# US 11,112,104 B2 · Relating to light-emitting diode modules > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,112,104 B2 - Document ID: US11112104B2 - Status: Granted - Kind: B2 - Application number: 16/575,231 - Filed: 2019-09-18 - Published: 2020-01-09 - Granted: 2021-09-07 - Earliest claimed: 2015-08-06 - Assignees: Schreder S.A. - Applicants: Schreder - Inventors: Samuel Joiris - Web page: https://patentgrep.com/patent/US11112104B2 ## CPC - F21V 31/005: {Sealing arrangements therefor} - F21K 9/20: Light sources comprising attachment means - F21K 9/69: Details of refractors forming part of the light source - F21V 5/007: {Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane (combination of two or more refractors F21V5/008)} - F21V 5/04: of lens shape - F21V 17/12: by screwing - F21V 19/003: {Fastening of light source holders, e.g. of circuit boards or substrates holding light sources} - F21V 23/002: {Arrangements of cables or conductors inside a lighting device, e.g. means for guiding along parts of the housing or in a pivoting arm} - F21V 23/06: the elements being coupling devices {, e.g. connectors} - F21V 29/70: characterised by passive heat-dissipating elements, e.g. heat-sinks - F21V 17/06: the fastening being onto or by the lampholder - F21V 27/02: Cable inlets - F21W 2131/10: Outdoor lighting - F21Y 2105/16: square or rectangular, e.g. for light panels - F21Y 2115/10: Light-emitting diodes [LED] - H05K 2201/09063: Holes or slots in insulating substrate not used for electrical connections - H05K 2201/10106: Light emitting diode [LED] - F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR - F21K: NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR - F21W: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS - F21Y: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED - H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS ## Abstract Described herein is an LED module (500) comprising a PCBA (200) having an array of LED elements, a secondary lens array (300) and a lens holder (510). The secondary lens array (300) has a peripheral lip (360) and a plurality of boss portions (330a) which are compressed between the lens holder (510) and the PCBA (200) to form water-tight gaskets. The secondary lens array (300) also forms gaskets around wires connecting with terminal blocks on the PCBA (200) and effectively seals with a base plate (100) on which the PCBA (200) is mounted. ## Claims ### Claim 1 A lens module designed to be mounted over a plurality of light-emitting diodes and electrical connections mounted on a first side of a printed circuit board, said electrical connections being electrically connected for supplying power to the plurality of light-emitting diodes; said lens module comprising: a secondary lens array mountable over the plurality of light-emitting diodes on the printed circuit board, the secondary lens array molded as a single component comprising a body portion integrally formed with at least one secondary lens element and integrally formed with a cover portion for the electrical connections; and a lens holder mounted over the secondary lens array, the lens holder comprising a frame comprising one or more apertures, said frame being configured for accommodating the at least one secondary lens element in said one or more apertures, and said frame being configured for accommodating the cover portion, and said frame being configured to compress at least a portion of the secondary lens array to form at least one gasket at a periphery of the lens holder. ### Claim 2 (depends on 1) The lens module according to claim 1, wherein the printed circuit board is mounted on a base plate, and wherein the secondary lens array has a peripheral lip portion configured to extend over a surface of the base plate. ### Claim 3 (depends on 2) The lens module according to claim 2, wherein the lens holder comprises a skirt portion arranged around its periphery, the skirt portion being configured for compressing the peripheral lip portion of the secondary lens array against the surface of the base plate. ### Claim 4 (depends on 1) The lens module according to claim 1, wherein the frame is provided with a plurality of holes arranged around its periphery, and wherein the lens array is provided with a corresponding plurality of holes, wherein a plurality of screws extends through the plurality of holes in the lens holder and through the corresponding plurality of holes in the lens array. ### Claim 5 (depends on 1) The lens module according to claim 1, wherein the secondary lens array is molded from an optical grade silicone material. ### Claim 6 (depends on 1) The lens module according to claim 1, wherein the frame is molded in one piece and extends between adjacent secondary lens elements of the secondary lens array. ### Claim 7 (depends on 1) A luminaire comprising a lens module according to claim 1. ### Claim 8 (depends on 1) The lens module according to claim 1, wherein the body portion is integrally formed with a plurality of secondary lens elements. ### Claim 9 A lens module designed to be mounted over a plurality of light-emitting diodes mounted on a first side of a printed circuit board, with wires for supplying power to the plurality of light-emitting diodes, said lens module comprising: a secondary lens array molded as a single component and mounted over the plurality of light-emitting diodes on the printed circuit board, the secondary lens array comprising a body portion integrally formed with at least one secondary lens element and integrally formed with at least one sheath portion for the wires; and a lens holder mounted over the secondary lens array, the lens holder comprising a frame comprising one or more apertures, said frame being configured for accommodating the at least one secondary lens element in said one or more apertures, and said frame being configured for accommodating the at least one sheath portion and being configured to compress at least a portion of the secondary lens array to form at least one gasket at a periphery of the lens holder. ### Claim 10 (depends on 9) The lens module according to claim 9, wherein the printed circuit board is mounted on a base plate, and wherein the secondary lens array has a peripheral lip portion configured to extend over a surface of the base plate on which the printed circuit board is mounted, wherein the lens holder comprises a skirt portion arranged around its periphery, the skirt portion being configured