Patent Application
20180328546
If (1) a term in the present application conflicts with the term used in a previous application to which the present application claims priority, or (2) conflicts with a term in an application incorporated by reference (2a) into the present application or into (2b) an application to which the present application claims priority, a construction based on the term as used or defined in the present application prevails.
The present invention relates to the features of LED incendiaries. More particularly, this invention describes various new and useful improvements for LED tube lamps.
LED lighting technology is rapidly developing to replace traditional incandescent and fluorescent lightings. LED tube lamps are mercury-free in comparison with fluorescent tube lamps that need to be filled with inert gas and mercury. Thus, it is not surprising that LED tube lamps are becoming a highly desirable illumination option among different available lighting systems used in homes and workplaces, which used to be dominated by traditional lighting options such as compact fluorescent light bulbs (CFLs) and fluorescent tube lamps. Benefits of LED tube lamps include improved durability and longevity and far less energy consumption; therefore, when taking into account all factors, they would typically be considered as a cost-effective lighting option.
Typical LED tube lamps have a variety of LED elements and driving circuits. The LED elements include LED chip-packaging elements, light diffusion elements, high efficient heat dissipating elements, light reflective boards and light diffusing boards. Heat generated by the LED elements and the driving elements is considerable and mainly dominates the illumination intensity such that the heat dissipation needs to be properly disposed to avoid rapid decrease of the luminance and the lifetime of the LED lamps. Problems including power loss, rapid light decay, and short lifetime due to poor heat dissipation are always the key factors in consideration of improving the performance of the LED illuminating system. It is therefore one of the important issues to solve the heat dissipation problem of the LED products.
Nowadays, most of the LED tube lamps use plastic tubes and metallic elements to dissipate heat from the LEDs. The metallic elements are usually exposed to the outside of the plastic tubes. This design improves heat dissipation but heightens the risk of electric shocks. The metallic elements may be disposed inside the plastic tubes. However, heat remains inside the plastic tubes and deforms the plastic tubes. Deformation of the plastic tubes also occurs even when the elements to dissipate heat from the LEDs are not metallic.
The metallic elements disposed to dissipate heat from the LEDs may be made of aluminum. However, aluminum is too soft to sufficiently support the plastic tubes when the deformation of plastic tubes occurs due to the heat as far as the metallic elements disposed inside the plastic tubes are concerned.
As a result, the current related skills still could not be applied to deal with the above-mentioned worse heat conduction, poor heat dissipation, heat deformation, and electric shock defects. On the other hand, the LED tube lamp may be provided with power via two ends of the lamp and a user is easily to be electric shocked when one end of the lamp is already inserted into a terminal of a power supply while the other end is held by the user to reach the other terminal of the power supply.
A fluorescent tube lamp includes a lamp tube having, traditionally, a circular cross section—for good reasons. The lamp tube is filled with a gas containing low-pressure mercury vapor and argon, xenon, neon or krypton. The pressure inside the lamp is around 0.3% of atmospheric pressure. The inner surface of the lamp is coated with a fluorescent (and often slightly phosphorescent) coating made of varying blends of metallic and rare-earth phosphor salts. The circular cross section provides the lamp tube with structural strength needed to overcome the weight of air on its surface outside the lamp. Other things equal, when a lamp tube provides a bigger inner surface to which fluorescent chemicals are coated, the lamp shines brighter. Lamp tubes having a circular cross section is a sound option. Also, omnidirectional light makes a circular cross section a perfect solution for a lamp tube. An LED tube lamp, however, operates on an entirely different set of principles. Maximizing coating surface is no longer essential for luminous output. Air pressure on the lamp tube becomes irrelevant. Cylindrical lamp tubes, when used in LED tube lamps, induce potential inconvenience if not loss under unfortunate circumstances. An LED tube lamp, whose light is inherently directional, must be correctly oriented before plugging into a light fixture. Cylindrical lamp tubes, unless otherwise pointed out, gives no visual indication of their correct orientation. Moreover, cylindrical lamp tubes roll off the desk easily. Thus, LED luminaries open up whole new possibilities for designing the shape of a lamp tube.
