Modular LED light bulb

• US 8,350,485 B2
• Filed: 03/28/2011
• Issued: 01/08/2013
• Est. Priority Date: 05/15/2009
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Bridgelux Incorporated
• Inventors: Hasnain, Ghulam
• Primary Examiner(s): A, Minh D
• Application Number:
  US13/073,726
• Publication Number:
  US 20110169407A1
• Time in Patent Office: 652 Days
• Field of Search: 315/291, 315/307, 315/312, 315/200.R, 315/185.R, 315/209.SC, 362/800
• US Class Current: 315/200.R
• CPC Class Codes: F21K 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• CPC Class Codes: F21K 9/238 Arrangement or mounting of circuit elements integrated in the light source
• CPC Class Codes: F21K 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21V 17/002 with provision for interchangeability, i.e. component parts being especially adapted to be replaced by another part with the same or a different function F21V17/10 takes precedence
• CPC Class Codes: F21V 17/164 the parts being subjected to bending, e.g. snap joints
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 23/0442 activated by means of a sensor, e.g. motion or photodetectors
• CPC Class Codes: F21V 23/0457 the sensor sensing the operating status of the lighting device, e.g. to detect failure of a light source or to provide feedback to the device
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/85 characterised by the material liquid coolants F21V29/56
• CPC Class Codes: F21V 29/90 Heating arrangements
• CPC Class Codes: F21V 3/12 the coatings comprising photoluminescent substances
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48137 the bodies being arranged next to each other, e.g. on a common substrate
• CPC Class Codes: H01L 2224/73265 Layer and wire connectors
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H05B 45/00 Circuit arrangements for operating light-emitting diodes [LED]
• CPC Class Codes: H05B 45/22 : using optical feedback

Abstract

An LED-based lighting device and method for making the same are disclosed. The lighting device includes an LED light source mounted on a heat sink, a power adaptor, and a controller. The power adaptor is configured to be interchangeable with a conventional incandescent bulb power adapter. The controller provides an average current to the LED light source when power is coupled to the device via the power adaptor. The average current causes the LED light source to generate light of a predetermined standard intensity that is substantially independent of variations in the LED light source from device to device. In one aspect of the invention, the LED light source includes a plurality of LEDs connected in series, the LEDs are bonded to the heat sink and connected to one another in series by wire bonds and to conducting traces on the heat sink.

Claims

1. An apparatus comprising:

a heat sink;

an LED light source mounted on said heat sink;

a power adapter configured to be interchangeable with a conventional bulb power adapter; and

a controller that provides an average current to said LED light source when power is coupled to said apparatus via said power adapter, said average current causing said LED light source to generate light of a predetermined standard intensity that is substantially independent of variations in said LED light source;

wherein said controller comprises an integrated circuit mounted on said heat sink.

2. The apparatus of claim 1 wherein said conventional bulb power adapter comprises a threaded base adapted to screw into a light socket adapter.

3. The apparatus of claim 1 wherein said LED light source comprises a plurality of LEDs connected in series, said LEDs being bonded to said heat sink and connected to one another in series by wire bonds.

4. The apparatus of claim 3 wherein two of said LEDs are connected to conducting traces on said heat sink.

5. The apparatus of claim 1 wherein said LED light source comprises an LED and a layer of phosphor that converts light from said LED to light of a different wavelength.

6. The apparatus of claim 1 further comprising an AC to DC converter that converts an AC voltage coupled to said power adapter to a DC power source that powers said controller.

7. The apparatus of claim 1 further comprising a first half-wave rectifier that converts an AC voltage coupled to said power adapter to a first half-wave rectified power source having a duty cycle that provides said predetermined light intensity when said first half-wave rectified power source is used to power said light source.

8. The apparatus of claim 7 wherein said first half-wave rectifier comprises a silicon-controlled rectifier having a control signal chosen to provide said predetermined light intensity, said control signal having a value that depends on a measured value of said light from said LED light source when said light source is operated on said heat sink.

9. The apparatus of claim 7 wherein said LED light source comprises first and second LEDs and wherein said first LED is powered by said first half-wave rectifier and said second LED is powered by a second half-wave rectifier having an output that is 180 degrees out of phase with said first half-wave rectified power source.

10. The apparatus of claim 1 wherein said heat sink is adapted for receiving any of a plurality of different light diffusing elements, each of said light diffusing elements being configured to diffuse and redirect light from said light source.

11. The apparatus of claim 10 further comprising a photodetector that measures an intensity of light in said diffusing element, said controller utilizing said measured light intensity to maintain said predetermined standard intensity.

12. The apparatus of claim 1 further comprising a globe that covers said LED light source, said globe comprising a layer of phosphor on a surface thereof.

13. The apparatus of claim 12 wherein said globe comprises a transparent shell and wherein said phosphor is deposited on a surface of said transparent shell.

14. The apparatus of claim 12 wherein said globe comprises an adapter for reversibly attaching said globe to said light source.

15. A method for providing a base element for use in constructing LED-based lighting devices, said method comprising:

providing a base element comprising

a heat sink;

an LED light source mounted on said heat sink;

a power adapter configured to be interchangeable with a conventional incandescent bulb power adapter; and

a base unit controller that provides an average current to said LED light source when power is coupled to said apparatus via said power adapter, said average current causing said LED light source to generate light;

connecting said base unit to a factory controller that includes a photodetector that measures light from said base unit;

causing said base unit controller to vary said average current through said LED light source while measuring an intensity of light generated by said LED light source utilizing said photodetector until a predetermined intensity of light is measured; and

storing information specifying said average current that caused said LED light source to generate said predetermined intensity of light, wherein said base unit controller provides said average current to said LED light source when power is coupled to said power adapter; and

wherein said base unit controller comprises an integrated circuit mounted on said heat sink.

16. The method of claim 15 wherein said base unit controller comprises an SCR and said information specifies a control signal for said SCR.

17. A lighting system comprising a base unit and a first detachable globe, said base unit comprising:

a heat sink;

an LED light source mounted on said heat sink, said LED light source generating light characterized by a first spectrum;

a power adapter configured to be interchangeable with a conventional bulb power adapter; and

a controller that provides an average current to said LED light source when power is coupled to said apparatus via said power adapter, said average current causing said LED light source to generate light of a predetermined standard intensity that is substantially independent of variations in said LED light source from one of said lighting systems to another of said lighting systems,

wherein said first detachable globe comprises a transparent shell having a first phosphor composition on or contained in said shell and an adapter for attaching said first detachable globe to said base unit, said phosphor composition converting a portion of said light from said LED light source to light having a second spectrum that is different from said first spectrum.

18. The system of claim 17 wherein said first detachable globe comprises a plastic and wherein said first phosphor composition comprises an organic phosphor dissolved in said plastic.