a rim module. The optoelectronic module comprises a light source driving board, a back housing, and a front housing. The light source driving board is disposed between the back housing and the front housing. The light source driving board comprises a light-emitting diode unit and a driving circuit. The rim module has a central opening configured to accommodate the optoelectronic module. The central opening of the rim module has a circular inner flange, in which when the optoelectronic module is inserted into the central opening of the rim module, the circular inner flange rests against and covers the outer peripheral of the front housing.

According to another embodiment of the present invention, a downlight is provided. Said downlight comprises an optoelectronic module, a rim module, and a trumpet-shaped sleeve. The optoelectronic module comprises a light source driving board, a back housing, and a front housing. The light source driving board is disposed between the back housing and the front housing. The light source driving board comprises a light-emitting diode unit and a driving circuit. The rim module has a central opening configured to accommodate the optoelectronic module. The trumpet-shaped sleeve has a first opening and a second opening. The first opening is in contact with the light source driving board, and is configured to expose the light-emitting diode unit. The second opening is disposed at the inner peripheral of the front housing.

As could be appreciated, this section presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the present invention or delineate the scope of the present invention.

In accordance with common practice, the various described features/elements are not drawn to scale but instead are drawn to best illustrate specific features/elements relevant to the present invention. Also, like reference numerals and designations in the various drawings are used to indicate like elements/parts.

DESCRIPTION

FIG. 1is a schematic diagram illustrating the light source driving board of the downlight according to one embodiment. Referring toFIG. 1, the light source driving board302comprises a light-emitting diode unit304and a driving circuit305. In some embodiments, the light source driving board302comprises a plurality of light-emitting diode units304arranged in a circular shape. In some embodiments, the light-emitting diode units304may be arranged in any other suitable shapes, such as in an array. In some embodiments, the light-emitting diode units304concentrate around the central portion of the light source driving board302, whereas the driving circuits305are arranged at the peripheral of the light source driving board302. In some embodiments, the light-emitting diode units304and the driving circuits305are surface mounted to the light source driving board302, thereby substantially decreasing the overall height of downlight.

FIG. 2is a three-dimensional view illustrating the dual-modular downlight according to one embodiment of the present invention.FIG. 3is an exploded three-dimensional view of the dual-modular downlight according to one embodiment of the present invention.FIG. 4is an exploded lateral view of the dual-modular downlight according to one embodiment of the present invention. Referring toFIG. 2,FIG. 3, andFIG. 4, the dual-modular downlight100comprises a rim module101and an optoelectronic module102. The rim module101comprises an outer ring103and a tubular wall104. The rim module101has an opening105for accommodating the optoelectronic module102. In some embodiments, the rim module101comprises a fastener106, which is connected with the tubular wall104. The fastener106has an acute-angle bent portion107. The acute-angle bent portion107is configured to engage with the interior of the opening on the ceiling or wall so that the rim module101may be secured in the ceiling or wall. In some embodiments, the outer ring103intersects with the tubular wall104at a right angle (i.e., the two are perpendicular). In some other embodiments, the intersecting portion of the outer ring103and the tubular wall104forms a curve surface.

In some embodiments, the fastener106is made of metal, and hence, it is flexible. When the rim module101is being pressed into the opening of the ceiling, the fastener106is bent slightly, and then when the rim module101is completely inserted into the opening of the ceiling, the fastener106rebounds to its original state, thereby engaging with the interior of the opening so as to securely fix the rim module101at position. In some embodiments, the central opening105of the rim module101has a circular inner flange, and when the optoelectronic module102is inserted into the central opening105of the rim module101, the circular inner flange rests against and covers the outer peripheral of the front housing303. The circular inner flange may provide the water-proof functionality.

Referring toFIG. 3, the optoelectronic module102comprises a back housing301, a light source driving board302, and a front housing303. In some embodiments, the front housing303is a diffusion plate, which is configured to diffuse the light so that the user will not feel dazzled. Also referring toFIG. 1, the light source driving board302comprises a light-emitting diode unit304and a driving circuit305. The light-emitting diode unit304and the driving circuit305are placed on a same board, thereby simplifying the manufacture and assembling processes and increasing the manufacture efficiency. In some embodiments, multiple light-emitting diode units304are arranged in a ring shape and placed at the central portion of the light source driving board302so as to maximize the luminous efficiency of the light-emitting diode304. In some embodiments, the driving circuits305are placed at the peripheral region of the light source driving board302, so that the voltage and current for driving the light-emitting diode units304may be supplied conveniently.

