LED lamp

• US 9,618,162 B2
• Filed: 05/22/2014
• Issued: 04/11/2017
• Est. Priority Date: 04/25/2014
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Bendtsen, Andrew, Wilcox, Kurt, Progl, Curt, Kinnune, Brian
• Primary Examiner(s): Mai, Anh
• Assistant Examiner(s): Snyder, Zachary J
• Application Number:
  US14/284,781
• Publication Number:
  US 20150308630A1
• Time in Patent Office: 1,055 Days
• 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 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21S 8/088 with lighting device mounted on top of the standard, e.g. for pedestrian zones
• CPC Class Codes: F21V 14/04 by movement of reflectors in vehicle head lamps F21S41/675
• CPC Class Codes: F21V 17/02 with provision for adjustment F21V17/04 - F21V17/08 take precedence
• CPC Class Codes: F21V 23/007 enclosed in a casing
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 29/503 of light sources cooling arrangements structurally associated with gas-discharge or vapour-discharge lamps H01J61/52; cooling arrangements structurally associated with electric incandescent lamps H01K1/58; cooling arrangements structurally associated with light-emitting diodes H01L33/64
• 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 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: F21V 7/0066 specially adapted to cooperate with point like light sources; specially adapted to cooperate with light sources the shape of which is unspecified F21V7/16 - F21V7/30 take precedence
• CPC Class Codes: F21W 2131/10 Outdoor lighting
• CPC Class Codes: F21W 2131/103 of streets or roads
• 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 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01R 43/00 Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors of trolley lines B60M1/28
• CPC Class Codes: H05B 45/14 using electrical feedback from LEDs or from LED modules
• CPC Class Codes: H05B 45/37 Converter circuits
• CPC Class Codes: H05B 45/46 having LEDs disposed in parallel lines
• CPC Class Codes: H05B 45/50 responsive to malfunctions or undesirable behaviour of LEDs; responsive to LED life; Protective circuits
• CPC Class Codes: Y02B 20/30 : Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]

Abstract

A LED lamp for use in an existing light fixture having an electrical receptacle comprises an at least partially optically transmissive enclosure and a base having an external size that may be the same size or smaller than an external size of the electrical receptacle. A LED assembly is operable to emit light when energized through an electrical path from the base. The base comprises a universal mounting mechanism for mounting the lamp to the light fixture. A surge protector and an electrical connector are positioned at least partially in the base and are in the electrical path. A heat sink comprises a first portion in the enclosure for supporting the LED assembly and a second portion external of the enclosure for dissipating heat. The base is connected to the heat sink.

Claims

1. A lamp for use in an existing light fixture having an electrical receptacle comprising:

an at least partially optically transmissive enclosure;

a LED assembly comprising at least one LED, the LED assembly being located in the enclosure and the at least one LED operable to emit light when energized through an electrical path;

a base having an external size that is approximately the same size or smaller than an external size of the electrical receptacle, the base comprising a universal mounting mechanism for mounting the lamp to the light fixture and an electrical connector in the electrical path for electrically connecting the light fixture to the lamp;

a heat sink structure comprising a heat dissipating portion for dissipating heat from the LED assembly, the heat dissipating portion being disposed between the optically transmissive enclosure and the base, and a cavity in the heat dissipating portion that is closed by the base and at least partially contains lamp electronics, the lamp electronics being in the electrical path.

2. The lamp of claim 1 wherein the base comprises a support structure comprising a mounting plate and a wall, the mounting plate and the wall being configured and dimensioned to have an external size that is approximately the same size or smaller than the external size of the electrical receptacle.

3. The lamp of claim 2 wherein the mounting plate includes the universal mounting mechanism connecting the lamp to an existing mounting structure of the fixture.

4. The lamp of claim 3 wherein the universal mounting mechanism comprises at least two sets of apertures.

5. The lamp of claim 1 further comprising a surge protector in the electrical path.

6. The lamp of claim 1 further comprising an electrical connector in the electrical path for receiving electrical supply wires from the fixture.

7. The lamp of claim 1 further comprising a cover that is releasably secured to the base.

8. The lamp of claim 1 further comprising a shield positioned to reflect some of the light emitted from the lamp.

9. The lamp of claim 8 wherein the shield is made of a thermally conductive material and is secured to the heat sink.

10. The lamp of claim 1 wherein the lamp produces between approximately 2500 and 4500 Lumens.

11. The lamp of claim 1 wherein the light has a color rendering index of greater than 70.

12. The lamp of claim 1 wherein the lamp produces approximately 100 Lumens per Watt.

13. The lamp of claim 1 wherein the light has a color temperature of approximately 2800-3300 K.

14. The lamp of claim 1 wherein the universal mounting mechanism is not in the electrical path.

15. The lamp of claim 1 further comprising a tower extending into the enclosure for supporting the LED assembly such that the at least one LED is positioned in a center of the enclosure.

16. The lamp of claim 15 further comprising a heat sink for dissipating heat from the at least one LED, the heat sink comprising the tower that extends along a longitudinal axis of the lamp.

