LED LIGHT BULBS

• US 20140043825A1
• Filed: 10/18/2013
• Published: 02/13/2014
• Est. Priority Date: 06/08/2010
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Brandes, George R., Garceran, Julio A.
• Granted Patent: US 8,858,029 B2
• Time in Patent Office: Days
• US Class Current: 362/294
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• 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 9/238 Arrangement or mounting of circuit elements integrated in the light source
• 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 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 29/506 of globes, bowls or cover glasses
• CPC Class Codes: F21V 29/507 of means for protecting lighting devices from damage, e.g. housings
• CPC Class Codes: F21V 29/51 using condensation or evaporation of a fluid, e.g. heat pipes
• CPC Class Codes: F21V 29/57 characterised by control arrangements
• CPC Class Codes: F21V 29/677 the fans being used for discharging
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 3/049 Patterns or structured surfaces for diffusing light, e.g. frosted surfaces
• CPC Class Codes: F21V 3/08 the material comprising photoluminescent substances
• CPC Class Codes: F21V 3/12 the coatings comprising photoluminescent substances
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2107/30 : on the outer surface of cylindrical surfaces, e.g. rod-shaped supports having a circular or a polygonal cross section
• CPC Class Codes: F21Y 2107/40 : on the sides of polyhedrons, e.g. cubes or pyramids
• CPC Class Codes: F21Y 2115/10 : Light-emitting diodes [LED]
• CPC Class Codes: F21Y 2115/30 : Semiconductor lasers
• CPC Class Codes: H05K 2201/047 : Box-like arrangements of PCBs
• CPC Class Codes: H05K 2201/10106 : Light emitting diode [LED]
• CPC Class Codes: Y10S 362/80 : Light emitting diode
• CPC Class Codes: Y10T 29/4913 : Assembling to base an electrical component, e.g., capacitor, etc.

Abstract

LED light bulbs include openings in base or cover portions, and optional forced flow elements, for convective cooling. Thermally conductive optically transmissive material may be used for cooling, optionally including fins. A LED light engine may be fabricated from a substrate via planar fabrication techniques and shaped to form a substantially rigid upright support structure. Mechanical, electrical, and thermal connections may be made between a LED light engine and a LED light bulb.

Claims

1. A light emitting diode (LED) light bulb comprising:

a LED light engine including a substrate having patterned thereon at least one electrical trace, wherein the substrate includes at least one bend to form multiple non-coplanar LED support surface portions to which multiple LEDs are mounted;

a base element including multiple electrical contacts arranged near a base end;

a light-transmissive cover defining an interior volume in which the multiple LEDs of the LED light engine are contained;

an externally accessible heatsink associated with the base element and arranged between the base end and the cover;

wherein the LED light engine is mated with the base element to make mechanical, electrical, and thermal connections to the base element.

2. A LED light bulb according to claim 1, wherein the at least one electrical trace comprises a plurality of electrical traces.

3. A LED light bulb according to claim 1, wherein the base end comprises an Edison-type threaded light bulb connector including a lateral electrical contact and a foot electrical contact.

4. A LED light bulb according to claim 1, wherein the base end comprises a threaded contact-defining end cap arranged to mate with a threaded electrical socket.

5. A LED light bulb according to claim 1, further comprising one or more electrical control circuit elements arranged in the base element.

6. A LED light bulb according to claim 5, wherein the one or more electrical control circuit elements comprises any of a LED drive circuit element and a LED control circuit element.

7. A LED light bulb according to claim 1, wherein the externally accessible heatsink comprises a plurality of fins arranged to dissipate heat generated by the multiple LEDs.

8. A LED light bulb according to claim 1, wherein the substrate comprises a metal core printed circuit board, or comprises a stamped metal layer and at least one electrically insulating layer.

9. A LED light bulb according to claim 1, further comprising at least one compression fitting arranged to promote mounting between the LED light engine and the base element.

10. A LED light bulb according to claim 1, wherein at least one support surface portion of the LED light engine comprises at least one edge connector portion arranged to promote connection between the LED light engine and the base element.

11. A LED light bulb according to claim 1, wherein the cover comprises any of a diffuser and a lens.

12. A LED light bulb according to claim 1, wherein the cover comprises a lumiphoric material.

13. A LED light bulb according to claim 1, wherein the cover comprises a plurality of openings to enable air or other fluid to flow between the interior volume and an ambient environment.

14. A LED light bulb according to claim 1, wherein at least a portion of the cover comprises a material having visible spectrum transmittance of least about 80% and a thermal conductivity of at least 25 W/(m·

°

K) at about 25°

C., and the cover is in conductive thermal communication the multiple LEDs.

15. A light fixture comprising the LED light bulb of claim 1.

16. A method for fabricating the LED light bulb of claim 1, the method comprising:

patterning a substantially planar substrate to define at least one electrical trace for multiple LEDs;

mounting multiple LEDs to the substrate in electrical communication with the at least one electrical trace; and

shaping the substrate to define at least one bend therein to form multiple non-coplanar LED mounting surface portions to which the multiple LEDs are mounted.

17. The method of claim 16, wherein the shaping of the substrate is performed after the mounting of the multiple LEDs to the substrate.

18. The method of claim 16, wherein following the shaping step, the method further comprises mating the substrate with the base element to make mechanical, electrical, and thermal connections to the base element.

19. The method of claim 16, further comprising mounting to, defining in, or defining on the substrate the at least one of a LED drive circuit element and a LED control circuit element.

20. A light emitting diode (LED) light bulb comprising:

a cover defining an interior volume, wherein at least a portion of the cover comprising a material having visible spectrum transmittance of least about 80% and a thermal conductivity of at least 25 W/(m·

°

K) at about 25°

C.; and

a substrate supporting at least one LED, wherein the at least one LED and at least a portion of the substrate are disposed within the interior volume.

21. The LED light bulb of claim 20, wherein said material has a thermal conductivity of at least about 100 W/(m·

°

K) at about 25°

C.

22. The LED light bulb of claim 21, wherein the cover comprises a plurality of fins.