Solid state lamp using light emitting strips

• US 8,791,640 B2
• Filed: 11/19/2012
• Issued: 07/29/2014
• Est. Priority Date: 02/22/2011
• Status: Active Grant

• Current Assignee: Quarkstar LLC
• Original Assignee: Quarkstar LLC
• Inventors: Steele, Robert V., Lerman, Louis, York, Allan Brent, Dau, Wilson, Teng, Jacqueline, Lerman, George
• Primary Examiner(s): Owens, Douglas W
• Assistant Examiner(s): COOPER, JONATHAN G
• Application Number:
  US13/681,099
• Publication Number:
  US 20130077298A1
• Time in Patent Office: 617 Days
• Field of Search: 315/192, 362/231, 362/235, 362/240, 362/800, 257/88
• US Class Current: 315/185.R
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• 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 9/233 specially adapted for generating a spot light distribution, e.g. for substitution of reflector lamps
• CPC Class Codes: F21K 9/235 Details of bases or caps, i.e. the parts that connect the light source to a fitting; Arrangement of components within bases or caps F21K9/238 takes precedence
• CPC Class Codes: F21K 9/237 Details of housings or cases, i.e. the parts between the light-generating element and the bases; Arrangement of components within housings or cases F21K9/238 takes precedence
• CPC Class Codes: F21K 9/238 Arrangement or mounting of circuit elements integrated in the light source
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• 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: F21K 9/65 specially adapted for changing the characteristics or the distribution of the light, e.g. by adjustment of parts
• CPC Class Codes: F21S 4/20 with light sources held by or within elongate supports
• CPC Class Codes: F21V 13/14 the elements being filters or photoluminescent elements, reflectors and refractors
• CPC Class Codes: F21V 17/12 by screwing
• CPC Class Codes: F21V 17/14 Bayonet-type fastening
• CPC Class Codes: F21V 19/0025 the fastening means engaging the conductors of the light source, i.e. providing simultaneous fastening of the light sources and their electric connections
• CPC Class Codes: F21V 21/00 Supporting, suspending, or attaching arrangements for lighting devices F21V17/00, F21V19/00 take precedence; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q, stands for supporting apparatus or articles in general F16M11/00; Hand grips
• CPC Class Codes: F21V 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 29/10 Arrangement of heat-generating components to reduce thermal damage, e.g. by distancing heat-generating components from other components to be protected
• CPC Class Codes: F21V 29/505 of reflectors
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 3/00 : Globes; Bowls; Cover glasses with refracting properties F21V5/00; with reflecting properties F21V7/00; characterised by cooling arrangements F21V29/506
• CPC Class Codes: F21V 3/02 : characterised by the shape
• CPC Class Codes: F21V 5/10 : comprising photoluminescent material
• CPC Class Codes: F21V 7/00 : Reflectors for light sources characterised by cooling arrangements F21V29/505
• CPC Class Codes: F21V 7/06 : with parabolic curvature
• CPC Class Codes: F21V 9/00 : Elements for modifying spectral properties, polarisation or intensity of the light emitted, e.g. filters coloured shades F21V1/00; elements characterised by cooling arrangements F21V29/502
• CPC Class Codes: F21V 9/30 : Elements containing photoluminescent material distinct from or spaced from the light source shades F21V1/17; globes, bowls or cover glasses F21V3/08, F21V3/12; refractors F21V5/10; reflectors F21V7/26, F21V7/30; elements with provision for controlling the spectral properties or intensity F21V9/40
• CPC Class Codes: F21V 9/32 : characterised by the arrangement of the photoluminescent material
• CPC Class Codes: F21V 9/38 : Combination of two or more photoluminescent elements of different materials
• CPC Class Codes: F21Y 2101/00 : Point-like light sources
• CPC Class Codes: F21Y 2103/10 : comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2105/00 : Planar light sources
• CPC Class Codes: F21Y 2107/00 : Light sources with three-dimensionally disposed light-generating elements
• CPC Class Codes: F21Y 2107/20 : on convex supports or substrates, e.g. on the outer surface of spheres
• CPC Class Codes: F21Y 2107/30 : on the outer surface of cylindrical surfaces, e.g. rod-shaped supports having a circular or a polygonal cross section
• CPC Class Codes: F21Y 2107/90 : on two opposite sides of supports or substrates
• CPC Class Codes: F21Y 2115/10 : Light-emitting diodes [LED]
• CPC Class Codes: F21Y 2115/15 : Organic light-emitting diodes [OLED]
• CPC Class Codes: H01L 25/0753 : the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00 : Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 : Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 33/62 : Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls

