Interior lamp

• US 7,244,058 B2
• Filed: 03/10/2005
• Issued: 07/17/2007
• Est. Priority Date: 03/10/2004
• Status: Active Grant

• Current Assignee: Truck-Lite Company LLC (Truck-Lite Holdings 2 Corp.)
• Original Assignee: Truck-Lite Company Incorporated (Truck-Lite)
• Inventors: Roller, Philip C., DiPenti, Timothy A.
• Primary Examiner(s): TSO, LAURA K
• Application Number:
  US11/077,918
• Publication Number:
  US 20050201098A1
• Time in Patent Office: 859 Days
• Field of Search: 362/490, 362/546, 362/547, 362/294, 362/373
• US Class Current: 362/547
• CPC Class Codes: B60Q 3/30 for compartments other than passenger or driving compartments, e.g. luggage or engine compartments
• CPC Class Codes: F21S 4/20 with light sources held by or within elongate supports
• 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: F21S 8/02 of recess-mounted type, e.g. downlighters specially adapted for vehicle exteriors F21S41/00-F21S45/00
• CPC Class Codes: F21V 15/013 the housing being an extrusion
• CPC Class Codes: F21V 15/015 Devices for covering joints between adjacent lighting devices; End coverings
• CPC Class Codes: F21V 17/104 using feather joints, e.g. tongues and grooves, with or without friction
• CPC Class Codes: F21V 29/505 of reflectors
• CPC Class Codes: F21V 29/67 characterised by the arrangement of fans
• 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 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: F21V 33/0044 Household appliances, e.g. washing machines or vacuum cleaners
• CPC Class Codes: F21V 7/005 with an elongated shape to cooperate with linear light sources
• CPC Class Codes: F21W 2106/00 Interior vehicle lighting devices
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: F25D 27/00 Lighting arrangements in general F21

Abstract

A vehicle lamp assembly comprised of: a heat sink with at least one flange extending beyond the lamp assembly; a circuit board functionally engaging the inner surface of the heat sink and having a power supply circuitry; at least one light emitting unit electrically connected to the heat sink; a potting compound substantially imbedding the circuit board and corresponding electrical connections; and a lens operatively attached to the heat sink. In one embodiment, the light emitting unit is an LED. In alternate embodiments, the lamp assembly can include fins and/or fans to further facilitate cooling of the assembly, and/or a reflective inner surface of the heat sink to increase the lamp assembly'"'"'s luminous output.

Claims

1. A lamp assembly comprised of:

a heat sink, said heat sink having an inside surface, a back surface, and at least one flange extending from said lamp assembly and into an environment;

a circuit board disposed on said inside surface of said heat sink, said circuit board having a power supply circuitry;

at least one light emitting unit, said at least one light emitting unit electrically connected to said circuit board by at least one corresponding electrical connection;

a potting compound substantially surrounding said circuit board and sealing said at least one corresponding electrical connection; and

a lens operatively attached to said heat sink, said lens allowing for the transmission of light emitted from said at least one light emitting unit.

2. The lamp assembly of claim 1, wherein said heat sink is made of aluminum.

3. The lamp assembly of claim 1, wherein said heat sink is further comprised of a plurality of fins for dissipating heat.

4. The lamp assembly of claim 1, wherein said heat sink is further comprised of two tracks adapted to receive said lens.

5. The lamp assembly of claim 1, wherein said inside surface of said heat sink is further comprised of a reflective surface.

6. The lamp assembly of claim 1, wherein said lamp assembly is further comprised of least one parabolic reflector.

7. The lamp assembly of claim 1, wherein said heat sink is extruded.

8. The lamp assembly of claim 7, wherein said lamp assembly further includes a first end cap and a second end cap mounted to said heat sink.

9. The lamp assembly of claim 8, wherein said first end cap and said second end cap have portions forming at least one slot for allowing air to pass through said lamp assembly.

10. The lamp assembly of claim 8, wherein said end caps are elongated and adapted to receive at least one fan for increasing air flow through said lamp assembly.

11. The lamp assembly of claim 1, wherein said heat sink further comprises a first end cap and a second end cap, said heat sink, said first end cap, and said second end cap being made of one contiguous die cast piece.

12. The lamp assembly of claim 11, wherein said first end cap and said second end cap have portions forming at least one slot for allowing air to pass through said lamp assembly.

