LED lamp with LED board heat sink

• US 9,488,322 B2
• Filed: 04/23/2014
• Issued: 11/08/2016
• Est. Priority Date: 04/23/2014
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Athalye, Praneet, Progl, Curt
• Primary Examiner(s): COUGHLIN, ANDREW J
• Application Number:
  US14/259,232
• Publication Number:
  US 20150308628A1
• Time in Patent Office: 930 Days
• US Class Current: 1/1
• 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 9/233 specially adapted for generating a spot light distribution, e.g. for substitution of reflector lamps
• CPC Class Codes: F21V 23/002 Arrangements of cables or conductors inside a lighting device, e.g. means for guiding along parts of the housing or in a pivoting arm
• CPC Class Codes: F21Y 2103/33 annular
• CPC Class Codes: F21Y 2107/00 Light sources with three-dimensionally disposed light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A LED lamp includes an optically transmissive enclosure and a base connected to the enclosure. LEDs are mounted on a substrate for emitting light when energized though an electrical path from the base. The substrate and the LEDs are mounted outside of the enclosure for transmitting light from the plurality of LEDs into the enclosure.

Claims

1. A LED lamp comprising:

an enclosure having an exterior surface that is exposed to the ambient environment, the enclosure being at least partially optically transmissive;

a base connected to the enclosure;

an LED assembly comprising a plurality of LEDs for emitting light when energized though an electrical path from the base and an LED board where the plurality of LEDs are mounted on a mounting surface of the LED board, the LED assembly and the plurality of LEDs being mounted outside of the enclosure for transmitting light through the enclosure into the interior of the enclosure, the LED board having a second surface that is exposed to the ambient environment for transmitting heat from the plurality of LEDs and dissipating heat to the ambient environment where the mounting surface and the second surface are surfaces of the same physical component, wherein the plurality of LEDs are disposed in an optically transmissive channel formed in the enclosure, the channel defining a recess that substantially surrounds the light emitting portion of the plurality of LEDs such that the second surface is formed to conform to the curvature of and be coextensive with the exterior surface of the enclosure.

2. The lamp of claim 1 wherein the base comprises an Edison base.

3. The lamp of claim 1 wherein the plurality of LEDs are disposed about the periphery of the enclosure.

4. The lamp of claim 1 wherein the LED board comprises a thermally conductive material.

5. The lamp of claim 1 wherein the electrical path comprises an electrical conductor formed on the LED board.

6. The lamp of claim 1 wherein the LED board comprises one of a MCPCB, flex circuit and a lead frame.

7. The lamp of claim 1 wherein the outer dimensions of the lamp fall within the ANSI standards for an A19 bulb.

8. The lamp of claim 1 wherein the LED assembly is formed into a three-dimensional shape that comprises portions that are shaped to conform to the shape of the enclosure.

9. The lamp of claim 8 wherein the LED board is bent to form the three-dimensional shape.

10. The lamp of claim 1 further comprising a plurality of LED boards where each of the plurality of LED boards supports at least one LED.

11. The lamp of claim 10 wherein the plurality of LED boards are connected to one another by a support.

12. The lamp of claim 1 wherein the channel is disposed in front of and to the sides of the plurality of LEDs.

13. The lamp of claim 1 wherein the LED assembly is dimensioned to enclose the channel such that light is reflected by the LED assembly into the enclosure.

14. The lamp of claim 1 wherein the LED assembly is ring shaped.

15. The lamp of claim 1 wherein the LED assembly is located at the approximate center of the enclosure.

16. The lamp of claim 1 wherein the plurality of LEDs face at various angles relative to the longitudinal axis of the lamp.

17. The lamp of claim 1 wherein the lamp is a directional lamp comprising a reflective surface mounted in the enclosure and a lens defining an exit surface of the lamp, the LED board being mounted adjacent the reflective surface.

18. The lamp of claim 1 wherein the base contains at least a portion of the lamp electronics.

19. The lamp of claim 1 wherein an electrical conductor in the electrical path extends between the LED assembly and the base.

20. The lamp of claim 19 wherein the electrical conductor extends outside of the enclosure between the LED assembly and the base.

21. The lamp of claim 20 wherein the electrical conductor extends in a channel formed in the outside of the enclosure.

22. The lamp of claim 19 wherein the electrical conductor extends inside of the enclosure between the LED assembly and the base.

23. The lamp of claim 22 wherein the electrical conductor extends through a hole in the enclosure.

24. The lamp of claim 19 wherein the electrical conductor comprises a part of the LED assembly.

25. A LED lamp comprising:

an enclosure having an exterior surface that is exposed to the ambient environment, the enclosure being at least partially optically transmissive;

a base connected to the enclosure;

an LED assembly comprising a plurality of LEDs for emitting light when energized though an electrical path from the base and flexible circuit board where the plurality of LEDs are mounted on a mounting surface of the flexible circuit board, the LED assembly and the plurality of LEDs being mounted outside of the enclosure for transmitting light through the enclosure into the interior of the enclosure, the flexible circuit board having a second surface that is exposed to the ambient environment for transmitting heat from the plurality of LEDs and dissipating heat to the ambient environment where the mounting surface and the second surface are surfaces of the same physical component, wherein the plurality of LEDs are disposed in an optically transmissive channel formed in the enclosure, the channel defining a recess that substantially surrounds the light emitting portion of the plurality of LEDs such that the second surface is formed to conform to the curvature of and be coextensive with the exterior surface of the enclosure.