LED lamp bulb assembly and reflector system

• US 20060061988A1
• Filed: 09/23/2004
• Published: 03/23/2006
• Est. Priority Date: 09/23/2004
• Status: Active Grant

• Current Assignee: Suzhou Lekin Semiconductor Company Limited
• Original Assignee: OSRAM Sylvania Inc. (Ams-Osram AG)
• Inventors: Lyman, Paul R., Johnson, Ralph J.
• Granted Patent: US 7,249,877 B2
• Time in Patent Office: Days
• US Class Current: 362/227
• CPC Class Codes: F21K 9/68 Details of reflectors forming part of the light source
• CPC Class Codes: F21S 41/147 the main emission direction of the LED being angled to the optical axis of the illuminating device
• CPC Class Codes: F21S 41/151 arranged in one or more lines
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A reflector lamp assembly may be formed with a reflector housing having a reflector with a prescribed reflective surface; the reflector formed with a wall defining a through passage. A lamp bulb assembly having an axially extending stem supports a head extending transverse to the axis, the head having a first generally linearly extending region, a first set of LEDs mounted generally in a row along the region oriented to face in one plane towards a reflector. Electrical connections for the LEDs extend through the head, and stem to the exterior of the assembly for electrical connection. A base extends in the through passage and is mechanically mounted to the optical housing with the LED assembly oriented to face the reflective surface.

Claims

1. A lamp bulb assembly comprising:

an axially extending stem supporting a head extending transverse to the axis, the head having a first generally linearly extending region,

a first set of LEDs mounted generally in a row along the region oriented to face towards a reflector,

electrical connections for the LEDs extending through the head, and stem to the exterior of the assembly for electrical connection, and

a base with a coupling to mechanically mount the assembly with respect to an optical housing.

2. The lamp bulb assembly in claim 1, wherein the head and the stem are formed with portions formed from materials with high thermal conductivity, and such portions are thermally coupled to the base.

3. The lamp bulb assembly in claim 2, wherein the head and stem are formed from copper or an alloy thereof.

4. The lamp bulb assembly in claim 1, wherein the normals from the LEDs are oriented in a common plane,

5. The lamp bulb assembly in claim 1, wherein the normals generally have a common intersection point.

6. The lamp bulb assembly in claim 4, wherein the linear surface includes a plurality of planar faces having normals oriented in a common plane, and generally having a common intersection point, and respective LEDs are mounted on respective planar faces.

7. The lamp bulb assembly in claim 5, wherein the linear surfaces are staircased with the normals of the step faces angled generally toward a common intersection point in front of the linear surfaces.

8. The lamp bulb assembly in claim 5, wherein the linear surfaces are staircased with the normals of the step faces angled generally from a common intersection point behind the linear surfaces.

9. The lamp bulb assembly in claim 5, having a second transverse region

a second set of LEDs mounted generally in a row along the second transverse region oriented to face in a second plane towards a reflector, and

electrical connections for the second set of LEDs extending through the head, and stem to the exterior of the assembly for electrical connection.

16. The assembly in claim 5, wherein the LEDs are oriented to the reflector and face way from an optical focal point of the reflector.

17. The assembly in claim 4, having a second generally horizontally transverse extending region similarly supporting a second plural set of LEDs oriented to generally face the reflector, wherein the first set of LEDs face an upper half of the reflector and the second set of LEDs faces a lower half of the reflector.

10. A reflector lamp assembly comprising:

A reflector housing having a reflector with a prescribed reflective surface;

the reflector formed with a wall defining a through passage,

a lamp bulb assembly having;

an axially extending stem supporting a head extending transverse to the axis, the head having a first generally linearly extending region,

a first set of LEDs mounted generally in a row along the region oriented to face in one plane towards a reflector,

electrical connections for the LEDs extending through the head, and stem to the exterior of the assembly for electrical connection, and

a base extending in the through passage and mechanically mounted to the optical housing with the LED assembly oriented to face the reflective surface.

12. A reflector lamp assembly in claim 10, wherein at least one reflector region provides a spread beam pattern.

13. A reflector lamp assembly in claim 10, wherein at least one reflector region provides a hot spot pattern.

14. A reflector lamp assembly in claim 10, wherein at least a first reflector region provides a spread beam pattern, wherein at least a second reflector region provides a hot spot pattern;

and wherein at least a third reflector region provides a third beam pattern.

11. A reflector lamp assembly comprising:

A reflector housing having a plurality of reflector regions each with a respective prescribed reflective surface;

each reflector region formed with a respective wall defining a respective through passage,

a plurality of lamp bulb assemblies each having

an axially extending stem supporting a head extending transverse to the axis, the head having a first generally linearly extending region,

a first set of LEDs mounted generally in a row along the region oriented to face in one plane towards a respective reflector,

electrical connections for the LEDs extending through the head, and stem to the exterior of the assembly for electrical connection, and

a base extending in the respective through passage and mechanically mounted in the respective one of the defined through passages, with the respective the LED assembly oriented to face the respective reflective surface.

15. The assembly in claim 11, wherein the transverse region is formed as a series of adjacent faces, each LED mounted on a respective region face, and each LED turned to face particular region of the reflector.

18. A vehicle lamps assembly comprising:

a headlamp housing enclosing a plurality of LED lamp assemblies and reflectors, with each LED lamp assembly paired to an associated reflector, with each LED lamp assembly and reflector pair providing substantially separate segments of the headlamp beam pattern.

19. A lamp bulb assembly comprising:

an axially extending stem supporting a head extending transverse to the axis, the head having a first generally linearly extending region, the linear region including a plurality of planar faces having normals oriented to pass near a common plane, and pass near a common point, the head and the stem are formed from copper or an alloy thereof

a first set of LEDs mounted generally in a row along the region oriented to face in one plane towards a reflector, the LEDs are mounted on planar faces, the normals from the LEDs are oriented to pass near a common plane, and near a common point,

electrical connections for the LEDs extending through the head, and stem to the exterior of the assembly for electrical connection,

a base with a coupling to mechanically mount the assembly with respect to an optical housing; and

having a second transverse second region;

a second set of LEDs mounted generally in a row along the second region oriented to pass near a second plane towards a reflector, and

electrical connections for the second set of LEDs extending through the head, and stem to the exterior of the assembly for electrical connection.