In view of above-mentioned issues, the claimed invention and the preferred embodiments are proposed below.
Therefore, it is an object of the claimed invention to provide an improved LED tube lamp having a redesigned lamp tube. In some embodiments, the cross section of the lamp tube has an irregular shape. In other embodiments, the cross section of the lamp tube defines a polygon, e.g. a triangle. The lamp tube will stay put on a desk even with an inclined plane. In some embodiments, the cross section of the lamp tube defines a triangle having edges curved outwards. In other embodiments, vertices of the triangle defined by the cross section of the lamp tube are filleted.
In accordance with an exemplary embodiment of the claimed invention, the LED tube lamp comprises a plastic lamp tube, which includes a light transmissive portion, a reinforcing portion and an end cap; a fillet configured on a corner of the lamp tube; and an LED light assembly, which includes an LED light source and an LED light strip, wherein: the light transmissive portion is fixedly connected to the reinforcing portion; the reinforcing portion includes a plurality of bracing structures at endpoints and a plurality of protruding parts spaced apart between the endpoints; the bracing structure includes a combination of vertical ribs and horizontal ribs; the LED light strip abuts against the bracing structure, which holds the LED light assembly in place; the LED light assembly finds upright support by the plurality of protruding parts; the LED light source is thermally and electrically connected to the LED light strip, which is in turn thermally connected to the reinforcing portion; and the end cap is attached to an end of the lamp tube.
The fillet on the corner of the lamp tube distributes stress over a broader area and effectively makes the LED tube lamp structurally more durable and capable of surviving harsh handling. Moreover, the fillet on an exterior corner of the lamp tube having a polygonal cross section eliminates sharp edges that otherwise can be easily damaged or that can cause injury when the LED tube lamp is handled. Furthermore, rounding of vertices of the light transmissive portion having a polygonal cross section alleviates undesirable dispersion of light otherwise caused by an un-filleted vertex functioning like a prism.
In an embodiment, the fillet is configured on an exterior corner of the lamp tube. As said, stress is distributed over a broader area and effectively makes the LED tube lamp structurally more durable and capable of surviving harsh handling. Moreover, sharp edges are eliminated that otherwise can be easily damaged or that can cause injury when the LED tube lamp is handled.
Turning to
In an embodiment, a first fillet is configured on an interior corner of the lamp tube; a second fillet is configured on an exterior corner of the lamp tube; and the first fillet and the second fillet are spaced apart by a fixed normal distance. As said, refraction of light coming from the LED light assembly is mitigated by the well-rounded corner.
In an embodiment, the fixed normal distance equals a thickness of the lamp tube.
In an embodiment, the fillet is configured on a corner of the light transmissive portion.
In an embodiment, the fillet is configured on a corner of the reinforcing portion.
Turning to
Turning to
In an embodiment, a cross section of the lamp tube defines a first hypothetical Reuleaux triangle; a cross section of the end cap defines a second hypothetical Reuleaux triangle; the first hypothetical Reuleaux triangle and the second hypothetical Reuleaux triangle are parallel curves; and the second hypothetical Reuleaux triangle encompasses the first hypothetical Reuleaux triangle.
The LED tube lamp, with a cross section of constant width, is capable being shipped in traditional tube-shaped packages designed for tube lamps having a circular cross section when the width of the Reuleaux triangle is the same as the diameter of the circular cross section. With a same width, a Reuleaux triangle displays a smaller area than a circular disk. The LED tube lamp is thus capable of being used with specialized light fixtures featuring a compact profile.
In an embodiment, a bottom edge of a cross section of the reinforcing portion defines a middle portion of a first side of the first hypothetical Reuleaux triangle; and a cross section of the light transmissive portion defines a right portion of the first side of the first hypothetical Reuleaux triangle; a left portion of the first side of the first hypothetical Reuleaux triangle; a second side the of the first hypothetical Reuleaux triangle; and a third side the of the first hypothetical Reuleaux triangle.
