Light emitting diode light bulb and incandescent lamp conversion apparatus

• US 9,140,413 B2
• Filed: 03/14/2014
• Issued: 09/22/2015
• Est. Priority Date: 03/02/2011
• Status: Active Grant

• Current Assignee: Texas Instruments, Inc.
• Original Assignee: Texas Instruments, Inc.
• Inventors: Aliberti, James
• Primary Examiner(s): Green, Tracie Y
• Application Number:
  US14/211,385
• Publication Number:
  US 20140240984A1
• Time in Patent Office: 557 Days
• Field of Search: 362/294, 362/249.02, 313/46, 313/318.04, 315/159, 315/185.R, 315/362
• US Class Current: 1/1
• 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: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/713 in direct thermal and mechanical contact of each other to form a single system
• 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: F21Y 2105/00 Planar light sources
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like 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 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: F21Y 2115/15 Organic light-emitting diodes [OLED]
• CPC Class Codes: H01R 13/00 Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
• 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

Apparatus and methods separate the functions of light emission, heat dissipation, and power conversion in LED lighting. Doing so may facilitate cost-effective LED lighting and enable the conversion of existing incandescent lamps to LED service. An LED light bulb includes a thermal path from LED dies to a thermal transfer contact having an externally available surface. The LED light bulb and an incandescent lamp adapter are consumer-installable in an incandescent lamp. A heat spreader component of the lamp adapter contacts the thermal transfer contact of the LED light bulb to dissipate heat originating at the LED dies. A lamp adaptable LED power supply plugs into a standard AC power outlet and includes a receptacle to accept insertion of a lamp cord plug to deliver power to the LED light bulb. A lock-in safety device prevents retraction of the lamp cord plug from the LED power supply once inserted.

Claims

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

a least one LED package mounted on a substrate, the LED package to include an LED die;

at least one thermal conductor coupled to the LED die to transfer heat away from the LED die; and

a thermal transfer contact thermally coupled to the thermal conductor, at least one surface of the thermal transfer contact configured to thermally contact a heat sink external to the LED light bulb.

2. The LED light bulb of claim 1, further comprising:

a base to support the LED light bulb in a socket and to provide electrical conductors to deliver power to the LED packages; and

a light-transmissive envelope extending from at least one of the base or the thermal transfer contact to surround and protect the LED package and to be used to grasp the LED light bulb during installation.

3. The LED light bulb of claim 2, the base configured as at least one of an Edison screw base less than 26 millimeters in diameter at the envelope (E26), a bayonet base, or a base with at least one protruding prong to make electrical contact with a corresponding receptacle at the socket.

4. The LED light bulb of claim 2, the thermal transfer contact formed in the shape of a band at a perimeter of the LED light bulb.

5. The LED light bulb of claim 4, the LED package-carrying substrate affixed around an inner circumference of the thermal transfer band.

6. The LED light bulb of claim 2, the thermal transfer contact configured to provide an electrical connection between the LED package and at least one of the base or the external heat sink.

7. The LED light bulb of claim 2, the base further comprising:

a center electrical contact situated at the bottom of the base and electrically isolated from the base to provide an electrical connection from an external power source to the LED package.

8. The LED light bulb of claim 1, the LED die manufactured according to at least one of an organic LED process, a polymer LED process, a quantum dot LED process, a half-cycle AC LED process, or a process incorporating electroluminescence.

9. The LED light bulb of claim 1, the package-carrying substrate comprising at least one of a rigid circuit board, a flex circuit, or a heat sink to include at least two electrically conductive portions, each portion electrically isolated from the other portion.

10. The LED light bulb of claim 1, the LED package-carrying substrate affixed around a cylindrical heat sink thermally coupled to the thermal transfer contact.

11. The LED light bulb of claim 1, the LED package-carrying substrate affixed around an ellipsoidally-shaped heat sink, a cylindrical extension of the heat sink thermally coupled to the thermal transfer contact.

12. An LED light bulb lamp adapter, comprising:

an adapter base to fit to an incandescent light bulb socket and to accept an LED light bulb; and

a heat spreader mechanically coupled to the adapter base for support and capable of thermal coupling to a thermal transfer contact associated with the LED light bulb, the heat spreader to sink and dissipate heat from the LED light bulb when the LED light bulb is operating in the adapter base.

13. The LED light bulb lamp adapter of claim 12, a male portion of the adapter base configured as at least one of an Edison screw 26 millimeter base (USA standard E26) or an Edison screw 27 millimeter base (European standard E27), and a female portion of the adapter base configured to accept at least one of an Edison screw base less than 26 millimeters in diameter (E26) associated with the LED light bulb, a bayonet base, or an LED light bulb base with at least one protruding prong to make electrical contact with a corresponding receptacle at the internal portion of the adapter base.

14. The LED light bulb lamp adapter of claim 12, the heat spreader formed as a skirt surrounding the adapter base.

15. An incandescent-to-LED lamp conversion kit, comprising:

a light emitting diode (LED) light bulb including at least one LED package mounted on a substrate to support an LED die, at least one thermal conductor coupled to the LED die to transfer heat away from the LED die, and a thermal transfer contact thermally coupled to the thermal conductor, at least one surface of the thermal transfer contact configured to thermally contact a heat sink external to the LED light bulb;

an LED light bulb lamp adapter including an adapter base configured for installation in an incandescent light bulb socket to accept the LED light bulb and a heat spreader mechanically coupled to the adapter base for support, the heat spreader capable of thermal coupling to the thermal transfer contact to sink and dissipate heat from the LED light bulb when the LED light bulb is operating in the adapter base; and

a lamp adaptable LED power supply assembly including a power supply module capable of electrical connection to an electrical outlet, the power supply module adapted to utilize AC current from the electrical outlet and to provide electrical power appropriate to at least one LED component of the LED light bulb, an electrical receptacle component of the power supply module to accept electrical contact prongs associated with a lamp cord plug, and a lock-in device to couple to the lamp cord plug and to the power supply module to prevent retraction of the lamp cord plug from the power supply module.