17. A lamp comprising:

an at least partially optically transmissive enclosure;

a base comprising a universal mounting mechanism for mounting the lamp to a light fixture;

a LED assembly comprising at least one LED, the LED assembly being located in the enclosure and the at least one LED operable to emit light when energized through an electrical path;

a surge protector and an electrical connector positioned at least partially in the base and being in the electrical path;

a heat sink comprising a first portion in the enclosure for supporting the LED assembly and a second portion external of the enclosure for dissipating heat, the base being connected to the heat sink, the second portion of the heat sink being disposed between and connected to the optically transmissive enclosure and the base, the second portion comprising a cavity that at least partially contains lamp electronics, the lamp electronics comprising a driver and being in the electrical path.

18. A lamp comprising:

an omnidirectional enclosure having a first dimension;

a LED assembly comprising at least one LED, the LED assembly being located in the enclosure and the at least one LED operable to emit light when energized through an electrical path;

a base, the base comprising a universal mounting mechanism for mounting the lamp to a light fixture and an electrical connector in the electrical path for electrically connecting the light fixture to the lamp;

a heat sink thermally coupled to the LED assembly for dissipating heat from the at least one LED, the heat sink comprising an external heat dissipating portion disposed between the enclosure and the base, the external heat dissipating portion having a second dimension where the second dimension corresponds to the first dimension and the second dimension is greater than the first dimension.

19. The lamp of claim 18 where the first dimension is a width of the enclosure and the second dimension is a width of the external heat dissipating portion.

20. The lamp of claim 18 where the first dimension is a height of the enclosure and the second dimension is a height of the external heat dissipating portion.

21. The lamp of claim 18 where the first dimension is a volume of the enclosure and the second dimension is a volume of the external heat dissipating portion.

22. The lamp of claim 18 wherein the lamp is mounted inside of a diffusive globe.

23. The lamp of claim 18 wherein the lamp produces between approximately 2500 and 4500 Lumens.

24. The lamp of claim 18 wherein the lamp produces between approximately 3000 and 4000 Lumens.

25. The lamp of claim 18 wherein the lamp produces approximately 3500 Lumens.

26. The lamp of claim 18 further comprising a tower extending into the enclosure for supporting the LED assembly such that the at least one LED is positioned in a center of the enclosure.

27. The lamp of claim 26 wherein the tower forms part of the heat sink, the tower extending along a longitudinal axis of the lamp.

28. An outdoor lamp comprising:

an omnidirectional enclosure;

a base comprising a universal mounting mechanism for mounting the lamp to a light fixture and an electrical connector in an electrical path for electrically connecting the light fixture to the lam where the universal mounting mechanism is not in the electrical path; and

a heat sink thermally coupled to the LED assembly for dissipating heat from the at least one LED the heat sink comprising an external heat dissipating portion where the enclosure is mounted to a first side of the external heat dissipating portion and the base is mounted to an opposite second side of the external heat dissipating portion, the electrical path extending through the heat dissipating portion;

a LED assembly comprising at least one LED, the LED assembly being located in the enclosure and the at least one LED operable to emit light when energized through the electrical path where the at least one LED produces between approximately 2500 and 4500 Lumens.

29. The outdoor lamp of claim 28 wherein the enclosure has a first width, the base has a second width and the external heat dissipating portion has a third width, the third width being greater than the first width and the second width.

30. The lamp of claim 28 further comprising a tower extending into the enclosure for supporting the LED assembly such that the at least one LED is positioned in a center of the enclosure.

31. The lamp of claim 30 further comprising a heat sink for dissipating heat from the at least one LED, the heat sink comprising the tower that extends along a longitudinal axis of the lamp.

32. A method of installing a lamp comprising:

disconnecting electrical supply wires from an electrical receptacle;

removing the electrical receptacle from a space in the light fixture, the space being defined by plate comprising an aperture;

inserting a lamp into the fixture, the lamp comprising;

an at least partially optically transmissive enclosure;

a base having an external size that is the same size or smaller than an external size of the electrical receptacle connecter;

a heat sink disposed between the enclosure and the base;

a LED assembly comprising at least one LED, the LED assembly being located in the enclosure and the at least one LED operable to emit light when energized through an electrical path;

the base comprising a universal mounting mechanism for mounting to the light fixture;

inserting the base through the aperture and positioning the base of the lamp in the space vacated by the electrical receptacle such that the base is positioned to a first side of the plate and the heat sink and enclosure are positioned to an opposite side of the plate;

mounting the universal mounting mechanism to the fixture;

connecting the electrical supply wires to the electrical path.

33. The method of claim 32 wherein the step of removing the electrical receptacle comprises removing screws from apertures in the fixture and the universal mounting mechanism includes a first pair of apertures and a second pair of apertures wherein the step of positioning the base of the lamp in the space includes aligning the apertures with one of the first pair of apertures and the second pair of apertures.

34. The method of claim 32 wherein the step of connecting the electrical supply wires to the path comprises connecting the electrical supply wires to a terminal block in the base.