Abstract:
A reflector assembly for a lighting device including a plurality of reflectors for at least one semiconductor light source each, wherein the reflectors are reflector sub-regions of a common, continuous sheet-metal part and the reflector sub-regions have wing regions bent at least partially from the sheet-metal part. A lighting device includes at least one reflector assembly, wherein at least one semiconductor light source is arranged on the sheet-metal part. A method may be used to produce a reflector assembly, wherein the method includes at least the following steps: introducing slits into a sheet-metal part in order to provide wing regions that can be bent from the sheet-metal part; and bending over the sheet-metal part including bending out the wing regions in order to form at least one reflector. The above can be applied in particular to lamps for general lighting, in particular for area lighting.

Description:
RELATED APPLICATIONS 
       [0001]    The present application is a national stage entry according to 35 U.S.C. §371 of PCT application No.: PCT/EP2014/058297 filed on Apr. 24, 2014 which claims priority from German application No.: 10 2013 207 609.6 filed on Apr. 25, 2013, and is incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    Various embodiments may relate to a reflector assembly for a lighting device, including a plurality of reflectors for in each case at least one semiconductor light source. The invention furthermore relates to a lighting device including at least one such reflector assembly. Various embodiments may also relate to a method for producing such a reflector assembly. Various embodiments are applicable, in particular, to luminaires for general lighting, in particular for area lighting. 
       BACKGROUND 
       [0003]    Linear arrangements of a plurality of reflectors have hitherto been provided either by the reflectors being produced individually and then mounted alongside one another on a common carrier, or by transverse lamellae being inserted into a linear reflector trough. A linear reflector trough typically includes a rectilinear, strip-shaped base and laterally with respect thereto obliquely raised, reflective side walls. The transverse lamellae can e.g. be plugged into slots in the side walls or be latched into place or adhesively bonded on the side walls. However, both arrangements are comparatively complicated to produce. 
       SUMMARY 
       [0004]    The object of the present disclosure is to overcome the disadvantages of the related art at least in part and, in particular, to provide a possibility for the simplified provision of a reflector assembly including a plurality of reflectors, in particular linearly arranged reflectors. 
         [0005]    Various embodiments provide a reflector assembly for a lighting device. The reflector assembly includes a plurality of reflectors for in each case at least one semiconductor light source. The reflectors are reflector sub-regions of a common, continuous plate part. The reflector sub-regions include wing region bent out at least partly from the plate part. 
         [0006]    This reflector assembly has the advantage that it is produced from a single piece, namely the plate part, such that no connecting techniques for connecting a plurality of parts such as adhesive bonding, soldering, welding, etc. need be used therefor. Simple methods for partly cutting out the wing regions and for reshaping the plate part suffice. The reflector assembly is configurable particularly stably, moreover, on account of its single-piece nature. 
         [0007]    A reflector may be a reflector for one semiconductor light source or a (common) reflector for a plurality of semiconductor light sources. 
         [0008]    The at least one semiconductor light source may include at least one light emitting diode. In the case where a plurality of light emitting diodes are present, they can emit light in the same color or in different colors. A color can be monochromatic (e.g. red, green, blue, etc.) or multichromatic (e.g. white). Moreover, the light emitted by the at least one light emitting diode can be infrared light (IR LED) or ultraviolet light (UV LED). A plurality of light emitting diodes can generate mixed light; e.g. white mixed light. The at least one light emitting diode can contain at least one wavelength-converting phosphor (conversion LED). The phosphor can alternatively or additionally be arranged in a manner remote from the light emitting diode (“remote phosphor”), e.g. on the reflector sub-region or onto the reflector. The at least one light emitting diode can be present in the form of at least one individually packaged light emitting diode or in the form of at least one LED chip. A plurality of LED chips can be mounted on a common substrate (“submount”). The at least one light emitting diode can be equipped with at least one dedicated and/or common optical unit for beam guiding, e.g. at least one Fresnel lens, collimator, and so on. Instead of or in addition to inorganic light emitting diodes, e.g. based on InGaN or AlInGaP, organic LEDs (OLEDs, e.g. polymer OLEDs) are generally usable as well. Alternatively, the at least one semiconductor light source may include e.g. at least one diode laser. 
