High intensity LED replacement of incandescent lamps

• US 9,599,322 B2
• Filed: 05/10/2011
• Issued: 03/21/2017
• Est. Priority Date: 05/11/2010
• Status: Expired due to Fees

• Current Assignee: Polybrite International, Inc. (Goeken Group Corp.)
• Original Assignee: Polybrite International, Inc. (Goeken Group Corp.)
• Inventors: Janik, Raymond G., Scianna, Carlo, Thompson, Ted Lowl
• Primary Examiner(s): Sawhney, Hargobind S
• Application Number:
  US13/678,887
• Publication Number:
  US 20130083533A1
• Time in Patent Office: 2,142 Days
• Field of Search: 362/227, 362/235, 362/240, 362/241, 362/249.01, 362/249.02, 362/294, 362/311.02, 362/311.03, 362/362, 362/363, 362/373, 362/800, 257 98-100, 313/318.01
• 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 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 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 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: H05K 1/0284 Details of three-dimensional rigid printed circuit boards H05K1/119 takes precedence; shaping of the substrate H05K3/0014
• CPC Class Codes: H05K 1/14 Structural association of two or more printed circuits providing electric connection to or between printed circuits H05K1/11, H01R12/00
• CPC Class Codes: H05K 2201/047 Box-like arrangements of PCBs
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/0052 Depaneling, i.e. dividing a panel into circuit boards; Working of the edges of circuit boards
• CPC Class Codes: H05K 3/0061 onto a metallic substrate, e.g. a heat sink heat sinks for electric apparatus H05K7/20
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A method of forming a light bulb core, and a light bulb or lamp incorporating the core. The method includes forming a heat sink having at least six working facets located equally on opposite sides of a central plane, and then mounting a light source on each of the working facets. The light sources are mounted on circuit boards, each circuit board corresponding to a respective one of the working facets. The boards are then applied to respective working facets. The bulb is composed of a screw base, an external heat sink mounted in the screw base, and the light bulb core mounted in and extending from the external heat sink. The light source comprises a plurality of light emitting diodes.

Claims

1. A method of forming a light bulb core, comprising the steps of

a. forming a heat sink having at least six working facets formed at an angular relationship with one another, said working facets being located equally on opposite sides of a central plane;

b. forming a light emitting source from a single panel comprising a plurality of divided rigid panels held together by a plurality of breakable tabs and flexible surface-mounted jumper wires, wherein each of the divided rigid panels of the single panel are configured to be separated via the breakable tabs and mounted on each working facet; and

c. mounting the light source on each working facet such that each of the divided rigid panels on each working facet are electrically coupled via the flexible jumper wires to provide overlapping beam angle light illumination among at least some of the working facets and to an area crossing the central plane.

2. The method according to claim 1, in which method step “

a”

includes locating said facets in mirror image relationship on opposite sides of said central plane.

3. The method according to claim 1, in which method step “

c”

includes the steps of

i. locating said light sources on the divided rigid panels, with each divided panel corresponding to a respective one of said working facets, and

ii. applying said circuit boards to the respective one of said working facets.

4. The method according to claim 3, including the step, between method steps “

i” and

“

ii”

, of electrically connecting said divided panels to one another.

5. The method according to claim 4, in which, before method step “

i”

, including the steps of forming said divided panels in a planar array interconnected by the breakable tabs, and electrically connecting said circuit boards while in said planar array.

6. The method according to claim 5, including fracturing at least some of said breakable tabs before method step “

b”

.

7. A method of forming a light bulb core, comprising the steps of

forming a heat sink having at least six working facets formed at an angular relationship with one another on opposite sides of a central plane;

forming a light emitting source from a single panel comprising a plurality of divided rigid panels held together by a plurality of breakable tabs and flexible surface-mounted jumper wires, wherein each of the divided rigid panels of the single panel are configured to be separated via the breakable tabs and mounted on each working facet; and

mounting the light source on each working facet such that each of the divided rigid panels on each working facet are electrically coupled one of directly or indirectly via the flexible jumper wires to provide overlapping beam angle light illumination among at least some of the working facets and to an area crossing the central plane.

8. The method according to claim 7, wherein forming the heat sink comprises locating said facets in mirror image relationship on opposite sides of said central plane.

9. The method according to claim 7, wherein mounting the light source comprises

locating the light sources on the divided panels, wherein each divided panel corresponds to a respective one of said working facets;

and

applying the divided panels to the respective one of the working facets.

10. The method according to claim 9, further comprising electrically connecting the divided panels to one another one of directly or indirectly prior to applying the divided panels to the respective one of said working facets.

11. The method according to claim 9, further comprising forming the divided panels in a planar array interconnected by the breakable tabs, and electrically connecting the divided panels while in the planar array prior to locating the light sources.

12. The method according to claim 11, further comprising including fracturing at least some of the tabs before forming the light emitting source.