LED lighting

• US 9,581,323 B2
• Filed: 07/21/2016
• Issued: 02/28/2017
• Est. Priority Date: 03/31/2015
• Status: Active Grant

• Current Assignee: Frank Shum
• Original Assignee: Frank Shum
• Inventors: Shum, Frank
• Primary Examiner(s): Tan, Vibol
• Application Number:
  US15/215,964
• Publication Number:
  US 20160363308A1
• Time in Patent Office: 222 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 9/235 Details of bases or caps, i.e. the parts that connect the light source to a fitting; Arrangement of components within bases or caps F21K9/238 takes precedence
• CPC Class Codes: F21K 9/238 Arrangement or mounting of circuit elements integrated in the light source
• CPC Class Codes: F21K 9/65 specially adapted for changing the characteristics or the distribution of the light, e.g. by adjustment of parts
• CPC Class Codes: F21K 9/68 Details of reflectors forming part of the light source
• CPC Class Codes: F21V 23/003 the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 23/006 the substrate being distinct from the light source holder
• CPC Class Codes: F21V 29/713 in direct thermal and mechanical contact of each other to form a single system
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/80 with pins or wires
• CPC Class Codes: F21V 29/81 with pins or wires having different shapes, lengths or spacing
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• 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 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/10 Controlling the intensity of the light
• CPC Class Codes: H05B 45/20 Controlling the colour of the light
• CPC Class Codes: H05B 45/3575 : by means of dummy loads or bleeder circuits, e.g. for dimmers
• CPC Class Codes: H05B 45/3725 : Switched mode power supply [SMPS]
• CPC Class Codes: H05B 45/395 : Linear regulators
• CPC Class Codes: H05B 45/44 : with an active control inside an LED matrix
• CPC Class Codes: H05B 45/56 : involving measures to prevent abnormal temperature of the LEDs
• 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 associated methods relate to development of a LED system with high thermal dissipation power relative to the system weight by the inclusion of open regions. The open regions reduce the weight of the optical system while improving airflow. Associated optics are described to efficiently and evenly distribute the light from an LED by tailoring the optical distribution. In addition, circuitry and methods are described to allow for the LED system to operate with existing power sources such as ballast or offline AC voltage sources or both.

Claims

1. An LED-based lighting system with enhanced convective through-flow in an approximately vertical direction, the apparatus comprising:

a light generation module comprising a first plurality of LED sources and a second plurality of LED sources, the first plurality of LED sources and the second plurality of LED sources arranged to illuminate along an optical axis in a distal direction;

a first region defined by a first perimeter, the first perimeter forming a first polygon such that each of the first plurality of LED sources defines a vertex of the first polygon;

a second region defined by a second perimeter, the second perimeter forming a second polygon such that each of the second plurality of LED sources defines a vertex of the second polygon;

a third region enclosed by the first region and outside of the second region; and

,

a first plurality of optics adapted to optically align with the first plurality of LED sources and a second plurality of optics adapted to optically align to the second plurality of LED sources;

for each one of the LED sources in the first plurality of LED sources and the second plurality of LED sources of the light generation module;

at least one heat transfer member in substantial thermal communication with the first plurality of LED sources and at least one heat transfer member in substantial thermal communication with the second plurality of LED sources, the heat transfer member comprising a thermally conductive path extending proximally along a heat transfer axis that is substantially parallel to the optical axis, wherein, in operation, the heat transfer member conducts heat generated by the LED source substantially proximally;

at least one aperture defined in the third region, each of the at least one apertures providing an axial fluid communication path through the aperture and approximately parallel to the optical axis to remove heat from one or more of the heat transfer members, wherein each of the axial fluid communication paths extends proximally to exhaust to ambient atmosphere.

2. The LED-based lighting system of claim 1, wherein the at least one aperture defined in the third region encompasses at least 25% of the area of the third region.

3. The LED-based lighting system of claim 1, the one or more heat transfer members further comprising a first plurality of fins and a second plurality of fins extending from the first perimeter in a radial direction of a substantially common center point, wherein the second plurality of fins is shorter in the radial direction than the first plurality of fins.

4. The LED-based lighting system of claim 1, further comprising at least one inner aperture enclosed by the second region, the at least one inner aperture providing an axial fluid communication path through the aperture and parallel to the optical axis to remove heat from one or more of the heat transfer members, wherein each of the axial fluid communication paths extends proximally to exhaust to ambient atmosphere.

5. The LED-based lighting system of claim 1, further comprising an optical accessory mounted along an edge of the first perimeter such that the optical accessory redirects a portion of light emitted through the first plurality of optics around the first perimeter to form an uplight.

6. The LED-based lighting system of claim 1, wherein each optic of the first plurality of optics and the second plurality of optics comprises a dielectric compound parabolic reflector (CPC) with a resulting peak in the optical distribution between 25 and 45 degrees from the optical axis.

7. The LED-based lighting system of claim 1, further comprising an E39 screw base such that the E39 screw base, the light generation module, the first plurality of LEDs, the second plurality of LEDs, the first plurality of optics and the second plurality of optics comprises an overall weight less than 1.7 Kg.

8. The LED-based lighting system of claim 1, further comprising a HID ballast having a series of outputs to supply an average ballast current and an electronic driver having at least a bridge rectifier electrically connected in parallel with a controllable switch, the electronic driver electrically connected to the outputs of the HID ballast such that the controllable switch intermittently substantially shorts the output of the HID ballast, wherein, when the light generation module is in operation at a nominal operating point, the electronic driver continuously operates the controllable switch to regulate an average total LED forward current to the first plurality of LED sources and the second plurality of LED sources such that the average total LED forward current is at least 5% less than the average ballast current.