         [0009]    The fact that the wing regions can be bent out from the rest of the plate part encompasses, in particular, the fact that the wing regions are partly separated from the rest of the plate part, e.g. by one or a plurality of cuts. As a result, they can be bent out at their at least one free edge relative to adjacent regions of the plate part. As a result, the bent-out wing region and, adjacent thereto, the non-bent-out region of the plate part are offset, e.g. offset in a stepped manner, with respect to one another. However, the wing regions are still connected to the rest of the plate part by at least one transition not cut through (also referred to as “material bridge”). The wing regions enable a particularly diverse shaping of the reflectors. The cuts can have been introduced e.g. by a laser separating method. 
         [0010]    It is generally preferred for the reflectors to be shell reflectors having correspondingly reflectively embodied inner walls. The reflector sub-regions or the reflectors may generally be specularly reflective or diffusely reflective. At least one semiconductor light source may then radiate light into the reflector through a neck opening or be arranged on the reflector at the neck opening. Light typically emerges at a light exit opening of the reflector opposite the neck opening. The light exit opening generally has a larger cross section than the neck opening. 
         [0011]    The plate part can be metallic, e.g. composed of aluminum or steel, but can also consist of thin plastic (“plastic plate”). However, the plate part is not restricted thereto and may e.g. also be a thin metal-clad plastic or the like. The plate part can therefore generally be embodied or referred to as a thin, planar and permanently flexible reflector part. 
         [0012]    In one configuration, the plate part is bent to form at least one linear reflector trough, wherein the reflector trough includes a strip-shaped base and laterally with respect thereto in each case at least one bent-up side wall. In particular, the linear reflector trough may include a continuous side wall along the base on each longitudinal side of the base. This configuration enables the shaping of the reflector trough by simple bendings or bends along straight bending lines running parallel to one another, in particular. Such a reflector trough is producible in a simple manner particularly if the plate part itself is already strip-shaped. 
         [0013]    In another configuration, the side walls include the reflector sub-regions and bent-out wing regions of the reflector sub-regions are bent into the reflector trough. As a result, the reflectors can be produced by simply bending the wing regions into the reflector trough. 
         [0014]    In particular, a reflector can be formed by at least two bent-over wing regions of opposite reflector sub-regions and by sections of the side walls that lie between the wing regions. Such a reflector may be, in particular, a circumferential reflector or shell reflector. 
         [0015]    In yet another configuration, the two reflector sub-regions of a common reflector are embodied symmetrically with respect to a central plane that is perpendicular to the base 
         [0016]    In one development, the two reflector sub-regions are embodied mirror-symmetrically with respect to the central plane. For this purpose, in particular, two wing regions are present on each side wall per reflector, that is to say four wing regions per reflector. The wing regions of a reflector sub-region are separated by an intervening (central) reflector section of the side wall (which remains on the side wall). The wing regions are arranged in front of and behind said central reflector section in particular in relation to a longitudinal extent of the reflector trough, but are otherwise cut free. For forming a reflector wall bent into the reflector trough, opposite wing regions can be bent into the reflector trough in a manner similar to gates, such that the reflector includes two bipartite reflector walls there. The wing regions can be bent into the reflector trough up to their parallel position or else such that they are situated obliquely with respect to one another. In particular, it is preferred for no or no significant gap through which light could emerge laterally to remain between adjoining wing regions. For this purpose, the wing regions are preferably provided with a width that corresponds to at least half a width of the reflector trough at the corresponding height. 
         [0017]    In another development, the two reflector sub-regions are embodied point-symmetrically or rotationally symmetrically through 180° with respect to a central axis that is perpendicular to the base. In order that the reflector walls are embodied transversely with respect to the reflector trough, only one wing region is then present on each side wall per reflector. For forming a reflector wall projecting into the reflector trough, the wing regions can be bent into the reflector trough in a manner similar to gates, although now in particular integrally. In particular, it is preferred for no or no significant gap through which light could emerge laterally to remain between such a wing region and the opposite side wall. For this purpose, the wing regions are preferably provided with a width that corresponds to at least a width of the reflector trough (at the corresponding height). 