Abstract

In one embodiment, an LED lamp has a generally bulb shape. The LEDs are low power types and are encapsulated in thin, narrow, flexible strips. The LEDs are connected in series in the strips to drop a desired voltage. The strips are affixed to the outer surface of a bulb form to provide structure to the lamp. The strips are connected in parallel to a power supply, which may be housed in the lamp. Since many low power LEDs are used and are spread out over a large surface area, there is no need for a large metal heat sink. Further, the light emission is similar to that of an incandescent bulb. In other embodiment, there is no bulb form and the strips are bendable to have a variety of shapes. In another embodiment, a light sheet is bent to provide 360 degrees of light emission. Many other embodiments are described.

Claims

1. A solid state lamp comprising:

a plurality of flexible strips, each of the flexible strips comprising a plurality of light emitting diodes (LEDs) and an end, the LEDs being connected to the end of the flexible strip;

a base structure having a plurality of connection locations, each connection location being configured to receive the end of a corresponding flexible strip and to provide drive current to the plurality of LEDs of the corresponding flexible strip; and

an electrical connector affixed to the base structure for connection to an external power source for providing the drive current to the flexible strips,

wherein electrical connections from each LED extend to the end of the flexible strip, and wherein the flexible strips are independently deformed into corresponding deformable resilient shapes that produce an illumination profile based on the deformable resilient shapes of the independently deformed flexible strips, the flexible strips being further deformable into alternative deformable resilient shapes with the end received by the base structure.

2. The solid state lamp of claim 1, wherein the flexible strips each comprise a layer of a metal sufficient configured to provide the flexible strips with resilience against relaxation from the deformed resilient shapes to non-deformed shapes.

3. The solid state lamp of claim 1, wherein the solid state lamp has a central

axis and the flexible strips are deformable between directions perpendicular to the central axis and parallel to the central axis.

4. The solid state lamp of claim 1, wherein each of the flexible strips comprises a longitudinal axis and the flexible strips are deformed about the longitudinal axis.

5. The solid state lamp of claim 1, wherein the flexible strips are laterally spaced apart.

6. The solid state lamp of claim 1, wherein a deformation of one or more flexible strips of the plurality of flexible strips is different from a deformation of other flexible strips of the plurality of flexible strips.

7. The solid state lamp of claim 1 wherein the plurality of connection locations is arranged such that the plurality of LEDs of the flexible strips emit light 360 degrees around the solid state lamp.

8. The solid state lamp of claim 1, wherein a first portion of the flexible strips are configured to emit a light emission pattern different from a second portion of the flexible strips.

9. The solid state lamp of claim 8, wherein the light emission pattern of the first portion of flexible strips is a substantially lambertian emission pattern, and the light emission pattern of the second portion of flexible strips is a substantially prescribed directional light emission pattern.

10. The solid state lamp of claim 1, further comprising an outer shell at least partially surrounding the plurality of flexible strips.

11. The solid state lamp of claim 10, wherein at least a portion of the outer shell is transparent.

12. The solid state lamp of claim 10, wherein at least a portion of the outer shell comprises a reflector to confine within the outer shell at least some of the light emitted by the LEDs.

13. The solid state lamp of claim 10, wherein at least a portion of the outer shell comprises a diffuser to diffuse at least some of the light emitted by the LEDs.

14. The solid state lamp of claim 1, wherein one or more flexible strips of the plurality of flexible strips comprises variable widths.

15. The solid state lamp of claim 14, wherein for a flexible strip of the flexible strips that has a varying width, a portion of the flexible strip adjacent to a second end opposing the end of the flexible strip is, at least in part, wider than a portion of the flexible strip adjacent to the end of the flexible strip, and wherein all of the LEDs of the flexible strip are distributed in the portion of the flexible strip adjacent to the second end.

