Patent Description:
The present invention concerns both the composition and the production method of said apparatus.

Lighting apparatuses are known which comprise a containing body, provided with a housing, in which a light source is located and possibly a compartment in which a power supply and control unit is located.

The light source is suitable to generate a beam of light intended, for example, to illuminate an internal or external environment, or to provide an alarm signal associated with a malfunction of machinery inside a production plant.

Lighting apparatuses are known in which the containing body is made of metal material and, in addition to the mechanical function of accommodating the various electronic/mechanical components that make up the apparatus, it also performs a function of thermal dissipation of the heat generated by the light source and by the power supply and control unit.

In other known lighting apparatuses, the containing body is made in two or more pieces and of polymeric material. In this case, the heat dissipation function is performed by a dissipation support of the light source made of metal material and mounted in correspondence with the housing.

In particular, the category of such apparatuses includes, for example, spotlights, projectors, illuminated fixtures and ceiling lights.

Currently, in the construction of lighting apparatuses that can be used in zones classified according to the ATEX (ATmosphere EXplosive) standard, and defined as explosion-proof, LED light sources are used, the main advantage of which lies above all in the long duration which, in addition to being advantageous in economic terms, brings with it the need for a lower number of maintenance interventions.

Consequently, the exposure of operators to the risk of explosions and/or fires is significantly reduced, increasing the safety of use of the lighting apparatuses.

In known lighting apparatuses, in particular in those which use a LED light source, there is the primary need to prevent any dangerous substance, in terms of flammability or explosion, from coming into contact with the light source.

In some known lighting apparatuses, the light source is hermetically insulated from the external atmosphere, for example, it is completely covered, and then sealed, by means of a layer of transparent polymeric resin.

A first disadvantage of known explosion-proof lighting apparatuses whose components in contact with the external atmosphere are made of metal material is that it is not possible to install them in chemically aggressive environments against the metal material itself.

Another disadvantage of known explosion-proof lighting apparatuses is that the presence of the sealing polymeric resin, as described above, alters the light emission and the color rendering index of the light source, causing an absorption of the light radiation emitted.

Furthermore, the polymeric resin is subject to degradation due to aging and, since it cannot be replaced, as time passes, it reduces the luminous efficiency of the apparatus.

Lighting apparatuses of known types are disclosed in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>.

There is therefore a need to perfect a lighting apparatus that can be used, at most, in all environments with an intermediate risk of explosion (zone <NUM> according to ATEX standards) which can overcome at least one of the disadvantages of the state of the art.

A first purpose of the present invention is to provide an explosion-proof lighting apparatus that is suitable to be installed even in environments that are chemically aggressive toward metal materials exposed to the external environment.

Another purpose of the present invention is to not alter the light emission and the color rendering index of the light source.

Another purpose is that the luminous efficiency of the apparatus is high and constant throughout its entire usable life.

Another purpose is to perfect a method to produce a lighting apparatus that is simple, repeatable in series, efficient, rapid and with low implementation costs, which allows easier assembly operations, and which allows to obtain a long duration of the apparatus itself.

Consequently, a final purpose of the present invention is to provide a lighting apparatus which, even by increasing its performance in terms of luminous efficiency and duration over time, has production costs that are no higher, or possibly lower, than those of the apparatuses belonging to the state of the art.

In accordance with the above purposes, the present document discloses a lighting apparatus, indicated hereafter as apparatus, which comprises a containing body, provided with two open ends, a dissipator support, which divides the containing body into a housing and a compartment, a light source attached to the dissipator support in correspondence with the housing, and two closing elements, both configured to close the open ends of the containing body.

The containing body is made in a single body and of polymeric material.

The housing and the compartment are hermetically sealed, with respect to the external environment, by means of the closing elements which are attached in correspondence with the open ends of the containing body.

The closing elements are made of polymeric material.

The housing and the compartment are hermetically sealed, with respect to the external environment, by means of the interposition of sealing elements made of a material with sealing properties between the open ends of the containing body and the closing elements.

The containing body comprises a containing portion and a diffusion portion, the latter being made of a transparent and/or translucent polymeric material.

According to some embodiments, the containing portion comprises inside it at least two upper protuberances and at least two lower protuberances.

Each upper protuberance faces the corresponding lower protuberance, so as to create a first cavity between them.

The first cavities are configured to accommodate and maintain in position the dissipator support.

According to some embodiments, the dissipator support comprises at least two first protuberances configured to be inserted inside the first cavities.

A sheet of glass is positioned in the housing, attached to the dissipator support, defining with the latter a chamber separated from the external environment, in which the light source is disposed.

The chamber is hermetically sealed by means of the sealing elements and sealing material applied along the entire periphery of the sheet of glass.

According to some embodiments, the dissipator support comprises two second protuberances configured to support the sheet of glass and to delimit the chamber.

