The present invention relates to a lamp, particularly of the type of emergency lamps, and a method for manufacturing lamps.

As is known, nowadays the use of emergency lamps and other emergency devices is very frequent, which are in varying degrees designed to ensure lighting in the event of power failure and/or to ensure the safety of people inside buildings, in particular in the event of natural disaster or fire, when it is necessary to ensure the possibility of immediate egress to a safe outside environment.

Precisely because of the importance of such devices, companies that design, produce and sell them are constantly seeking implementation solutions that offer the highest assurances in terms of reliability, robustness, lifetime etc.

More precisely, it is known that emergency lamps are available on the market which have gaskets, which are arranged at the junction line between the reflective screen and the body of the lamp, for the purpose of preventing water, dust and other impurities, even if they are very small, from penetrating inside the body and making contact with other components, thus damaging them.

The use of a gasket thus makes it possible to raise the level of reliability of the lamp, enabling it to attain the IP65 class of protection (under the Italian CEI 70-1 standard, corresponding to the European EN 60529 standard, which identifies the degree of protection of the enclosure of electrical apparatuses against contact with solid external bodies and against access to hazardous parts).

Thus, in order to produce lamps that attain such levels of reliability, according to conventional methods the manufacturing process involves the manual insertion of the gaskets, by technicians, into seats which are especially provided along the edges of the body, typically box-like, of the lamp, and are adapted for coupling with the reflective screen.

Such solution is not however devoid of drawbacks.

The necessity of manually assembling the gaskets inevitably raises the labor costs of the product, and also the logistic costs, since it is necessary to purchase an additional component (i.e. the gasket) and manage stocks thereof in storage.

Moreover, inevitably the presence of an additional processing step, and a manual one to boot, increases the risks of error and thus the probability of producing, and possibly selling, defective lamps.

The aim of the present invention is to solve the above-mentioned problems, by providing a lamp, particularly of the type of emergency lamps, which has a high degree of protection and a low production cost.

Within this aim, an object of the invention is to provide a method that enables the manufacturing at low cost of lamps, particularly of the type of emergency lamps, which have a high degree of protection.

Another object of the invention is to provide a lamp that has a high degree of protection and can be produced in short production times.

Another object of the invention is to provide a method that reduces the need for intervention by technicians and the possibility of error.

Another object of the invention is to provide a lamp that ensures a high reliability of operation.

Another object of the invention is to provide a method that makes it possible to provide a lamp that has a high degree of protection and is feasible with short production times.

Another object of the invention is to provide a lamp that can be easily implemented using elements and materials that are readily available on the market.

Another object of the invention is to provide a lamp which is safe to use.

This aim, these objects and others that will become more apparent hereinafter, are achieved by a lamp, particularly of the type of emergency lamps, comprising an open shell for supporting and accommodating at least partially a light source, and a transparent flap, which is arranged so as to close said shell, for the passage of the light beam emitted by said source, a reflective screen being coupled stably to said shell for the conveyance of the light beam emitted by said source toward a predefined direction, characterized in that said shell has a co-molded gasket, which is interposed between respective mutually facing and proximate portions of said shell and either said flap or said screen, to increase the tightness of the mutual coupling and for optimum protection against the entry of water and other substances into said shell.

This aim, these objects and others are also achieved by a method for at least partially manufacturing lamps, particularly of the type of emergency lamps, which consists in preparing a mold that has at least one impression of an open shell for supporting and accommodating at least partially a light source, provided with a gasket, which is arranged at a predefined portion thereof; providing by co-molding said shell, provided with said co-molded gasket; and coupling stably with said portion of said shell a respective facing and proximate portion of either a transparent flap, which is arranged so as to close said shell, for the passage of the light beam emitted by said source, or a reflective screen, for the conveyance of the light beam emitted by said source toward a predefined direction, with said co-molded gasket interposed between said mutually facing portions.