         [0018]    In one configuration, furthermore, placement regions for arranging the semiconductor light sources are situated on the base. As a result thereof, in particular, the reflectors can serve as shell reflectors for at least one semiconductor light source. 
         [0019]    The semiconductor light sources can be arranged on a placement region directly or indirectly. By way of example, a packaged semiconductor light source may be connected by its underside directly to the base of the reflector trough, e.g. by being adhesively bonded thereto. Electrical contacting of a semiconductor light source may take place via contacts on the top side, for example, which contacts can be connected to associated electrical connection lines, in particular conductor semiconductor light source may be a packaged semiconductor light source which bears with at least one electrical contact on the underside directly on an electrical connection line, in particular conductor track, and can be e.g. soldered thereto. The packaged semiconductor light sources can be surface-mountable components (SMT components), in particular. However, the semiconductor light sources may e.g. also be a semiconductor chip, e.g. LED chip, fitted on a substrate on the front side, wherein the substrate bears on the plate part on the rear side. 
         [0020]    It is possible, in principle, to arrange, in particular to fix, the at least one semiconductor light source on that side of the base on which the reflector is embodied as well. Without restricting the generality, said side hereinafter is also referred to as the front side of the base. Alternatively or additionally, it is possible for at least one semiconductor light source to be arranged, in particular fixed, on that side of the base which faces away from the reflector. Without restricting the generality, said side hereinafter is also referred to as the rear side of the base. In the case of a rear-side arrangement, the at least one semiconductor light source can send radiation in the direction of the front side in particular through a cutout in the base. Alternatively or additionally, the at least one semiconductor light source can be introduced into a cutout in the base or led through to the front side. 
         [0021]    In one configuration, moreover, electrical connection lines run to the placement regions on the base. A simple electrical connection of the semiconductor light sources is made possible as a result. The semiconductor light sources can be interconnected in series and/or in parallel with one another by the electrical connection lines. The electrical connection lines may be cables, wires or conductor tracks, for example. In the case where non-insulated connection lines, e.g. conductor tracks, are used, they can bear in particular via an electrically insulating layer on the base. 
         [0022]    Very generally, a course of the electrical connection lines is not restricted to any region of the plate part. They can e.g. also run on regions of the plate part which do not correspond to a base of a reflector trough. 
         [0023]    In one configuration, moreover, wing regions that cross electrical connection lines cross the connection lines in a spaced-apart manner. As a result, it is possible to prevent undesired electrical contacting with exposed connection lines and undesired mechanical loading of the connection lines by the wing regions. 
         [0024]    In another configuration, the reflector assembly includes a plurality of reflector troughs. As a result, by a one-piece reflector assembly, a particularly high number of reflectors can be provided, in particular also over a large area. This is advantageous in particular for surface luminaires. 
         [0025]    In another configuration, the plurality of reflector troughs are surrounded by a common frame that holds the reflector troughs. As a result, a plurality of reflector troughs can be provided on the same reflector assembly in a simple manner, which reflector troughs are shapeable in a diverse fashion and largely independently of one another. 
         [0026]    The plate part can generally have at least one cutout. The cutout can be introduced into the plate part for example by local cutting out, stamping out, etc. The at least one cutout can serve in particular for leading through a semiconductor light source and be introduced e.g. in the base of a reflector trough. 
         [0027]    Various embodiments also provide a lighting device, including at least one reflector assembly as described above, wherein at least one semiconductor light source is arranged on the plate part. The lighting device can be embodied analogously to the reflector assembly and have the same advantages. 
         [0028]    In this regard, in one development, the lighting device includes at least one reflector assembly including at least one reflector trough, wherein the at least one semiconductor light source is arranged on the base of the reflector trough. In one configuration, moreover, at least one electrical connection line runs on the base of the reflector trough. 
