Gas-discharge lamp replacement with passive cooling

• US 8,926,139 B2
• Filed: 04/29/2010
• Issued: 01/06/2015
• Est. Priority Date: 05/01/2009
• Status: Active Grant

• Current Assignee: Express Imaging Systems, LLC
• Original Assignee: Express Imaging Systems, LLC
• Inventors: Reed, William G., Renn, John O.
• Primary Examiner(s): CRAWFORD, JASON
• Application Number:
  US12/769,956
• Publication Number:
  US 20100277082A1
• Time in Patent Office: 1,713 Days
• Field of Search: 315117-118, 315/159, 315/307, 362/276, 362/294, 362/373, 362/800
• US Class Current: 362/294
• 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: F21V 23/04 the elements being switches safety devices F21V25/00
• CPC Class Codes: F21V 23/0442 activated by means of a sensor, e.g. motion or photodetectors
• CPC Class Codes: F21V 23/0478 by means of an image recording device, e.g. a camera
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/89 Metals
• CPC Class Codes: F21Y 2103/33 annular
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/10 Controlling the intensity of the light
• CPC Class Codes: H05B 45/385 using flyback topology
• CPC Class Codes: H05B 47/125 by using cameras
• CPC Class Codes: H05B 47/13 by using passive infrared detectors
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]
• CPC Class Codes: Y02B 20/40 Control techniques providing energy savings, e.g. smart controller or presence detection
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

An illumination device comprises a solid-state lighting device and a heat sink. The heat sink is configured to be attachable to a fixture for a gas-discharge lamp to retrofit existing gas-discharge fixtures. The heat sink is conductively thermally coupled to the solid-state lighting device to dissipate heat generated by the solid-state lighting device.

Claims

1. An illumination device, comprising:

a solid-state lighting device including at least one light-emitting diode (LED), an electronic ballast to regulate electrical power supplied to the LED, and a base plate on which the at least one LED and the electronic ballast are mounted;

a lamp base directly, selectively, and physically receivable by a socket disposed in a lighting fixture, the socket configured to accept the electrical coupling of a gas-discharge lamp; and

a heat sink having a plurality of fins;

wherein, the heat sink includes a number of fasteners that selectively, directly, and physically couple the heat sink to the lighting fixture such that, in use, the heat sink forms at least a portion of an exterior surface of the lighting fixture with at least a portion of the plurality of fins exposed to an ambient environment that is external to the exterior surface of the lighting fixture;

wherein the heat sink includes a contact plate in direct physical contact with and conductively thermally coupled to the base plate on which the at least one LED is mounted to dissipate a majority of heat generated by the solid-state lighting device via convective and/or radiant heat transfer with the ambient environment via the plurality of fins which are exposed to the ambient environment during use; and

wherein the heat sink couples to the lamp base via one or more flexible connectors.

2. The illumination device of claim 1 wherein the plurality of fins includes a plurality of die-cast fins.

3. The illumination device of claim 2 wherein the plurality of fins has a total exposed surface area equal to or greater than an area of 30 square centimeters per Watt (cm²/Watt) times a maximum Wattage rating of the lighting device, the total exposed surface area comprising a cumulative area of the surfaces of the fins that provide convective and/or radiative heat transfer.

4. The illumination device of claim 1 wherein the heat sink has a total exposed surface area sufficient to convectively and/or radiatively dissipate heat generated by the at least one LED to maintain a temperature on the base plate proximate where the at least one LED is located to be no more than 20 degrees Celsius (°

C.) above an ambient temperature.

5. The illumination device of claim 1 wherein the electronic ballast comprises a switch-mode flyback current regulator.

6. The illumination device of claim 1 wherein the solid-state lighting device further includes:

a light transmissive cover mountable on the base plate.

7. The illumination device of claim 6 wherein the light transmissive cover includes at least one optical refractor that directs light emitted from the at least one LED into a National Electrical Manufacturers Association (NEMA) butterfly pattern.

8. The illumination device of claim 6 wherein the light transmissive cover is at least optically refractive or optically reflective.

9. The illumination device of claim 1, further comprising:

a sensor switch device that senses an ambient characteristic indicative of a presence, the sensor switch device coupled to control operation of the solid-state lighting device based on the sensed ambient characteristic.

10. The illumination device of claim 9 wherein the sensing device comprises a motion activated sensor.

11. The illumination device of claim 9 wherein the sensor switch device comprises a passive infrared (PIR) detector.

12. The illumination device of claim 9 wherein the sensor switch device includes:

a solid-state camera operable to capture images of an area over a period of time; and

a controller coupled to process the captured images from the solid-state camera and control operation of the solid-state lighting device based on the captured images.