for compressing the peripheral lip portion of the secondary lens array against the surface of the base plate. ### Claim 11 (depends on 10) The lens module according to claim 10, wherein the skirt portion has at least one cut-out portions therein, said at least one cut-out portion being configured to align substantially with the at least one sheath portion. ### Claim 12 (depends on 9) The lens module according to claim 9, wherein the at least one sheath portion is configured to form at least one gasket around a wire inserted therethrough. ### Claim 13 (depends on 9) The lens module according to claim 9, wherein each sheath portion of said at least one sheath portion is configured to receive only one wire and to form a sheathing gasket around said wire inserted therethrough. ### Claim 14 (depends on 9) A luminaire comprising a lens module according to claim 9. ### Claim 15 (depends on 9) The lens module according to claim 9, wherein the body portion is integrally formed with a plurality of secondary lens elements. ### Claim 16 A lens module designed to be mounted over a plurality of light-emitting diodes mounted on a first side of a printed circuit board; said lens module comprising: a secondary lens array mounted over the plurality of light-emitting diodes on the printed circuit board, the secondary lens array being molded in one piece and being integrally formed of a single material with a plurality of secondary lens elements aligned with the plurality of light-emitting diodes; and a lens holder mounted over the secondary lens array, the lens holder comprising a frame comprising one or more apertures, said frame being configured for accommodating the plurality of secondary lens elements in said one or more apertures, and said frame being configured to compress at least a portion of the secondary lens array to form at least one gasket at a periphery of the lens holder. ### Claim 17 (depends on 16) The lens module according to claim 16, wherein the secondary lens array is molded from an optical grade silicone material. ### Claim 18 (depends on 16) The lens module according to claim 16, wherein the printed circuit board is mounted on a base plate, and wherein the secondary lens array has a peripheral lip portion configured to extend over a surface of the base plate. ### Claim 19 (depends on 18) The lens module according to claim 18, wherein the lens holder comprises a skirt portion arranged around its periphery, the skirt portion being configured for compressing the peripheral lip portion of the secondary lens array against the surface of the base plate. ### Claim 20 (depends on 16) The lens module according to claim 16, wherein the secondary lens array comprises a plurality of array mounting holes formed therein, each array mounting hole having an array boss portion associated therewith which is configured for passing through a corresponding mounting hole formed in the printed circuit board. ### Claim 21 (depends on 20) The lens module according to claim 20, wherein the lens holder further comprises a plurality of holder mounting holes formed therein, each holder mounting hole having a holder boss portion associated therewith which is configured for engaging a corresponding array boss portion of the secondary lens array and for compressing the array boss portion against the corresponding hole formed in the printed circuit board. ### Claim 22 (depends on 21) A lens module according to claim 21, further comprising a plurality of mounting screws for mounting the lens holder and the secondary lens array to a base plate on which the printed circuit board is mounted, each mounting screw passing through one of the holder mounting holes and its associated holder boss portion and into an associated hole in the base plate. ### Claim 23 (depends on 16) The lens module according to claim 16, wherein the lens holder is provided with a plurality of holes arranged around its periphery, and wherein the lens array is provided with a corresponding plurality of holes, wherein a plurality of screws extends through the plurality of holes in the lens holder and through the corresponding plurality of holes in the lens array. ### Claim 24 (depends on 16) The lens module according to claim 16, wherein the frame is molded in one piece and extends between adjacent secondary lens elements of the plurality of secondary lens elements of the secondary lens array. ### Claim 25 (depends on 16) A luminaire comprising a lens module according to claim 16. ### Claim 26 A lens module designed to be mounted over a plurality of light-emitting diodes mounted on a first side of a printed circuit board, with wires for supplying power to the plurality of light-emitting diodes, said lens module comprising: a secondary lens array mounted over the plurality of light-emitting diodes on the printed circuit board, the secondary lens array comprising a body portion formed with at least one secondary lens element and with at least one sheath portion for the wires; and a lens holder mounted over the secondary lens array, the lens holder comprising a frame comprising one or more apertures, said frame being configured for accommodating the at least one secondary lens element in said one or more apertures, and said frame being configured for accommodating the at least one sheath portion and being configured to compress at least a portion of the secondary lens array to form at least one gasket at a periphery of the lens holder; wherein the printed circuit board is mounted on a base plate, and wherein the secondary lens array has a peripheral lip portion configured to extend over a surface of the base plate on which the printed circuit board is mounted, wherein the lens holder comprises a skirt portion arranged around its periphery, the skirt portion being configured for compressing the peripheral lip portion of the secondary lens array against the surface of the base plate; wherein the skirt portion has at least one cut-out portion therein, said at least one cut-out portion being configured to align substantially with the at least one sheath portion. ### Claim 27 (depends on 26) The lens module according to claim 26, wherein the at least one sheath portion is configured to form at least one gasket around a wire inserted therethrough. ### Claim 28 (depends on 26) The lens module according to claim 26, wherein each sheath portion is configured to receive only one wire and to form a sheathing gasket around said wire inserted therethrough.