         [0029]    In one development, moreover, the semiconductor light sources and associated connection lines arranged in a reflector trough, are arranged on a common substrate. As a result, they can be arranged on the plate part in a particularly simple and time-saving manner. In this regard, by arranging, in particular fixing, the common substrate on the plate part (e.g. by adhesively bonding a rear side of the substrate), all functional elements situated thereon are concomitantly arranged, in particular fixed, in one work step. Moreover, an alignment of the functional elements in the case of the arrangement can be obviated. 
         [0030]    In another development, the common substrate is a strip-shaped—flexible or rigid—printed circuit board which together with the semiconductor light sources and the connection lines forms a so-called luminous strip, in particular an LED strip. Such luminous strips are commercially available e.g. in the form of LED strips from Osram, e.g. of the LINEARLight type. The use of a luminous strip has the further advantage that it is fixable to the plate part in a positively locking and/or force-locking manner by holding lugs, for example. In this case, the holding lugs are in particular likewise sub-regions that can be bent out onto the plate part. 
         [0031]    The type of the lighting device is not restricted and may be a lamp or a luminaire, for example. Particular preference is given to a configuration as a luminaire for general lighting, in particular for area lighting. The luminaire may be, in particular, a ceiling luminaire or a wall luminaire. 
         [0032]    Various embodiments also provide a method for producing a reflector assembly as described above. 
         [0033]    The method may include at least the following steps: (i) introducing slots into a plate part for providing wing regions that can be bent out from the plate part; and (ii) bending over the plate part including bending out the wing regions for forming at least one reflector, in particular shell reflector. 
         [0034]    The method may be embodied analogously to the reflector assembly and/or the lighting device and has the same advantages. 
         [0035]    The method may include, in particular in step (ii), bending over the plate part—including bending out the wing regions—for forming at least one linear reflector trough in particular with in each case at least two reflectors. Forming the reflectors may include bending out the wing regions into the associated reflector trough. 
         [0036]    Bending over may include, in particular, bending away or angling two sub-regions of the plate part at a common bending line. 
         [0037]    In one development, bending over the plate part for forming at least one linear reflector trough includes bending over to the same side along two parallel bending lines. The region between the two bending lines can serve as a base; the two regions laterally with respect to the base can serve as side walls. The wing regions can be bent out at least partly from the side walls. The wing regions can be bent out in particular completely from the side walls, alternatively or additionally can be bent out from the side walls and from the base. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0038]    In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the disclosed embodiments. In the following description, various embodiments described with reference to the following drawings, in which: 
           [0039]      FIG. 1  shows in plan view a plate part for producing a reflector assembly in accordance with a first embodiment; 
           [0040]      FIG. 2  shows the finished reflector assembly from  FIG. 1  in a view obliquely from above; 
           [0041]      FIGS. 3-6  show the reflector assembly from  FIG. 2  in a cross-sectional view with differently fashioned side edges; 
           [0042]      FIG. 7  shows the plate part from  FIG. 1  with additional electrical wiring and placement with semiconductor light sources; 
           [0043]      FIG. 8  shows in plan view a plate part for producing a reflector assembly in accordance with a second embodiment; and 
           [0044]      FIG. 9  shows in plan view a plate part for producing a reflector assembly in accordance with a third embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0045]      FIG. 1  shows in plan view an excerpt from a plate part  11  for producing a reflector assembly in accordance with a first embodiment. The plate part  11  consists of metal, e.g. steel or aluminum, which is embodied in a reflective fashion at least on one side. The plate part  11  here is embodied in a linearly strip-shaped fashion with a longitudinal axis L. The plate part  11  is partly provided with slots  23  and partly bent over in order to produce the reflector assembly  24  shown in  FIG. 2 . In this regard, parallel and symmetrically with respect to the longitudinal axis L there are four longitudinally extending bending lines B 1 , B 2 , B 3  and B 4 , at which the plate part  11  is bent over. In particular, the plate part  11  is bent up at the inner bending lines B 2  and B 3  from the plane of the drawing in the direction of the observer. This gives rise to a trench or linear reflector trough  13  to  15  having a central base  13  extending in the longitudinal direction L and two side walls  14  and  15  proceeding laterally therefrom. The base  13  is delimited from the side walls  14  and  15  by the inner bending lines B 2  and B 3 , respectively. The side walls  14  and  15  can be bent over at the outer bending lines B 1  and B 4  and form side edges  16  and  17  there. 
