Lamp device and method to retrofit a lighting fixture

• US 7,845,832 B2
• Filed: 05/06/2008
• Issued: 12/07/2010
• 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:
  US12/115,849
• Publication Number:
  US 20080278956A1
• Time in Patent Office: 945 Days
• Field of Search: 362/249, 362/252, 362/294, 362/345, 362/373, 362/545, 362/800, 362/647, 362/649, 362/650, 362/249.01, 362/249.02, 362/246, 362/247
• 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 an incandescent or metal halide lamp, to use with another 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 lighting 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;

3) a replaceable lamp comprising an annular wall and a distal end extending from the annular wall, the annular wall having a shaped outside surface in direct surface contact with an inner surface of the annular wall of the collar, to establish a heat-transferring interface between the lamp and the collar to dissipate heat through the shade, the lamp configured to be insertable in the fixture without requiring removal of the collar or shade;

4) a light module comprising at least one light source disposed at the distal end of the lamp, wherein the collar need not conduct electricity to cause light to emit from the at least one light source.

2. The fixture according to claim 1 wherein the collar is made of a material having a thermal conductivity of at least 50 W/mK.

3. The fixture according to claim 1 wherein the lamp further has a first recessed level formed into the distal end to receive the light module.

4. The fixture according to claim 3 wherein 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. The fixture according to claim 1 the outside surface of the lamp annular wall having a first surface portion that is substantially cylindrical about a centerline of the lamp, and a second surface portion that has at least one frustoconical surface that tapers toward the centerline.

6. The fixture of claim 1, wherein the light source comprises an LED.

7. The fixture according to claim 6, wherein a power unit, a control unit, and the LED are mounted on a printed circuit board within the lamp.

8. The fixture according to claim 1, wherein the lamp further comprises a power unit and a control unit.

9. The fixture according to claim 1, wherein the light module comprises a reflective coverplate.

10. The fixture of claim 1 wherein the heat from the light module is in direct thermal communication to the collar via the lamp annular wall.

11. A lamp for retrofitting into a conventional lamp fixture that has a collar that has a base, an annular outer wall extending out from the base, and a shade extending from a distal end of the collar the lamp comprising an annular wall and a distal end extending from the annular wall, the annular wall defining an outermost perimeter of the lamp and having a shaped outside surface that is placed into direct surface contact with an inner surface of the annular outer wall of the collar, to establish a heat-transferring interface between the lamp and the collar, and the distal end of the lamp configured to receive a light module comprising at least one light source, wherein the collar need not conduct electricity to cause light to emit from the at least one light source.

12. The lamp according to claim 11, made from a material having a heat transfer coefficient of at least 50 W/mK.

13. The lamp according to claim 11, further having a first recessed level formed into the distal end to receive the light module.

14. The lamp according to claim 11 wherein the outside surface of the annular wall has a first surface portion that is substantially cylindrical about a centerline of the lamp, and a second surface portion that has at least one frustoconical surface that tapers toward the centerline.

15. The lamp of claim 11, wherein the light source comprises an LED.

16. The lamp according to claim 15, wherein a power unit, a control unit, and the LED are mounted on a printed circuit board within the lamp device.

17. The lamp according to claim 11, wherein the lamp comprises a power unit and a control unit.

18. The lamp according to claim 11, wherein the light module comprises a reflective coverplate.

19. The lamp of claim 11 wherein the heat from the light module is in direct thermal communication to the collar via the lamp annular wall.

20. A method for retrofitting an existing lighting fixture mounted to a structure with a lamp, the fixture having a collar having an annular wall with an inner wall surface, and a base for attaching the lamp fixture to a structure, the method comprising the steps of:

a. providing a lamp having an annular wall and a distal end extending from the annular wall, the annular wall having a shaped outside annular surface and a light module disposed at the distal end;

b. affixing the lamp to the fixture, wherein the shaped outside annular surface is placed into direct surface contact with the inner wall surface of the annular wall of the collar while the collar is mounted to the structure, to establish a heat-transferring interface between the lamp and the collar, wherein the collar need not conduct electricity to cause light to emit from the light module.

21. The method according to claim 20 wherein the lamp is made from a material that has a heat transfer coefficient of at least 50 W/mK.

22. The method according to claim 20 wherein the outside surface of the annular wall has a first surface portion that is substantially cylindrical about a centerline of the lamp, and a second surface portion that has at least one frustoconical surface that tapers toward the centerline.

23. The method of claim 20, wherein the connecting comprises connecting the electrical power source to the light module to provide power to an LED.

24. The method of claim 20 wherein the electrical power source is connected to a power unit on a printed circuit board within the light module.

25. The method of claim 20 wherein step b places the heat from the light module is in direct thermal communication to the collar via the lamp annular wall.

