Illumination device with folded light source carrier and method of assembly

• US 9,989,195 B2
• Filed: 05/02/2014
• Issued: 06/05/2018
• Est. Priority Date: 05/14/2013
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Philips Lighting Holding BV (Signify N.V.)
• Inventors: Marinus, Antonius Adrianus Maria, Bukkems, Peter Johannes Martinus, Kadijk, Simon Eme, Gielen, Vincent Stefan David
• Primary Examiner(s): Negron, Ismael
• Application Number:
  US14/890,755
• Publication Number:
  US 20160097490A1
• Time in Patent Office: 1,495 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 9/232 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 9/90 Methods of manufacture
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 29/506 of globes, bowls or cover glasses
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21V 3/06 characterised by the material
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

An illumination device includes a carrier, at least two light sources mounted on a first side of a carrier, and an envelope at least partially enclosing light sources and the carrier. At least one of the light sources is mounted on a portion of the carrier and at least another one of the light sources is mounted on a different portion of the carrier, and the carrier is folded such that the second side of the first portion of the carrier at least partially faces the second side of the second portion of the carrier.

Claims

1. An illumination device, comprising:

at least two light sources arranged to emit light;

a carrier, having a first side and a second side, wherein the at least two light sources are coupled to the first side of the carrier;

an envelope comprising at least two enveloping parts that are joined together to form the envelope, which at least partially encloses the at least two light sources and the carrier; and

a thermal conductor arranged in thermal contact with the second side of the carrier, at least a portion of the envelope, and both an inner surface and an outer surface of at least one enveloping part of the at least two enveloping parts, enabling heat to be dissipated via the thermal conductor, wherein the thermal conductor is further arranged at a junction between at least two of the enveloping parts;

wherein a light source of the at least two light sources is coupled to a first portion of the carrier and another light source of the at least two light sources is coupled to a second portion of the carrier, wherein the first portion and the second portion of the carrier each form different regions of the carrier, and

wherein the carrier is folded such that;

the second side of the first portion of the carrier at least partially faces the second side of the second portion of the carrier, and the thermal conductor is arranged between the first portion of the carrier and the second portion of the carrier.

2. The illumination device according to claim 1, wherein the envelope comprises ceramic, glass, plastic, or paper.

3. The illumination device according to claim 1, further comprising:

at least one driver circuit that is coupled to the first portion or the second portion of the carrier, wherein the at least one driver circuit is adapted to supply current to at least one light source of the light sources.

4. The illumination device according to claim 1, wherein the carrier is arranged such that the second side of the first portion of the carrier and the second side of the second portion of the carrier are parallel.

5. The illumination device according to claim 1, wherein the carrier is a printed circuit board or a lead frame.

6. The illumination device according to claim 1, wherein the first portion or the second portion of the carrier is aligned with a longitudinal axis extending from a base of the illumination device.

7. The illumination device according to claim 1, wherein the envelope comprises a reflective region arranged to reflect at least part of the light emitted by the light sources.

8. The illumination device according to claim 1, wherein the thermal conductor comprises one or more metal strips.

9. The illumination device according to claim 1, wherein the thermal conductor comprises one or more heat pipe strips.

10. The illumination device according to claim 1, wherein the envelope and carrier are fixated in a socket assembly.

11. A system, comprising:

at least two light sources arranged to emit light;

a carrier, having a first side and a second side, wherein the at least two light sources are coupled to the first side of the carrier;

an envelope comprising at least two enveloping parts that are joined together to form the envelope, which at least partially encloses the at least two light sources and the carrier; and

a thermal conductor arranged in thermal contact with the second side of the carrier, at least a portion of the envelope, and both an inner surface and an outer surface of at least one enveloping part of the at least two enveloping parts, enabling heat to be dissipated via the portion of the thermal conductor, wherein the thermal conductor is further arranged at a junction between at least two of the enveloping parts;

wherein a light source of the at least two light sources is coupled to a first portion of the carrier and another light source of the light sources is coupled to a second portion of the carrier, wherein the first portion and the second portion of the carrier each form different regions of the carrier, and

wherein the carrier is folded such that;

the second side of the first portion of the carrier at least partially faces the second side of the second portion of the carrier, and the thermal conductor is arranged between the first portion of the carrier and the second portion of the carrier.

12. The system according to claim 11, wherein the thermal conductor comprises one or more metal strips.

13. The system according to claim 11, wherein the thermal conductor comprises one or more heat pipe strips.

14. The system according to claim 11, wherein the envelope and carrier are fixated in a socket assembly.

15. The system according to claim 11, wherein the envelope comprises ceramic, glass, plastic, or paper.

16. A method of manufacturing an illumination device, the method comprising:

providing at least two light sources;

providing a carrier, having a first side and a second side;

coupling the at least two light sources to the first side of the carrier such that at least one of the light sources is coupled to a first portion of the carrier and at least another of the light sources is coupled to a second portion of the carrier, wherein the first portion and second portion of the carrier each form different regions of the carrier,

providing an envelope that includes at least two enveloping parts that are joined together to form the envelope, which is arranged to at least partially enclose the at least two light sources and the carrier;

arranging a thermal conductor to be in thermal contact with the second side of the carrier, at least a portion of the envelope, and both an inner surface and an outer surface of at least one enveloping part of the at least two enveloping parts enabling heat to be dissipated via the thermal conductor, wherein the thermal conductor is further arranged at a junction between the at least two enveloping parts; and

folding the carrier such that;

the second side of the first portion of the carrier at least partially faces the second side of the second portion of the carrier, and the thermal conductor is arranged between the first portion of the carrier and the second portion of the carrier.

17. The method according to claim 16, wherein the envelope comprises ceramic, glass, plastic, or paper.

18. The method according to claim 16, further comprising coupling at least one driver circuit to the first portion or the second portion of the carrier, wherein the at least one driver circuit is adapted to supply current to at least one of the light sources.

19. The method according to claim 16, further comprising:

arranging a reflective region of the envelope to reflect at least part of the light emitted by the light sources.

20. The method according to claim 16, further comprising:

arranging the carrier and the envelope in a socket assembly.