In an embodiment, a cross section of the lamp tube defines a first hypothetical circular triangle; the first hypothetical circular triangle has a trio of convex arc edges; vertices on the first hypothetical circular triangle define a first hypothetical isosceles triangle including a base and a pair of legs; a cross section of the end cap defines a second hypothetical circular triangle; the second hypothetical circular triangle has a trio of convex arc edges; and vertices on the second hypothetical circular triangle define a second hypothetical isosceles triangle; the first hypothetical isosceles triangle and the second hypothetical isosceles triangle are parallel curves; and the second hypothetical isosceles triangle encompasses the first hypothetical isosceles triangle.
In an embodiment, a bottom edge of a cross section of the reinforcing portion defines a middle portion of the base of the first hypothetical isosceles triangle; and a cross section of the light transmissive portion defines a right portion of the base of the first hypothetical isosceles triangle; a left portion of the base of the first hypothetical isosceles triangle; and the pair of legs of the first hypothetical isosceles triangle.
In an embodiment, a cross section of the lamp tube defines a first hypothetical isosceles triangle including a base and a pair of legs; edges of the first hypothetical isosceles triangle curve outwards; a cross section of the end cap defines a second hypothetical isosceles triangle; edges of the second hypothetical isosceles triangle curve outwards; the first hypothetical isosceles triangle and the second hypothetical isosceles triangle are parallel curves; and the second hypothetical isosceles triangle encompasses the first hypothetical isosceles triangle.
In an embodiment, a bottom edge of a cross section of the reinforcing portion defines a middle portion of the base of the first hypothetical isosceles triangle; and a cross section of the light transmissive portion defines a right portion of the base of the first hypothetical isosceles triangle; a left portion of the base of the first hypothetical isosceles triangle; and the pair of legs of the first hypothetical isosceles triangle.
In an embodiment, a left vertical rib extends upwards from a first left base at which the light transmissive portion and the reinforcing portion merge; a left horizontal rib merge with the left vertical rib at a point slightly higher than an upper surface of the LED light strip; a right vertical rib extends upwards from a first right base at which the light transmissive portion and the reinforcing portion merge; a right horizontal rib merge with the right vertical rib at a point slightly higher than the upper surface of the LED light strip; and a distance between the first left base and the first right base is slightly greater than a width of the LED light strip.
In an embodiment, the left vertical rib leans slightly inwards towards a left edge of the LED light strip; and the right vertical tib leans slightly inwards towards a right edge of the LED light strip.
In an embodiment, the left horizonal rib angles slightly downwards towards an upper surface of the LED light strip; and the right horizontal rib angles slightly downwards towards the upper surface of the LED light strip.
In an embodiment, a left protruding part erects from a second left base towards a lower surface of the LED light strip; a right protruding part erects from a second right base towards the lower surface of the LED light strip; friction arising from the surface of the LED light strip, the bracing structure and the protruding bar holds the LED light assembly in place unless otherwise overcome by a lateral force.
In an embodiment, a distance from the first left base to the second left base is identical to a distance from the first right base to the second right base; and the distance from the first left base to the second left base is less than a distance from the second left base to the second right base.
In accordance with an exemplary embodiment of the claimed invention, the LED tube lamp comprises a plastic lamp tube, which includes a light transmissive portion, a reinforcing portion and an end cap; and an LED light assembly, which includes an LED light source and an LED light strip, wherein: the light transmissive portion is fixedly connected to the reinforcing portion; the reinforcing portion includes a plurality of bracing structures at endpoints and a plurality of protruding parts spaced apart between the endpoints; the bracing structure includes a combination of vertical ribs and horizontal ribs; the LED light strip abuts against the bracing structure, which holds the LED light assembly in place; the LED light assembly finds upright support by the plurality of protruding parts; the LED light source is thermally and electrically connected to the LED light strip, which is in turn thermally connected to the reinforcing portion; the end cap is attached to an end of the lamp tube; and a cross section of the lamp tube defines a hypothetical curve of constant width.
Shifting to
In another embodiment, the cross section of the lamp tube defines a first hypothetical Reuleaux triangle.
In an embodiment, a fillet is configured on a vertex of the cross section of the lamp tube.
In an embodiment, a fillet is configured on all vertices of the cross section of the lamp tube.
In an embodiment, a fillet is configured on an interior corner of the vertex of the cross section of the lamp tube.
