Flexible substrate mounted solid-state light sources for use in line current lamp sockets

• US 6,580,228 B1
• Filed: 08/22/2000
• Issued: 06/17/2003
• Est. Priority Date: 08/22/2000
• Status: Expired due to Fees

• Current Assignee: Effectively Illuminated Pathways LLC (IPNav)
• Original Assignee: Light Sciences Corporation
• Inventors: Wiscombe, Brent, Chen, James C., Huston, Darrin
• Primary Examiner(s): Philogene, Haissa
• Application Number:
  US09/644,253
• Time in Patent Office: 1,029 Days
• Field of Search: 315/185.R, 315/185.S, 315/192, 315/206, 315/276, 315/324, 315/294, 315/51, 315/70, 362/800, 362/294, 362/240
• US Class Current: 315/185.00R
• 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 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 3/06 characterised by the material
• CPC Class Codes: F21V 3/061 the material being glass
• CPC Class Codes: F21V 3/062 the material being plastics
• 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 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A lamp using solid-state light emitting sources is configured to be used in a conventional socket. The lamp includes a flexible substrate on which are mounted a plurality of light emitting sources, such as light emitting diodes (LEDs) in spaced-apart array. In one embodiment, a flexible substrate configured as a generally rectangular panel formed into a cylindrical shape includes a plurality of conductive traces to which the LEDs are connected both mechanically and electrically. The flexible substrate is then enclosed within a light transmissive translucent cover that is attached to a base in which is disposed a power supply. The base is shaped and configured to be threaded into a conventional incandescent light socket and includes a center terminal through which AC line power is supplied to the power supply. The power supply provides an appropriate voltage and current to energize the light sources so that they produce a white light that is emitted radially outward around a longitudinal axis of the lamp. In a different embodiment, the light sources are mounted on a flexible substrate formed as a strand or thread that is wound in a helix around a cylindrical support. The light sources are also provided on a flap that covers the end of the cylinder so that light is emitted through the top or end of the cover. Also included is a solid-state lamp adapted to work in a conventional three-way socket.

Claims

1. A lamp for use in a conventional line current powered incandescent lamp socket, for providing area or task lighting, comprising:

(a) a base that is adapted to electrically and mechanically engage a conventional line current powered incandescent lamp socket, to receive an alternating current (AC) via electrical terminals disposed on the base;

(b) a power supply electrically connected to the electrical terminals on the base, said power supply receiving the AC and providing an output electrical current;

(c) a flexible substrate strand on which are disposed a plurality of electrical conductors, said flexible substrate strand having one end disposed adjacent to the base, said plurality of electrical conductors being electrically connected to the output of the power supply;

(d) a plurality of solid-state light sources mounted on an outer surface of the flexible substrate strand in a spaced-apart array that is configured so that light emitted by the plurality of solid-state light sources when they are electrically energized by the electrical current radiates outwardly about an entire circumference of the lamp, each of said plurality of solid-state light sources being electrically connected to the plurality of electrical conductors disposed on the flexible substrate strand, enabling the plurality of solid-state light sources to be energized by the electrical current produced by the power supply; and

(e) a light transmissive envelope having an end attached to the base, said envelope enclosing the flexible substrate strand and the plurality of solid-state light sources, providing protection to the plurality of solid-state light sources, while transmitting the light emitted by the plurality of solid-state light sources generally radially outward from the lamp.

2. The lamp of claim 1, wherein the plurality of solid-state light sources comprise light emitting diodes that emit a white light.

3. The lamp of claim 1, wherein the plurality of conductors disposed on the flexible substrate strand are configured to electrically couple at least a portion of the plurality of solid-state light sources in parallel with each other.

4. The lamp of claim 1, wherein the plurality of conductors disposed on the flexible substrate strand extend substantially in alignment with each other along a surface of the flexible substrate strand.

5. The lamp of claim 1, wherein the power supply comprises a transformer.

6. The lamp of claim 1, wherein the power supply includes a rectifier.

7. The lamp of claim 1, wherein the plurality of solid-state light sources are mounted on the flexible substrate strand with one of a conductive adhesive and solder.

