Replaceable LED lamp capsule

• US 7,150,553 B2
• Filed: 08/22/2003
• Issued: 12/19/2006
• Est. Priority Date: 09/28/2001
• Status: Expired due to Term

• Current Assignee: OSRAM Sylvania Inc. (Ams-Osram AG)
• Original Assignee: OSRAM Sylvania Inc. (Ams-Osram AG)
• Inventors: Huang, Kun, Garrison, Robert L., English, George J.
• Primary Examiner(s): CARIASO, ALAN B
• Application Number:
  US10/646,916
• Publication Number:
  US 20040037088A1
• Time in Patent Office: 1,215 Days
• Field of Search: 362/247, 362/249, 362/294, 362/373, 362/545, 362/547, 362/800, 362/226
• US Class Current: 362/545
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/195 Details of lamp holders, terminals or connectors
• CPC Class Codes: F21S 45/48 with means for conducting heat from the inside to the outside of the lighting devices, e.g. with fins on the outer surface of the lighting device
• 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 7/0008 providing for indirect lighting
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• 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

Open LED chips may be arranged directly on the surface of a replaceable lamp capsule without intervening packages that reduce overall light emission. The chips may be oriented in such a way that the lamp generates a unique “donut” shape radiation pattern, which is suitable for a flat and shallow secondary optics to collimate the light into a desired beam pattern, and to reduce the unaesthetic appearance of points of light in an onlooker'"'"'s view. The LED chips are driven in such a way that one chip fails, the whole lamp fails to avoid a partially lit appearance. At the same time the heat generated by the LED chips may be conducted away by the support structure to possibly vehicle'"'"'s sheet metal to enhance life of the LED chip. The standardization of this LED lamp makes this product more cost effective thus to be used in broader lighting applications.

Claims

1. A vehicle light source comprising:

a lamp capsule having a support, wherein the support includes an umbrella like head portion,

a plurality of LEDs mounted on the support, and positioned with respect to the head portion so that the head portion is substantially intermediate the LEDs and the field to be illuminated, wherein the support is made from material having a high thermal conductivity to conduct heat away from the plurality of LEDs.

2. The vehicle light source in claim 1,

wherein the lamp capsule is replaceable, and

wherein the support includes a base structure having a thermally conductive connection to a heat sink.

3. The vehicle light source in claim 2, wherein the connection is to an attached spacially extended heat radiator forming a portion of the lamp capsule.

4. The vehicle light source in claim 3, wherein the heat radiator is a flange.

5. The vehicle light source in claim 3, wherein the connection is a thermally conductive coupling to a thermally conductive portion of a vehicle.

6. The vehicle light source in claim 2, wherein the LEDs are mounted in a plurality of bands extending around the support.

7. The vehicle light source in claim 2, wherein the LEDs are arranged in a plurality of separate circuits coupled to separate inputs enabling alternative light outputs.

8. The vehicle light source in claim 2, wherein the support is substantially cylindrical.

9. A vehicle light assembly comprising:

a) a replaceable lamp capsule having a support defining a lamp axis extending in a forward direction towards a field to be illuminated, one or more LEDs mounted on the support, each LED having a predominate LED axis of light emission, the majority of the LEDs being oriented so the respective LED axes form an angle with respect to the forward lamp axis direction of ninety or more degrees;

b) a reflector having reflective surface formed with a rear opening to receive the LEDs of the lamp capsule therethrough, the reflector further having a height measured along an axis of the reflector and a maximal diameter measured transverse to the axis, wherein the reflector is offset from and oriented with respect to a majority of the LEDs to intercept the LED axes, and reflect light emitted from the LEDs generally in the forward direction to the field to be illuminated,

c) wherein the ratio of the reflector diameter to the reflector height is more than 1.0, and

d) wherein the reflector height is less than 5.0 centimeters.

10. The vehicle light assembly in claim 9, further including a lens enclosing the lamp capsule in the reflector, wherein the reflector and lens assembly has an interior axial measurement from an inner face of the lens to an transverse plane intersecting the reflector at the formed opening of less than 4.0 centimeters.

11. A vehicle light assembly of claim 9, further including a coupling to mount the vehicle light assembly in an indentation formed in a vehicle hull.

12. A vehicle light source comprising:

a replaceable lamp capsule having a support, a plurality of LEDs mounted on the support, wherein the support is made from material having a high thermal conductivity to conduct heat away from the plurality of LEDs,

wherein the support includes a base structure having a thermally conductive connection to a heat sink

wherein the support is substantially cylindrical, and

wherein the base structure includes a heat conductive flange and a coupling to press the flange to a thermally conductive portion of a vehicle hull.

13. A vehicle light source comprising:

a replaceable lamp capsule having a support, a plurality of LEDs mounted on the support, wherein the support is made from material having a high thermal conductivity to conduct heat away from the plurality of LEDs,

wherein the support includes a base structure having a thermally conductive connection to a heat sink, and

wherein the LEDs are supported on an intermediate flexible substrate, and the flexible substrate is bent to conform with the exterior contour of the support, the flexible substrate being mechanically coupled to the support.

14. The vehicle light source in claim 13, wherein for flexible substrate is thermally coupled to the support for heat conduction from LEDs through the flexible substrate to the support.

15. The vehicle light source in claim 13, wherein the flexible substrate is supported in a groove formed on the support.

16. The vehicle light source in claim 13, wherein the LEDs are supported respectively on spoke portions of a flexible hub and spokes structure.

17. The vehicle light source in claim 16, wherein the hub and spoke structure provides an electrical connection in the hub portion.

18. The vehicle light source in claim 16, wherein the support includes a lower sidewall including a reflective skirt directing light from the LEDs away from the support.

19. A vehicle light source comprising:

a replaceable lamp capsule having a support, a plurality of LEDs mounted on the support, wherein the support is made from material having a high thermal conductivity to conduct heat away from the plurality of LEDs,

wherein the support includes a base structure having a thermally conductive connection to a heat sink, and

wherein the support includes an umbrella like head portion, and the LEDs are mounted with the head portion positioned substantially intermediate the LEDs and the field to be illuminated.

20. A vehicle light assembly comprising:

a lamp capsule having a support, wherein the support includes an umbrella like head portion,

a plurality of LEDs mounted on the support, and positioned with respect to the head portion so that the head portion is substantially intermediate the LEDs and the field to be illuminated, thereby substantially blocking direct view of the LEDs, wherein the support is made from material having a high thermal conductivity to conduct heat away from the plurality of LEDs, wherein the support defines a lamp axis extending in a forward direction towards a field to be illuminated, and the plurality of LEDs mounted on the support each LED have a predominate LED axis of light emission, the majority of the LEDs being oriented so the respective LED axes form an angle with respect to the forward lamp axis direction of ninety or more degrees; and

a reflector having reflective surface formed with a rear opening to receive the LEDs of the lamp capsule there through, the reflector further having a height measured along an axis of the reflector and a maximal diameter measured transverse to the axis, wherein the reflector is offset from and oriented with respect to a majority of the LEDs to intercept the LED axes, and reflect light emitted from the LEDs generally in the forward direction to the field to be illuminated.

21. The vehicle light assembly in claim 20, wherein the support includes a lower sidewall including a reflective skirt directing light from the LEDs away from the support.