Heat removal design for LED bulbs

• US 8,853,921 B2
• Filed: 08/27/2013
• Issued: 10/07/2014
• Est. Priority Date: 05/02/2006
• Status: Expired due to Fees

• Current Assignee: Switch Bulb Company, Inc.
• Original Assignee: Switch Bulb Company, Inc.
• Inventors: Lenk, Ronald J., Lenk, Carol, Chandler, Daniel, Galla, Matthew
• Primary Examiner(s): RALEIGH, DONALD L
• Application Number:
  US14/011,636
• Publication Number:
  US 20140167592A1
• Time in Patent Office: 406 Days
• US Class Current: 313/46
• 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 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21V 29/58 characterised by the coolants
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

An LED bulb having bulb-shaped shell and thermally conductive fluid or gel within the shell. The bulb includes at least one LED within the shell. The bulb includes at least one LED within the shell and a base. The base can be configured to fit within an electrical socket and can include a series of screw threads and a base pin, wherein the screw threads and base pin are dimensioned to be received within a standard electrical socket. Alternatively, the base can be configured to fit within a suitable electric socket.

Claims

1. A light emitting diode (LED) bulb comprising:

a shell;

a thermally conductive liquid in contact with the shell;

a plurality of LEDs thermally connected to the thermally conductive liquid, wherein the thermally conductive liquid and the shell are the only means to transfer heat generated by the plurality of LEDs;

a base, wherein the base is configured to receive electrical power; and

a support extending into the shell, wherein the plurality of LEDs is connected to the support.

2. The LED bulb as set forth in claim 1, further comprising a power source connected to the plurality of LEDs, and wherein the power source is compatible with pre-existing power sources, permitting the bulb to be used in pre-existing fixtures.

3. The LED bulb as set forth in claim 1, wherein the plurality of LEDs is thermally connected to the liquid through a shell-wall.

4. The LED bulb as set forth in claim 1, wherein the liquid is static.

5. The LED bulb as set forth in claim 1, wherein the liquid gels when exposed to air.

6. The LED bulb as set forth in claim 1, wherein the liquid is mineral oil.

7. The LED bulb as set forth in claim 1, wherein the liquid is water.

8. The LED bulb as set forth in claim 1, further comprising a plurality of bubbles within the liquid, wherein the bubbles are configured to disperse the light from the plurality of LEDs.

9. The LED bulb as set forth in claim 1, further comprising a dye added to the liquid, wherein the dye shifts the light of an LED in the plurality of LEDs from a first color spectrum to a second color spectrum.

10. The LED bulb as set forth in claim 1, further comprising a dye added to the shell, wherein the dye shifts the light of an LED in the plurality of LEDs from a first color spectrum to a second color spectrum.

11. The LED bulb as set forth in claim 1 wherein the plurality of LEDs is configured to emit light through the thermally conductive liquid and the shell.

12. The LED bulb as set forth in claim 1, wherein the LEDs are positioned proximate the middle of the interior volume of the shell.

13. A light emitting diode (LED) bulb comprising:

a shell;

a thermally conductive liquid within the shell, wherein the thermally conductive liquid is thermally connected to the shell;

a plurality of LEDs thermally connected to the thermally conductive liquid, wherein the thermally conductive liquid and the shell are the only means to transfer heat generated by the plurality of LEDs;

a base, wherein the base is configured to receive electrical power; and

a support within the shell, wherein the plurality of LEDs is connected to the support.

14. The LED bulb as set forth in claim 13, further comprising a power source connected to the plurality of LEDs, and wherein the power source is compatible with pre-existing power sources, permitting the bulb to be used in pre-existing fixtures.

15. The LED bulb as set forth in claim 13 wherein the plurality of LEDs is configured to emit light through the thermally conductive liquid and the shell.

16. A method of manufacturing a light emitting diode (LED) bulb comprising:

creating a shell;

at least partially filling the interior of the shell with a thermally conductive liquid, wherein the thermally conductive liquid is in contact with the shell;

installing a plurality of LEDs on a support;

inserting the support with the LEDs within the shell; and

electrically connecting the plurality of LEDs to a base;

wherein the plurality of LEDs are thermally connected to the thermally conductive liquid, wherein the thermally conductive liquid and the shell are the only means to transfer heat generated by the plurality of LEDs.

17. The method as set forth in claim 16, further comprising installing a power source for the plurality of LEDs within the bulb, and wherein the power source is compatible with pre-existing power sources, permitting the bulb to be used in preexisting fixtures.

18. The method as set forth in claim 16, wherein installing the plurality of LEDs within the shell comprises:

mounting the plurality of LEDs on the support; and

installing the support within the bulb, wherein the plurality of LEDs is within the shell after the support is installed.

19. The method as set forth in claim 16, wherein the plurality of LEDs is configured to emit light through the thermally conductive liquid and the shell.

20. The method as set forth in claim 16, wherein the LEDs are positioned proximate the middle of the interior volume of the shell.