LED light bulbs

• US 9,933,148 B2
• Filed: 08/12/2014
• Issued: 04/03/2018
• Est. Priority Date: 06/08/2010
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Brandes, George R., Garceran, Julio A.
• Primary Examiner(s): Truong, Bao Q
• Application Number:
  US14/457,859
• Publication Number:
  US 20140355270A1
• Time in Patent Office: 1,330 Days
• Field of Search: 36224901, 36224902, 36224914, 362294, 36231102, 362373, 362800
• 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 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• CPC Class Codes: F21K 9/238 Arrangement or mounting of circuit elements integrated in the light source
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• 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: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 29/506 of globes, bowls or cover glasses
• CPC Class Codes: F21V 29/507 of means for protecting lighting devices from damage, e.g. housings
• CPC Class Codes: F21V 29/51 using condensation or evaporation of a fluid, e.g. heat pipes
• CPC Class Codes: F21V 29/57 characterised by control arrangements
• CPC Class Codes: F21V 29/677 the fans being used for discharging
• 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: F21V 3/08 the material comprising photoluminescent substances
• CPC Class Codes: F21V 3/12 the coatings comprising photoluminescent substances
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• 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 2107/40 : on the sides of polyhedrons, e.g. cubes or pyramids
• CPC Class Codes: F21Y 2115/10 : Light-emitting diodes [LED]
• CPC Class Codes: F21Y 2115/30 : Semiconductor lasers
• CPC Class Codes: H05K 2201/047 : Box-like arrangements of PCBs
• CPC Class Codes: H05K 2201/10106 : Light emitting diode [LED]
• CPC Class Codes: Y10S 362/80 : Light emitting diode
• CPC Class Codes: Y10T 29/4913 : Assembling to base an electrical component, e.g., capacitor, etc.

Abstract

LED light bulbs include openings in base or cover portions, and optional forced flow elements, for convective cooling. Thermally conductive optically transmissive material may be used for cooling, optionally including fins. A LED light engine may be fabricated from a substrate via planar fabrication techniques and shaped to form a substantially rigid upright support structure. Mechanical, electrical, and thermal connections may be made between a LED light engine and a LED light bulb.

Claims

1. A light emitting diode (LED) light bulb comprising:

a light-transmissive cover defining an interior volume;

at least one LED disposed within the interior volume;

a support column comprising a plurality of electrical conductors in electrical communication with the at least one LED; and

first and second electrical contacts disposed in or on the support column proximate to a base end of the LED light bulb and arranged to mate with an electrical receptacle to receive electric current, wherein the first and second electrical contacts are accessible along an exterior of the LED light bulb and are in electrical communication with the plurality of electrical conductors;

wherein a portion of the support column arranged between the base end and the light-transmissive cover is disposed outside of the interior volume and is exposed to an ambient environment.

2. The LED light bulb of claim 1, further comprising a substrate within the interior volume, wherein the at least one LED is arranged on or over the substrate, and the substrate is supported by the support column.

3. The LED light bulb of claim 2, wherein the support column comprises at least one heat transfer device arranged to promote dissipation of heat from the substrate to the ambient environment.

4. The LED light bulb of claim 3, wherein the at least one heat transfer device comprises at least one of a fan or a heatpipe.

5. The LED light bulb of claim 3, wherein the at least one heat transfer device comprises a plurality of fins.

6. The LED light bulb of claim 2, further comprising a cap disposed along an end of the support column distal from the substrate, wherein the cap includes the first and second electrical contacts.

7. The LED light bulb of claim 1, wherein the at least one LED comprises a plurality of LEDs.

8. The LED light bulb of claim 1, wherein the at least one LED is adapted to output light having at least one peak wavelength, and the light-transmissive cover comprises at least one lumiphoric material adapted to receive light from the at least one LED and responsively emit light having at least one other peak wavelength that differs from the at least one peak wavelength.

9. The LED light bulb of claim 1, wherein:

at least a portion of the support column has a hollow core;

the support column defines at least one first opening disposed within the interior volume and arranged for passage of fluid;

the support column defines at least one second opening disposed outside of the interior volume and exposed to the ambient environment; and

each of the at least one first opening and the at least one second opening is in fluid communication with the hollow core.

10. The LED light bulb of claim 1, wherein at least an outer portion of the support column comprises an electrically insulating material.

11. The LED light bulb of claim 10, wherein the support column comprises an electrically conductive inner portion, and the electrically insulating material comprises a coating or covering disposed over the electrically conductive inner portion.

12. The LED light bulb of claim 1, wherein at least a portion of the light-transmissive cover comprises a material having visible spectrum transmittance of at least about 80% and a thermal conductivity of at least 25 W/(m·

°

K) at about 25°

C.

