Glass jacketed LED lamp

• US 9,958,116 B2
• Filed: 03/21/2016
• Issued: 05/01/2018
• Est. Priority Date: 03/20/2015
• Status: Active Grant

• Current Assignee: Eye Lighting International Of North America Inc.
• Original Assignee: Eye Lighting International Of North America Inc.
• Inventors: Cai, Dengke, Jurkovic, Paul J., Salpietra, Thomas G.
• Primary Examiner(s): Lee, Y M
• Application Number:
  US15/326,456
• Publication Number:
  US 20170268730A1
• Time in Patent Office: 771 Days
• 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 9/272 Details of end parts, i.e. the parts that connect the light source to a fitting; Arrangement of components within end parts F21K9/278 takes precedence
• CPC Class Codes: F21K 9/275 Details of bases or housings, i.e. the parts between the light-generating element and the end caps; Arrangement of components within bases or housings F21K9/278 takes precedence
• CPC Class Codes: F21K 9/278 Arrangement or mounting of circuit elements integrated in the light source
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21V 3/061 the material being glass
• CPC Class Codes: F21V 31/00 Gas-tight or water-tight arrangements
• CPC Class Codes: F21V 5/02 of prismatic shape F21V5/04 takes precedence
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• 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: H05B 45/30 Driver circuits

Abstract

A glass jacketed led lamp is characterized by a prismatic LED module positioned coaxial to the axis of a cylindrical glass jacket having an inside diameter D1, wherein the LED module comprises: a prismatic LED carrier structure having N longitudinal sides, and LEDs that are operationally mounted on at least one of the N sides; wherein: the carrier structure was formed by folding a single metal core printed circuit board (MCPCB) into a convex prismatic polyhedron; the prism cross section is an irregular and incomplete polygon such that the N sides are bounded by N+1 longitudinal fold edges, wherein a first edge and the (N+1)th edge are back edges that are spaced apart by a first separation GAP1.

Claims

1. A glass jacketed LED lamp comprising:

a prismatic LED module positioned coaxial to a center axis of a cylindrical glass jacket having an inside diameter D1, wherein the LED module comprises;

a prismatic LED carrier structure having a quantity N of longitudinal sides, and LEDs that are operationally mounted on at least one of the N sides;

wherein;

the carrier structure was formed by folding a single metal core printed circuit board (MCPCB) into a convex prismatic polyhedron having a cross section that is an irregular and incomplete polygon such that the N sides are bounded by a quantity equal to N+1 of longitudinal fold edges;

a first edge and the (N+1)th edge are back edges that are spaced apart by a first separation GAP1;

one or two of the N longitudinal sides being distal to the back edges are front side(s), and the MCPCB board extends from at least one of the back edges inward toward the front side(s), thereby forming at least one interior wall that divides the structure into an open cavity flanked by at least one side cavity; and

at least the second through the Nth edges are in thermal contact with the glass jacket.

2. The lamp of claim 1 wherein:

the back edges are spaced inward from the jacket inside diameter D1 by a second separation GAP2.

3. The lamp of claim 1 wherein:

the at least one interior wall is thermally attached to the front side(s), thereby additionally heat sinking the front side(s).

4. The lamp of claim 3 further comprising:

LEDs mounted only on the front side(s);

thereby providing directed light output with a beam spread substantially determined by the angles at the edges of the one or two front sides.

5. The lamp of claim 1 wherein:

in an unbiased neutral state, the LED carrier edges are circumscribed by a circle of diameter D2′

that is greater than the jacket inside diameter D1, and the MCPCB is resilient with a spring bias toward the neutral state, such that the module is in a constricted state when inside the jacket, thereby biasing the fold edges into thermal contact with the jacket wall, and providing friction to hold the LED module in a predetermined longitudinal position within the jacket.

6. The lamp of claim 1 further comprising:

a wool-like porous and highly interconnected lightweight material having thermal conductivity greater than about 10 W/mK, substantially filling one or more of the center and the side cavities, and thermally contacting the interior walls and the sides therearound.

7. The lamp of claim 1 wherein:

the MCPCB comprises a polyimide dielectric layer, and copper traces without a solder mask layer;

thereby enabling MCPCB bending without surface cracking, and minimizing potential volatile organic compound emissions.

8. The lamp of claim 7 further comprising:

an AC LED driver circuit mounted on at least one carrier side that is separate from any side that is an LED mounting face.

9. The lamp of claim 7 further comprising:

an AC LED driver circuit mounted on at least one of the at least one interior walls.

10. The lamp of claim 1 further comprising:

a lamp base adhered over an open end of the jacket.

11. The lamp of claim 10 wherein:

the base is plastic.

12. The lamp of claim 10 wherein:

the base has thermal conductivity greater than 1 W/mK.

13. The lamp of claim 12 wherein:

the LED carrier extends into thermal contact with the base.

14. The lamp of claim 10 wherein:

the base comprises a watertight seal for the lamp wherein vent openings are sealed or covered by a methyl silicone breathable membrane or adhesive or sealant, thereby allowing egress of volatile materials while blocking liquid water.

15. The lamp of claim 10 further comprising:

a desiccant material inside the jacket.

16. The lamp of claim 10 further comprising:

one or a combination of getters inside the jacket for capturing volatile materials, wherein the getters are selected from a group that includes;

active carbon, natural zeolite, de-aluminized zeolite, surface treated zeolite, and silica.

17. The lamp of claim 10 wherein:

the base is at least partly made from a porous ceramic having pores too small to allow passage of liquid water.

18. The lamp of claim 17 wherein:

the porous ceramic is etched polycrystalline alumina.