VERSATILE SEALED LED LAMP

• US 20120127707A1
• Filed: 08/11/2010
• Published: 05/24/2012
• Est. Priority Date: 08/12/2009
• Status: Active Grant

• Current Assignee: Edward Bryant Stoneham
• Original Assignee: Edward Bryant Stoneham
• Inventors: Stoneham, Edward Bryant
• Granted Patent: US 9,322,542 B2
• Time in Patent Office: Days
• US Class Current: 362/231
• CPC Class Codes: F21S 4/28 rigid, e.g. LED bars
• CPC Class Codes: F21V 29/71 using a combination of separate elements interconnected by heat-conducting means, e.g. with heat pipes or thermally conductive bars between separate heat-sink elements
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A lamp assembly (1800) may include a circuit board (201), one or more light-emitting devices (100) disposed on the circuit board (201), a heat sink (600) in thermal contact with a surface of the circuit board (201), a gasket (700) with a first surface in mechanical contact with the circuit board (201), a bezel (800) a surface (805) of which is in mechanical contact with a second surface of the gasket (700), and one or more fasteners (901) that may apply a force between the bezel (800) and the heat sink (600). A lamp array (2100) may include two or more lamp assemblies (1800), not all of which supply illumination with the same spectral characteristic, and a bearing mount (2000) that may support each lamp assembly (1800) and allow each to be oriented rotationally. A supply circuit (2500, 2600) may include a nonlinear resistive element (2501, 2601).

Claims

1. A lamp assembly comprising:

a circuit board having an electrically insulating layer of material, a thermally conductive backing layer, and one or more electrically conductive traces disposed on a first major surface of the electrically insulating layer of material an opposing surface of which is in thermal contact with a surface of the thermally conductive backing layer;

one or more light-emitting devices disposed on the circuit board, in thermal contact with the circuit board, and in electrical contact with at least one of the electrically conductive traces;

a heat sink composed of thermally conductive material a surface of which is in thermal contact with the thermally conductive backing layer;

a gasket having a first surface and an opposing second surface, the first surface being in mechanical contact with a surface of the circuit board;

a bezel a surface of which is in mechanical contact with the second surface of the gasket; and

one or more fasteners configured to apply force between the bezel and the heat sink resulting in the application of pressure between the bezel and the gasket, between the gasket and the circuit board, and between the circuit board and the heat sink.

2. The lamp assembly according to claim 1, wherein the one or more fasteners include a screw or a rivet that either passes through or engages the bezel and either passes through or engages the heat sink.

3. The lamp assembly according to claim 1, wherein the one or more fasteners include a clamp or a clamping mechanism.

4. The lamp assembly according to claim 1, wherein the one or more electrically conductive traces includes a first electrically conductive trace in proximity to an edge of the circuit board, the presence of which first electrically conductive trace results in a raised portion of the circuit board, which raised portion is in contact with the gasket.

5. The lamp assembly according to claim 4, wherein the first electrically conductive trace is continuous along and spaced from the edge, and forms a border that separates a portion of the circuit board near the edge from a portion of the circuit board distal from the edge.

6. The lamp assembly according to claim 4, wherein the first electrically conductive trace is not electrically connected to a light-emitting device.

7. The lamp assembly according to claim 6, wherein the first electrically conductive trace is not electrically connected to any other electrical conductor.

8. The lamp assembly according to claim 1, further comprising an electrically conductive wire a first end of which is electrically connected to the circuit board and a second end of which is distal to the circuit board, the gasket, and the bezel.

9. The lamp assembly according to claim 8, wherein a gap extends through the gasket, through which gap the electrically conductive wire passes.

10. The lamp assembly according to claim 9, wherein the circuit board, the bezel and the gasket form a tunnel through which the electrically conductive wire passes, wherein space in the tunnel not occupied by the electrically conductive wire is filled with a sealant to prevent flow of fluids through the tunnel.

11. The lamp assembly according to claim 10, wherein the sealant is a silicone rubber material.

12. The lamp assembly according to claim 9, wherein the bezel and the circuit board exert sufficient pressure from opposing sides on the electrically conductive wire extending through the gap to resist movement of the electrically conductive wire through the gap.

13. The lamp assembly according to claim 1, wherein the gasket is composed of a material that is reflective of light, its reflectivity being at least fifty percent.