13. The lamp assembly of claim 11, wherein said end caps are elongated and adapted to receive at least one fan for increasing air flow through said lamp assembly.

14. The lamp assembly of claim 1, wherein said power supply circuitry of said circuit board is selected from a group comprised of a linear regulator or a switching power supply for DC to DC conversion.

15. The lamp assembly of claim 1, wherein each of said at least one light emitting unit is a light emitting diode.

16. The lamp assembly of claim 1, wherein said at least one light emitting unit emits white light with a luminous flux within a range of approximately 10 to approximately 1000 lumens.

17. The lamp assembly of claim 1, wherein said lens is made of a material selected from a group comprising acrylic, polycarbonate, and translucent nylon.

18. The lamp assembly of claim 1, wherein said lens is further comprised of an optical element, said optical element selected from a group comprised of at least one rib, at least one pillow, and at least one ring.

19. The lamp assembly of claim 1, wherein said environment is a cold-temperature environment.

20. A device comprised of:

a heat sink, said heat sink having an inside surface, a back surface, at least one flange extending into an environment and one or more fins for dissipating heat;

a circuit board disposed on said inside surface of said heat sink, said circuit board having power supply circuitry;

at least one light emitting unit, said at least one light emitting unit electrically connected to said circuit board by at least one corresponding electrical connection;

a potting compound substantially surrounding said circuit board and sealing said at least one corresponding electrical connection; and

a lens operatively attached to said heat sink, said lens allowing for the transmission of light emitted from said at least one light emitting unit.

21. The device of claim 20, wherein said heat sink is made of aluminum.

22. The device of claim 20, wherein said heat sink is further comprised of two tracks adapted to receive said lens.

23. The device of claim 20, wherein said inside surface of said heat sink is further comprised of a reflective surface.

24. The device of claim 23, wherein said reflective surface is at least one parabolic reflector.

25. The device of claim 23, wherein said heat sink is extruded.

26. The device of claim 25, wherein said device further includes a first end cap and a second end cap mounted to said heat sink.

27. The device of claim 26, wherein said first end cap and said second end cap have portions forming at least one slot for allowing air to pass through said lamp assembly.

28. The device of claim 26, wherein said end caps are elongated and adapted to receive at least one fan for increasing air flow through said device.

29. The device of claim 20, wherein said heat sink further comprises a first end cap and a second end cap, said heat sink, said first end cap, and said second end cap being made of one contiguous die cast piece.

30. The device of claim 29, wherein said first end cap and said second end cap have portions forming at least one slot for allowing air to pass through said device.

31. The device of claim 29, wherein said end caps are elongated and adapted to receive at least one fan for increasing air flow through said device.

32. The device of claim 20, wherein said power supply circuitry of said circuit board is selected from a group comprised of a linear regulator or a switching power supply for DC to DC conversion.

33. The device of claim 20, wherein each of said at least one light emitting unit is a light emitting diode.

34. The device of claim 20, wherein said at least one light emitting unit emits white light with a luminous flux within a range of approximately 10 to approximately 1000 lumens.

35. The device of claim 20, wherein said lens is made of a material selected from a group comprising acrylic, polycarbonate, and translucent nylon.

36. The device of claim 20, wherein said lens is further comprised of an optical element, said optical element selected from a group comprised of at least one rib, at least one pillow, and at least one ring.

37. The device of claim 20, wherein said device is for use in a cold-temperature environment.

38. A device for use in a low-temperature environment comprised of:

a heat sink, said heat sink having an inside surface, a back surface, a first end, a second end, and at least one flange extending from said device into said low-temperature environment;

a circuit board disposed on said inside surface of said heat sink, said circuit board having a power supply circuitry;

at least one light emitting unit, said at least one light emitting unit electrically connected to said circuit board by at least one corresponding electrical connection;

a potting compound substantially surrounding said circuit board and sealing said at least one corresponding electrical connection;

a lens operatively attached to said heat sink, said lens allowing for the transmission of visible light emitted from said at least one light emitting unit; and

a first end cap at said first end of said heat sink and a second end cap at said second end of said heat sink, wherein said first end cap and said second end cap each have portions forming a box, said box adapted to receive at least one fan for cooling said device.

39. The device of claim 38, wherein said heat sink is made of aluminum.

40. The device of claim 38, wherein said heat sink is further comprised of a plurality of fins for dissipating heat.

41. The device of claim 38, wherein said heat sink is further comprised of two tracks adapted to receive said lens.

42. The device of claim 38, wherein said inside surface of said heat sink is further comprised of a reflective surface.

43. The device of claim 42, wherein said reflective surface of said heat sink is a least one six millimeter parabolic reflector.

