Method of assembling a lighting device with flexible circuits having light-emitting diodes positioned thereon

• US 9,464,788 B2
• Filed: 08/16/2013
• Issued: 10/11/2016
• Est. Priority Date: 08/16/2013
• Status: Active Grant

• Current Assignee: Lighting Science Group Corporation (Pegasus Capital Advisors, L.P.)
• Original Assignee: Lighting Science Group Corporation (Pegasus Capital Advisors, L.P.)
• Inventors: Boomgaarden, Mark Penley, Romeu, Ricardo, Holland, Eric
• Primary Examiner(s): Kim, Paul D
• Application Number:
  US13/969,090
• Publication Number:
  US 20150047186A1
• Time in Patent Office: 1,152 Days
• Field of Search: 298/32
• 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 9/238 Arrangement or mounting of circuit elements integrated in the light source
• CPC Class Codes: F21V 14/02 by movement of light sources in vehicle head lamps F21S41/657
• CPC Class Codes: F21V 23/006 the substrate being distinct from the light source holder
• CPC Class Codes: F21V 29/506 of globes, bowls or cover glasses
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/78 with helically or spirally arranged fins or blades
• 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 31/03 with provision for venting for vehicle head lights F21S45/33; for vehicle rear lights F21S41/192
• CPC Class Codes: F21Y 2107/40 on the sides of polyhedrons, e.g. cubes or pyramids
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.

Abstract

A method of assembling a lighting device that has a base, an optic defining an optical chamber, a driver circuit positioned in electrical communication with the base, and a flexible circuit board positioned within the optical chamber along and generally circumscribing a longitudinal axis of the optical chamber and in electrical communication with the driver circuit. The flexible circuit board may comprise a plurality of longitudinal sections. Each longitudinal section may comprise a first inclined section, a second inclined section, and a plurality of light-emitting diodes (LEDs). The first inclined section may be positioned in the direction of the base relative to the second inclined section. The lighting device may further include a longitudinal translation device to translate longitudinally part of the flexible circuit board.

Claims

1. A method of assembling a lighting device having a base, an optic having an inner surface defining an optical chamber, a structural member, a flexible circuit board having a plurality of LEDs positioned thereupon and being fixedly attached at a first end to the structural member, a longitudinal translation device configured to translate longitudinally a second end of the flexible circuit board, and a driver circuit, the method comprising the steps of:

positioning the structural member within the optical chamber;

then

attaching the flexible circuit board to the structural member;

then

positioning the flexible circuit board in a collapsed position;

then

disposing the flexible circuit board within the optical chamber by passing the flexible circuit board through an aperture of the optic;

then

transitioning the flexible circuit board into an expanded position by operating the longitudinal translation device;

then

attaching the base to the optic; and

then

positioning the driver circuit in electrical communication with the base.

2. The method of claim 1 further comprising orienting the plurality of LEDs to emit light in a direction that results in the lighting device being adapted to emit light in a selected distribution.

3. The method of claim 1 wherein the structural member is integrally formed with the optic.

4. The method of claim 1 wherein the longitudinal translation device has a generally spiraled configuration;

wherein the longitudinal translation device interfaces with the structural member; and

wherein the second end of the flexible circuit board is translated longitudinally by turning the longitudinal translation device.

5. The method of claim 1 wherein the flexible circuit board comprises a plurality of longitudinal sections, each longitudinal section comprising a first inclined section and a second inclined section;

wherein each of the first and second inclined sections have associated therewith an LED of the plurality of LEDs; and

wherein an orientation of the LED associated with each of the first and second inclined sections may be altered by operation of the longitudinal translation device;

the method further comprising the step of operating the longitudinal translation device so as orient the LEDs associated with the first and second inclined sections to emit light in a direction that results in the lighting device being adapted to emit light in a selected distribution.

6. The method of claim 1 wherein the flexible circuit board is provided in a substantially flat configuration;

and wherein the step of positioning the flexible circuit board in the collapsed position comprises folding the flexible circuit board so as to form a generally prismatic structure.

7. The method of claim 6 wherein the step of folding the flexible circuit board comprises folding the flexible circuit board so as to define a plurality of longitudinal sections.

8. The method of claim 7 wherein the step of folding the flexible circuit board comprises folding each of the longitudinal sections so as to define a first inclined section and a second inclined section.

9. The method of claim 1 wherein the flexible circuit board is formed into a generally cylindrical structure.

10. The method of claim 1 wherein the flexible circuit board defines a bounded region of the optical chamber;

the method further comprising the step of positioning the driver circuit within the bounded region.

11. The method of claim 1 wherein the driver circuit is included on the flexible circuit board.

12. The method of claim 1 wherein the optic comprises an distal section and a proximal section;

wherein the proximal section is configured to be attachable to the distal section; and

wherein the aperture of the optic is defined by an opening of the distal section where the proximal section is not attached to the distal section;

the method further comprising the step of attaching the proximal section to the distal section.