16. The solid state lamp of claim 1, wherein each flexible strip comprises:

a first substrate having a first set of conductors; and

a second transparent substrate having a second set of conductors,

the plurality of LEDs being sandwiched between the first and second substrates, such that, without wires, a first portion of the first set of conductors connects to a first electrode of each of the LEDs, a second portion of the first set of conductors connects to a first portion of the second set of conductors, and a second portion of the second set of conductors connects to a second electrode of each of the LEDs, to provide power to the plurality of LEDs, and light emitted by the plurality of LEDs is transmitted through the second substrate.

17. The solid state lamp of claim 1, wherein each flexible strip comprises:

a first substrate having a top set of conductors formed on a top surface of the first substrate and a bottom set of conductors formed on a bottom surface of the first substrate, wherein the top surface opposes the bottom surface;

a second transparent substrate having a second set of conductors; and

a third transparent substrate having a third set of conductors,

a first portion of LEDs of the plurality of LEDs being sandwiched between the first and second substrates, such that, without wires, a first portion of the top set of conductors connects to a first electrode of each LED of the first portion of LEDs, a second portion of the top set of conductors connects to a first portion of the second set of conductors, and a second portion of the second set of conductors connects to a second electrode of each LED of the first portion of LEDs, to provide power to the first portion of LEDs, and light emitted by the first portion of LEDs is transmitted through the second substrate,

a second portion of LEDs of the plurality of LEDs being sandwiched between the first and second substrates, such that, without wires, a first portion of the bottom set of conductors connects to a first electrode of each LED of the second portion of LEDs, a second portion of the bottom set of conductors connects to a first portion of the third set of conductors, and a second portion of the third set of conductors connects to a second electrode of each LED of the second portion of LEDs, to provide power to the second portion of LEDs, and light emitted by the second portion of LEDs is transmitted through the third substrate.

18. The solid state lamp of claim 1, wherein

each LED of the plurality of LEDs comprises a first electrode coupled to a first surface of the LED and a second electrode coupled to a second surface of the LED, wherein the first surface opposes the second surface;

and

each flexible strip comprises;

a first transparent substrate having a first set of conductors; and

a second transparent substrate having a second set of conductors,

the plurality of LEDs being sandwiched between the first and second substrates, such that, without wires, a portion of the first set of conductors connects to the first electrode of a first LED of the plurality of LEDs, a second portion of the first set of conductors connects to the second electrode of a second LED of the plurality of LEDs, the second LED being adjacent to the first LED, a first portion of the second set of conductors connects to the second electrode of the first LED, and a second portion of the second set of conductors connects to the first electrode of the second LED, where light emitted by the first LED is transmitted through the first transparent substrate and light emitted by the second LED is transmitted through the second transparent substrate.

19. The solid state lamp of claim 1, wherein each LED is encapsulated in a wavelength conversion material.

20. The solid state lamp of claim 19, wherein the wavelength conversion material comprises phosphor to create an alternative composition of light wavelengths.

21. The solid state lamp of claim 1, further comprising a power converter, the power converter providing power to the end of each of the flexible strips of the plurality of flexible strips.

22. The solid state lamp of claim 21, further comprising a plurality of current sources connected to the power converter, wherein each current source is connected to the end of a corresponding flexible strip.

23. The solid state lamp of claim 1, wherein the electrical connector comprises a connector for an Edison type socket.

24. The solid state lamp of claim 1, wherein the base structure is configured to receive one or more flexible strips to connect to the base structure and to operate the solid state lamp with different combinations of flexible strips to generate a desired output from the solid state lamp.

25. The solid state lamp of claim 1, wherein the plurality of connection locations comprises at least four connection locations for supporting at least four flexible strips.

26. The solid state lamp of claim 1, wherein each of the flexible strips comprises a longitudinal axis and the flexible strips are independently aimed by at least one of rotation about the longitudinal axis or angular displacement about the end of the flexible strip.

27. The solid state lamp of claim 1, wherein the LEDs are connected in series.