Each second protuberance delimits a second cavity configured to position and possibly additionally prevent the displacement of the sealing material.

According to other embodiments, the dissipator support is configured to rest on the at least two upper protuberances and comprises at least one end portion configured to attach the dissipator support to the containing body by means of attachment means of the closing elements.

In this way, a lighting apparatus is obtained that overcomes the limits of the state of the art and eliminates the defects present therein.

In particular, a simple and versatile apparatus is obtained that can be used in all environments that are chemically aggressive toward metal materials and that have at most an intermediate risk of explosion (zone <NUM> according to ATEX regulations).

The present invention also concerns a method to produce a lighting apparatus which comprises the following steps:.

The method to produce the lighting apparatus also includes the steps of:.

In this way, a simple, repeatable and reliable method to produce a lighting apparatus is obtained, in which the production steps and the corresponding assembly times are optimized, minimizing the final production costs of the apparatus itself.

The attached drawings are used to describe some embodiments of a lighting apparatus <NUM>, hereafter referred to as apparatus, and of a corresponding production method.

The present apparatus <NUM> comprises a containing body <NUM> provided with two open ends, a dissipator support <NUM>, at least one light source <NUM> and two closing elements <NUM>, <NUM>.

The closing elements <NUM>, <NUM> are configured to close the open ends of the containing body <NUM>.

The closing elements <NUM>, <NUM> can be configured to be applied to the respective opposite ends of the containing body <NUM> by means of suitable attachment means <NUM> such as, for example, self-tapping screws.

In accordance with a preferential embodiment, the containing body <NUM>, as well as the closing elements <NUM>, <NUM>, can be made of polymeric material.

The polymeric material can be selected from polycarbonate, polyester resin, epoxy resin, polyester resin reinforced with glass fibers, or suchlike, or combinations thereof.

One advantage of using polymeric materials is that the apparatus <NUM> can be used in all environments that are chemically aggressive toward metal materials. For example, it can be used in environments where corrosive substances such as nitric acid or pentane, or suchlike, are present.

According to the present invention, as shown in the attached drawings, the containing body <NUM> is made in a single body.

Furthermore, the containing body <NUM> can have horizontal sections, according to a horizontal plane Y, having at least two parallel opposite sides, for example in the shape of a parallelogram, rectangular, square or trapezoidal. The containing body <NUM> also has a transverse section, according to a plane perpendicular to the horizontal plane Y, closed and empty inside, for example, shaped almost as an O, rectangular or square.

According to some embodiments, the containing body <NUM> is made by means of molding, extrusion or coextrusion, preferably by means of coextrusion, while the closing elements <NUM>, <NUM> are made by means of molding.

According to some embodiments, the containing body <NUM> comprises a containing portion 11a and a diffusion portion 11b which are made in a single body, each made of polymeric material.

The diffusion portion 11b is disposed in the lower part of the containing body <NUM> facing the light source <NUM>. The diffusion portion 11b is configured to suitably diffuse the beam of light generated by the light source <NUM>. For example, the diffusion portion 11b can eliminate the risk of glare and therefore considerably increase visual comfort.

According to one possible embodiment, the diffusion portion 11b is made of a transparent and/or translucent polymeric material such as, for example, polycarbonate (<FIG>, <FIG>).

The containing portion 11a, on the other hand, can be made of an opaque polymeric material such as a polyester or epoxy resin, or a transparent and/or translucent material, such as polycarbonate.

According to some embodiments, the containing portion 11a and the diffusion portion 11b are each made of a transparent and/or translucent polymeric material, possibly of the same transparent and/or translucent polymeric material.

According to some embodiments, the external surface of the containing portion 11a and of the diffusion portion 11b can be smooth or rough to the touch, for example, it can be provided with grooves parallel to a longitudinal axis X of the apparatus <NUM>.

The light source <NUM> can be any device whatsoever capable of converting the electrical power supplied by a power supply and control unit <NUM> into a beam of light such as, for example, incandescent, halogen, discharge, LED lights or suchlike.

According to some embodiments, as shown in <FIG>, <FIG>, the containing body <NUM> can be configured to accommodate the dissipator support <NUM> on which, in correspondence with a rest surface 22a thereof facing the diffusion portion 11b, the light source <NUM> is attached.

According to some embodiments, the rest portion 22a is parallel to the horizontal plane Y and extends along the longitudinal axis X of the apparatus <NUM>.

The dissipator support <NUM> is configured to optimally disperse the heat generated by the light source <NUM>.

In this regard, the dissipator support <NUM> can be made of metal material, for example steel, aluminum or copper, preferably of aluminum alloy. Metal materials, in fact, have the advantage of having a good thermal conductivity, being able to dissipate the heat produced, for example, by the light source <NUM>. Furthermore, the aluminum alloy is also a light and corrosion resistant material.

