HEAT REMOVAL DESIGN FOR LED BULBS

• US 20090309473A1
• Filed: 04/27/2007
• Published: 12/17/2009
• Est. Priority Date: 05/02/2006
• Status: Active Grant

• Current Assignee: Switch Bulb Company, Inc.
• Original Assignee: Superbulbs, Inc.
• Inventors: Galla, Matthew, Lenk, Carol, Lenk, Ronald J., Chandler, Daniel
• Granted Patent: US 8,547,002 B2
• Time in Patent Office: Days
• US Class Current: 313/46
• 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 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21V 29/58 characterised by the coolants
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

An LED bulb having bulb-shaped shell and thermally conductive fluid or gel within the shell. The bulb includes at least one LED within the shell. The bulb includes at least one LED within the shell and a base. The base can be configured to fit within an electrical socket and can include 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. Alternatively, the base can be configured to fit within a suitable electric socket.

Claims

1-140. -140. (canceled)

141. An LED bulb comprising:

a shell;

a thermally conductive fluid within the shell;

at least one LED within the shell; and

a base configured to be received within an electrical socket.

142. The LED bulb as set forth in claim 141, further comprising a power source, 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.

143. The LED bulb as set forth in claim 141, wherein the at least one LED is thermally connected to the fluid through a thin shell-wall.

144. The LED bulb as set forth in claim 141, wherein the fluid is static.

145. The LED bulb as set forth in claim 141, wherein the fluid gels when exposed to air.

146. The LED bulb as set forth in claim 141, wherein the fluid is mineral oil.

147. The LED bulb as set forth in claim 141, wherein the fluid is water.

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

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

150. The LED bulb as set forth in claim 141, further comprising a dye added to the fluid, wherein the dye shifts the light of the at least one LED from a first color spectrum to a second color spectrum.

151. The LED bulb as set forth in claim 141, 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.

152. The LED bulb as set forth in claim 141, wherein the base is a screw-in base, the screw-in base comprising 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.

153. An LED bulb comprising:

a shell;

a thermally conductive gel within the shell;

at least one LED within the shell; and

a base configured to be received within an electrical socket.

154. The LED bulb as set forth in claim 153, further comprising a power source, 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.

155. The LED bulb as set forth in claim 153, wherein the at least one LED is thermally connected to the gel through a thin shell-wall.

156. The LED bulb as set forth in claim 153, wherein the gel is hydrogenated poly (2-hydroxyethyl methacrylate).

157. The LED bulb as set forth in claim 153, further comprising a plurality of bubbles within the gel, wherein the bubbles disperse the light from the at least one LED.

158. The LED bulb as set forth in claim 153, further comprising a plurality of bubbles within the shell, wherein the bubbles disperse the light from the at least one LED.

159. The LED bulb as set forth in claim 153, further comprising a dye added 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.

160. The LED bulb as set forth in claim 153, 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.

161. The LED bulb as set forth in claim 153, further comprising a dispersion material within the gel, or wherein the gel itself is the dispersion material, and wherein the dispersion material disperses the light from the at least one LED.

162. The LED bulb as set forth in claim 153, further comprising a color shifting material within the gel, or wherein the gel itself is the color shifting material, and wherein the color shifting material shifts light from the LED from a first color spectrum to a second color spectrum.

163. The LED bulb as set forth in claim 153, wherein the base is a screw-in base, the screw-in base comprising 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.

164. A method of manufacturing an LED bulb comprising:

creating a shell;

at least partially filling the shell with a thermally conductive fluid; and

installing at least one LED within the shell, and wherein the at least one LED is thermally connected with the fluid.

165. The method as set forth in claim 164, further comprising attaching a screw-in base to the shell, the base comprising 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.

166. The method as set forth in claim 164, further comprising installing a power source within the bulb, and wherein the power source for the LEDs is compatible with pre-existing power sources, permitting the bulb to be used in pre-existing fixtures.

167. A method of manufacturing an LED bulb comprising:

creating a shell;

at least partially filling the shell with a thermally conductive gel; and

installing at least one LED thermally within the shell, and wherein the at least one LED is thermally connected with the gel.

168. The method as set forth in claim 167, further comprising a dispersion material within the gel, or wherein the gel itself is the dispersion material, and wherein the dispersion material disperses the light from the at least one LED.

169. The method as set forth in claim 167, further comprising a color shifting material within the gel, or wherein the gel itself is the color shifting material, and wherein the color shifting material shifts light from the LED from a first color spectrum to a second color spectrum.

170. The method as set forth in claim 167, further comprising a plurality of bubbles within the gel, wherein the bubbles disperse the light from the at least one LED.

171. The method as set forth in claim 167, wherein the gel is hydrogenated poly (2-hydroxyethyl methacrylate).