8. The lamp of claim 1, wherein the plurality of solid-state light sources each include at least one terminal that is coupled to at least one of the plurality of conductors on the flexible substrate strand by a conductive lead.

9. The lamp of claim 1, further comprising a cylindrical support for the flexible substrate strand, said flexible substrate strand being helically wound around an outer surface of the cylindrical support.

10. The lamp of claim 1, wherein the base includes three electrical terminals that are adapted to electrically connect with corresponding terminals of a three-way incandescent lamp socket, at least two of said three electrical terminals of the base being connected to the power supply, said power supply responding to application of an AC line voltage to specific ones of the electrical terminals to provide an electrical current to energize a predetermined portion of the plurality of solid-state light sources, thereby varying a light intensity produced by the plurality of solid-state light sources as a function of the electrical terminals that are energized with the AC line voltage.

11. The lamp of claim 9, wherein the cylindrical support includes an end portion opposite the base, a portion of said flexible substrate strand being disposed on said end portion, such that said end portion also includes a plurality of the solid-state light sources disposed thereon in a spaced-apart array.

12. The lamp of claim 1, wherein the power supply is disposed within the base.

13. The lamp of claim 1, wherein the light transmissive envelope is generally cylindrical.

14. The lamp of claim 9, wherein the cylindrical support for the flexible substrate strand comprises at least one of a plastic material and a phenolic resin material.

15. The lamp of claim 9, wherein the cylindrical support for the flexible substrate strand comprises an electrically insulating material.

16. A lamp adapted to replace an incandescent lamp in a conventional line voltage alternating current (AC) lamp socket, comprising:

(a) a base having male threads and sized so that it is adapted to be threaded into a conventional line voltage AC lamp socket, said base including electrical terminals adapted to contact corresponding electrical terminals in a conventional line voltage AC lamp socket;

(b) a flexible substrate that is formed so as to generally define a cylinder and which includes a plurality of conductive traces disposed thereon, said flexible substrate comprising an end section being disposed over and generally closing an end of the cylinder;

(c) a first plurality of solid-state light sources disposed on an outer surface of the flexible substrate in a spaced-apart array, and a second plurality of solid-state light sources disposed on an outer surface of said end section, each of said first and second plurality of solid-state light sources being connected to the plurality of conductive traces, and when energized by an electrical current, each first solid-state light source emitting substantially white light that is directed outwardly away from the flexible substrate and radially outwardly from the lamp, and each second solid-state light source emitting substantially white light that is directed outwardly away from the end section;

(d) a power supply disposed in the base and electrically connected to the terminals to enable the power supply to receive input current therefrom, said power supply being connected to the conductive traces on the flexible substrate and when supplied with a line voltage AC, producing an electrical current at a voltage sufficient to energize the first and second pluralities of solid-state light sources; and

(e) a light transmissive cover sized and shaped to enclose and protect the plurality of solid-state light sources mounted on the flexible substrate, the light emitted by the plurality of solid-state light sources being transmitted through the cover.

17. The lamp of claim 16, wherein the power supply limits at least one of the electrical current and the voltage applied to energize the first and second pluralities of solid-state light sources to magnitudes that do not damage the first and second pluralities of solid-state light sources.

18. The lamp of claim 16, therein the first and second pluralities of solid-state light sources are connected in parallel to the power supply via the plurality of conductive traces.

19. The lamp of claim 16, wherein the light transmissive cover is generally cylindrical.

20. The lamp of claim 16, wherein the terminals include a center terminal, an annular terminal, and a threaded terminal, said center terminal and said annular terminal being adapted to electrically connect with corresponding terminals in a three-way lamp socket that includes a four-position switch, when the threaded terminal of the lamp is mated with a three-way lamp socket.

21. The lamp of claim 20, wherein the power supply energizes a different portion of at least one of the first and second pluralities of solid-state light sources as a function of whether an AC line voltage is applied to the threaded terminal and:

(a) the center terminal; and

/or

(b) the annular terminal.