         [0046]    The side walls  14  and  15  in each case have a plurality of reflector sub-regions  18   a,    18   b,    19   a,    19   b,  wherein in each case two sub-regions  18   a,    18   b  and  19   a,    19   b  are opposite one another and embodied symmetrically in relation to the longitudinal axis L. Adjacent reflector sub-regions  18   a,    19   a  and  18   b,    19   b  of the same side wall  14  and  15 , respectively, are arranged equidistantly with respect to one another. 
         [0047]    Each of the reflector sub-regions  18   a,    18   b,    19   a,    19   b  has a central region  20  extending continuously between the two associated bending lines B 1 , B 2  and B 3 , B 4 , respectively. On both sides of the central regions  20 , as viewed in a longitudinal extension along the longitudinal axis L, there are situated regions which hereinafter are designated as “wing regions”  21 ,  22  and which are delimited from the central region  20  by bending lines B 5 , B 6 . The bending lines B 5 , B 6  extend rectilinearly over the entire height of the central region  20  between the bending lines B 1 , B 2  and B 3 , B 4 , respectively. In this case, the bending lines B 5 , B 6  run obliquely, specifically in such a way that the central region  20  widens or is increased in terms of its width from the inner bending line B 2  and respectively B 3  toward the outer bending line B 1  and respectively B 4 . The central region  20  therefore has the shape of an isosceles trapezoid. 
         [0048]    The wing regions  21 ,  22  are separated from the rest of the plate part  11  by respectively continuous slots  23 . The wing regions  21  and  22  are therefore still linked with the rest of the plate part  11  only at the bending lines B 5  and B 6 , respectively, and can thus be bent out from the plate part  11  at the bending line B 5  and B 6 , respectively. 
         [0049]    The wing regions  21 ,  22  can also alternatively be cut right into the base  13 , as indicated by the dotted lines. As a result, the wing regions  21 ,  22  acquire a larger area, which increases a luminous efficiency. 
         [0050]      FIG. 2  shows in a view obliquely from above the reflector assembly  24  bent over to completion from the plate part  11 . The side walls  14  and  15  and the base  13  form the linear reflector trough  13  to  15  with the side edges  16  and  17  adjacent thereto. The side edges  16  and  17  can constitute part of the reflector trough  13  to  15 . 
         [0051]    The reflector regions  18   a  and  18   b,    19   a  and  19   b  form respective reflectors  18  and  19 . The reflectors  18  and  19  are embodied in each case as truncated-pyramid-shaped shell reflectors. The four reflective side walls are composed of the central regions and opposite wing regions  21  and  22  bent perpendicularly into the reflector trough  13  to  15 . Since mutually adjoining wing regions  21  and  22  of opposite reflector sub-regions  18   a ,  18   b  and  19   a,    19   b,  respectively form the reflective side walls situated in the reflector trough  13  to  15 , their width amounts to half a width of the reflector trough  13  to  15  or of the distance between the side walls  14 ,  15  at the corresponding height. This prevents a formation of a gap between mutually adjoining wing regions  21  and  22  or at least keeps it small enough that no significant light loss results therefrom. 
         [0052]    That section of the base  13  that is bounded by the wing regions  21  and  22  may likewise be reflective and serves as a placement region  25  for in each case at least one semiconductor light source. 
         [0053]    The wing regions  21  and  22  are also removed from the base  13  here at their underside, such that they can reach as far as the base  13  in the bent-out state. 
         [0054]    The wing regions  21  and  22  in each case have a cutout  26  (not depicted in  FIG. 1 ) at their underside facing the base  13 , wherein the cutouts  26  adjoin one another and jointly form a central lead-through. 