14. The lamp assembly according to claim 1, wherein the gasket is composed of a silicone rubber compound.

15. The lamp assembly according to claim 14, wherein the silicone rubber compound contains particles that reflect light and cause the silicone rubber compound to reflect light, its reflectivity being at least fifty percent.

16. The lamp assembly according to claim 1, wherein a portion of the surface of the circuit board is coated with a coating substance that is reflective of light, its reflectivity being at least fifty percent.

17. The lamp assembly according to claim 16, wherein the coating substance includes a white or silver-colored soldermask material.

18. The lamp assembly according to claim 16, wherein the coating substance includes a white or silver-colored silkscreen ink.

19. The lamp assembly according to claim 1, wherein the bezel includes a window configured to allow light emitted by a light-emitting device to escape from the lamp assembly.

20. The lamp assembly according to claim 19, wherein the edges of the window are beveled in a manner that reduces the amount of emitted light striking the bezel.

21. The lamp assembly according to claim 19, wherein the window is filled with a transparent material in such a way that fluids may not flow through the window to reach the light-emitting device or the circuit board.

22. The lamp assembly according to claim 21, wherein the transparent material makes optical contact to the light-emitting device and has an index of refraction between that of the surrounding atmosphere and that of the surface of the light-emitting device from which light is emitted.

23. The lamp assembly according to claim 21, wherein the transparent material is clear silicone rubber.

24. The lamp assembly according to claim 21, wherein the beveled surface is reflective of light, its reflectivity being at least fifty percent, and wherein the angle of the bevel is between 20 and 80 degrees with respect to the normal to the major plane of the window.

25. The lamp assembly according to claim 21, wherein the surface of the transparent material that is distal to the light-emitting device has a shape that through refraction distributes the light emerging from the lamp assembly over a wide range of angles.

26. The lamp assembly according to claim 25, wherein the surface of the transparent material that is distal to the light-emitting device has a shape that is flat, concave, meniscus-shaped, or multi-faceted.

27. The lamp assembly according to claim 21, wherein a portion of the transparent material contains light-scattering elements such as particles or bubbles.

28. The lamp assembly according to claim 8, further comprising an end axle mechanically attached to the heat sink and/or the bezel, the end axle including a shaft portion capable of being rotated in a bearing.

29. The lamp assembly according to claim 28, wherein the end axle includes a passageway along the axis of the shaft portion, through which passageway the electrically conductive wire passes.

30. The lamp assembly according to claim 28, wherein the end axle includes a first widened portion at a first end of the shaft portion, which first widened portion extends beyond the radius of the shaft portion in a direction normal to the axis of the shaft portion.

31. The lamp assembly according to claim 30, wherein the end axle includes a second widened portion at a second end of the shaft portion, which second widened portion extends beyond the radius of the shaft portion in a direction normal to the axis of the shaft portion.

32. The lamp assembly according to claim 28, wherein the end axle includes a knob on an end distal to the bezel and the heat sink, which knob can facilitate rotation by hand of the lamp about the axis of the shaft portion.

33. A lamp array comprising:

two or more lamp assemblies, one of which supplies illumination with a first spectral characteristic and another of which supplies illumination with a second spectral characteristic different from the first spectral characteristic, each of which lamp assemblies includes two or more light-emitting devices, and

a bearing mount having one or more bearings supporting each lamp assembly in a manner that allows each lamp assembly to be individually oriented rotationally about an axis of rotation.

34. The lamp array according to claim 33, wherein the light-emitting devices in each lamp assembly are arranged in a line having a direction.

35. The lamp array according to claim 34, wherein the lamp assemblies are positioned such that the direction of the line is substantially the same for all of the lamp assemblies.

36. The lamp array according to claim 35, wherein the lamp assemblies are positioned in two or more rows in each of which the lines in which the light-emitting devices are arranged in the lamp assemblies are collinear and in which every lamp assembly in the same row supplies illumination with the same spectral characteristic.

37. The lamp array according to claim 36, wherein the rows are all substantially in the same plane and are spaced between two inches and twelve inches apart.

38. The lamp array according to claim 36, wherein the spectral characteristic of the lamp assemblies in each row results in light of a distinct color, with the color of the light from a first row being substantially red, the color of the light from a second row being substantially red-orange or orange, the color of the light from a third row being substantially green, the color of the light from a fourth row being substantially cyan, and the color of the light from a fifth row being substantially blue or blue-violet.