In an embodiment, a fillet is configured on an exterior corner of the vertex of the cross section of the lamp tube.
In an embodiment, a first fillet is configured on an interior corner of the vertex of the cross section of the lamp tube; a second fillet is configured on an exterior corner of the vertex of the cross section of the lamp tube; and the first fillet and the second fillet are spaced apart by a fixed normal distance.
In an embodiment, the fixed normal distance equals a thickness of the lamp tube.
In an embodiment, a cross section of the end cap defines a hypothetical circle.
In an embodiment, a cross section of the end cap defines a second hypothetical Reuleaux triangle.
In an embodiment, the first hypothetical Reuleaux triangle and the second hypothetical Reuleaux triangle are parallel curves; and the second hypothetical Reuleaux triangle encompasses the first hypothetical Reuleaux triangle.
In an embodiment, a fillet is configured on a vertex of the cross section of the end cap.
In an embodiment, a fillet is configured on all vertices of the cross section of the end cap.
In an embodiment, a fillet is configured on an interior corner of the vertex of the cross section of the end cap.
In an embodiment, a fillet is configured on an exterior corner of the vertex of the cross section of the end cap.
In an embodiment, a bottom edge of a cross section of the reinforcing portion defines a first side of the first hypothetical Reuleaux triangle.
In an embodiment, the bottom edge of the cross section of the reinforcing portion defines a first portion of the first side of the first hypothetical Reuleaux triangle.
In an embodiment, the first portion of the first side of the first hypothetical Reuleaux triangle is a middle portion on the first side of the first hypothetical Reuleaux triangle.
In an embodiment, a cross section of the light transmissive portion defines a right portion of the first side of the first hypothetical Reuleaux triangle; a left portion of the first side of the first hypothetical Reuleaux triangle; a second side the of the first hypothetical Reuleaux triangle; and a third side the of the first hypothetical Reuleaux triangle.
In an embodiment, a left vertical rib extends upwards from a first left base at which the light transmissive portion and the reinforcing portion merge; a left horizontal rib merge with the left vertical rib at a point slightly higher than an upper surface of the LED light strip; a right vertical rib extends upwards from a first right base at which the light transmissive portion and the reinforcing portion merge; a right horizontal rib merge with the right vertical rib at a point slightly higher than the upper surface of the LED light strip; and a distance between the first left base and the first right base is slightly greater than a width of the LED light strip.
In an embodiment, the left vertical rib leans slightly inwards towards a left edge of the LED light strip; and the right vertical rib leans slightly inwards towards a right edge of the LED light strip.
In an embodiment, the left horizonal rib angles slightly downwards towards an upper surface of the LED light strip; and the right horizontal rib angles slightly downwards towards the upper surface of the LED light strip.
In an embodiment, a left protruding part erects from a second left base towards a lower surface of the LED light strip; a right protruding part erects from a second right base towards the lower surface of the LED light strip; friction arising from the upper surface of the LED light strip, the lower surface of the LED light strip, the bracing structure and the protruding bar holds the LED light assembly in place unless otherwise overcome by a lateral force.
In an embodiment, a distance from the first left base to the second left base is identical to a distance from the first right base to the second right base; and the distance from the first left base to the second left base is less than a distance from the second left base to the second right base.
In accordance with an exemplary embodiment of the claimed invention, the LED tube lamp comprises a plastic amp tube, which includes a light transmissive portion, a reinforcing portion and an end cap; and an LED light assembly, which includes an LED light source and an LED light strip, wherein: the light transmissive portion is fixedly connected to the reinforcing portion; the reinforcing portion includes a plurality of bracing structures at endpoints and a plurality of protruding parts spaced apart between the endpoints; the bracing structure includes a combination of vertical ribs and horizontal ribs; the LED light strip abuts against the bracing structure, which holds the LED light assembly in place; the LED light assembly finds upright support by the plurality of protruding parts; the LED light source is thermally and electrically connected to the LED light strip, which is in turn thermally connected to the reinforcing portion; the end cap is attached to an end of the lamp tube; and a cross section of the lamp tube defines a hypothetical curve constructed by three hypothetical circles intersecting one another.
