PLASTIC LED BULB

• US 20090257220A1
• Filed: 04/27/2007
• Published: 10/15/2009
• Est. Priority Date: 05/02/2006
• Status: Active Grant

• Current Assignee: Switch Bulb Company, Inc.
• Original Assignee: Superbulbs, Inc.
• Inventors: Chandler, Daniel, Lenk, Carol, Lenk, Ronald J.
• Granted Patent: US 8,702,257 B2
• Time in Patent Office: Days
• US Class Current: 362/186
• 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 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 29/58 characterised by the coolants
• CPC Class Codes: F21V 29/85 characterised by the material liquid coolants F21V29/56
• 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: F21V 3/0625 the material diffusing light, e.g. translucent plastics
• CPC Class Codes: F21V 3/08 the material comprising photoluminescent substances
• CPC Class Codes: F21V 9/12 with liquid-filled chambers
• CPC Class Codes: F21Y 2107/00 Light sources with three-dimensionally disposed light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01J 9/395 Filling vessels
• CPC Class Codes: H01R 33/22 for screw type base, e.g. for lamp
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

An LED bulb having a bulb-shaped shell, a thermally conductive plastic material within the bulb-shaped shell, and at least one LED within the bulb-shaped shell. The bulb also includes a base, wherein the base is dimensioned to be received within a standard electrical socket.

Claims

1-130. -130. (canceled)

131. An LED bulb comprising:

a shell;

a thermally conductive plastic material within the shell;

at least one LED within the shell; and

a base configured to fit within a socket.

132. The LED bulb as set forth in claim 131, wherein the base comprises a series of screw threads and a base pin, wherein the screw threads and base pin are dimensioned to be received within a standard electrical socket.

133. The LED bulb as set forth in claim 131, wherein the shell is a plastic material.

134. The LED bulb as set forth in claim 131, wherein at least a portion of the at least one LED is mounted within the thermally conductive material.

135. The LED bulb as set forth in claim 131, wherein the at least one LED is thermally connected to the thermally conductive material through a thin shell-wall.

136. The LED bulb as set forth in claim 131, further comprising a power source, wherein the power source for the at least one LED is contained within the bulb, and wherein the power source for the at least one LED is compatible with pre-existing power sources, permitting the bulb to be used in pre-existing fixtures.

137. The LED bulb as set forth in claim 131, further comprising a dispersion material within the shell, wherein the dispersion material disperses the light from the at least one LED.

138. The LED bulb as set forth in claim 131, wherein the shell disperses the light from the at least one LED.

139. The LED bulb as set forth in claim 131, further comprising a dispersion material within the thermally conductive material, wherein the dispersion material disperses the light from the at least one LED.

140. The LED bulb as set forth in claim 131, wherein the thermally conductive material has the characteristics to disperse and/or color shift the light.

141. The LED bulb as set forth in claim 131, further comprising a plurality of bubbles within the thermally conductive material, wherein the bubbles disperse the light from the at least one LED.

142. The LED bulb as set forth in claim 131, further comprising a color shifting material within the shell, wherein the color shifting material shifts light from the LED from a first color spectrum to a second color spectrum.

143. The LED bulb as set forth in claim 131, further comprising a dye added to the shell, wherein the dye shifts the light of the at least one LED from a first color spectrum to a second color spectrum.

144. The LED bulb as set forth in claim 131, further comprising a color shifting material within the thermally conductive material, wherein the color shifting material shifts light from the LED from a first color spectrum to a second color spectrum.

145. The LED bulb as set forth in claim 131, further comprising a dye added to the thermally conductive material, wherein the dye shifts the light of the at least one LED from a first color spectrum to a second color spectrum.

146. The LED bulb as set forth in claim 131, wherein the thermally conductive material is a gel.

147. The LED bulb as set forth in claim 131, wherein the thermally conductive material is a liquid plastic.

148. The LED bulb as set forth in claim 131, wherein the shell and the thermally conductive material are of the same material.

149. A method of manufacturing an LED bulb comprising:

creating a shell;

installing at least one LED in the shell;

filling the shell with a thermally conductive material; and

curing the thermally conductive material.

150. The method as set forth in claim 149, further comprising attaching a base to the shell, wherein the base is dimensioned to be received within a standard electrical socket.

151. The method as set forth in claim 149, further comprising installing a power source within the bulb, and wherein the power source for the at least one LED is compatible with pre-existing power sources, permitting the bulb to be used in pre-existing fixtures.

152. The method as set forth in claim 149, further comprising a means to disperse and/or means to color shift the light within the thermally conductive material.

153. The method as set forth in claim 149, further comprising a means to disperse and/or means to color shift the light contained within the shell.