44. The device of claim 38, wherein said heat sink is extruded.

45. The device of claim 38, wherein said first end cap and said second end cap have portions forming slots for allowing air to pass through said device.

46. The device of claim 38, wherein said heat sink, said first end cap, and said second end cap are made of one contiguous die cast piece.

47. The device of claim 38, wherein said power supply circuitry of said circuit board is selected from a group comprised of a linear regulator or a switching power supply for DC to DC conversion.

48. The device of claim 38, wherein each of said at least one light emitting units is a light emitting diode.

49. The device of claim 38, wherein said at least one light emitting unit emits white light with a luminous flux within a range of approximately 10 to approximately 1000 lumens.

50. The device of claim 38, wherein said lens is made of a material selected from a group comprising acrylic, polycarbonate, and translucent nylon.

51. The device of claim 38, wherein said lens is further comprised of an optical element, said optical element selected from a group comprised of at least one rib, at least one pillow, and at least one ring.

52. The device of claim 38, wherein said device is for use in a cold-temperature environment.

53. A lamp assembly comprised of:

a heat sink, said heat sink having an inside surface, a back surface, a first end, a second end, and at least one flange extending from said lamp assembly, at least one fin, and at least one parabolic reflector;

a circuit board disposed on said inside surface of said heat sink, said circuit board having a power supply circuitry;

at least one LED, said at least one LED electrically connected to said circuit board by at least one corresponding electrical connection;

a potting compound substantially surrounding said circuit board and sealing said at least one corresponding electrical connection;

a lens operatively attached to said heat sink, said lens allowing for the transmission of light emitted from said at least one LED;

a first end cap at said first end of said heat sink and a second end cap at said second end of said heat sink, wherein said first end cap and said second end cap each have portions forming a box, said box adapted to receive at least one fan for forcing air through and cooling said lamp assembly.

54. The lamp assembly of claim 53, wherein said heat sink is made of aluminum.

55. The lamp assembly of claim 53, wherein said heat sink is further comprised of two tracks adapted to receive said lens.

56. The lamp assembly of claim 53, wherein said heat sink is extruded.

57. The lamp assembly of claim 53, wherein said first end cap and said second end cap have portions forming slots for allowing air to pass through said lamp assembly.

58. The lamp assembly of claim 53, wherein said heat sink, said first end cap, and said second end cap being made of one contiguous die cast piece.

59. The lamp assembly of claim 53, wherein said power supply circuitry of said circuit board is selected from a group comprised of a linear regulator or a switching power supply for DC to DC conversion.

60. The lamp assembly of claim 53, wherein said at least one LED emits white light with a luminous flux within a range of approximately 10 to approximately 1000 lumens.

61. The lamp assembly of claim 53, wherein said lens is made of a material selected from a group comprising acrylic, polycarbonate, and translucent nylon.

62. The lamp assembly of claim 53, wherein said lens is further comprised of an optical element, said optical element selected from a group comprised of at least one rib, at least one pillow, and at least one ring.

63. The lamp assembly of claim 53, wherein said lamp assembly is for use in a cold-temperature environment.

64. A lamp assembly comprised of:

a heat sink, said heat sink having an inside surface, a back surface, and at least one flange extending from said lamp assembly, said flange having at least one surface exposed to an environment such that the flange is adapted to dissipate heat generated by said lamp assembly;

a circuit board disposed on said inside surface of said heat sink;

at least one light emitting unit, said at least one light emitting unit electrically connected to said circuit board at least one corresponding electrical connection; and

a lens operatively attached to said heat sink, said lens allowing for the transmission of light emitted from said at least one light emitting unit.

65. The lamp assembly of claim 64, wherein said heat sink is further comprised of a plurality of fins for dissipating heat.

66. The lamp assembly of claim 64, wherein said inside surface of said heat sink is further comprised of a reflective surface.

67. The lamp assembly of claim 64, wherein said lamp assembly is further comprised of least one parabolic reflector.

68. The lamp assembly of claim 64, wherein said heat sink is extruded.

69. The lamp assembly of claim 64, wherein each of said at least one light emitting unit is a light emitting diode.

70. The lamp assembly of claim 64, wherein said environment is a cold-temperature environment.