Turning to
In another embodiment, the cross section of the lamp tube defines a first hypothetical circular triangle.
In an embodiment, the first hypothetical circular triangle has a trio of convex arc edges.
In an embodiment, vertices on the first circular triangle define a first hypothetical isosceles triangle including a base and a pair of legs.
In an embodiment, vertices on the first hypothetical circular triangle define an equilateral triangle.
In an embodiment, a fillet is configured on a vertex of the cross section of the lamp tube.
In an embodiment, a fillet is configured on all vertices of the cross section of the lamp tube.
In an embodiment, a fillet is configured on an interior corner of the vertex of the cross section of the lamp tube.
In an embodiment, a fillet is configured on an exterior corner of the vertex of the cross section of the lamp tube.
In an embodiment, a first fillet is configured on an interior corner of the vertex of the cross section of the lamp tube; a second fillet is configured on an exterior corner of the vertex of the cross section of the lamp tube; and the first fillet and the second fillet are spaced apart by a fixed normal distance.
In an embodiment, the fixed normal distance equals a thickness of the lamp tube.
In an embodiment, a cross section of the end cap defines a second hypothetical circular triangle; the second hypothetical circular triangle has a trio of convex arc edges; and vertices on the second hypothetical circular triangle define a second hypothetical isosceles triangle.
In an embodiment, a fillet is configured on a vertex of the cross section of the end cap.
In an embodiment, a fillet is configured on all vertices of the cross section of the end cap.
In an embodiment, a fillet is configured on an interior corner of the vertex of the cross section of the end cap.
In an embodiment, a fillet is configured on an exterior corner of the vertex of the cross section of the end cap.
In an embodiment, the first hypothetical isosceles triangle and the second hypothetical isosceles triangle are parallel curves; and the second hypothetical isosceles triangle encompasses the first hypothetical isosceles triangle.
In an embodiment, a bottom edge of a cross section of the reinforcing portion defines the base of the first hypothetical isosceles triangle.
In an embodiment, the bottom edge of the cross section of the reinforcing portion defines a first portion of the base of the first hypothetical isosceles triangle.
In an embodiment, the first portion of the base of the first hypothetical isosceles triangle is a middle portion on the base of the first hypothetical isosceles triangle.
In an embodiment, a cross section of the light transmissive portion defines a right portion of the base of the first hypothetical isosceles triangle; a left portion of the base of the first hypothetical isosceles triangle; and the pair of legs of the first hypothetical isosceles triangle.
In an embodiment, the leg of length a is greater than the base of length b.
In an embodiment, the first hypothetical circular triangle having a vertex defines an axis of symmetry passing through the vertex.
In an embodiment, a cross section of the LED light strip defines a hypothetical line; and the hypothetical line meets the perpendicular bisector of the first hypothetical isosceles triangle at a right angle.
In an embodiment, a perpendicular bisector of a hypothetical curve defined by the cross section of the lamp tube is divided by the hypothetical curve defined by the cross section of the lamp tube and the hypothetical line defined by the cross section of the LED light strip into an upper segment of length c and a lower segment of length d; and the upper segment of length c is greater than the lower segment of length d.
In an embodiment, a perpendicular bisector of a hypothetical curve defined by the cross section of the lamp tube is divided by the hypothetical curve defined by the cross section of the lamp tube and the hypothetical line defined by the cross section of the LED light strip into an upper segment of length c and a lower segment of length d; and the upper segment of length c is less than the lower segment of length d.
In an embodiment, the hypothetical line defined by the cross section of the LED light strip coincides with the base of the first hypothetical isosceles triangle.
In an embodiment, the hypothetical line defined by the cross section of the LED light strip rises above the base of the first hypothetical isosceles triangle.
In an embodiment, the hypothetical line defined by the cross section of the LED light strip sits below the base of the first hypothetical isosceles triangle.
In an embodiment, the first hypothetical isosceles triangle has an area e; the first circular triangle has an area f, and In an embodiment, a hypothetical curve defined by the first circular triangle and the pair of legs of the first hypothetical isosceles triangle has an area g; a hypothetical curve defined by the first circular triangle and the base of the first hypothetical isosceles triangle has an area h; and g is greater than 2h.