9. The LED-based lighting system of claim 1, further comprising an electronic driver having a power conversion circuit adapted to source an input current from a power source in accordance with a control signal tailored to match the power source, the power source having a fundamental frequency, the control signal having a pattern that is periodic with at least a multiple of the fundamental frequency to cause the power conversion circuit to present an effective impedance to match an impedance of the power source, wherein, the effective impedance of the power conversion circuit comprises one or more members of the group consisting of resistive, inductive, capacitive, and nonlinear.

10. The LED-based lighting system of claim 9, wherein the power source comprises an HID Ballast.

11. An LED-based lighting system with enhanced convective through-flow in an approximately vertical direction, the apparatus comprising:

a light generation module comprising a first plurality of LED sources and a second plurality of LED sources, the first plurality of LED sources and the second plurality of LED sources arranged to illuminate along an optical axis in a distal direction;

a first region defined by a first perimeter, the first perimeter forming a first polygon such that each of the first plurality of LED sources defines a vertex of the first polygon;

a second region defined by a second perimeter, the second perimeter forming a second polygon such that each of the second plurality of LED sources defines a vertex of the second polygon;

a third region enclosed by the first region and outside of the second region; and

,

for each one of the LED sources in the first plurality of LED sources and the second plurality of LED sources of the light generation module;

at least one heat transfer member in substantial thermal communication with the first plurality of LED sources and at least one heat transfer member in substantial thermal communication with the second plurality of LED sources, the heat transfer member comprising a thermally conductive path extending proximally along a heat transfer axis that is substantially parallel to the optical axis, wherein, in operation, the heat transfer member conducts heat generated by the LED source substantially proximally;

at least one aperture defined in the third region, each of the at least one apertures providing an axial fluid communication path through the aperture and approximately parallel to the optical axis to remove heat from one or more of the heat transfer members, wherein each of the axial fluid communication paths extends proximally to exhaust to ambient atmosphere.

12. The LED-based lighting system of claim 11, wherein the at least one aperture defined in the third region encompasses at least 25% of an area of the third region.

13. The LED-based lighting system of claim 11, the one or more heat transfer members further comprising a first plurality of fins and a second plurality of fins extending from the first perimeter in a radial direction of a substantially common center point, wherein the second plurality of fins is shorter in the radial direction than the first plurality of fins.

14. The LED-based lighting system of claim 11, further comprising at least one inner aperture enclosed by the second region, the at least one inner aperture providing an axial fluid communication path through the aperture and parallel to the optical axis to remove heat from one or more of the heat transfer members, wherein each of the axial fluid communication paths extends proximally to exhaust to ambient atmosphere.

15. The LED-based lighting system of claim 11, further comprising a HID ballast having a series of outputs to supply an average ballast current and an electronic driver having at least a bridge rectifier electrically connected in parallel with a controllable switch, the electronic driver electrically connected to the outputs of the HID ballast such that the controllable switch intermittently substantially shorts the output of the HID ballast, wherein, when the light generation module is in operation at a nominal operating point, the electronic driver continuously operates the controllable switch to regulate an average total LED forward current to the first plurality of LED sources and the second plurality of LED sources such that the average total LED forward current is at least 5% less than the average ballast current.

16. An LED-based lighting system with enhanced convective through-flow in an approximately vertical direction, the apparatus comprising:

a light generation module comprising a first plurality of LED sources and a second plurality of LED sources, the first plurality of LED sources and the second plurality of LED sources arranged to illuminate along an optical axis in a distal direction;

a first region defined by a first perimeter, the first perimeter forming a first polygon such that each of the first plurality of LED sources defines a vertex of the first polygon;

a second region defined by a second perimeter, the second perimeter forming a second polygon such that each of the second plurality of LED sources defines a vertex of the second polygon;

a third region enclosed by the first region and outside of the second region; and

,

means for conducting heat generated by the LED source substantially proximally;

at least one aperture defined in the third region, each of the at least one apertures providing an axial fluid communication path through the aperture and approximately parallel to the optical axis to remove heat from one or more of heat transfer members, wherein each of the axial fluid communication paths extends proximally to exhaust to ambient atmosphere.

17. The LED-based lighting system of claim 16, wherein the at least one aperture defined in the third region encompasses at least 25% of an area of the third region.

18. The LED-based lighting system of claim 16, the one or more heat transfer members further comprising a first plurality of fins and a second plurality of fins extending from the first perimeter in a radial direction of a substantially common center point, wherein the second plurality of fins is shorter in the radial direction than the first plurality of fins.

19. The LED-based lighting system of claim 16, further comprising at least one inner aperture enclosed by the second region, the at least one inner aperture providing an axial fluid communication path through the aperture and parallel to the optical axis to remove heat from one or more of the heat transfer members, wherein each of the axial fluid communication paths extends proximally to exhaust to ambient atmosphere.

20. The LED-based lighting system of claim 16, further comprising a HID ballast having a series of outputs to supply an average ballast current and an electronic driver having at least a bridge rectifier electrically connected in parallel with a controllable switch, the electronic driver electrically connected to the outputs of the HID ballast such that the controllable switch intermittently substantially shorts the output of the HID ballast, wherein, when the light generation module is in operation at a nominal operating point, the electronic driver continuously operates the controllable switch to regulate an average total LED forward current to the first plurality of LED sources and the second plurality of LED sources such that the average total LED forward current is at least 5% less than the average ballast current.