Utility lamp

• US 7,275,841 B2
• Filed: 08/08/2006
• Issued: 10/02/2007
• Est. Priority Date: 02/17/2004
• Status: Expired due to Fees

• Current Assignee: William M. Kelly
• Original Assignee: William M. Kelly
• Inventors: Kelly, William M
• Primary Examiner(s): Husar; Stephen F.
• Assistant Examiner(s): Dunwiddie; Meghan K.
• Application Number:
  US11/500,422
• Publication Number:
  US 20060268555A1
• Time in Patent Office: 420 Days
• Field of Search: 362/294, 362/296, 362/341, 362/344, 362/373, 362/345, 362/800, 257/98
• US Class Current: 362/345
• CPC Class Codes: F21K 9/233 specially adapted for generating a spot light distribution, e.g. for substitution of reflector lamps
• CPC Class Codes: F21L 14/023 having two or more, or different light sources
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 19/001 the light sources being semiconductors devices, e.g. LEDs
• CPC Class Codes: F21V 29/505 of reflectors
• 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 29/767 the planes containing the fins or blades having directions perpendicular to the light emitting axis
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/777 the planes containing the fins or blades having directions perpendicular to the light emitting axis
• CPC Class Codes: F21V 5/048 the lens being a simple lens adapted to cooperate with a point-like source for emitting mainly in one direction and having an axis coincident with the main light transmission direction, e.g. convergent or divergent lenses, plano-concave or plano-convex lenses
• CPC Class Codes: F21V 5/10 comprising photoluminescent material
• CPC Class Codes: F21V 7/0008 providing for indirect lighting
• CPC Class Codes: F21V 7/0025 Combination of two or more reflectors for a single light source array of reflectors for a cluster of light sources F21V7/0083
• CPC Class Codes: F21Y 2107/10 on concave supports or substrates, e.g. on the inner side of bowl-shaped supports
• 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: Y10S 362/80 Light emitting diode

Abstract

A utility lamp (1) comprises a curved reflector (2) having a spherically curved surface. An array of LEDs (3) is arranged in an electrical circuit on a thin substrate mounted via thermally conductive epoxy on a thermally-conductive base (4), which in turn forms an integral part of the reflector (2). The LEDs are mounted for efficient heat transfer by conduction to the reflector (2). The reflector (2) thus operates as both a light reflector and as a radiative heat sink. The heat radiating properties of the reflector are enhanced by integral fins (7) extending in the radial direction around the periphery of the reflector (2). The reflector (2) is of integral aluminium construction.

Claims

1. A utility lamp comprising:

a group of at least one light emitting diode;

a reflector comprising;

a base,

a wall having an internal light-reflecting surface, and thermal dissipation fins

the diode group being mounted on a thermally-conductive circuit board which is secured to the reflector base;

some emitted light reflects from the internal surface of the reflector wall, and

heat from the diode group is conducted into the reflector, and the reflector radiates this heat from its exposed surfaces;

wherein the reflector is of greater cross-sectional area at the base than at the wall;

wherein the fins extend from an external surface of the reflector wall, opposed to the internal light-reflecting surface;

wherein the circuit board comprises a metal layer; and

wherein each diode is of the surface mount type, the anode and cathode of which are soldered to metal tracks which have a thermal path to the reflector.

2. The lamp as claimed in claim 1, wherein the circuit board is secured to the reflector base by a thermally-conductive bonding agent.

3. The lamp as claimed in claim 1, wherein the metal layer underlies a multi-layer circuit board structure.

4. The lamp as claimed in claim 1, further comprising a diode drive circuit mounted in a housing on the reflector base on a side opposed to that of the diode group, the housing being in thermal contact with the reflector.

5. The lamp as claimed in claim 4, wherein an electrical connector fixture is secured to the housing.

6. The utility lamp as claimed in claim 1, wherein the reflector shape is spherical.

7. The utility lamp as claimed in claim 1, wherein the reflector shape is parabolic.

8. The utility lamp as claimed in claim 1, wherein the reflector shape is hyperbolic.

9. The utility lamp as claimed in claim 1, wherein the reflector shape is ellipsoidal.

10. The utility lamp as claimed in claim 1, further comprising an optical element mounted over the diode group.

11. The utility lamp as claimed in claim 1, further comprising an optical element mounted over the diode group;

and wherein the optical element comprises an internal reflector for reflecting light from the diode group onto the reflector.

12. The utility lamp as claimed in claim 11, wherein the internal reflector is of conical or frusto-conical shape.

13. The utility lamp as claimed in claim 11, wherein the internal reflector comprises a central aperture for narrow-angle light and a lens aligned with the aperture for focusing said light.

14. The utility lamp as claimed in claim 1, wherein the fins have an annular configuration, extending around the reflector.

15. A utility lamp comprising:

a group of at least one light emitting diode;

a reflector comprising;

a base,

a wall having an internal light-reflecting surface, and thermal dissipation fins

the diode group being mounted on a thermally-conductive circuit board which is secured to the reflector base;

some emitted light reflects from the internal surface of the reflector wall, and

heat from the diode group is conducted into the reflector, and the reflector radiates this heat from its exposed surfaces;

wherein the reflector is of greater cross-sectional area at the base than at the wall;

wherein the fins extend from an external surface of the reflector wall, opposed to the internal light-reflecting surface; and

wherein the lamp further comprises a diode drive circuit mounted in a housing on the reflector base on a side opposed to that of the diode group, the housing being in thermal contact with the reflector.

16. The lamp as claimed in claim 15, wherein an electrical connector fixture is secured to the housing.

17. A utility lamp comprising:

a group of at least one light emitting diode;

a reflector comprising;

a base,

a wall having an internal light-reflecting surface, and thermal dissipation fins

the diode group being mounted on a thermally-conductive circuit board which is secured to the reflector base;

some emitted light reflects from the internal surface of the reflector wall, and

heat from the diode group is conducted into the reflector, and the reflector radiates this heat from its exposed surfaces;

wherein the reflector is of greater cross-sectional area at the base than at the wall;

wherein the fins extend from an external surface of the reflector wall, opposed to the internal light-reflecting surface;

wherein the lamp further comprises an optical element mounted over the diode group;

wherein the optical element comprises an internal reflector for reflecting light from the diode group onto the reflector; and

wherein the internal reflector comprises a central aperture for narrow-angle light and a lens aligned with the aperture for focusing said light.