In some embodiments, the optoelectronic module102further comprises a metallic heat dissipation component110. The metallic heat dissipation component110may have a ring shape and is disposed between the back housing301and the light source driving board302. The metallic heat dissipation component110may provide a better heat dissipation, thereby avoiding the optoelectronic module102from overheating. In some embodiments, the dual-modular downlight100comprises a trumpet-shaped sleeve111; the trumpet-shaped sleeve111has a first opening112and a second opening113, in which the diameter of the first opening112is less than the diameter of the second opening113. The first opening112of the trumpet-shaped sleeve111is disposed on the light source driving board302, wherein the first opening112is configured to expose the light-emitting diode unit304. The second opening113of the trumpet-shaped sleeve111is disposed right at the interior edge of the front housing303; in this way, the trumpet-shaped sleeve111may be securely clapped between the light source driving board302and the front housing303. The trumpet-shaped sleeve111is used as a cover for the driving circuit305so that the downlight has a more appealing appearance. When the light-emitting diode304emits light, the trumpet-shaped sleeve may also block the dark spots on the front housing303caused by the light illuminating on the components of the driving circuit305. In another embodiment, the trumpet-shaped sleeve111may be substituted by a sleeve of any other shapes, such as a conical-shape sleeve. The trumpet-shaped sleeve may be white or beige in color, or have a matte or glossy surface. The trumpet-shaped sleeve is configured to reflect or soften the light.

The rim module101and optoelectronic module102of the dual-modular downlight100are two separate individual modules, rather than a module formed integrally. In this way, the two modules may be manufactured and tested separately. Since these two modules are separate modules, the respective size of each module is smaller. As could be appreciated, conventional downlights use an integrally formed module comprising the rim module and the optoelectronic module; and the size of this module is greater. During the testing period, the number of downlights that can be stored in the specific space is smaller for products with greater sizes, which is inconvenient for the testing. In contrast, the present disclosure proposed a multi-modular approach that compartmentalized the downlight100into separate, individual modules, so that the respective size of each module decreases, thereby allowing a more convenient manufacturing and testing process. For example, during the aging test, using the same space, more optoelectronic modules102may be subjected to the aging test, as compared with conventional downlights. Accordingly, the testing efficiency improves, and testing speeds increases. Similarly, when one of the separate modules is damaged or broken, it is feasible to replace the damaged or broken module, rather than replacing the whole downlight. Therefore, the cost for material may be reduced.

In some embodiments, there is a raised flat face at the center of the heat dissipation component110; said raised flat face may be in close contact with the back of the light source driving board302. As could be appreciated, light-emitting diode units304tend to generate heat; therefore, disposing the raised flat face at the center of the heat dissipation component110so that it is in close contact with the center region of the front face of the light source driving board302where the light-emitting diode units304concentrate, facilitates heat dissipation. In some embodiments, the peripheral of the heat dissipation component110is disposed with a recess through hole; said recess through hole allows the passage of the power cable. After passing through the recess through hole, the power cable connects with the light source driving board302, so as to supply the power to the light source driving board302. In some embodiments, there may be a plurality of recess through holes. In some embodiments, the outer ring103may be a circular ring. In some other embodiments, the outer ring103may be a rectangular ring. The outer ring103may come in various sizes for optoelectronic modules102of different specifications and for different sizes of installation holes. This modularized approach may reduce the cost and increase the flexibility.

In some embodiments, referring toFIG. 2andFIG. 3, the fastener106, in addition to the bent portion107, comprises another bent portion108. The bent portion108has a barb-shape, in which the bard may be inserted into the inner groove109of the outer ring. The barb-shaped bent portion108may be pressed or locked into the outer ring103without using a screw, which is convenient.

The dual-modular downlight100according to the present disclosure simplifies the structure design, increases the manufacturing efficiency, and decreases the cost. Each functional part is modularized, in which the single module may function on its own and separately manufactured, thereby expanding the application of the product, enhancing the manufacturing efficiency and increasing the competitiveness of the product. The present light-emitting diode unit304and driving circuit305are designed combinatorially, and are surface-mounted on a single light source driving board302. This manufacturing process are suitable for automated mass production, which provides a higher manufacturing efficiency and is easy to assemble; in particular, the screws are only required for fixing the heat dissipation component, while all the other components do not require a screw. The overall height of the final light is substantially decreased to a ratio of about 20-25%, thereby greatly reducing the costs for material and manufacturing with a cost reduction rate of about 25-30%.

Both the rim module101and the optoelectronic module102may be manufactured separately, and the two modules are easy to assemble using a highly automated process, thereby improving the manufacturing efficiency significantly. The optoelectronic module102may come in various sizes; for example, it is feasible to manufacture optoelectronic modules102of 4 inches, 5 inches, or 6 inches separately, and these modules can be sold as individual products. By using other surface ring configuration, the module may be used to form products of new shapes, thereby greatly increasing the adaptability of the product and significantly increasing the competitiveness of the product. This modular design realizes the combinations of 4-inch 5-inch, and 6-inch optoelectronic modules102with various rim modules101(e.g., N44 and N48 surface ring), which realizes the standardized manufacturing of products, decreases the number of modules for different products, shortens the development cycle of the product, reduces the number of times of changing modules during the manufacture, and increases the manufacturing efficiency. At the same time, the present design also decreases the time required by the worker to get familiar with different assembly processes for various products; the skill of the worker increases by making only one product, which in turn increases the manufacturing efficiency. Moreover, the decrease in the height of the product reduces the cost for the packaging materials, and increases the number of products that can be loaded in a cargo, which decreases the transportation cost and lowers the overall cost.

The above-mentioned embodiments may solve one or more technical problems due to their respective technical feature(s).

Although various embodiments of the invention have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those with ordinary skill in the art could make numerous alterations to the disclosed embodiments, such as the addition or deletion of one or more elements, without departing from the spirit or scope of this invention.