26. A lighting fixture comprising:

1) a collar having an annular wall, a base and a shade extending from a distal end of the collar;

2) a replaceable lamp comprising an annular wall and a distal end extending from the annular wall, the annular wall having a length being circumscribed along its entirety by the collar and having a shaped outside surface along at least a portion of the length in direct surface contact with an inner surface of the annular wall of the collar to establish a heat-transferring interface between the lamp and the collar to dissipate heat through the shade; and

3) a light module comprising at least one light source disposed at the distal end of the lamp.

27. The fixture of claim 26 wherein the collar is made of a material having a thermal conductivity of at least 50 W/mK.

28. The fixture of claim 26 wherein the lamp further has a first recessed level formed into the distal end to receive the light module.

29. The fixture of claim 28 wherein 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.

30. The fixture of claim 26 the outside surface of the lamp annular wall having a first surface portion that is substantially cylindrical about a centerline of the lamp, and a second surface portion that has at least one frustoconical surface that tapers toward the centerline.

31. The fixture of claim 26, wherein the light source comprises an LED.

32. The fixture of claim 26 wherein the heat from the light module is in direct thermal communication to the collar via the lamp annular wall.

33. A lighting 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, the collar exposed to ambient air;

2) a shade having a frustum extending from a distal end of the collar;

3) a lamp comprising an annular wall and a distal end extending from the annular wall, the annular wall and distal end defining a cup, the annular wall having a shaped outside surface in direct surface contact with an inner surface of the annular wall of the collar, to establish a heat-transferring interface between the lamp and the collar to dissipate heat through the shade, the lamp configured to be insertable in the fixture without requiring removal of the collar or shade;

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

34. The fixture according to claim 33 wherein the collar is made of a material having a thermal conductivity of at least 50 W/mK.

35. The fixture according to claim 33 wherein the lamp further has a first recessed level formed into the distal end to receive the light module.

36. The fixture according to claim 35 wherein 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.

37. The fixture according to claim 33 the outside surface of the lamp annular wall having a first surface portion that is substantially cylindrical about a centerline of the lamp, and a second surface portion that has at least one frustoconical surface that tapers toward the centerline.

38. The fixture of claim 33, wherein the light source comprises an LED.

39. The fixture according to claim 38, wherein a power unit, a control unit, and the LED are mounted on a printed circuit board within the lamp.

40. The fixture according to claim 33, wherein the lamp further comprises a power unit and a control unit.

41. The fixture according to claim 33, wherein the light module comprises a reflective coverplate.

42. The fixture of claim 33 wherein the heat from the light module is in direct thermal communication to the collar via the lamp annular wall.

43. A lamp for retrofitting into a conventional lamp fixture that has a collar exposed to ambient air, the collar having a base, an annular outer wall extending out from the base, and a shade extending from a distal end of the collar the lamp comprising an annular wall and a distal end extending from the annular wall, the annular wall and distal end define a cup, the annular wall defining an outermost perimeter of the lamp and having a shaped outside surface that is placed into direct surface contact with an inner surface of the annular outer wall of the collar, to establish a heat-transferring interface between the lamp and the collar, and the distal end of the lamp configured to receive a light module comprising at least one light source.

44. The lamp according to claim 43, made from a material having a heat transfer coefficient of at least 50 W/mK.

45. The lamp according to claim 43, further having a first recessed level formed into the distal end to receive the light module.

46. The lamp according to claim 43 wherein the outside surface of the annular wall has a first surface portion that is substantially cylindrical about a centerline of the lamp, and a second surface portion that has at least one frustoconical surface that tapers toward the centerline.

47. The lamp of claim 43, wherein the light source comprises an LED.

48. The lamp according to claim 43, wherein the lamp comprises a power unit and a control unit.

49. The lamp according to claim 43, wherein the light module comprises a reflective coverplate.

50. The lamp according to claim 43, wherein a power unit, a control unit, and the LED are mounted on a printed circuit board within the lamp device.

51. The lamp of claim 43 wherein the heat from the light module is in direct thermal communication to the collar via the lamp annular wall.

52. A method for retrofitting an existing lighting fixture mounted to a structure with a lamp, the fixture having a collar exposed to ambient air and having an annular wall with an inner wall surface, and a base for attaching the lamp fixture to a structure, the method comprising the steps of:

a. providing a lamp having an annular wall and a distal end extending from the annular wall, the annular wall and distal end define a cup, the annular wall having a shaped outside annular surface and a light module disposed at the distal end;

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

53. The method according to claim 52 wherein the lamp is made from a material that has a heat transfer coefficient of at least 50 W/mK.

54. The method according to claim 52 wherein the outside surface of the annular wall has a first surface portion that is substantially cylindrical about a centerline of the lamp, and a second surface portion that has at least one frustoconical surface that tapers toward the centerline.

55. The method of claim 52, wherein the connecting comprises connecting the electrical power source to the light module to provide power to an LED.

56. The method of claim 52 wherein the electrical power source is connected to a power unit on a printed circuit board within the light module.

57. The method of claim 52 wherein step b places the heat from the light module is in direct thermal communication to the collar via the lamp annular wall.