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(11) | EP 3 327 333 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | LAMP AND MANUFACTURING METHOD THEREOF |
| (57) A lamp comprises a lamp body (10; 110), at least one lighting source (20), at least
one optical element (30) associated with said lighting source, an outer casing (40),
and a bracket (50; 500) for anchoring the lamp to a wall, ceiling, or support element.
The lamp body (10; 110) is obtained by a die-casting process and comprises at least
one end portion (12) wherein a source seat (14) is made, where the lighting source
(20) is housed. The outer casing (40) is a tubular casing fitted onto the lamp body
(10; 110), has an axial extension at least equal to that of the lamp body and at least
one open axial end. The end portion (12) of the lamp body (10; 110) is configured
so as to realize a shaped coupling with the outer casing (40) and is positioned to
close said open axial end of the outer casing (40).
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[0001] The present invention relates to a wall, ceiling or pole lamp, and a manufacturing method thereof.
[0002] In the designing of lamps of style, the research of new lines must also take into account the production and assembling aspects of the lamp, so that the final product can be made on an industrial scale and with sustainable costs.
[0003] For example, lamps are known, in particular outdoors, made with a die-casting process, for example in aluminium. However, the die-casting process imposes some constraints on the shapes of the lamp.
[0004] For example, in the presence of asymmetric shapes of the lamp body, shrinkages or suction phenomenons in the material may happen in the moulding step which result in aesthetic defects on the outer surface of the lamp body, or the separating lines between the parts of the mould create junction lines on the surface of the lamp body. Moreover, in certain cases a constraint on the shape of the lamp body is due to the body mass itself, which naturally should not be excessive given that the lamp should be fixed to the wall.
[0005] The object of the present invention is to propose a lamp that can be made in series with low costs but that, at the same time, has a shape less susceptible to constraints imposed by the production process thereof with respect to the current lamps.
[0006] Such objects are achieved with a lamp according to claim 1 and with a manufacturing method of such a lamp according to claim 15. The dependent claims describe preferred embodiments of the invention.
[0007] The features and the advantages of the lamp and the method according to the invention shall be made readily apparent from the following description of preferred embodiments thereof, provided purely by way of a non limiting example, with reference to the accompanying figures, in which:
- Figure 1 shows a perspective view in separate parts of the wall lamp according to the invention, in a first embodiment;
- Figure 1a shows a perspective exploded view of part of the lamp body, of the lighting source and of the optical element associated thereto;
- Figures 2 and 2a show a front view and side view of the lamp body in figure 1;
- Figures 3-3d show as many views of the assembled lamp;
- Figure 4 shows an axial sectional view of the assembled lamp in figure 1;
- Figures 5, 5a and 5b show a perspective, front and side view of a lamp body in an embodiment variant; and
- Figure 6 shows an axial sectional view of a lamp according to the invention which uses the lamp body in figures 5-5b.
[0008] In the following description, elements common to the various embodiments of the lamp are indicated with the same reference numerals. Moreover, if not otherwise stated, features described as belonging to an embodiment of a lamp according to the invention may also be present in another embodiment.
[0009] In said drawings, reference numeral 1; 100 globally indicates a wall lamp according to the invention. The idea at the basis of the present invention is to make the lamp in two parts: an inner part which constitutes the actual lamp body (and which in turn can be formed by assembling multiple subcomponents), obtainable with a die-casting process and having a shape dictated by the need of reducing the material used as much as possible, and an outer part which forms the casing for the lamp body, obtainable from a drawn tube and which provides the desired shape to the lamp.
[0010] In a general embodiment, the lamp 1; 100 therefore comprises a lamp body 10; 110, at least one lighting source 20, at least one optical element 30 associated to the lighting source 20, and an outer casing 40.
[0011] The lamp 1; 100 is further provided with a bracket 50; 500 for a wall, ceiling, or a pole or other support anchoring thereof.
[0012] The lamp body 10; 110 is obtained by a die-casting process. In an embodiment particularly suitable for an outdoor use, the lamp body 10; 110 is made in a metal material, for example aluminium.
[0013] The lamp body 10; 110 mainly extends along a body axis X. For example, in use the body axis X is a vertical axis.
[0014] The lamp body 10; 110 comprises at least one end portion 12 wherein a source seat 14 is made, where the lighting source 20 is housed.
[0015] For example, the end portion 12 mainly extends in a perpendicular direction with respect to the body axis X.
[0016] In an embodiment, the end portion 12 forms an end wall 12' substantially planar, perpendicular to the body axis X.
[0017] In an embodiment shown in the drawings, the source seat 14, for example of cylindrical or truncated-conical shape, is suitable for receiving a printed circuit electronic board 202 on which one or more LED lighting devices 204 are mounted. The optical element 30 may comprise a lens or reflector 302 optically coupled to the lighting source 20 and configured as a function of the desired shape of the light beam. In an embodiment, the optical element 30 further comprises a transparent or semitransparent protection element 304, for example of planar shape, placed to close the source seat 14. For example, the protection element 304 seals the source seat 14 so as to allow the use of the lamp in external environments.