154. The method as set forth in claim 149, wherein the shell and the thermally conductive material are of the same material.

155. A method of manufacturing an LED bulb, comprising:

creating a shell;

filling the shell with a thermally conductive material;

installing at least one LED in the thermally conductive material; and

curing the thermally conductive material after the filling of the shell and the installing of the at least one LED are completed.

156. The method as set forth in claim 155, further comprising;

attaching a base to the shell, wherein the base is dimensioned to be received within a standard electrical socket; and

installing a power source within the bulb, and wherein the power source for the at least one LED is compatible with pre-existing power sources permitting the bulb to be used in pre-existing fixtures.

157. A method of manufacturing an LED bulb comprising:

creating a shell;

filling the shell with a thermally conductive material;

installing at least one LED in the thermally conductive material; and

gelling the thermally conductive material.

158. The method as set forth in claim 157, further comprising;

attaching a base to the shell, wherein the base is dimensioned to be received within a standard electrical socket; and

installing a power source within the bulb, and wherein the power source for the at least one LED is compatible with pre-existing power sources permitting the bulb to be used in pre-existing fixtures.

159. The method as set forth in claim 157, wherein the thermally conductive material has the characteristics to disperse and/or color shift the light.

160. A method of manufacturing an LED bulb comprising:

creating a shell;

installing at least one LED within the shell;

filling the shell with a thermally conductive material; and

gelling the thermally conductive material.

161. The method as set forth in claim 160, further comprising;

attaching a base to the shell, wherein the base dimensioned to be received within a standard electrical socket; and

installing a power source within the bulb, and wherein the power source for the at least one LED is compatible with pre-existing power sources permitting the bulb to be used in pre-existing fixtures.

162. The method as set forth in claim 160, wherein the thermally conductive material has the characteristics to disperse and/or color shift the light.

163. A method of manufacturing an LED bulb comprising:

installing at least one LED into a mold;

filling the mold with a thermally conductive material; and

curing the thermally conductive material.

164. The method as set forth in claim 163, further comprising processing the outside of the bulb to produce a shell.

165. The method as set forth in claim 163, further comprising adding a shell to the bulb.

166. A method of manufacturing an LED bulb comprising:

installing at least one LED into a mold;

filling the mold with a thermally conductive material; and

gelling the thermally conductive material.

167. The method as set forth in claim 166, further comprising processing the outside of the bulb to produce a shell.

168. The method as set forth in claim 166, further comprising adding a shell to the bulb.

169. A method of manufacturing an LED bulb comprising:

creating a shell;

installing at least one LED in the shell; and

filling the shell with a gel.

170. The method as set forth in claim 169, further comprising a dispersion material within the gel, wherein the dispersion material disperses the light from the at least one LED.

171. The method as set forth in claim 169, wherein the gel has the characteristics to disperse and/or color shift the light.

172. The method as set forth in claim 169, further comprising a plurality of bubbles within the gel, wherein the bubbles disperse the light from the at least one LED.

173. The method as set forth in claim 169, further comprising a color shifting material within the shell, wherein the color shifting material shifts light from the LED from a first color spectrum to a second color spectrum.

174. The method as set forth in claim 169, further comprising adding a dye to the shell, wherein the dye shifts the light of the at least one LED from a first color spectrum to a second color spectrum.

175. The method as set forth in claim 169, further comprising a color shifting material within the gel, wherein the color shifting material shifts light from the LED from a first color spectrum to a second color spectrum.

176. The method as set forth in claim 169, further comprising adding a dye to the gel, wherein the dye shifts the light of the at least one LED from a first color spectrum to a second color spectrum.

177. A method of manufacturing an LED bulb comprising:

creating a shell;

filling the shell with gel; and

installing at least one LED in the gel filled shell.

178. The method as set forth in claim 177, further comprising a dispersion material within the gel, wherein the dispersion material disperses the light from the at least one LED.

179. The method as set forth in claim 177, wherein the gel has the characteristics to disperse and/or color shift the light.

180. The method as set forth in claim 177, further comprising a plurality of bubbles within the gel, wherein the bubbles disperse the light from the at least one LED.

181. The method as set forth in claim 177, further comprising a color shifting material within the shell, wherein the color shifting material shifts light from the LED from a first color spectrum to a second color spectrum.

182. The method as set forth in claim 177, further comprising adding a dye to the shell, wherein the dye shifts the light of the at least one LED from a first color spectrum to a second color spectrum.

183. The method as set forth in claim 177, further comprising a color shifting material within the gel, wherein the color shifting material shifts light from the LED from a first color spectrum to a second color spectrum.

184. The method as set forth in claim 177, further comprising adding a dye to the gel, wherein the dye shifts the light of the at least one LED from a first color spectrum to a second color spectrum.