13. A light emitting diode (LED) light bulb comprising:

a light-transmissive cover defining an interior volume, the light-transmissive cover comprising a material adapted to transmit at least a portion of light in the visible spectrum;

a substrate supporting at least one LED, wherein the at least one LED and at least a portion of the substrate are disposed within the interior volume; and

at least one opening defined in the light-transmissive cover, wherein the at least one opening is in fluid communication with an ambient environment;

wherein the LED light bulb comprises at least one of the following features (a) or (b);

(a) the LED light bulb comprises at least one baffle arranged to prevent unobstructed visibility of the at least one LED through the at least one opening defined in the light-transmissive cover;

or

(b) the light-transmissive cover comprises a plurality of fins, and the plurality of fins comprises a material adapted to transmit at least a portion of light in the visible spectrum.

14. The LED light bulb of claim 13, wherein the LED light bulb comprises at least one baffle arranged to prevent unobstructed visibility of the at least one LED through the at least one opening defined in the light-transmissive cover.

15. The LED light bulb of claim 14, wherein the light-transmissive cover defines a plurality of openings to enable air or other fluid to flow between the interior volume and the ambient environment.

16. The LED light bulb of claim 15, wherein openings of the plurality of openings are sized and configured to promote movement of air or other fluid between the interior volume and the ambient environment via natural convection.

17. The LED light bulb of claim 15, wherein the at least one baffle is disposed within or partially bounds the interior volume.

18. The LED light bulb of claim 17, wherein the at least one baffle is integrally formed with the light-transmissive cover.

19. The LED light bulb of claim 17, wherein the at least one baffle is spaced apart from the light-transmissive cover.

20. The LED light bulb of claim 17, wherein the at least one baffle and the light-transmissive cover are arranged to diffuse light emissions of the at least one LED.

21. The LED light bulb of claim 17, further comprising a support column extending between a base end of the LED light bulb and the light-transmissive cover, wherein the support column defines at least one support column opening between the base end and the light-transmissive cover, and the at least one support column opening in combination with the plurality of openings defined in the light-transmissive cover enables air or other fluid to flow between the interior volume and the ambient environment.

22. The LED light bulb of claim 17, wherein the at least one LED comprises a plurality of LEDs.

23. The LED light bulb of claim 22, wherein the substrate comprises a substantially rigid support element within the interior volume, the substantially rigid support element comprises a plurality of non-coplanar support surfaces, and different LEDs of the plurality of LEDs are arranged on different surfaces of the plurality of non-coplanar support surfaces.

24. The LED light bulb of claim 23, wherein surfaces of the plurality of non-coplanar support surfaces are coated or covered with an electrically insulating material.

25. The LED light bulb of claim 13, wherein the light-transmissive cover defines a plurality of openings to enable air or other fluid to flow between the interior volume and the ambient environment.

26. The LED light bulb of claim 13, further comprising at least one additional opening defined in at least one of (a) the light-transmissive cover or (b) a base portion of the LED light bulb disposed outside the light-transmissive cover.

27. The LED light bulb of claim 26, further comprising a fluid circulation element adapted to cause air or other fluid to flow through the at least one opening defined in the light-transmissive cover and the at least one additional opening.

28. The LED light bulb of claim 13, wherein the LED light bulb comprises a filter element arranged to inhibit passage of dust or other particulate matter through the at least one opening defined in the light-transmissive cover.

29. The LED light bulb of claim 28, further comprising at least one sensor arranged to sense a condition indicative of a need for the filter element to be cleaned or changed.

30. The LED light bulb of claim 13, wherein the light-transmissive cover comprises a plurality of fins, and the plurality of fins comprises a material adapted to transmit at least a portion of light in the visible spectrum.

31. A light emitting diode (LED) light bulb comprising:

a light-transmissive cover defining an interior volume;

a plurality of LEDs disposed within the interior volume;

a plurality of openings defined in the light-transmissive cover to enable air or other fluid to flow between the interior volume and an ambient environment; and

at least one baffle disposed within or partially bounding the interior volume and configured to prevent unobstructed visibility of at least one LED of the plurality of LEDs through at least one opening of the plurality of openings.

32. The LED light bulb of claim 31, wherein the at least one baffle is spaced apart from the light-transmissive cover.

33. The LED light bulb of claim 31, wherein the at least one baffle is integrally formed with the light-transmissive cover.

34. The LED light bulb of claim 31, wherein the at least one baffle and the light-transmissive cover are arranged to diffuse light emissions of the at least one LED.

35. The LED light bulb of claim 31, wherein the plurality of LEDs is supported by a substantially rigid support element that comprises a plurality of non-coplanar support surfaces, wherein different LEDs of the plurality of LEDs are arranged on different surfaces of the plurality of non-coplanar support surfaces.

36. The LED light bulb of claim 35, wherein surfaces of the plurality of non-coplanar support surfaces are coated or covered with an electrically insulating material.