22. The lamp of claim 16, wherein the cover is formed of one of a glass and a plastic material.

23. The lamp of claim 16, wherein the cover diffuses the white light emitted by the first and second pluralities of solid-state light sources.

24. The lamp of claim 16, wherein each of the solid-state light sources comprises a light emitting diode.

25. A lamp for use in a conventional line current powered incandescent lamp socket, for providing area or task lighting, comprising:

(a) a base that is adapted to electrically and mechanically engage a conventional line current powered incandescent lamp socket, to receive an alternating current (AC) via electrical terminals disposed on the base, said base including three electrical terminals that are adapted to electrically connect at least two of said three electrical terminals of the base with corresponding terminals of a three-way incandescent lamp socket;

(b) a power supply electrically connected to at least two of said three electrical terminals of the base, said power supply receiving the AC and providing an output electrical current;

(c) a flexible substrate on which are disposed a plurality of electrical conductors, said flexible substrate being formed to generally define a cylindrical shape and having one end disposed adjacent to the base, said plurality of electrical conductors being electrically connected to the output of the power supply;

(d) a plurality of solid-state light sources mounted on an outer surface of the flexible substrate in a spaced-apart array that is configured so that light emitted by the plurality of solid-state light sources when they are electrically energized by the electrical current radiates outwardly about a circumference of the lamp, each of said plurality of solid-state light sources being electrically connected to the plurality of electrical conductors disposed on the flexible substrate, enabling the plurality of solid-state light sources to be energized by the electrical current produced by the power supply, such that said power supply responds to application of an AC line voltage to specific ones of the electrical terminals to provide an electrical current to energize a predetermined portion of the plurality of solid-state light sources, thereby varying a light intensity produced by the plurality of solid-state light sources as a function of the electrical terminals that are energized with the AC line voltage; and

(e) a generally cylindrical light transmissive envelope having an end attached to the base, said envelope enclosing the flexible substrate and the plurality of solid-state light sources, providing protection to the plurality of solid-state light sources, while transmitting the light emitted by the plurality of solid-state light sources generally radially outward from the lamp.

26. A lamp for use in a conventional line current powered incandescent lamp socket, for providing area or task lighting, comprising:

(a) a base that is adapted to electrically and mechanically engage a conventional line current powered incandescent lamp socket, to receive an alternating current (AC) via electrical terminals disposed on the base;

(b) a power supply electrically connected to the electrical terminals on the base, said power supply receiving the AC providing an output electrical current;

(c) a flexible substrate on which are disposed a plurality of electrical conductors, said flexible substrate being formed to generally define a cylindrical shape and having a first end disposed adjacent to the base, and a second end opposite said first end, said plurality of electrical conductors being electrically connected to the output of the power supply;

(d) a plurality of solid-state light sources mounted on an outer surface of the flexible substrate, and on an outer surface of said second end, said plurality of solid-state light sources being configured in a spaced-apart array that enables light emitted by the plurality of solid-state light sources, when they are electrically energized by the electrical current, to radiate outwardly about an entire circumference of the lamp and outwardly from said second end, each of said plurality of solid-state light sources being electrically connected to the plurality of electrical conductors disposed on the flexible substrate, enabling the plurality of solid-state light sources to be energized by the electrical current produced by the power supply; and

(e) a generally cylindrical light transmissive envelope having an end attached to the base, said envelope enclosing the flexible substrate and the plurality of solid-state light sources, providing protection to the plurality of solid-state light sources, while transmitting the light emitted by the plurality of solid-state light sources generally outward from the lamp.