In accordance with an exemplary embodiment of the claimed invention, the LED tube lamp comprises a plastic lamp tube, which includes a light transmissive portion, a reinforcing portion and an end cap; and an LED light assembly, which includes an LED light source and an LED light strip, wherein: the light transmissive portion is fixedly connected to the reinforcing portion; the reinforcing portion includes a plurality of bracing structures at endpoints and a plurality of protruding parts spaced apart between the endpoints; the bracing structure includes a combination of vertical ribs and horizontal ribs; the LED light strip abuts against the bracing structure, which holds the LED light assembly in place; the LED light assembly finds upright support by the plurality of protruding parts; the LED light source is thermally and electrically connected to the LED light strip, which is in turn thermally connected to the reinforcing portion; and the end cap is attached to an end of the lamp tube; and a cross section of the lamp tube defines a hypothetical polygon.
In an embodiment, the cross section of the lamp tube defines a hypothetical triangle.
In an embodiment, the cross section of the lamp tube defines a first hypothetical isosceles triangle including a base and a pair of legs.
In an embodiment, the cross section of the lamp tube defines a hypothetical equilateral triangle.
In an embodiment, edges of the first hypothetical isosceles triangle curve outwards.
In an embodiment, a fillet is configured on a vertex of the cross section of the lamp tube.
In an embodiment, a fillet is configured on all vertices of the cross section of the lamp tube.
In an embodiment, a fillet is configured on an interior corner of the vertex of the cross section of the lamp tube.
In an embodiment, a fillet is configured on an exterior corner of the vertex of the cross section of the lamp tube.
In an embodiment, a first fillet is configured on an interior corner of the vertex of the cross section of the lamp tube; a second fillet is configured on an exterior corner of the cross section of the lamp tube; and the first fillet and the second fillet are spaced apart by a fixed normal distance.
In an embodiment, the fixed normal distance equals a thickness of the lamp tube.
In an embodiment, a cross section of the end cap defines a second hypothetical isosceles triangle; and edges of the second hypothetical isosceles triangle curve outwards.
In an embodiment, a fillet is configured on a vertex of the cross section of the end cap.
In an embodiment, a fillet is configured on all vertices of the cross section of the end cap.
In an embodiment, a fillet is configured on an interior corner of the vertex of the cross section of the end cap.
In an embodiment, a fillet is configured on an exterior corner of the vertex of the cross section of the end cap.
In an embodiment, the first hypothetical isosceles triangle and the second hypothetical isosceles triangle are parallel curves; and the second hypothetical isosceles triangle encompasses the first hypothetical isosceles triangle.
In an embodiment, a bottom edge of a cross section of the reinforcing portion defines the base of the first hypothetical isosceles triangle.
In an embodiment, the bottom edge of the cross section of the reinforcing portion defines a first portion of the base of the first hypothetical isosceles triangle.
In an embodiment, the first portion of the base of the first hypothetical isosceles triangle is a middle portion on the base of the first hypothetical isosceles triangle.
In an embodiment, a cross section of the light transmissive portion defines a right portion of the base of the first hypothetical isosceles triangle; a left portion of the base of the first hypothetical isosceles triangle; and the pair of legs of the first hypothetical isosceles triangle.
In an embodiment, the leg of length a is greater than the base of length b.
In an embodiment, a perpendicular bisector of the first hypothetical isosceles triangle having edges curved outwards coincides with a perpendicular bisector of a second hypothetical isosceles triangle having straight edges defined by vertices of the first hypothetical isosceles triangle.
In an embodiment, a cross section of the LED light strip defines a hypothetical line; and the hypothetical line meets the perpendicular bisector of the first hypothetical isosceles triangle at a right angle.
In an embodiment, a perpendicular bisector of a hypothetical curve defined by the cross section of the lamp tube is divided by the hypothetical curve defined by the cross section of the lamp tube and the hypothetical line defined by the cross section of the LED light strip into an upper segment of length c and a lower segment of length d; and the upper segment of length c is greater than the lower segment of length d.