Further characteristics and advantages of the invention will become more apparent from the description of the method and of two preferred, but not exclusive, embodiments of the lamp according to the invention, which are illustrated by way of non-limiting example in the accompanying drawings wherein:

Figures 1 to 10 show the lamp according to the invention, in the first embodiment; more specifically: Figure 1 is a partially exploded front elevation view of the lamp according to the invention;

Figure 2 is a view from above of the lamp according to the invention; Figure 3 is a front elevation view of the lamp according to the invention;

Figure 4 is a sectional view of Figure 1 , along the line IV-IV;

Figure 5 is a first greatly enlarged detail of Figure 4;

Figure 6 is a second greatly enlarged detail of Figure 4;

Figure 7 is a sectional view of Figure 2, along the line VII- VII;

Figure 8 is a greatly enlarged detail of Figure 7;

Figure 9 is a perspective view from above of the shell;

Figure 10 is a perspective view from below of the flap and the screen;

Figures 11 to 17 show the lamp according to the invention, in the second embodiment; more specifically:

Figure 11 is a partially exploded perspective view of the lamp according to the invention;

Figure 12 is a view from above of the lamp according to the invention;

Figure 13 is a front elevation view of the lamp according to the invention;

Figure 14 is a greatly enlarged detail of Figure 11 ;

Figure 15 is a sectional view of Figure 13, along the line XV-XV;

Figure 16 is a greatly enlarged detail of Figure 15;

Figure 17 is a perspective view from above of the shell;

Figure 18 is a block diagram illustrating the method according to the invention.

With reference to the figures, the lamp according to the invention, particularly of the type of emergency lamps, is generally designated by the reference numeral 1 and comprises an open shell 2 for supporting and accommodating, at least partially, a light source 3, of various types, including conventional types.

The lamp 1 moreover comprises a transparent flap 4 (typically, but not exclusively, made of mineral glass), which is arranged so as to close the shell 2 (which can moreover contain other components necessary for the operation of the lamp 1 and of the source 3), in order to allow the passage of the light beam emitted by the source 3.

In addition, the shell 2 is stably coupled to a reflective screen 5 (typically interposed between the shell 2 and the flap 4), which is capable of conveying the light beam emitted by the light source 3 toward a predefined direction (and thus toward the surrounding area to be lit).

It should be noted that the field of emergency lamps (which are used to ensure lighting for buildings and other structures, in the event of emergencies and power failures, typically, but not exclusively, for the purpose of indicating, or identifying, exit routes in the absence of the normal lighting system), constitutes a preferred application of the present invention.

The possibility is not ruled out moreover of using lamps 1 according to the invention in different fields, according to specific requirements, without departing from the scope of protection claimed herein.

According to the invention, the shell has a co-molded gasket 6, which is interposed between respective mutually facing and proximate portions of the shell 2 and either the flap 4 or the screen 5, to increase the tightness of the mutual coupling and for thus obtaining optimum protection against the entry of water and other substances into the shell 2.

In particular, the co-molded gasket 6 is made of an elastomeric material, optionally of a recyclable type, whereas the remaining part of the shell 2 is made of a polymeric material, preferably of the type of polycarbonates. Such choice of materials is particularly advantageous, in that it is possible to exploit the respective chemical/physical properties in order to cause the gasket 6, as a result of the process of co-molding with which it is provided, to chemically bind to the shell 2, thus obtaining a stable adhesion that ensures an optimal resistance to water.

It should be noted moreover that the screen 5 can also be made of a polymeric material, preferably of the type of polycarbonates (for example the same material as used for the shell 2), whereas the flap 4 is typically, but not exclusively, made of glass (for example mineral glass).

According to a possible embodiment, the shell 2 is substantially shaped like a parallelepiped (optionally rounded at the corner edges, as in the embodiment in Figures 1 to 10) and comprises a substantially rectangular base plane 2a and four containment walls 2b that extend (preferably, but not exclusively, along a perpendicular direction) up from the sides of the base plane 2a to delimit on opposite sides an opening 2c, which is closed by the flap 4.

