LED lighting device with cured structural support

• US 9,857,031 B2
• Filed: 12/12/2016
• Issued: 01/02/2018
• Est. Priority Date: 03/13/2013
• Status: Expired due to Fees

• Current Assignee: Palo Alto Research Center, Inc. (Xerox Holdings Corp.)
• Original Assignee: Palo Alto Research Center, Inc. (Xerox Holdings Corp.)
• Inventors: Veres, Janos, Schmaelzle, Philipp, Paulson, Christopher, Pattekar, Ashish, Maeda, Patrick Y.
• Primary Examiner(s): Breval, Elmito
• Assistant Examiner(s): ROJAS CADIMA, OMAR
• Application Number:
  US15/375,752
• Publication Number:
  US 20170089519A1
• Time in Patent Office: 386 Days
• Field of Search: 362235, 36221701, 36224901, 362333, 362353, 362343
• 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 method of making an LED lighting device, comprising:

applying a curable coating to a first major surface of at least one LED assembly, the LED assembly comprising a flexible substrate and LEDs spaced apart along the flexible substrate;

after applying the curable coating and before curing the curable coating, shaping the coated LED assembly into a predetermined shape defining an open central volume;

after shaping the coated LED assembly, curing the coating, wherein after the curing, the cured coating maintains the LED assembly in the predetermined shape; and

applying a thermal management layer comprising fins to a second major surface of the LED assembly, the fins extending at least one of outside the open central volume and inside the open central volume.

2. The method of claim 1, wherein the curable coating comprises a thermosetting material.

3. The method of claim 1, wherein the curable coating comprises metal particles including at least one of mica, silver, gold, and copper particles.

4. The method of claim 1, wherein the curable coating comprises a radiation curable material.

5. The method of claim 1, further comprising treating a surface of the structural coating to impart a surface roughness that provides an effective surface area that is at least three times a surface area of the an untreated surface of the same material and same size.

6. The method of claim 1, further comprising depositing a thermally conductive layer on or over a major surface of the LED assembly, the thermally conductive layer comprising a material that dissipates heat generated by the LEDs.

7. The method of claim 1, further comprising depositing an optical layer on or over a major surface of the LED assembly, the optical layer comprising a material that provides one or more of light transmission, reflection, and diffusion.

8. The method of claim 7, wherein the material has transmissivity greater than about 85% in a wavelength range of light between about 390 nm and about 700 nm.

9. The method of claim 7, wherein the material has reflectivity greater than about 85% in a wavelength range of light between about 390 nm and about 700 nm.