27. A lamp adapted to replace an incandescent lamp in a conventional line voltage alternating current (AC) lamp socket, comprising:

(a) a base having male threads and sized so that it is adapted to be threaded into a conventional line voltage AC lamp socket, said base including electrical terminals adapted to contact corresponding electrical terminals in a conventional line voltage AC lamp socket;

(b) a flexible substrate that is formed so as to generally define a cylinder, said flexible substrate including an end section disposed over and generally closing an end of the cylinder, said flexible substrate including a plurality of conductive traces disposed thereon;

(c) a plurality of solid-state light sources disposed on an outer surface of the flexible substrate, including an outer surface of said end section, in a spaced-apart array, each of said plurality of solid-state light sources being connected to the plurality of conductive traces, and when energized by an electrical current, emitting substantially white light that is directed outwardly away from the flexible substrate, both radially outwardly from the lamp, and away from the end section of the flexible substrate;

(d) a power supply disposed in the base and electrically connected to the terminals to enable the power supply to receive input current therefrom, said power supply being connected to the conductive traces on the flexible substrate and when supplied with a line voltage AC, producing an electrical current at a voltage sufficient to energize the plurality of solid-state light sources; and

(e) a light transmissive cover sized and shaped to enclose and protect the plurality of solid-state light sources mounted on the flexible substrate, the light emitted by the plurality of solid-state light sources being transmitted through the cover.

28. A lamp adapted to replace an incandescent lamp in a conventional line voltage alternating current (AC) lamp socket, comprising:

(a) a base having male threads and sized so that it is adapted to be threaded into a conventional line voltage AC lamp socket, said base including electrical terminals adapted to contact corresponding electrical terminals in a conventional line voltage AC lamp socket, said terminals including a center terminal, an annular terminal, and a terminal comprising the male threads, said center terminal and said annular terminal being adapted to electrically connect with corresponding terminals in a three-way lamp socket that includes a four-position switch, when the male threads of the lamp are mated with corresponding female threads of a three-way lamp socket;

(b) a flexible substrate that is formed so as to generally define a cylinder and which includes a plurality of conductive traces disposed thereon;

(c) a plurality of solid-state light sources disposed on an outer surface of the flexible substrate in a spaced-apart array, each of said plurality of solid-state light sources being connected to the plurality of conductive traces, and when energized by an electrical current, emitting substantially white light that is directed outwardly away from the flexible substrate and radially outwardly from the lamp;

(d) a power supply disposed in the base and electrically connected to the terminals to enable the power supply to receive input current therefrom, said power supply being connected to the conductive traces on the flexible substrate and when supplied with a line voltage AC, producing an electrical current at a voltage sufficient to energize the plurality of solid-state light sources; and

(e) a light transmissive cover sized and shaped to enclose and protect the plurality of solid-state light sources mounted on the flexible substrate, the light emitted by the plurality of solid-state light sources being transmitted through the cover.

29. The lamp of claim 28, wherein the power supply energizes a different portion of the plurality of solid-state light sources as a function of whether an AC line voltage is applied to the terminal coupled to the male threads, and to:

(a) the center terminal; and

/or

(b) the annular terminal.

30. A lamp for use in a conventional line current powered incandescent lamp socket, for providing area or task lighting, comprising:

(a) a base that is adapted to electrically and mechanically engage a conventional line current powered incandescent lamp socket, to receive an alternating current (AC) via electrical terminals disposed on the base;

(b) a power supply electrically connected to the electrical terminals on the base, said power supply receiving the AC providing an output electrical current;

(c) a flexible substrate being formed to generally define a cylindrical shape and having one end disposed adjacent to the base, said flexible substrate having an outer surface on which are disposed a plurality of electrical conductors, said plurality of electrical conductors being electrically connected to the output of the power supply;

(d) a plurality of solid-state light sources mounted on said outer surface of the flexible substrate in a spaced-apart array that is configured so that light emitted by the plurality of solid-state light sources when they are electrically energized by the electrical current radiates outwardly about an entire circumference of the lamp, each of said plurality of solid-state light sources being electrically connected to the plurality of electrical conductors disposed on the flexible substrate, enabling the plurality of solid-state light sources to be energized by the electrical current produced by the power supply;

said solid-state light sources being selected to produce visible light useful for at least one of task lighting and area lighting; and

(e) a light transmissive envelope having an end attached to the base, said envelope enclosing the flexible substrate and the plurality of solid-state light sources, providing protection to the plurality of solid-state light sources, while transmitting the light emitted by the plurality of solid-state light sources generally outward from the lamp.