LED lighting device with cured structural support

• US 9,528,689 B2
• Filed: 03/13/2013
• Issued: 12/27/2016
• Est. Priority Date: 03/13/2013
• Status: Active Grant

• Current Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Original Assignee: Palo Alto Research Center, Inc. (Xerox Holdings Corp.)
• Inventors: Veres, Janos, Schmaelzle, Philipp, Paulson, Christopher, Pattekar, Ashish, Maeda, Patrick Yasuo
• Primary Examiner(s): Han, Jason Moon
• Assistant Examiner(s): ROJAS CADIMA, OMAR
• Application Number:
  US13/802,343
• Publication Number:
  US 20140268740A1
• Time in Patent Office: 1,385 Days
• Field of Search: 362/235
• 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 9/90 Methods of manufacture
• CPC Class Codes: F21V 1/00 Shades for light sources , i.e. lampshades for table, floor, wall or ceiling lamps
• CPC Class Codes: F21V 19/002 the fastening means engaging the encapsulation or the packaging of the semiconductor device
• CPC Class Codes: F21V 21/00 Supporting, suspending, or attaching arrangements for lighting devices F21V17/00, F21V19/00 take precedence; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q, stands for supporting apparatus or articles in general F16M11/00; Hand grips
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 3/049 Patterns or structured surfaces for diffusing light, e.g. frosted surfaces
• CPC Class Codes: F21Y 2107/00 Light sources with three-dimensionally disposed 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 2107/70 on flexible or deformable supports or substrates, e.g. for changing the light source into a desired form
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 33/52 Encapsulations
• CPC Class Codes: H01L 33/54 having a particular shape
• CPC Class Codes: H05K 1/0209 External configuration of printed circuit board adapted for heat dissipation, e.g. lay-out of conductors, coatings
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/051 Rolled
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/284 : for encapsulating mounted components H05K1/185 takes precedence

Abstract

A light emitting diode (LED) lighting device includes at least one LED assembly comprising a substrate and two or more LEDs configured to generate light spaced apart along the substrate. A cured structural coating is disposed on at least a portion of the LED assembly, wherein the cured structural coating is configured to maintain the LED assembly in a predetermined shape. The substrate of the LED assembly may comprise an elongated and/or flexible substrate.

Claims

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

at least one LED assembly comprising a substrate and two or more LEDs configured to generate light spaced apart along the substrate, the LED assembly having a width and a length that is greater than the width;

a cured structural coating that coats at least a portion of the LED assembly, wherein the cured structural coating is configured to be applied to the LED assembly before the LED assembly is shaped into a predetermined rigid shape, the cured structural coating configured to maintain the LED assembly in the predetermined shape defining an open central volume, wherein a width of the structural coating is about equal to the width of the LED assembly, the cured structural coating comprising fins that extend at least one of outside the open central volume and inside the open central volume; and

openings between neighboring segments of the LED assembly, the openings extending into the open central volume and allowing airflow between the neighboring segments from outside the open central volume into the open central volume.

2. The LED lighting device of claim 1, wherein the predetermined shape is a spiral.

3. The LED lighting device of claim 1, wherein the at least one LED assembly comprises only one continuous LED assembly.

4. The LED lighting device of claim 1, wherein the substrate has a first major surface and an opposing a second major surface and each of the LEDs has a light emitting surface or edge that is substantially perpendicular to the first major surface or the second major surface of the substrate.

5. The LED lighting device of claim 1, wherein the substrate has a first major surface and an opposing second major surface and each of the LEDs has a light emitting surface or edge that is substantially parallel to the first major surface or the second major surface of the substrate.

6. The LED lighting device of claim 1, wherein the substrate has a first major surface and a second major surface and the LEDs are disposed on at least one of the first major surface and the second major surface.

7. The LED lighting device of claim 1, wherein the substrate comprises a flexible circuit board having conductors that electrically connect the LEDs and the LEDs are discrete surface mount components.

8. The LED lighting device of claim 1, wherein the LEDs comprise micro LEDs formed together as an integrated circuit.

9. The LED lighting device of claim 1, wherein the cured structural coating is configured to dissipate heat generated by the LEDs.

10. The LED lighting device of claim 1, wherein the cured structural coating is disposed over at least a portion of the LEDs and is configured to transmit the light generated by the LEDs.

11. The LED lighting device of claim 1, wherein the cured structural coating has a surface texture with an effective surface area at least three times greater than an untextured surface of the same size.

12. The LED lighting device of claim 1, wherein the cured structural coating comprises a thermosetting material.

13. The LED lighting device of claim 1, wherein the cured structural coating comprises a radiation cured material.

14. The LED lighting device of claim 1, wherein the cured structural coating has an optical transmissivity of at least 85% in a wavelength range of light between about 390 nm and about 700 nm.

15. The LED lighting device of claim 1, wherein the substrate has a first major surface and an opposing second major surface, the LEDs are disposed on the first major surface and the cured structural coating is disposed on the second major surface.

16. The LED lighting device of claim 1, further comprising an optical coating layer, the optical coating layer configured reflect, scatter, direct, or transmit the light emitted by the LEDs.

17. The LED lighting device of claim 1, further comprising a thermal coating layer, the thermal coating layer configured to dissipate heat generated by the LEDs and having a thermal conductivity greater than about 100 W/mK.

18. The LED lighting device of claim 1, further comprising an optical sheet disposed over the LEDs, the optical sheet configured to guide the light between the sheet and the LED assembly for a distance before outcoupling the light.

19. The LED lighting device of claim 1, wherein overall dimensions of the LED light bulb are similar to an incandescent light bulb of equivalent luminosity.