According to the preferred embodiment, proposed by way of non- limiting example in Figures 1 to 10, the above-mentioned mutually facing and proximate portions are respectively and substantially constituted by the top of the containment walls 2b (which delimit the opening 2c and are therefore on the side opposite to the base plane 2a) and by a substantially perimetric slot 7 of the screen 5.

More precisely, as can be seen in the accompanying figures, the slot 7 is provided along a perimetric protrusion 8 which extends from the screen 5 and is directed toward the shell 2. Such protrusion 8 has moreover, externally with respect to the slot 7, a perimetric seat 9 which is also directed toward the shell 2 and is capable of accommodating a corresponding outer bezel 10 which extends from the top of the containment walls 2b of the shell 2, to ensure the mutual coupling between shell 2 and screen 5.

In addition, as can be seen in particular in Figure 6, on the opposite side the protrusion 8 forms a circumferential receptacle 11 for receiving an end rim 12 which extends from the flap 4, so as to allow the coupling between the flap 4 and the screen 5.

The co-molded gasket 6 made of elastomeric material is thus arranged along the above-mentioned top of the containment walls 2b and accommodated in the slot 7 when the shell 2 and the screen 5 are mutually coupled.

Conveniently, as can be seen in particular in Figure 6, the side walls 7a of the slot 7 are mutually inclined, so as to form, for the slot 7 itself, a transverse cross-section that is substantially cusp-shaped, with an average center distance that is substantially smaller than the transverse space occupation, in a non-deformed configuration, of the gasket 6.

Thanks to such specific dimensioning, the gasket 6 is accommodated in the slot 7 in a deformed configuration (the gasket 6 can in fact be deformed, thus adapting to the shape structure of the slot 7, thanks to the properties of the elastomeric material of which it is made), and this ensures its optimal adhesion to the side walls 7a of the slot 7.

It should moreover be observed that the choice to effectively accommodate the gasket 6 in the screen 5 (since it is accommodated by the slot 7 formed on a protrusion 8 that extends from the screen 5), provides further assurances against the action of water, even if the water exerts a high degree of pressure. In fact, with the increase in pressure exerted by the water on the screen 5, the force with which the gasket 6 is pressed against the screen 5 rises correspondingly, and this ensures an optimal seal and total protection against the inflow of water into the shell 2 (which is effectively sealed by the screen 5).

According to a different embodiment, proposed by way of example in

Figures 11 to 17, the shell 2 is provided with a perimetric lip 13, which protrudes outward, at its side walls 2b, while the flap 5 is substantially constituted by a plate 14, which is arranged stably so as to cover the opening 2c and rests against the shell at the aforementioned lip 13.

In such embodiment, the co-molded gasket 6 is arranged along the lip 13 and is pressed and compressed between the latter and a perimetric region of the plate 14 (and therefore it is precisely the lip 13 and such perimetric region that constitute the above-mentioned mutually facing and proximate portions), so as to achieve the consequent optimal adhesion of the gasket 6 to the plate 14, and thus the protection against the inflow of water and other substances into the shell 2.

Moreover, Figures 15 and 16 show the coupling between the shell 2 and the screen 5, which involves the insertion of a ridge 15, protruding from the screen 5, into a corresponding recess 16 which is provided on the top of the side walls 2b of the shell 2.

As can be seen in Figure 18, the method of manufacturing, at least partially, lamps, and particularly, but not exclusively, lamps 1 of the type of emergency lamps, consists, in a first step a, of preparing a mold that has at least one impression of a shell 2 for supporting and accommodating, at least partially, a light source 3, the shell 2 being provided with a gasket 6, which is arranged at a predefined portion thereof.

Subsequently, in a step b, the method according to the invention provides, by co-molding, the shell 2, which is thus provided with the co- molded gasket 6.

