LED lamp with an interior electrical connection

• US 9,518,704 B2
• Filed: 02/25/2014
• Issued: 12/13/2016
• Est. Priority Date: 02/25/2014
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Reier, Bart P.
• Primary Examiner(s): Mai, Anh
• Assistant Examiner(s): HORIKOSHI, STEVEN Y
• Application Number:
  US14/189,330
• Publication Number:
  US 20150240998A1
• Time in Patent Office: 1,022 Days
• 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: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 19/003 Fastening of light source holders, e.g. of circuit boards or substrates holding light sources
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 29/77 with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section

Abstract

An LED lamp includes an enclosure and a base. LEDs are mounted on a first portion of a substrate and an electrical contact is mounted on a second portion of the substrate. The LEDs emit light from the enclosure when energized through an electrical path from the base. A heat sink conducts heat to the ambient environment. The first portion of the substrate is mounted on an outside surface of a tower that extends into the enclosure. The second portion of the substrate is located inside of the tower. An extension is electrically coupled to the base and includes a second electrical contact that is electrically coupled to the first electrical contact.

Claims

1. A lamp comprising:

at least one LED mounted on a submount operable to emit light through an at least partially optically transmissive enclosure when energized through an electrical path from a base, the submount comprising electrical conductors and a dielectric material, the electrical conductors forming at least one anode and at least one cathode for mounting the at least one LED and at least one first electrical contact pad to electrically couple the at least one LED to the electrical path;

a tower located within the enclosure and extending in an axial direction, the tower comprising an interior and an exterior in communication with one another through an aperture in the tower, wherein at least a first portion of the submount containing the at least one anode and at least one cathode is located on the exterior of the tower and a second portion of the submount containing the at least one first electrical contact pad extends through the aperture and into the interior of the tower; and

electrical circuitry on aboard, the board extending into the interior of the tower, the submount being electrically coupled to the electrical circuitry at the at least one first electrical contact pad by an electrical coupling, the electrical coupling being in the interior of the tower and within the enclosure, where the electrical circuitry and the electrical conductors on the submount are in the electrical path.

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

3. The lamp of claim 1 wherein an extension extends from the base and comprises at least one second electrical contact that is electrically coupled to the at least one first electrical contact.

4. The lamp of claim 3 wherein one of the at least one first electrical contact and the at least one second electrical contact is biased into engagement with the other one of the at least one first electrical contact and the at least one second electrical contact.

5. The lamp of claim 4 wherein the one of the at least one first electrical contact and the at least one second electrical contact is resiliently deformable.

6. The lamp of claim 5 wherein the at least one first electrical contact and the at least one second electrical contact are located internally of the tower.

7. The lamp of claim 3 wherein the extension comprises a board where the board supports a lamp electronics in the base.

8. The lamp of claim 3 wherein the at least one second electrical contact is electrically coupled to a lamp electronics.

9. The lamp of claim 3 wherein the at least one first electrical contact and the at least one second electrical contact are electrically isolated in the tower from the external environment.

10. The lamp of claim 1 wherein the submount comprises one of a flex circuit, MCPCB and a lead frame.

11. The lamp of claim 1 wherein a plurality of LEDs are mounted on the first portion of the submount.

12. The lamp of claim 1 wherein the tower extends into the enclosure and supports the at least one LED at the optical center of the enclosure.

13. The lamp of claim 1 wherein a reflector reflects light from the at least one LED to an exit surface of the enclosure.

14. The lamp of claim 1 wherein the tower is thermally conductive and forms part of a heat sink for dissipating heat from the at least one LED.

15. The lamp of claim 14 wherein the heat sink comprises a heat dissipating portion that is at least partially exposed to the ambient environment.

16. A lamp comprising:

an at least partially optically transmissive enclosure having an opening;

a base;

a plurality of LEDs mounted on a submount, the submount comprising electrical conductors and a dielectric material, the electrical conductors forming at least one anode and at least one cathode for mounting the at least one LED on a first portion of the submount and a first electrical contact pad on a second portion of the submount to electrically couple the at least one LED to the electrical path, the plurality of LEDs being located in the enclosure and operable to emit light when energized through an electrical path from the base;

a heat sink secured to the enclosure at the opening comprising a heat dissipating portion that is at least partially exposed to the ambient environment and a heat conducting portion that comprising a tower that extends from the opening toward the interior of the enclosure and is located within the enclosure and is thermally coupled to the plurality of LEDs, the tower comprising an interior and an outside surface and an aperture extending from the interior and the outside surface, wherein the first portion of the submount is mounted on the outside surface of the heat conducting portion and the second portion of the submount extends through the aperture and into the interior, electrical circuitry extending from the base into the interior of the tower, the first electrical contact pad on the second portion of the submount being connected to the electrical circuitry within the interior.

17. The lamp of claim 16 comprising wherein

an extension electrically coupled to the base comprising a second electrical contact that is directly electrically coupled to the first electrical contact.

18. The lamp of claim 17 wherein one of the first electrical contact and the second electrical contact is biased into engagement with the other one of the first electrical contact and the second electrical contact.

19. The lamp of claim 17 wherein the one of the first electrical contact and the second electrical contact is resiliently deformable.

20. The lamp of claim 16 wherein a reflector reflects light from the plurality of LEDs to an exit surface of the enclosure.

21. The lamp of claim 20 wherein the reflector comprises a reflective surface that surrounds a portion of the heat sink.

22. The lamp of claim 16 wherein the heat sink is disposed between the enclosure and the base.

23. The lamp of claim 16 wherein the base comprises an Edison screw.

24. The lamp of claim 16 wherein the plurality of LEDs are disposed about the periphery of the heat sink in a band and face outwardly toward the enclosure to create a source of the light that appears as a glowing filament.

25. A lamp comprising:

an at least partially optically transmissive enclosure having an open end and

a base defining a longitudinal axis of the lamp extending from the base to the enclosure;

a flex circuit comprising an electrical conductor and a layer of dielectric material a plurality of LEDs connected to the electrical conductor, the plurality of LEDs being operable to emit light when energized through an electrical path from the base;

a heat sink secured to the open end and comprises a heat dissipating portion that is at least partially exposed to the ambient environment and a heat conducting portion that forms a tower that extends into the enclosure and has an outer periphery facing radially away from the longitudinal axis and an interior, the flex circuit mounted around the outer periphery of the tower such that the plurality of LEDs are disposed in approximately the center of the enclosure along the longitudinal axis of the lamp;

a first electrical contact extending from the base and a second electrical contact pad formed from the electrical conductor of the flex circuit and extending from the outer periphery into the interior of the heat conducting portion, the first electrical contact and the second electrical contact pad biased into engagement to create an electrical coupling with one another, the electrical coupling being electrically isolated inside of the heat conducting portion and in the enclosure.