Integrated LED bulb

• US 7,661,852 B2
• Filed: 09/04/2007
• Issued: 02/16/2010
• Est. Priority Date: 07/26/2005
• Status: Active Grant

• Current Assignee: Santa's Best
• Original Assignee: 1 Energy Solutions Incorporated
• Inventors: Yu, Jing Jing
• Primary Examiner(s): Payne; Sharon E
• Application Number:
  US11/849,939
• Publication Number:
  US 20080013324A1
• Time in Patent Office: 896 Days
• Field of Search: 362/362, 362/646, 362/650, 362/649, 362/647, 362/429, 362/435, 362/437, 362/448, 362/378, 362/353, 313/200.R, 313/205, 313/207, 313/200.A, 313/185.S, 313/312, 313322-325, 315/200.R, 315/205, 315/207, 315/200.A, 315/185.S, 315/312, 315322-325
• US Class Current: 362/362
• CPC Class Codes: F21K 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21W 2121/00 Use or application of lighting devices or systems for decorative purposes, not provided for in codes F21W2102/00 – F21W2107/00
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/34 Voltage stabilisation; Maintaining constant voltage
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

Disclosed is an integrated LED bulb that utilizes LEDs and can be used as a standard replacement bulb for incandescent lights that operate on standard household current. One or more LEDs are disposed in a lens 102 that is capable of high optical transmission efficiencies. A base portion encapsulates a printed circuit board and connectors, as well as the LED pin leads to hold the package in a secure mounting. The lens can be molded directly to the base or can be removable. The base can be formed to fit standard threaded sockets or bayonet sockets.

Claims

1. An integrated LED lamp that replaces C-type incandescent lamps comprising:

a hollow lens having air disposed in a hollow interior portion of said hollow lens;

a printed circuit board comprising;

conductor leads that are connected to electrical conductors that connect to an alternating current electrical source;

a full wave rectifier that rectifies said alternating current electrical source to generate a full wave rectified output signal;

an integrating capacitor that integrates said full wave rectified output signal to generate an integrated direct current signal;

a zener diode that controls the voltage level of said integrated direct current signal to produce a substantially constant output voltage;

at least one light emitting diode disposed in said hollow lens that transmits light through said air disposed in said hollow lens with low attenuations, said light emitting diode connected in parallel with said zener diode, which generates a substantially constant optical output in response to said substantially constant output voltage produced by said zener diode, said light emitting diode having pin leads that are soldered directly to said printed circuit board;

a lamp base having connectors that connect said integrated LED bulb to C-type bulb sockets, said lamp base forming an over-molded base that fits inside of said C-type lamp socket and is over-molded around said printed circuit board, said conductors, and said pin leads that are connected to said conductor leads on said printed circuit boards to form a secure, stable lamp base that does not cover said light emitting diode but protects said printed circuit board, said pin leads and said conductor leads, and which has a standard format for connection to C-type bulbs, so that said lamp base fits into an interior portion of said C-type bulb sockets that are attached to said alternating current electrical source, said lamp base being molded to said hollow lens to secure said hollow lens to said lamp base.

2. The integrated bulb of claim 1 wherein said integrated bulb replaces C-7 type bulbs.

3. The integrated bulb of claim 1 wherein said integrated bulb replaces C-9 type bulbs.

4. The integrated bulb of claim 1 further comprising:

a resistor and capacitor that are connected in parallel to form an RC module, said RC module connected in series to one of said conductor leads, said RC module providing complex impedance to efficiently reduce voltage levels of said alternating current electrical source.

5. A method of making an LED lamp that replaces C-type incandescent lamps comprising:

providing a hollow lens having air disposed in a hollow interior portion of said hollow lens;

providing at least one LED that is disposed in said hollow lens that transmits light through said air disposed in said hollow interior portion of said hollow lens with low dispersion;

connecting said at least one LED in parallel with a zener diode disposed on a printed circuit board using LED pin leads that are soldered to connectors on said printed circuit board;

connecting said zener diode in parallel with an integrating capacitor disposed on said printed circuit board so that a substantially constant output voltage is produced that is applied to said at least one LED to provide a substantially constant optical output;

connecting said integrating capacitor in parallel with a full wave rectifier disposed on said printed circuit board so that an alternating current electrical signal that is applied to said full wave rectifier is integrated by said integrating capacitor;

connecting electrical conductors to said full wave rectifier; and

molding a lamp base with plastic around said printed circuit board, said LED pin leads, said conductors and said conductor leads, but not around said LED, to form a secure, stable lamp base that has a standard format for C-type bulbs, so that said lamp base fits into an interior portion of standard C-type bulb sockets that are attached to said source of alternating current and light emitted from said LED is not attenuated by said plastic as a result of said LED being embedded in said plastic;

molding said lamp base to said hollow lens to secure said lens to said lamp base.

6. The method of claim 5 further comprising:

connecting a parallel connected resistor and capacitor to said electrical conductors to form an RC module that provides complex impedance that efficiently reduces voltage levels of said alternating current electrical signal.