[0018] The outer casing 40 is a tubular casing fitted onto the lamp body 10; 110. In an embodiment particularly suitable for an outdoor use, the outer casing 40 is made in a metal material, for example aluminium.
[0019] The outer casing 40 has an axial extension at least equal to that of the lamp body. Moreover, the outer casing 40 has at least one open axial end 42.
[0020] The end portion 12 of the lamp body substantially has the same cross section of the outer casing 40 and, when the latter is fitted onto the lamp body 10; 110, the end wall 12' of the end portion 12 is coplanar to the open axial end 42. In other words, the end portion 12 of the lamp body 10 closes the open end 42 of the outer casing 40.
[0021] In an embodiment, only part of the optical element 30 axially projects from the outer casing 40.
[0022] In an embodiment, the outer casing 40 completely covers the lamp body 10; 110. The outer casing 40 therefore gives shape to the lamp 1; 100.
[0023] In an embodiment, only the end portion or portions 12 are configured so as to realize a shape coupling with the inner section of the outer casing, so as to completely close the open end or ends 42 of the outer casing 40.
[0024] The lamp body 10 comprises a central portion 102; 1002 which extends between two end ports 12. In an embodiment, this central portion 102; 1002 is shaped so as to reduce the weight of the lamp body 10 as much as possible.
[0025] In other words, the central portion 102; 1002 essentially carries out the function of connecting element between the two end portions 12.
[0026] In an embodiment, as will be described hereinafter, the central portion 102 further carries out a guiding and stiffening function for the outer casing 40 which, as said, is made from a drawn tube and therefore has a thin thickness.
[0027] In an embodiment, the central portion 102; 1002 has a hollow structure adapted to contain the electrical/electronic components used for power and control of each lighting source 20. For example, such electrical/electronic components are contained in an electrical box 60 housed in the central portion 102; 1022 of the lamp body.
[0028] Each source seat 14 has an opening for the passage of the electrical wires that connect the electrical/electronic components to the lighting source 20.
[0029] For example, the central portion 102; 1002 is delimited by a front wall 102a; 1002a and by two side walls 102b; 1022b.
[0030] In an embodiment, the central portion 102; 1002, shown in plan view, has a transverse extension, i.e. an overall dimension smaller than that of the end portions 12.
[0031] In other words, once the outer casing 40 is fitted on the lamp body 10, there is an interspace 70 between the walls of the central portion 102; 1002 of the lamp body and the walls of the outer casing 40, significant in terms of saving material of the lamp body and therefore of reducing the weight of the lamp.
[0032] In an embodiment, the lamp body 10; 110 and the outer casing 40 are symmetrical with respect to a median transverse plane and have the same axial extension.
[0033] In other words, the lamp body 10; 100 supports two lighting sources 20 positioned on opposite end portions 12 of the lamp body 10.
[0035] In an embodiment, the outer casing 40 extends between a rear side 44, intended to be facing the wall on which the lamp is installed, and a front side 46 opposite to the rear side 44. The rear 44 and front 46 sides are joined together by side walls 48.
[0036] In an embodiment, such side walls 48 diverge from each other moving away from the rear side 44.
[0037] For example, such side walls 48 are inclined walls. In an embodiment, such walls could have parallel portions and curved or rectilinear portions that extend in opposite directions before joining together at the front side 46.
[0038] In an embodiment shown in figures 1-4, from the front wall 102a of the central portion 102 radial projections 104 extend against which a corresponding front wall of the outer casing 40 leans.
[0039] In such an embodiment, a rear portion of the side walls 102b of the central portion 102 may be provided with a raised edge 106 that forms a support surface for corresponding side walls of the outer casing 40.
[0040] The radial projections 104 and the raised edges 106 therefore act as guiding and stiffening means for the outer casing 40.
[0042] In an embodiment variant show in figures 5 and 6, particularly suitable for a lamp of larger dimensions with respect to the dimensions of the lamp in figures 1-4, the lamp body 110 is made in two parts, separately obtained by a die-casting process and assembled together. For example, the central portion 1002 is made separately from the end portions 12.
[0043] In the embodiment show in figures 5 and 6, the end portions 12 are further provided with a finned surface 122 for dissipating the heat generated by the lighting source 20.
[0044] In an embodiment, the outer casing 40 is attached to the lamp body 10; 110 by means of one or more radial attachment screws 49.
[0046] In an embodiment, the bracket 50; 500 comprises at least one radial end portion 52; 522, preferably two opposite each other, which extends towards a rear opening 53 made in the outer casing and which axially superimposes a respective end portion 12 of the lamp body 10, 110. Each end portion 12 of the lamp body 10 is attached to a respective radial end portion 52; 522 of the bracket, for example by a body attachment screw 54; 540.