In accordance with possible embodiments, the dissipator support <NUM> can be made by means of molding, die casting or extrusion, preferably by means of extrusion.

According to some embodiments, with reference to <FIG>, <FIG>, the containing portion 11a of the containing body <NUM> can comprise inside it at least two upper protuberances 27a and at least two lower protuberances 27b. Each upper protuberance 27a faces the corresponding lower protuberance 27b, in such a way as to create a first cavity <NUM> between them.

According to the present invention, the first cavity <NUM> has a development parallel to the longitudinal axis X of the containing body <NUM>.

According to some embodiments, the first cavity <NUM> is also configured to accommodate and maintain in position the dissipator support <NUM>.

In this regard, the dissipator support <NUM> comprises at least two first protuberances <NUM>.

In accordance with a first variant, the first protuberances <NUM> are configured to be inserted inside the respective first cavities <NUM>.

In accordance with a second variant, the first protuberances <NUM> are configured to rest on the at least two upper protuberances 27a.

In the latter case, the dissipator support <NUM> can comprise at least one end portion <NUM> configured to attach the dissipator support <NUM> to the containing body <NUM> by means of attachment means <NUM> of the closing elements <NUM>, <NUM>.

The dissipator support <NUM>, once mounted inside the containing body <NUM>, divides the latter into a housing <NUM> and a compartment <NUM> which are disposed, respectively, in the upper part and in the lower part of the containing body <NUM>.

The housing <NUM> can be configured to accommodate the light source <NUM> inside it.

According to a preferential embodiment, the dissipator support <NUM> is configured to position a dissipator element 16a of the light source <NUM> in contact with the rest surface 22a, capable of dissipating the heat produced by the light source <NUM>.

In order to obtain a watertight insulation of the light source <NUM>, sealing elements <NUM> are applied between the open ends of the containing body <NUM> and the closing elements <NUM>, <NUM>, the sealing elements <NUM> being made of a material with sealing properties and being configured to insulate the light source <NUM> from the external environment.

In this way, an apparatus <NUM> is obtained which can be used in all environments which have a risk of explosion that is, at most, low (zone <NUM> according to ATEX regulations). The apparatus <NUM> can also be used in environments with a lower risk than the low one, for example in environments in which there is no risk of explosion.

According to some embodiments, the dissipator support <NUM> can be configured to position a sheet of glass <NUM> in such a way that it is distanced from or, possibly, in contact with, the light source <NUM>.

In order to obtain a watertight insulation of the light source <NUM>, sealing material <NUM> and the sealing elements <NUM> are applied along the entire periphery of the sheet of glass <NUM>.

In this way, the apparatus <NUM> can be used, at most, in environments with an intermediate risk of explosion (zone <NUM> according to ATEX regulations).

The sealing material <NUM> can be a synthetic elastomer used to make packings (for example, silicone).

The sheet of glass <NUM>, positioned on the dissipator support <NUM>, delimits a chamber <NUM> separated from the external environment, comprising the light source <NUM> inside it.

According to one possible embodiment, the dissipator support <NUM> is equipped with two second protuberances <NUM> which extend outward and along its entire length. Each second protuberance <NUM> comprises a lower surface 30a configured to support the sheet of glass <NUM>. These second protuberances <NUM> are also configured to obtain, during the assembly step, the centering of the light source <NUM> by means of the possible dissipator element 16a.

According to some embodiments, the lower surface 30a faces toward the external side.

The second protuberances <NUM> can also be configured to delimit the chamber <NUM>.

Furthermore, at least each second protuberance <NUM> is disposed in such a way as to delimit a second cavity <NUM>, placed laterally with respect to the rest zone of the light source <NUM>. This second cavity <NUM> extends without a break in continuity between the two open ends of the containing body <NUM>.

According to some embodiments, the dissipator support <NUM> comprises at least two third protuberances <NUM> disposed on the same side and outside the second protuberances <NUM>, in such a way as to delimit the second cavity <NUM>.

The second cavity <NUM> is configured to position and possibly additionally prevent the displacement of the sealing material <NUM>.

According to a preferential embodiment, and with reference to <FIG> and <FIG>, a wall 28a of each second cavity <NUM> which cooperates with the sealing material <NUM> has an inclination angle α, with respect to the vertical, facing toward the inside of the second cavity <NUM>.

This solution has the advantage of preventing the sealing material <NUM>, which fills each second cavity <NUM>, from being displaced, for example, following impacts or due to aging. In this way, the sheet of glass <NUM>, once positioned, remains fixed in any condition whatsoever.

According to a preferential embodiment, each third protuberance <NUM> can comprise at least one holding mean <NUM> which protrudes outward, laterally with respect to the second cavity <NUM>.