13. The illumination device of claim 9 wherein the sensor switch device controls an intensity of illumination by the solid-state lighting device based on the sensed ambient characteristic.

14. The illumination device of claim 1 wherein the contact plate is in direct physical contact with the base plate over a relatively large area of the base plate.

15. The illumination device of claim 1, wherein said base plate has a coupling face contacting the contact plate, and the electronic ballast is mounted on the coupling face, wherein the contact plate has one or more apertures to accommodate the mounted ballast.

16. The illumination device of claim 1, wherein the heat sink comprises a plurality of fins positioned perpendicular to and arranged concentrically around the contact plate, and conductively thermally coupled to said contact plate.

17. An illumination device, comprising:

a solid-state lighting device including at least one light-emitting diode (LED), an electronic ballast to regulate electrical power supplied to the LED, and a base plate on which the at least one LED and the electronic ballast are mounted;

a heat sink having a plurality of fins;

wherein the heat sink includes a number of fasteners that directly, physically, and selectively couple the heat sink to the lighting fixture such that, in use, the heat sink forms at least a portion of an exterior surface of the lighting fixture with at least a portion of the plurality of fins exposed to an ambient environment that is external to the exterior surface of the lighting fixture;

wherein the heat sink conductively thermally coupled to the base plate on which the at least one LED is mounted to dissipate heat generated by the solid-state lighting device via the plurality of fins which are exposed to the ambient environment during use; and

a lamp base coupled via a flexible coupling to the heat sink and coupled to the solid-state lighting device;

wherein the lamp base is directly, selectively, and physically receivable by a lamp socket disposed in the lighting fixture, the lamp socket configured to receive a gas-discharge lamp; and

wherein, in operation, the lamp base provides electrical power from power mains to the solid-state lighting device via one or more conductors included in the flexible coupling between the lamp base and the heat sink when the lamp base is received in the lamp socket that is electrically coupled to the power mains.

18. An illumination device, comprising:

a lighting device including;

a lamp base that is directly, selectively, and physically receivable in a lamp socket of a lighting fixture configured to receive a gas-discharge lamp to receive power through the lamp socket of the lighting fixture;

a plurality of solid-state light emitters;

an electronic ballast that regulates power supplied to the solid-state light emitters;

a base plate on which the solid-state light emitters and the electronic ballast are mounted; and

a heat sink having a plurality of fins;

wherein the heat sink includes at least one fastener that rigidly, directly, and physically couple the heat sink to the lighting fixture such that, in use, the heat sink forms at least a portion of an exterior surface of the lighting fixture with at least a portion of the plurality of fins exposed to an ambient environment that is external to the exterior surface of the lighting fixture;

wherein the heat sink includes a contact plate in direct physical contact with and conductively thermally coupled to the base plate to convectively and/or radiantly dissipate heat generated by the lighting device into an ambient environment via the plurality of fins which are exposed to the ambient environment during use; and

wherein the heat sink couples to the lamp base via at least one flexible coupling that, in use, transfers electrical power from the lamp socket of the lighting fixture to at least the electronic ballast.

19. The illumination device of claim 18 wherein the plurality of solid-state light emitters comprises a plurality of light-emitting diodes (LEDs).

20. The illumination device of claim 18 wherein the at least one fastener includes a plurality of latches.

21. The illumination device of claim 18 wherein the plurality of fins comprises a plurality of die-cast fins.

22. The illumination device of claim 18 wherein the plurality of fins comprises a plurality of stamped metal plates.

23. The illumination device of claim 18 wherein the heat sink has a total exposed surface area equal to or greater than an area of 30 square centimeters per Watt (cm²/Watt) times a maximum Wattage rating of the lighting device.

24. The illumination device of claim 18 wherein the heat sink has a total exposed surface area sufficient to dissipate heat generated by the lighting device to maintain a temperature on the base plate proximate the solid-state light emitter be no more than 20 degrees Celsius (°

C.) above an ambient temperature.

25. The illumination device of claim of claim 18, further comprising:

a control device controllingly coupled to the lighting device to control operation of the lighting device.

26. The illumination device of claim 25 wherein the control device comprises a motion sensor to detect motion.

27. The illumination device of claim 25 wherein the control device comprises a passive infrared (PIR) detector to detect heat.

28. The illumination device of claim 25 wherein the control device comprises:

a solid-state camera capturing images of an area; and

a processor coupled to receive and process the captured images from the solid-state camera and filter coupled to control operation of the solid-state lighting device based on the captured images.

29. The illumination device of claim 25 wherein the control device controls an intensity of illumination by the lighting device based on a sensed ambient characteristic.

30. The illumination device of claim 18, wherein the contact plate is in direct physical contact with the second end of the heat sink.