         [0055]      FIG. 3  shows the finished reflector assembly  24  from  FIG. 1  in a cross-sectional view with differently fashioned side edges  16  and  17 . While the side edges  16  and  17  rise perpendicularly in the variant of the reflector assembly  24  as shown in  FIG. 2 , said side edges are bent downward perpendicularly along the outer bending lines B 1  and B 4  in  FIG. 3 . In  FIG. 4 , by contrast, the side edges  16  and  17  are bent over horizontally along the outer bending lines B 1  and B 4 . The side edges  16  and  17  are embodied in a manner curved downward in cross section starting from the bending line B 1  and B 4 , respectively, in  FIG. 5 , and in a manner curved toward the side in  FIG. 6 . 
         [0056]      FIG. 7  shows the plate part  11  with additional electrical wiring and placement with semiconductor light sources. In addition to the plate part  11  from  FIG. 1 , now the strip-shaped base  13  is occupied in each case with a semiconductor light source in the form of a light emitting diode  27  at the placement regions  25 . The type of the light emitting diodes  27  is arbitrary, in principle; they are embodied here as LED chips which are fixed, e.g. adhesively bonded, to the placement region  25  via an electrically insulating substrate  28 . Electrical connection lines in the form of two conductor tracks  29  running parallel run between the placement regions  25  or the light emitting diodes  27 . The conductor tracks  29  are applied on the base  13  via an electrically insulating layer  30  and supply the light emitting diodes  27  with electrical energy. In the finished bent-over state of the plate part  11 , the conductor tracks  29  run through the cutout  26  of the wing regions  21  and  22 , such that the wing regions  21  and  22  cross the conductor tracks  29  in a spaced-apart fashion. 
         [0057]    The plate part  11  bent over to completion and equipped in this way can serve as a lighting device  31 . 
         [0058]      FIG. 8  shows in plan view a simplified schematic diagram of a plate part  41  for producing a reflector assembly  42  in accordance with a second embodiment. 
         [0059]    The plate part  41  differs from the plate part  11  in that now it has three rows R 1 , R 2 , R 3  of in each case four reflectors  18  or  18   a,    18   b  arranged linearly, rather than only one row. The plate part  41  can thus be bent to form a reflector assembly  42  including three continuous linear reflector troughs T 1 , T 2 , T 3  similar to the reflector troughs  13  to  15 . Adjacent reflector troughs T 1  to T 3  are connected to one another by identical side edges  16 . 
         [0060]    Alternatively, the reflector sub-regions  18   a,    18   b,  etc. can also be completely bent out from the plate part  41  and may subsequently be additionally fixed, in particular, e.g. by a cover. 
         [0061]      FIG. 9  shows in plan view a simplified schematic diagram of a plate part  51  for producing a reflector assembly  52  in accordance with a third exemplary embodiment. The plate part  51  is embodied in a manner similar to the plate part  41 , but now the rows of in each case four reflectors  18   a,    18   b  forming common reflector troughs T 4 , T 5  or T 6  are cut out from the plate part  51  in rectangular fashion apart from a transition  53  at the end sides of the base  13 . The associated rectangular cuts  54  therefore run between the two transitions  53 . This reflector assembly  52  has the advantage that the reflector troughs T 4  to T 6  now are no longer linked at their side edges, but rather can be shaped independently of one another. The reflector troughs T 1  to T 3  are nevertheless linked with one another mechanically by a common, circumferential frame  55  that holds the reflector troughs T 4  to T 6  at their transitions  53 . The reflector troughs T 4  to T 6  can also be electrically connected to one another, e.g. by virtue of common conductor tracks crossing the transitions  53  and running on the common frame  55 . 
         [0062]    Although the invention has been more specifically illustrated and described in detail by the embodiments shown, nevertheless the invention is not restricted thereto, and other variations can be derived therefrom by the person skilled in the art without departing from the scope of protection of the invention. 
         [0063]    Generally, “a(n)”, “one”, etc. can be understood to mean a singular or a plural, in particular in the sense of “at least one” or “one or a plurality”, etc., as long as this is not explicitly excluded, e.g. by the expression “exactly one”, etc. 
         [0064]    Moreover, a numerical indication can encompass exactly the indicated number and also a customary tolerance range, as long as this is not explicitly excluded. 
         [0065]    While the disclosed embodiments have been particularly shown and described with reference to specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the disclosed embodiments as defined by the appended claims. The scope of the disclosed embodiments is thus indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced.