Flat LED lamp assembly

• US 8,882,297 B2
• Filed: 07/11/2012
• Issued: 11/11/2014
• Est. Priority Date: 02/09/2011
• Status: Expired due to Fees

• Current Assignee: Differential Energy Products, LLC
• Original Assignee: Differential Energy Products, LLC
• Inventors: Flaherty, Richard A., Burton, Christopher A., Ahrens, Phil
• Primary Examiner(s): Sawhney, Hargobind S
• Application Number:
  US13/546,959
• Publication Number:
  US 20120314414A1
• Time in Patent Office: 853 Days
• Field of Search: 362/184, 362/196, 362/197, 362/200, 362/202, 362/208, 362/219.17, 362/230, 362/231, 362/234, 362/249.01, 362/24, 362/9.02, 362/249.03, 362/249.11, 362/282, 362/287, 362/294, 362/372, 362/545, 362/429, 362/548, 362/549, 362/6, 362/12, 362/646, 362/647, 362/649, 362/650, 362/652, 362/800, 362/802, 313/45, 313/46, 313/318.01, 313/318.09, 313/499, 313/500, 439/10, 439/11, 439135-139, 439/220, 439/232, 439/237, 439240-244, 439253-257, 439/320, 439/339, 439/370, 439/447, 439/620.02, 439/620.22, 439/620.25, 439/699.2, 439/700, 439/7, 439/86, 439815-817, 439/824, 439/859
• US Class Current: 362/249.02
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• 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 9/90 Methods of manufacture
• CPC Class Codes: F21V 17/12 by screwing
• CPC Class Codes: F21V 19/0065 at least one conductive element acting as a support means, e.g. spring-mounted contact plate in a bayonet base
• CPC Class Codes: F21V 23/008 the casing being outside the housing of the lighting device
• CPC Class Codes: F21V 29/507 of means for protecting lighting devices from damage, e.g. housings
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/76 with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/357 specially adapted for retrofit LED light sources
• CPC Class Codes: H05B 45/395 Linear regulators
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]

Abstract

An LED-based lamp assembly with a driver assembly having a base portion rotatably engageable with the socket of a light fixture to make a first electrical contact with the light fixture. The driver assembly makes electrical contact with the light fixture. A lamp housing assembly operably connected to the driver assembly has a lamp housing connected to the driver assembly. The lamp housing is coupled to an integrated circuitry arrangement with at least one LED light thereon. The integrated circuitry arrangement is connected to, or is an integral part of, a heat sink that carries heat away from the substrate and/or LED light. The heat sink and the integrated circuitry arrangement have apertures hat allows heated air from the heat sink to pass therethrough and away from the LED light.

Claims

1. An LED-based lamp assembly for use with a light fixture having a socket portion, the lamp assembly comprising:

a driver assembly having a base portion rotatably engageable with the socket portion to make a first electrical contact with the light fixture, the driver assembly having an electrically conductive tip portion coupled to the base portion, the tip portion being engageable with the socket portion to make a second electrical contact with the light fixture; and

a lamp housing assembly connected to the driver assembly, the LED lamp assembly having a lamp housing connected to the driver assembly, the lamp housing having electrical contacts operatively connected to the driver assembly, the lamp housing assembly having a heat sink coupled to the lamp housing, the heat sink having a support portion and a plurality of fins coupled to the support portion and configured to form air columns between adjacent fins, the support portion having a plurality of first apertures therethrough in communication with the air columns, the lamp housing assembly having at least one LED circuitry layer having a plurality of second apertures therethrough and at least one LED light thereon, the LED circuitry layer being connected to the support portion of the heat sink, the second apertures being in alignment with the plurality of first apertures and in alignment with the air columns, the lamp housing assembly having a fan positioned adjacent to the heat sink with the heat sink positioned between the fan and the LED circuitry layer, the fan being positioned to move air through the air columns in the heat sink and through the plurality of first and second apertures to move a flow of heated air away from the LED circuitry layer, the lamp housing assembly being rotatable relative to the light fixture to adjust the angular position of the LED circuitry layer while maintaining the first and second electrical contacts between the driver assembly and the socket portion.

2. The assembly of claim 1 wherein lamp housing assembly is removeably connected to the driver housing assembly, the lamp housing assembly being removable from the driver housing assembly while the driver housing assembly is connected to the light fixture.

3. The assembly of claim 1 wherein the driver assembly has a first connection member with the first electrical contacts thereon, and the lamp housing has a second connection member that releasably mates with the first connection member, the second connection member having the second electrical contacts that engage the first electrical contacts when the first and second connection members are in mating engagement.

4. The assembly of claim 1 wherein the driver assembly is removeably connected to the lamp housing assembly, the driver assembly having a first quick connect portion, and the lamp housing having a second quick connect portion that releasably mates with the first quick connect portion.

5. The assembly of claim 1 wherein the electrically conductive tip portion is retractable relative to the base portion when in the second electrical contact.

6. The assembly of claim 1 wherein the lamp housing assembly is rotatable relative to the driver assembly.

7. The assembly of claim 1 wherein the lamp housing is rotatable relative to the driver assembly through a rotational range of approximately 90 degrees while maintaining electrical contact therebetween.

8. The assembly of claim 1 wherein the lamp housing assembly has an electrical interface board intermediate and electrically interfacing with the LED circuitry layer and the driver assembly.

9. The assembly of claim 1 wherein the LED circuitry layer is an integral portion of the heat sink.

10. The assembly of claim 1 wherein the LED circuitry layer is a substrate having integrated circuitry coupled to the LED light, and the substrate is attached to the support portion of the heat sink.

11. A lamp assembly for use with a light fixture having a socket, the lamp assembly comprising:

A driver assembly having a threaded base portion that screws into the socket, the driver assembly having an electrically conductive tip portion coupled to the base portion and positioned to electrically engage the socket when the base portion is being screwed into the socket portion, the driver assembly having driver housing with a first connection member spaced apart from the threaded base portion; and

A lamp housing assembly removeably and electrically connected to the driver assembly, the lamp housing assembly having a lamp housing with a second connection member that releasably mates with the first connection member, the lamp housing connected to a heat sink and an LED chip board mounted to the heat sink, wherein the LED chip board has a plurality of LED lights thereon and a plurality of first apertures therethrough, wherein the heat sink has a support portion coupled to the LED chip board, and the support portion having a plurality of second apertures therethrough, the second apertures being in axial alignment with the first apertures, the lamp housing assembly having an airflow device positioned to move airflow over the heat sink and through the first and second apertures to carry heat away from the LED chip board during operation of the lamp assembly, the LED chip board and heat sink being rotatable as a unit relative to the light fixture to adjust the angular position of the LED chip board while maintaining electrical engagement between the tip portion and the socket.

12. The assembly of claim 11 wherein the tip portion of the driver assembly is retractable relative to the base portion after the tip portion electrically engages the socket portion and before the base portion is fully screwed into the socket.

13. The assembly of claim 12 wherein airflow device is at least one fan, and the lamp housing assembly has an electrical interface board electrically interconnecting the driver assembly with the LED chip board, the LED lights, and the fan.

14. The assembly of claim 13 wherein the first connection member has first electrical contacts, and the second connection member has second electrical contacts that engage the first electrical contacts when the first and second connection members are in mating engagement.

15. The assembly of claim 13 wherein the heat sink has a plurality of contoured fins spaced apart from each other, the LED lights each being positioned on the LED chip board in alignment with at least one of the contoured fins.