LED lamp with heat sink optic

• US 7,588,351 B2
• Filed: 09/27/2007
• Issued: 09/15/2009
• Est. Priority Date: 09/27/2007
• Status: Expired due to Fees

• Current Assignee: OSRAM Sylvania Inc. (Ams-Osram AG)
• Original Assignee: OSRAM Sylvania Inc. (Ams-Osram AG)
• Inventors: Meyer, William E
• Primary Examiner(s): Ward; John A
• Application Number:
  US11/904,339
• Publication Number:
  US 20090086492A1
• Time in Patent Office: 719 Days
• Field of Search: 362/235, 362/241, 362/243, 362/268, 362/650, 362/294, 362/297, 700/83, 700/87
• US Class Current: 362/294
• 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 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21V 13/14 the elements being filters or photoluminescent elements, reflectors and refractors
• CPC Class Codes: F21V 17/06 the fastening being onto or by the lampholder
• CPC Class Codes: F21V 29/00 Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems lighting fixtures combined with outlets for air-treatment systems F24F13/078
• CPC Class Codes: F21V 29/506 of globes, bowls or cover glasses
• CPC Class Codes: F21V 29/85 characterised by the material liquid coolants F21V29/56
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21V 3/049 Patterns or structured surfaces for diffusing light, e.g. frosted surfaces
• CPC Class Codes: F21V 3/10 characterised by coatings
• CPC Class Codes: F21V 5/045 the lens having discontinuous faces, e.g. Fresnel lenses
• CPC Class Codes: F21V 5/10 comprising photoluminescent material
• CPC Class Codes: F21V 7/0008 providing for indirect lighting
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

An LED lamp may be made with a heat sink optic. The lamp has a base having a first electrical contact and a second electrical contact for receiving current. At least one LED is mounted on a thermally conductive support; that supports electrical connections for the LED and provides thermal conduction of heat from the LED to the optic. The LED support mounted in the base and electrically coupled through the first electrical contact to electrical current. The light transmissive, and heat diffusing optic has an external an internal wall defining a cavity with the LED positioned in the cavity. The optic is in thermal contact with the LED support and mechanically coupled to the base. The snap together structure enables rapid manufacture while allowing numerous variations.

Claims

1. An LED lamp with a heat sink optic comprising:

a base having a first electrical contact and a second electrical contact for receiving current;

at least one LED mounted on a thermally conductive LED support;

the LED support having at least one electrical connection for the at least one LED and providing thermal conduction of heat from the at least one LED;

the LED support mounted in the base and electrically coupled through the first electrical contact to electrical current; and

a light transmissive, and heat sink optic having an external wall and an internal wall defining a cavity, the at least one LED positioned in the cavity, the optic being in thermal contact with the LED support and diffusing heat from the at least one LED, the optic being mechanically coupled to the base.

2. The lamp in claim 1, wherein a light transmissive coupling material is in intimate contact with the at least one LED and with the optic.

3. The lamp in claim 1, wherein the optic includes at least one light refractive element.

4. The lamp in claim 1, wherein the optic includes a mechanical coupling for mating with the support of the at least one LED.

5. The lamp in claim 1, wherein the optic includes at least one refractive element formed on the exterior wall of the optic.

6. The lamp in claim 1, having a light diffusing element intermediate the at least one LED and the optic.

7. The lamp in claim 6, wherein the diffusing element is formed on a portion of the optic.

8. The lamp in claim 6, wherein the diffusing element is a separate body intermediate the optic and the at least one LED.

9. The lamp in claim 6, wherein the light coloring element is formed on a portion of the optic.

10. The lamp in claim 6, wherein the light coloring element is a separate body intermediate the optic and the at least one LED.

11. The lamp in claim 6, wherein the light deflecting element is a light refracting element.

12. The lamp in claim 6, wherein the light refracting element is a lens.

13. The lamp in claim 6, wherein the light deflecting element is a light reflecting element.

14. The lamp in claim 1, having a light coloring element intermediate the at least one LED and the optic.

15. The lamp in claim 1, having a light deflecting element intermediate the at least one LED and the optic.

16. The lamp in claim 1, wherein the LED support includes a first electrical contact in electrical contact with the base wall.

17. The lamp in claim 1, wherein the LED support includes a center contact in electrically contact with a center contact of the base.

18. The lamp in claim 1 wherein the optic is a light transmissive plastic such as polycarbonate plastic.

19. The lamp in claim 1 wherein the LED support includes a skirt portion in close mechanical contact with the optic.

20. The lamp in claim 19 wherein the skirt portion sets the axial positioning of the LED support with respect to the optic.

21. An LED lamp with a heat sink optic comprising:

a base having a first electrical contact and a second electrical contact for receiving current;

at least one LED mounted on a thermally conductive LED support;

the LED support having at least one electrical connection for the at least one LED and providing thermal conduction of heat from the at least one LED;

the LED support mounted in the base and electrically coupled through the first electrical contact to electrical current; and

a light transmissive, and heat sink optic having an external wall and an internal wall defining a cavity, the at least one LED positioned in the cavity, the optic being in thermal contact with the LED support and diffusing heat from the at least one LED, the optic being mechanically coupled to the base, and

wherein the optic comprises a cylindrical light guide optically coupled at a first end to the one or more LEDs and having a second end including a refractive element facing a field to be illuminated.

22. The lamp in claim 21, wherein the optic is formed from a light transparent ceramic selected from the group including:

glass and quartz.

23. The lamp in claim 21, wherein the optic is formed from a light transparent ceramic selected from the group including:

aluminum nitride (AlN), sapphire, alumina (Al₂O₃), and magnesium oxide (MgO).

24. The lamp in claim 21, wherein the optic is formed from a light transparent ceramic selected from the group including:

spinel, AlON, YAG, and yttria.