Lighting element using electronically activated light emitting elements and method of making same

• US 20050207152A1
• Filed: 08/09/2004
• Published: 09/22/2005
• Est. Priority Date: 03/18/2004
• Status: Active Grant

• Current Assignee: Lighting Science Group Corporation (Pegasus Capital Advisors, L.P.)
• Original Assignee: Lighting Sciences, Inc. (Underwriters Laboratories Incorporated)
• Inventors: Maxik, Fredric
• Granted Patent: US 7,086,756 B2
• Time in Patent Office: Days
• US Class Current: 362/231
• CPC Class Codes: F21K 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 3/00 Globes; Bowls; Cover glasses with refracting properties F21V5/00; with reflecting properties F21V7/00; characterised by cooling arrangements F21V29/506
• CPC Class Codes: F21Y 2107/00 Light sources with three-dimensionally disposed light-generating elements
• CPC Class Codes: F21Y 2107/20 on convex supports or substrates, e.g. on the outer surface of spheres
• CPC Class Codes: F21Y 2107/70 on flexible or deformable supports or substrates, e.g. for changing the light source into a desired form
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

The present lighting element uses, as a source of light generation, electronically activated light emitting elements, such as light emitting diodes, organic crystals and the like to provide one or more functions and are surface mounted on a flexible substrate, such that the substrate can bend and conform to a pre-established structure. In addition, standoffs of varying lengths are used to provide adjustable distances between the flexible substrate and the housing of the LED light bulb to provide adjustable light dispersion patterns. In this case, the circuit board is adapted to extend about and fit within the interior surface of a light bulb with the light emitting elements carried on the circuit board. A center post can be used to extend electrical conductors to the circuit board from the base and, if required, a power supply can also be carried in the post. A portion of the circuit board itself could also effectively operate as the post. Methods for making same are also provided.

Claims

1. A lighting element, comprising:

a housing having a base and a form, which housing has an inside wall;

a substrate including electrical conductors in connection with said base and conforming substantially to said inside wall;

a plurality of light emitting devices located on said substrate in electrical connection with said substrate.

2. The lighting element of claim 1 wherein said light emitting device is a light emitting diode.

3. The lighting element of claim 2 wherein said light emitting device produces a visible wavelength light.

4. The lighting element of claim 2 wherein said light emitting device produces a non-visible wavelength light.

5. The lighting element of claim 1 wherein said form is predetermined for a use for said lighting element.

6. The lighting element of claim 1 wherein said housing includes:

an optical tuning element substantially interposed between said light emitting device and a portion of said housing.

7. The lighting element of claim 1 wherein said substrate further comprises:

a substantially planar form such that when inserted into said housing said substantially planar form enables said substrate to conform to said inside wall.

8. The lighting element of claim 1 wherein said housing further comprises:

a support connected to said substrate and said base for supporting said substrate in said housing in a desired arrangement, said support in contact with said substrate at one contact point.

9. The lighting element of claim 8 wherein said support contains said electrical leads connecting said base with said substrate.

10. The lighting element of claim 1 wherein said substrate comprises a flexible circuit board.

11. The lighting element of claim 1 wherein said substrate includes an outer edge and said electrical conductors extending toward said outer edge and along said outer edge of said substrate.

12. The lighting element of claim 1 further comprising:

at least one standoff interposed between said substrate and a portion of said housing for providing a distance between said substrate and said portion of said housing.

13. The lighting element of claim 7 wherein said substantially planar form comprises a center portion with at least one finger-like extension extending outwardly and radially from said center portion, such that when said substantially planar form is inserted into said housing said at least one finger-like extension conforms substantially to the form of said housing.

14. The lighting element of claim 2 wherein said light emitting diode is a lensless light emitting diode.

15. The lighting element of claim 1 wherein said substrate further comprises relief spots interposed between said flexible substrate and said housing for providing a distance between said substrate and said housing.

16. A lighting element, comprising:

means for housing a plurality of light emitting elements, said housing means having a desired form;

means for supporting said plurality of light emitting elements inside of said housing and in substantial conformity to said form; and

means for energizing said plurality of light emitting elements.

17. The lighting element of claim 16 wherein a portion of said plurality of light emitting elements provides a first function and are orientated relative to said housing means to optimize said first function.

18. The lighting element of claim 16 wherein a portion of said plurality of light emitting elements provides a second function and are oriented relative to said housing means to optimize said second function.

19. The lighting element of claim 16 wherein said first function is lighting.

20. The lighting element of claim 16 wherein said second function is selected from the group consisting of bacteriological control, insect control, pest control, and pollution control.

21. The lighting element of claim 17 wherein said portion of said plurality of light emitting elements are light emitting diodes.

22. The lighting element of claim 18 wherein said portion of said plurality of light emitting elements are light emitting diodes.

23. The lighting element of claim 16 wherein said light emitting diodes are lensless light emitting diodes.

24. The lighting element of claim 16 further comprising:

means for spacing said plurality of light emitting elements from said housing means for adjusting the dispersion of light emitted from said lighting device.

25. The lighting device of claim 16 wherein said supporting means further comprises:

means for relief for spacing said plurality of light emitting elements from said housing means for adjusting the dispersion of light emitted from said lighting device.

26. A method for manufacturing a lighting device, comprising:

providing a housing of a desired form for accommodating at least one light emitting element;

forming a flexible substrate which is capable of conforming to said desired form;

connecting said at least one light emitting element having a first function on said flexible substrate so as to provide said first purpose;

inserting said flexible substrate into said housing so as to provide said first purpose; and

connecting said flexible substrate to said housing with electrical leads.

27. The method for manufacturing a lighting device of claim 26 wherein said connecting said at least one light emitting element further comprises:

connecting said at least one light emitting element having a second function on said flexible substrate so as to optimize said second function.

28. The method for manufacturing a lighting device of claim 26 further comprising:

supporting said flexible substrate in conformity to said housing.

29. The method for manufacturing a lighting device of claim 26 further comprising:

interposing at least one standoff between said flexible substrate and said housing for providing a distance between said substrate and said housing.

30. The method for manufacturing a lighting device of claim 26 wherein said providing a housing further comprises:

shaping said housing to change the light dispersion pattern emitted from said housing.

31. The method for manufacturing a lighting device of claim 26 wherein said providing a housing comprises providing a housing with relief spots interposed between said flexible substrate and said housing for providing a distance between said substrate and said housing.

32. A method for manufacturing a lighting device housing, comprising:

providing a mold for forming said lighting device housing, said mold having a housing lens portion;

injecting a material into said mold; and

molding said material into said lighting device housing.

33. The method for manufacturing a lighting device housing of claim 32 wherein said providing a mold for forming said housing lens portion further comprises:

producing a first pattern in said housing lens portion.

34. The method for manufacturing a lighting device housing of claim 32 wherein said providing a mold for forming said housing lens portion further comprises:

producing a second pattern in said housing lens portion.

35. The method for manufacturing a lighting device housing of claim 33 wherein said providing a mold for forming said housing lens portion further comprises:

producing a micro-optic structure in said housing lens portion for providing a desire light dispersion of said light device.