LED lamp device and method to retrofit a lighting fixture

• US 7,677,766 B2
• Filed: 05/07/2007
• Issued: 03/16/2010
• Est. Priority Date: 05/07/2007
• Status: Active Grant

• Current Assignee: LSI Industries Incorporated
• Original Assignee: LSI Industries Incorporated
• Inventors: Boyer, John Delmore
• Primary Examiner(s): Sember; Thomas M
• Application Number:
  US11/745,126
• Publication Number:
  US 20080278955A1
• Time in Patent Office: 1,044 Days
• Field of Search: 362/249, 362/252, 362/294, 362/345, 362/373, 362/545, 362/800, 362/249.02
• US Class Current: 362/294
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21V 19/00 Fastening of light sources or lamp holders fastening electric light source solely by the coupling device H01R33/00 ; special means for attaching candle to candle holder F21V35/003
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]

Abstract

A device and method for retrofitting a light fixture from use with a lamp socket that employs a conventional incandescent or metal halide lamp, to use with a light emitting diode (LED)-based lamp assembly. The lamp fixture has a collar with a base and an annular outer wall extending out from the base. The LED lamp device includes a neck base having an annular outer wall having a shaped outside surface that is placed into direct surface contact with the inner surface of the annular outer wall of the collar, to establish an effective heat-transferring interface. The shaped outer surface of the neck base provides proper fitting of the LED lamp device into the lighting fixture, and provides a heat-transferring interface over substantially all of the outer surface of the neck base, to dissipate heat away from the LED module. Aluminum material provides high thermal conductivity, light weight, availability, and low cost.

Claims

1. A light emitting diode (LED)-based lamp fixture securable to a structure having an electrical power source, comprising:

1) a collar having an annular wall and a base securable to the structure,

2) an LED lamp device comprising a neck base having an annular wall having a shaped outside surface that is placed into direct surface contact with the inner surface of the annular wall of the collar, to establish a heat-transferring interface between the LED lamp device and the collar, and having a distal end, and

3) an LED module comprising at least one LED disposed at the distal end of the LED lamp device

wherein the LED lamp device comprises a neck base having the shaped outside surface, and a lamp head moveably affixed to the distal end of the neck base, having formed therein a first recess to receive the LED module and a second recess formed to a depth less than the depth of the first recess, and being registered over the first recess, and further comprising a transparent lens disposed in the second recess.

2. A method for retrofitting an existing lamp fixture to replace a threaded lamp socket with an LED-based lamp assembly, the lamp fixture having a collar having an annular wall with an inner wall surface, and a base to which the threaded lamp socket is secured for attaching the lamp fixture to a structure, and for communicating electrical power from an electrical power source to the threaded socket lamp, the method comprising the steps of:

a. removing the threaded lamp socket from the collar;

b. providing an LED lamp device having an annular wall having a shaped outside annular surface and an LED module, wherein the outside surface of the annular wall has a first surface portion that is substantially cylindrical about a centerline of the device, and a second surface portion that has at least one frustoconical surface that tapers toward the centerline;

c. affixing the LED lamp device to the lamp fixture, wherein the first portion and the second portion are placed inside the collar and at least a portion of the shaped outside annular surface is placed into direct surface contact with the inner surface of the annular wall of the collar, to establish a heat-transferring interface between the annular wall of the lamp device and the collar, and

d. connecting the electrical power source to the LED module.

3. A method for retrofitting an existing lamp fixture to replace a threaded lamp socket with an LED-based lamp assembly, the lamp fixture having a collar having an annular wall with an inner wall surface, and a base to which the threaded lamp socket is secured for attaching the lamp fixture to a structure, and for communicating electrical power from an electrical power source to the threaded socket lamp, the method comprising the steps of:

a. removing the threaded lamp socket from the collar;

b. providing an LED lamp device having an annular wall having a shaped outside annular surface and an LED module, the LED lamp device comprises a neck base having the shaped outside surface, and a lamp head moveably affixed to the distal end of the neck base, having formed therein the first recess to receive the LED module;

c. affixing the LED lamp device to the lamp fixture, wherein the shaped outside annular surface is placed into direct surface contact with the inner surface of the annular wall of the collar, to establish a heat-transferring interface between the annular wall of the lamp device and the collar, and

d. connecting the electrical power source to the LED module.

4. A lamp fixture securable to a structure having an electrical power source, comprising:

1) a collar having an annular wall and a base securable to the structure;

2) a shade having a frustum extending from a distal end of the collar, where the shade is at least partially in contact with freely-flowable air for increased heat dissipation;

3) a replaceable lamp device comprising a neck base having an annular wall having a shaped outside surface that is placed into direct surface contact with an inner surface of the annular wall of the collar, to establish a heat-transferring interface between the lamp device and the collar to dissipate heat through the shade, and having a distal end; and

4) a light module comprising at least one light source disposed at the distal end of the lamp device;

wherein the lamp device further has a first recessed level formed into the distal end to receive the light module and the first recessed level has an elongated slot having a length and a width sufficiently sized to allow passing therethrough the light module, and having at least one secondary slot extending transversely from a middle portion along the length of the elongated slot.

5. A lamp fixture securable to a structure having an electrical power source, comprising:

a collar having an annular wall and a base securable to the structure;

a lamp device comprising a neck base having an annular wall having a shaped outside surface that is placed into direct surface contact with an inner surface of the annular wall of the collar, to establish a heat-transferring interface between the lamp device and the collar, and having a distal end;

a light module comprising at least one light source disposed at the distal end of the lamp device; and

wherein the lamp device further comprises a power unit connected to the electrical power source and a control unit for the light module, where the power unit and control unit are in sufficient thermal communication with the direct surface contact to transfer heat generated in the power unit and control unit;

wherein the lamp device further has a first recessed level formed into the distal end to receive the light module and the first recessed level has an elongated slot having a length and a width sufficiently sized to allow passing therethrough the light module, and having at least one secondary slot extending transversely from a middle portion along the length of the elongated slot.