39. A supply circuit comprising:

an output terminal for providing current to a load;

a drive voltage terminal for receiving an electromotive force for driving current through a load; and

a nonlinear resistive element with a first terminal electrically connected to the drive voltage terminal and a second terminal electrically connected to the output terminal, the nonlinear resistive element having a dynamic electrical resistance that varies with the magnitude of the electrical current through the nonlinear resistive element, the resistance tending to rise when the magnitude of the electrical current rises and to fall when the magnitude of the electrical current falls.

40. The supply circuit according to claim 39, wherein the nonlinear resistive element includes a filament that is heated by electrical current flowing through the filament, which filament has a dynamic electrical resistance that increases as the filament rises in temperature.

41. The supply circuit according to claim 40, wherein the nonlinear resistive element is an incandescent lamp.

42. The supply circuit according to claim 39, further comprising:

a first alternating-current power terminal for providing alternating current to a circuit;

a second alternating-current power terminal for returning alternating current from a circuit;

a common terminal for returning current from a load; and

a rectifier with a first alternating-current input terminal electrically connected to the first alternating-current power terminal, a second alternating-current input terminal electrically connected to the second alternating-current power terminal, a first direct-current output terminal electrically connected to the drive voltage terminal, and a second direct-current output terminal electrically connected to the common terminal.

43. The supply circuit according to claim 42, further comprising:

a filter capacitor one terminal of which is electrically connected to the drive voltage terminal and the other terminal of which is electrically connected to the common terminal.

44. The supply circuit according to claim 42, further comprising:

a line input terminal for receiving power from a power line; and

a current-impeding circuit for limiting the magnitudes of current surges that may result from surges in voltage on a power line, the current-impeding circuit having a first terminal electrically connected to the line input terminal and a second terminal electrically connected to the first alternating-current power terminal.

45. The supply circuit according to claim 44, wherein the current-impeding circuit includes as an element a resistor, an inductor, a capacitor, a current limiter, or a series combination of two or more of these elements.

46. The supply circuit according to claim 45, wherein the current limiter includes:

a current limiter input terminal;

a current limiter output terminal;

a current limiter control terminal;

a current limiter feedback terminal;

a blocking transistor having a control electrode electrically connected to the current limiter control terminal, an inverting electrode electrically connected to the current limiter input terminal, and a non-inverting electrode electrically connected to the current limiter feedback terminal;

a control transistor having a control electrode electrically connected to the current limiter feedback terminal, an inverting electrode electrically connected to the current limiter control terminal, and a non-inverting electrode electrically connected to the current limiter output terminal;

a feedback resistor having one terminal electrically connected to the current limiter feedback terminal and another terminal electrically connected to the current limiter output terminal; and

a bias resistor having one terminal electrically connected to the current limiter input terminal and another terminal electrically connected to the current limiter control terminal.

47. The supply circuit according to claim 46, further comprising a capacitor having one terminal electrically connected to the current limiter control terminal and another terminal electrically connected to the current limiter output terminal.

48. The supply circuit according to claim 46, further comprising one or more auxiliary blocking circuits, each of which auxiliary blocking circuits is comprised of:

an auxiliary feedback terminal;

an auxiliary blocking transistor having a control electrode electrically connected to the current limiter control terminal, an inverting electrode electrically connected to the current limiter input terminal, and a non-inverting electrode electrically connected to the auxiliary blocking circuit'"'"'s auxiliary feedback terminal; and

an auxiliary feedback resistor having one terminal electrically connected to the auxiliary blocking circuit'"'"'s auxiliary feedback terminal and another terminal electrically connected to the current limiter output terminal.

49. The supply circuit according to claim 48, wherein the auxiliary blocking transistor in each auxiliary blocking circuit is substantially identical in characteristics to the blocking transistor, and the auxiliary feedback resistor in each auxiliary blocking circuit is substantially identical in characteristics to the feedback resistor.

50. The supply circuit according to claim 46, wherein the blocking transistor and the control transistor are each one of an NPN bipolar junction transistor or an N-channel field effect transistor.

51. The supply circuit according to claim 46, wherein the blocking transistor and the control transistor are each one of a PNP bipolar junction transistor or a P-channel field effect transistor.

