MAXIMIZING THE LIGHTING EFFICIENCY OF LED LAMPS

• US 20140110096A1
• Filed: 10/19/2013
• Published: 04/24/2014
• Est. Priority Date: 10/19/2012
• Status: Abandoned Application

• Current Assignee: Lumen Led
• Original Assignee: Lumen Led
• Inventors: NORBERG, SHELDON STEWART, MASSA, JOHN ALBERT, GOODSON, DAVID R., MARQUIS, CHRISTOPHER, CHAI, FELIX MING HAN
• Application Number:
  US14/058,230
• Publication Number:
  US 20140110096A1
• Time in Patent Office: Days
• US Class Current: 165/185
• 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 17/04 the fastening being onto or by the light source
• CPC Class Codes: F21V 29/74 with fins or blades
• 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: Y10T 29/49771 Quantitative measuring or gauging
• CPC Class Codes: Y10T 29/4978 Assisting assembly or disassembly

Abstract

Disclosed is a method of making an LED light bulb using a plurality of surface mount light emitting diodes mounted on a variety of semiregular polyhedrons and optimizing the number and placement of the surface mount light emitting diodes for the widest lighting angle (to achieve as close to 360-degrees in three dimensions) with a heat sink matched to the thermal output of the surface mount light emitting diodes and the heat conductive capacity of the polyhedron. Also described are a light emitting diode light bulb made using a plurality of surface mount light emitting diodes mounted on a variety of semiregular polyhedrons. Some embodiments may include a heat conductor comprising a plurality of curved-T shaped heat fins.

Claims

1. ) A method of making an LED light bulb comprising:

evaluating a surface mount light emitting diode having a beam angle, chip dimensions, efficacy curve, and heat-sinking requirements,

determining an arrangement of beam angles of a plurality of the surface mount light emitting diodes such that the arrangement covers a rough approximation of 360-degrees,

evaluating the plurality of the surface mount light emitting diodes as to minimize the plurality of the surface mount light emitting diodes as to best emulate a point-source of illumination,

selecting a polyhedron having a material composition for a maximal thermal conduction and size for optimal lighting angle to comport with the minimized arrangement of the plurality of the surface mount light emitting diodes covering an approximation of 360-degrees, and

mounting the minimized number of the plurality of the surface mount light emitting diodes on the polyhedron as to best emulate a point-source of illumination.

2. ) The method of making an LED light bulb of claim 1 wherein the polyhedron is an uniform prism.

3. ) The method of making an LED light bulb of claim 1 wherein the polyhedron is an uniform antiprism.

4. ) The method of making an LED light bulb of claim 1 wherein the polyhedron is a regular polyhedron.

5. ) The method of making an LED light bulb of claim 1 wherein the polyhedron is a semiregular polyhedron.

6. ) The method of making an LED light bulb of claim 1 wherein the polyhedron is an Archimedean solid.

7. ) The method of making an LED light bulb of claim 1 further comprising attaching a heat conductor to the polyhedron that has a radial cross-section surrounded by a plurality of curved T-shaped heat fins.

8. ) The method of making an LED light bulb of claim 1 further comprising inserting a heat conductor into the polyhedron for drawing heat away from an interior space of the polyhedron.

9. ) An LED light bulb made using a method comprising the steps of:

evaluating a surface mount light emitting diode having a beam angle, chip dimensions, efficacy curve, and heat-sinking requirements,

determining an arrangement of beam angles of a plurality of the surface mount light emitting diodes such that the arrangement covers a rough approximation of 360-degrees,

evaluating the plurality of the surface mount light emitting diodes as to minimize the plurality of the surface mount light emitting diodes as to best emulate a point-source of illumination,

selecting a polyhedron having a material composition for a maximal thermal conduction and size for optimal lighting angle to comport with the minimized arrangement of the plurality of the surface mount light emitting diodes covering an approximation of 360-degrees, and

mounting the minimized number of the plurality of the surface mount light emitting diodes on the polyhedron as to best emulate a point-source of illumination.

10. ) The light bulb of claim 9 wherein the light bulb has a plurality of luminous intensities measured in values of candelas of which 90% shall vary by no more than 25% from an average of all measured values, and all measured values in candelas vary by no more than 50% from the average of all measured values, and the light bulb has a 135°

to 180°

zone in which no less than 5% of total flux measure in values of zonal lumens are emitted.

11. ) A light bulb comprising a plurality of surface mount light emitting diodes affixed to a plurality of outside surfaces comprising a semi-regular polyhedron.

12. ) The light bulb of claim 11 further comprising a heat conductor comprising a support core, a plurality of curved-T shaped heat fins around the support core, and a plurality of interstitial channels between the plurality of curved-T shaped heat fins.

13. ) A heat conductor for use with a plurality of surface mounted light emitting diodes affixed to a semiregular polyhedron comprising a support core, a plurality of curved-T shaped heat fins around the support core, and a plurality of interstitial channels between the plurality of curved-T shaped heat fins.

14. ) The heat conductor of claim 13 wherein the heat conductor is hollow.

15. ) The heat conductor of claim 13 wherein the heat conductor contains a working fluid.

16. ) The heat conductor of claim 13 wherein the heat conductor is substantially solid.

17. ) The heat conductor of claim 13 wherein the heat conductor comprises a material selected from the group consisting of copper, aluminum, ceramic and a polymer.

18. ) The heat conductor of claim 13 wherein the heat conductor further comprises a plurality of curved-T shaped heat fins interspersed within the plurality of interstitial channels between the plurality of curved-T shaped heat fins.

19. ) A method of making an LED light bulb comprising:

matching a light output of a plurality of surface mount light emitting diodes to a predetermined light output requirement,

selecting a polyhedron having a suitable size for the plurality of surface mount light emitting diodes,

selecting a thermally conductive material for the polyhedron suitable for affixing the surface mount light emitting diodes,

selecting a thermally conductive material for a heat sink,

affixing the surface mount light emitting diodes and power supply to the polyhedron, and

affixing the heat sink to the polyhedron.