Integrated light-emitting diode lamp and method of producing the same

• US 5,808,592 A
• Filed: 04/21/1995
• Issued: 09/15/1998
• Est. Priority Date: 04/28/1994
• Status: Expired due to Fees

• Current Assignee: Hewlett-Packard Company (HP Inc.), Toyoda Gosei Company Limited (Toyota Motor Corporation)
• Original Assignee: Toyoda Gosei Company Limited (Toyota Motor Corporation)
• Inventors: Takahashi, Yuji, Naganawa, Hideyuki, Mizutani, Junichi
• Primary Examiner(s): BRIER, JEFFERY A
• Application Number:
  US08/426,940
• Time in Patent Office: 1,243 Days
• Field of Search: 345/82, 345/83, 340/815.45, 362/800, 362/812, 348/801, 348/802, 313/500, 313/511, 313/512
• US Class Current: 345/83
• CPC Class Codes: F21V 31/00 Gas-tight or water-tight arrangements
• CPC Class Codes: F21W 2111/02 for roads, paths or the like
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G09F 27/008 Sun shades, shades, hoods or louvres on electronic displays to minimise the effect of direct sun light on the display
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes
• CPC Class Codes: H01L 25/13 the devices being of a type provided for in group H01L33/00
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

The invention involves an integrated LED lamp (1) whose hood (3) for shielding sun light is detachable and adjustable according to its necessity. Even after the hood is attached to the lamp case, its length is easily altered. A waterproof structure, which is provided by fixing an LED substrate (2) to the case (4) by inserting the hood (3) to the case (4) and printing sealing material (11) at a circumference of the LED substrate (2), edges (32) of the hood, and grades (47) of the case, prevents potting material from leaking into an inner space (44) of the case and reduces manufacturing process for airtight sealing. Further, a through hole (2) on the LED substrate (2) for a pair of leads (13) of an LED (10) is tilted from the horizontal direction by a predetermined degree resulting in an expanding light distribution characteristic to the direction perpendicular to the connecting line k. Also, the direction of light distribution can be controlled by altering the tilt angle of the through holes (20) according to necessity. Further, the integrated lamp (1) has a controlled LEDs arrangement of each color of red, blue, and green in a 5×5 matrix structure assuring homogeneous luminous intensity of each color and white color display with a high quality resulting in improvement in the display quality of a plane display which is made of plural integrated lamps.

Claims

1. An integrated light-emitting diode lamp as one display unit comprising:

a substrate;

at least three light-emitting diodes respectively emitting red, green, and blue color light arranged on said substrate, leads of said diodes being embedded in to a waterproof material;

a hood with an end;

a case with an edge surface in a step shape on an open side of said case; and

wherein said substrate is fixed between said end and said edge surface by inserting said hood into said case.

2. An integrated light-emitting diode lamp comprising:

a lamp substrate;

a plurality of light-emitting diodes arranged on a front surface of said substrate, leads of said diodes being embedded into a potting material;

a lamp case with an edge surface in step shape on an open side of said case; and

wherein an elastic material for sealing is disposed at the circumference of a back side of said lamp substrate and sandwiched between said lamp substrate and said edge surface for preventing leakage of said potting material into an inner space between said lamp substrate and said lamp case.

3. An integrated light-emitting diode lamp of claim 2, wherein said elastic material has a thickness to be piled by screen printing at the time of manufacturing said lamp substrate.

4. An integrated light-emitting diode lamp with a matrix structure of 5×

5 light-emitting diodes, said matrix structure comprising;

a first luminous part made of a blue light-emitting diode placed at center of said matrix structure;

a second luminous part made of eight light-emitting diodes surrounding said first luminous part squarely with four blue light-emitting diodes placed at each corner and respective two red and green light-emitting diodes placed between said blue light-emitting diodes in symmetrical regarding said first luminous part as a point of symmetry; and

a third luminous part made of sixteen light-emitting diodes surrounding said second luminous part squarely with four green light-emitting diodes placed at each corner and a blue, a green, and a red light-emitting diodes placed at each side clockwise in this order.

7. An integrated light-emitting diode lamp of claim 4 further comprising:

a series circuit of six red light-emitting diodes

two series circuits of five green light-emitting diodes arranged in parallel; and

three series circuits of three blue light-emitting diodes arranged in parallel.

9. An integrated light-emitting diode lamp of claim 7, wherein applied voltages to each of said series circuit of respective color light-emitting diodes are controlled to satisfy applied voltage Vr to said series circuit of red light-emitting diodes, Vg to said series circuit of green light-emitting diodes, and Vb to said series circuit of blue light-emitting diodes with the formula Vg≧

Vb≧

Vr.

5. An integrated light-emitting diode lamp with a matrix structure of 5×

5 light-emitting diodes, said matrix structure comprising;

a first luminous part made of a blue light-emitting diode placed at center of said matrix structure;

a second luminous part made of eight light-emitting diodes surrounding said first luminous part squarely with four blue light-emitting diodes placed at each corner and respective two red and green light-emitting diodes placed between said blue light-emitting diodes in symmetrical regarding said first luminous part as a point of symmetry; and

a third luminous part made of sixteen light-emitting diodes surrounding said second luminous part squarely with four red light-emitting diodes placed at each corner and a blue and two green light-emitting diodes placed at each side clockwise in this order.

8. An integrated light-emitting diode lamp of claim 5 further comprising:

a series circuit of six red light-emitting diodes

two series circuits of respective five green light-emitting diodes arranged in parallel; and

three series circuits of respective three blue light-emitting diodes arranged in parallel.

6. An integrated light-emitting diode lamp with matrix structure of 5×

5 light-emitting diodes, said matrix structure comprising;

a first luminous part made of a red light-emitting diode placed at center of said matrix structure;

a second luminous part made of eight light-emitting diodes surrounding said first luminous part squarely with four green light-emitting diodes placed at each corner and a blue light-emitting diodes placed between said green light-emitting diodes at each side; and

a third luminous part made of sixteen light-emitting diodes surrounding said second luminous part squarely with four green light-emitting diodes placed at each corner and a blue, a green, and a red light-emitting diodes placed at each side clockwise in this order.

10. An integrated light-emitting diode lamp comprising:

a substrate;

a plurality of light-emitting diodes arranged in matrix structure on said substrate;

a case surrounding outer surface of said substrate;

a hood jutting out from tips of said light-emitting diodes by a projection roof; and

wherein cutting caves are formed on an outer surface of said projection roof in a direction parallel to said substrate for altering the length of said projection roof by breaking said projection roof at each of said cutting caves.

11. An integrated light-emitting diode lamp of claim 10, wherein said cutting caves are formed at uneven intervals so as to alter sun light protective angles from θ

1 to θ

n (n>

1) in steps at an uniform degree.