52. A supply circuit comprising:

an output terminal for providing current to a load;

a common terminal for returning current from a load;

a drive voltage terminal for receiving the electromotive force for driving current through a load;

a surge-limiting circuit having a first terminal electrically connected to the drive voltage terminal and having a second terminal electrically connected to the output terminal, which surge-limiting circuit is capable of limiting the magnitudes of current surges that may result from temporary excesses in electromotive force between the drive voltage terminal and the common terminal;

a first alternating-current power terminal for providing alternating current to a circuit;

a second alternating-current power terminal for returning alternating current from a circuit;

a rectifier with a first alternating-current input terminal electrically connected to the first alternating-current power terminal, a second alternating-current input terminal electrically connected to the second alternating-current power terminal, a first direct-current output terminal electrically connected to the drive voltage terminal, and a second direct-current output terminal electrically connected to the common terminal;

a line input terminal for obtaining power from a power line; and

a current-impeding circuit having one terminal electrically connected to the line input terminal and another terminal electrically connected to the first alternating-current power terminal, which current-impeding circuit is capable of limiting the magnitudes of current surges that may result from surges in the electric potential between the line input terminal and the second alternating-current power terminal, and which current-impeding circuit includes a nonlinear resistive element having a dynamic electrical resistance that varies with the magnitude of the electrical current through the nonlinear resistive element, the resistance tending to rise when the magnitude of the electrical current rises and to fall when the magnitude of the electrical current falls, and which current-impeding circuit causes to flow through the nonlinear resistive element most of the electrical current that flows through the current-impeding circuit from the line input terminal to the first alternating-current power terminal.

53. The supply circuit according to claim 52, wherein the nonlinear resistive element includes a filament that is heated by electrical current flowing through the filament, which filament has a dynamic electrical resistance that increases as the filament rises in temperature.

54. The supply circuit according to claim 53, wherein the nonlinear resistive element is an incandescent lamp.

55. The supply circuit according to claim 52, further comprising a filter capacitor one terminal of which is electrically connected to the drive voltage terminal and the other terminal of which is electrically connected to the common terminal.

56. The supply circuit according to claim 52, wherein the surge-limiting circuit includes as an element a resistor, an inductor, or a current limiter, or a series combination of two or more of these elements.

57. The supply circuit according to claim 56, wherein the current limiter includes:

a current limiter input terminal;

a current limiter output terminal;

a current limiter control terminal;

a current limiter feedback terminal;

a blocking transistor having a control electrode electrically connected to the current limiter control terminal, an inverting electrode electrically connected to the current limiter input terminal, and a non-inverting electrode electrically connected to the current limiter feedback terminal;

a control transistor having a control electrode electrically connected to the current limiter feedback terminal, an inverting electrode electrically connected to the current limiter control terminal, and a non-inverting electrode electrically connected to the current limiter output terminal;

a feedback resistor having one terminal electrically connected to the current limiter feedback terminal and another terminal electrically connected to the current limiter output terminal; and

a bias resistor having one terminal electrically connected to the current limiter input terminal and another terminal electrically connected to the current limiter control terminal.

58. The supply circuit according to claim 57, further comprising a capacitor having one terminal electrically connected to the current limiter control terminal and another terminal electrically connected to the current limiter output terminal.

59. The supply circuit according to claim 57, further comprising one or more auxiliary blocking circuits, each of which auxiliary blocking circuits comprises:

an auxiliary feedback terminal;

an auxiliary blocking transistor having a control electrode electrically connected to the current limiter control terminal, an inverting electrode electrically connected to the current limiter input terminal, and a non-inverting electrode electrically connected to the auxiliary blocking circuit'"'"'s auxiliary feedback terminal; and

an auxiliary feedback resistor having one terminal electrically connected to the auxiliary blocking circuit'"'"'s auxiliary feedback terminal and another terminal electrically connected to the current limiter output terminal.

60. The supply circuit according to claim 59, wherein the auxiliary blocking transistor in each auxiliary blocking circuit is substantially identical in characteristics to the blocking transistor, and the auxiliary feedback resistor in each auxiliary blocking circuit is substantially identical in characteristics to the feedback resistor.

61. The supply circuit according to claim 57, wherein the blocking transistor and the control transistor are each one of an NPN bipolar junction transistor or an N-channel field effect transistor.

62. The supply circuit according to claim 57, wherein the blocking transistor and the control transistor are each one of a PNP bipolar junction transistor or a P-channel field effect transistor.