The at least one holding mean <NUM> acts as a striker to correctly position and center the sheet of glass <NUM> during the assembly steps, delimiting the chamber <NUM> in which the light source <NUM> is disposed.

In particular, by also using a sheet of glass <NUM> with sealing material <NUM>, an apparatus <NUM> is obtained which can be used, at most, even in environments with an intermediate risk of explosion (zone <NUM> according to ATEX regulations).

Furthermore, the sheet of glass <NUM> is not subject to alteration of transparency characteristics with aging, throughout the entire operating life of the apparatus <NUM>.

In order to reduce the number of items stored in the warehouse, the dissipator support <NUM> can always comprise at least two second protuberances <NUM> and at least two third protuberances <NUM> which delimit the two second cavities <NUM>. In this way, two possible variants of the apparatus <NUM> can be provided with the same dissipator support <NUM> (without sheet of glass <NUM> and without sealing material <NUM>; with sheet of glass <NUM> and with sealing material <NUM>).

According to one possible variant, the dissipator support does not comprise any second <NUM> and third <NUM> protuberance whatsoever.

According to preferred embodiments, the containing body <NUM> acts as a casing for the other elements that make up the apparatus <NUM>, and constitutes the bearing structure of the latter.

The compartment <NUM> of the containing body <NUM> can be configured to accommodate at least one support element <NUM>.

The support element <NUM> is configured in such a way as to accommodate and attach on it the power supply and control unit <NUM>, which comprises electronic elements configured to power and control the light source <NUM>.

The at least one support element <NUM> can be made, in a single body, during the production of the containing body <NUM> or of the dissipator support <NUM>, for example by means of extrusion.

This solution has the advantage of eliminating any mechanical work with stock removal and reducing assembly times for the production of the apparatus <NUM>.

According to some embodiments, the containing body <NUM> can comprise, facing inward, first coupling elements <NUM>.

Alternatively or in addition, the dissipator support <NUM> can comprise, on the opposite side of the rest surface 22a, second coupling elements <NUM>.

The first <NUM> and second <NUM> coupling elements are configured to mount the support element <NUM> of the power supply and control unit <NUM>, without the aid of additional attachment elements.

According to one possible embodiment, shown in <FIG>, one of the closing elements <NUM> comprises a hole <NUM> concentric, or not, with the longitudinal axis X, while the other closing element <NUM> is blind.

The hole <NUM> is configured to accommodate a watertight cable gland element <NUM>.

The cable gland element <NUM> is configured to allow the passage of the electrical cables that connect to the power supply and control unit <NUM>.

According to a preferential alternative embodiment, the closing elements <NUM>, <NUM> are the same and both comprise a hole <NUM>.

In this case, the cable gland element <NUM> is mounted on one of the closing elements <NUM>, while a watertight cap is mounted on the other closing element <NUM>, making it blind.

According to another embodiment, the closing elements <NUM>, <NUM> can be made of a material with sealing properties, thus simultaneously achieving both the functions of the closing elements <NUM>, <NUM> and of the sealing elements <NUM>.

In accordance with some embodiments, a method to produce a lighting apparatus <NUM> is provided, which comprises the steps of:.

The mounting of the dissipator support <NUM> can occur without the aid of attachment elements, such as screws, bolts and suchlike, by inserting it, for example sliding or by applying pressure, in correspondence with two first cavities <NUM> made in the containing body <NUM> which are parallel to the longitudinal axis X.

The method to produce the apparatus <NUM>, according to the present invention, also includes the steps of:.

It is clear that modifications and/or additions of parts or steps may be made to the lighting apparatus <NUM> and to the corresponding production method as described heretofore.

Claim 1:
Lighting apparatus (<NUM>) comprising a containing body (<NUM>) provided with two open ends and a dissipator support (<NUM>) which divides said containing body (<NUM>) into a housing (<NUM>) and a compartment (<NUM>) as well as two closing elements (<NUM>, <NUM>) and at least one light source (<NUM>), wherein said containing body (<NUM>) is made in a single body and of polymeric material and said housing (<NUM>) and compartment (<NUM>) are hermetically sealed by means of said closing elements (<NUM>, <NUM>) made of polymeric material, which are attached in correspondence with the open ends of said containing body (<NUM>) and the interposition of sealing elements (<NUM>) between the open ends of said containing body (<NUM>) and said closing elements (<NUM>, <NUM>), wherein said at least one light source (<NUM>) is attached to said dissipator support (<NUM>) in correspondence with said housing (<NUM>)
characterized
in that a sheet of glass (<NUM>) is positioned in said housing (<NUM>), attached to said dissipator support (<NUM>), delimiting with the latter a chamber (<NUM>) separated from the external environment and hermetically sealed by means of said sealing elements (<NUM>) and sealing material (<NUM>), wherein said light source (<NUM>) is disposed in said chamber (<NUM>).