Once the shell 2 (with the co-molded gasket 6) is obtained, the method according to the invention proceeds with a step c, of stably coupling the aforementioned portion of the shell 2 with a respective facing and proximate portion of either a transparent flap 4, which is arranged so as to close the shell 2, for the passage of the light beam emitted by the source 3, or a reflective screen 5, for the conveyance of the light beam emitted by the source 3 toward a predefined direction, with the co-molded gasket 6 interposed between the mutually facing portions which are thus defined.

It should be noted that the step b of providing, and the step c of coupling, can be repeated a number of times selected at will, in order to produce the desired number of lamps 1 according to the invention. Naturally, the possibility is not excluded of making use of molds provided with a larger number of impressions, each one of which is adapted to contribute to the manufacturing of a respective shell 2 provided with a corresponding co-molded gasket 6.

In order to arrive at the complete manufacture of the lamp 1 , obviously there will be an additional step of assembly between the shell 2 and the flap 4 (if the gasket 6 is interposed between the shell 2 and the screen 5), subsequent to the step c of coupling, or an additional step of assembly between the shell 2 and the screen 5 (if the gasket 6 is interposed between the shell 2 and the flap 4), which in this case will be previous to the step c of coupling.

More specifically, the step b of providing, by co-molding, the shell 2 which is provided with the gasket 6 consists, in a step bl, of injecting into the mold, substantially simultaneously, a first predefined quantity of elastomeric material in the liquid state, which will constitute the gasket 6, and a second predefined quantity of polymeric material in the liquid state, preferably of the type of polycarbonates, which will constitute the remaining part of the shell 2.

Subsequently, the step b of providing involves, in a step b2, waiting for the hardening of the first predefined quantity of elastomeric material and of the second predefined quantity of polymeric material, in order to provide the shell 2 which is provided with the co-molded gasket 6, chemically bonded to the remaining part of the shell 2.

It is thus evident that the choice to make use of a shell 2 provided with a co-molded gasket 6 makes it possible to eliminate the activities of manual insertion of the gasket 6, which are normally included in production cycles of conventional lamps, thus reducing labor costs and the risks of error.

Moreover, the possibility of obtaining the simultaneous injection (and hardening) of the gasket 6 and of the remaining part of the shell 2, in addition to ensuring, as previously observed, an effective chemical bond between such elements, makes it possible to keep the cycle time necessary for the molding of the shell 2 unaltered, thus ensuring very short production times.

In addition it can immediately be seen that, by providing the gasket 6 by co-molding, the necessity is eliminated of managing supplies (and reorders) of stocks of gaskets to be assembled using conventional methods with shells made in a previous step, thus also reducing purchasing and storage costs.

The lamps 1 according to the invention thus offer a high degree of protection against contact with solid and liquid external bodies (such as water and other substances) and against access to hazardous parts, thus making it possible to straightforwardly obtain high degrees of protection, for example the IP65 class of protection or at least IP42 (under the Italian CEI 70-1 standard, corresponding to the European EN 60529 standard).

In practice it has been found that the lamp and the method according to the invention fully achieve the set aim, in that the use of a shell, which is designed to support and accommodate at least partially a light source and has a co-molded gasket which is interposed between respective mutually facing and proximate portions of the shell and either the flap, which permits the passage of the light beam emitted by the source, and the screen, which conveys such light beam, so as to increase the tightness of the coupling between the shell and the screen, makes it possible to obtain lamps that offer a high degree of protection and a low production cost.

The invention, thus conceived, is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims. Moreover, all the details may be substituted by other, technically equivalent elements.

In the embodiments illustrated, individual characteristics shown in relation to specific examples may in reality be interchanged with other, different characteristics, existing in other embodiments.

In practice, the materials employed, as well as the dimensions, may be any according to requirements and to the state of the art.

The disclosures in Italian Patent Application No. BO2011A000616 from which this application claims priority are incorporated herein by reference.

Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.