[0047] In an embodiment shown in figure 5 and 6, the body attachment screws 540 join the end portions 12 to the central portion 1022 of the lamp 110 and at the same time also engage the bracket 500.
[0048] To make the lamp 1; 10 described above, a die-casting process is used to obtain the lamp body 10; 110.
[0050] Each lighting source 20 is positioned in the relative source seat 14 and subsequently the optical element 30 is applied.
[0051] The electrical/electronic components are inserted in the central portion 102; 1002 of the lamp body 10; 110 and the electrical connection between such components and the lighting sources is carried out.
[0052] At this point the outer casing 40 is fitted onto the lamp body 10 and attached to the latter, for example by radial screws.
[0053] Once the bracket 50 is attached to the wall, ceiling or to a support and the electrical wiring of the lamp is carried out, the assembly consisting of the lamp body, lighting sources with relative optical elements and outer casing may be attached to the bracket, for example by body attachment screws.
[0054] A man skilled in the art may make several changes, adjustments, adaptations and replacements of elements with other functionally equivalent ones to the embodiments of the lamp and manufacturing method thereof according to the invention in order to meet incidental needs, without departing from the scope of the following claims. Each of the features described as belonging to a possible embodiment can be obtained independently of the other embodiments described.
1. Lamp comprising a lamp body (10; 110), at least one lighting source (20), at least
one optical element (30) associated with said lighting source, an external casing
(40), and a bracket (50; 500) for anchoring the lamp to a wall, ceiling, or support
element, wherein:
- the lamp body (10; 110) is obtained by a die casting process, extends mainly along a body axis (X) and comprises at least one end portion (12) wherein a source seat (14) is made, said source seat (14) housing the lighting source (20);
- the outer casing (40) is a tubular casing fitted onto the lamp body (10; 110), has an axial extension at least equal to that of the light body and at least one open axial end;
- the end portion (12) of the lamp body (10; 110) is configured so as to realize a shaped coupling with the outer casing (40) and is positioned to close said open axial end of the outer casing (40).
2. Lamp according to claim 1, wherein the end portion (12) of the lamp body has an end
wall (12') substantially planar and which extends mainly perpendicular to the axis
of the body (X).
3. Lamp according to claim 1 or 2, wherein the lamp body (10; 110) and the outer casing
(40) are symmetrical with respect to a median transverse plane and have the same axial
extension.
4. Lamp according to any of the preceding claims, wherein the outer casing (40) extends
between a rear side (44) suitable to be facing the wall, and a front side (46) opposite
the rear side, said rear and front sides being connected to each other by side walls
(48) which diverge from each other moving away from the rear side.
5. Lamp (1) according to any of the preceding claims, wherein the outer casing (40) is
made from a drawn tube.
6. Lamp according to any of the preceding claims, wherein the lamp body comprises a central
portion (102; 1002) extending between the two end portions (12) and having a transverse
extension less than that of the end portions (12), so as to form an interspace (70)
between said central portion (102; 1002) and the outer casing (40) .
7. Lamp according to the preceding claim, wherein the central portion (102) is provided
with radial projections (104) and/or raised edges (106) against which the outer casing
(40) leans.
8. Lamp according to any of the preceding claims, wherein the lamp body is made in a
single piece.
9. Lamp according to any of the claims from 1-7, wherein the central portion (1002) of
the lamp body (110) is made separately from at least one end portion (12), said central
and end portions being connected to each other, for example by means of body attachment
screws (540) .
10. Lamp according to any of the preceding claims, wherein the central portion (102; 1002)
has a hollow structure suitable to contain the electrical/electronic power and control
components of each lighting source (20) .
11. Lamp according to any of the preceding claims, wherein the outer casing (40) has a
rear opening (53) through which the bracket (50; 500) is attached directly to the
lamp body (10; 110).
12. Lamp according to any of the preceding claims, wherein each end portion (12) forms,
around the source seat (14), a finned wall (122) to dissipate the heat generated by
the lighting source (20).
13. Lamp according to any of the preceding claims, wherein the bracket (50; 500) comprises
at least one radial end portion (52; 522) which extends through a rear opening (53)
made in the outer casing (40) and which axially superposes a respective end portion
(12) of the lamp body, each end portion of the lamp body being attached to a respective
radial end portion of the bracket, for example by means of a body attachment screw
(54; 540) .
14. Lamp according to any of the preceding claims, wherein the outer casing is attached
to the lamp body by means of at least one radial attachment screw (49).
15. Method of making a lamp according to any of the preceding claims, comprising the steps
of:
- making the lamp body (10; 110) using a die-casting process;
- placing a light source (20) and a respective optical element (30) in the source seat (14);
- making the outer casing (40) from a drawn tube;
- inserting the outer casing (40) on the lamp body (10).