In an embodiment, the hypothetical line defined by the cross section of the LED light strip coincides with the base of the first hypothetical isosceles triangle.
In an embodiment, the hypothetical line defined by the cross section of the LED light strip rises above the base of the first hypothetical isosceles triangle.
In an embodiment, the hypothetical line defined by the cross section of the LED light strip sits below the base of the first hypothetical isosceles triangle.
In an embodiment, a hypothetical curve defined by the curved pair of legs of the first hypothetical isosceles triangle and a hypothetical curve defined by a straight pair of legs of a second hypothetical isosceles triangle defined by vertices on the first hypothetical isosceles triangle has an area g; a hypothetical curve defined by the curved base of the first hypothetical isosceles triangle and a hypothetical curve defined by a straight base of the second hypothetical isosceles triangle has an area h; and g is greater than 2h.
Various other objects, advantages and features of the present invention will become readily apparent from the ensuing detailed description, and the novel features will be particularly pointed out in the appended claims.
The following detailed descriptions, given by way of example, and not intended to limit the present invention solely thereto, will be best be understood in conjunction with the accompanying figures:
Referring to
The LED light assembly is disposed inside the lamp tube 1 and includes an LED light source 202 and an LED light strip 2. The LED light source 202 is thermally and electrically connected to the LED light strip 2, which is in turn thermally connected to the reinforcing portion 107. Heat generated by the LED light source 202 is first transmitted to the LED light strip 2 and then to the reinforcing portion 107 before egressing the lamp tube 1. Thermal connection is achieved with thermally conductive tapes or conventional mechanical fasteners such as screws aided by thermal grease to eliminate air gaps from interface areas.
Typically, the lamp tube 1 has a shape of an elongated cylinder, which is a straight structure. However, the lamp tube 1 can take any curved structure such as a ring or a horseshoe. The cross section of the lamp tube 1 defines, typically, a circle, or not as typically, an ellipse or a polygon. Alternatively, the cross section of the lamp tube 1 takes an irregular shape depending on the shapes of, respectively, the light transmissive portion 105 and the reinforcing portion 107 and on the manner the two portions interconnect to form the lamp tube 1.
The lamp tube 1 is a glass tube, a plastic tube or a tube made of any other suitable material or combination of materials. A plastic lamp tube is made from light transmissive plastic, thermally conductive plastic or a combination of both. The light transmissive plastic is one of translucent polymer matrices such as polymethyl methacrylate, polycarbonate, polystyrene, poly(styrene-co-methyl methacrylate) and a mixture thereof. Optionally, the strength and elasticity of thermally conductive plastic is enhanced by bonding a plastic matrix with glass fibers. When a lamp tube employs a combination of light transmissive plastic and thermally conductive plastic, does in the combination. In an embodiment, an outer shell of lamp tube includes a plurality of layers made from distinct materials. For example, the lamp tube includes a plastic tube coaxially sheathed by a glass tube.
In an embodiment, the light transmissive portion 105 is made from light transmissive plastic. The reinforcing portion is 107 made from thermally conductive plastic. Injection molding is used for producing the light transmissive portion 105 in a first piece and for producing the reinforcing portion 107 in a separate second piece. The first piece and the second piece are configured to be clipped together, buckled together, glued together or otherwise fixedly interconnect to form the lamp tube 1. Alternatively, injection molding is used for producing the lamp tube 1, which includes the light transmissive portion 105 and the reinforcing portion 107, in an integral piece by feeding two types of plastic materials into a molding process. In an alternative embodiment, the reinforcing portion is made of metal having good thermal conductivity such as aluminum alloy and copper alloy.
Respective shapes of the light transmissive portion 105 and the reinforcing portion 107, how the two portions 105, 107 interconnect to form the lamp tube 1 and, particularly, the respective proportions of the two portions 105, 107 in the lamp tube depend on a desired totality of considerations such as field angle, heat dissipation efficiency and structural strength. A wider field angle—potentially at the expense of heat dissipation capability and structural strength—is achieved when the proportion of the light transmissive portion increases 105 in relation to that of the reinforcing portion 107. By contrast, the lamp tube benefits from an increased proportion of the reinforcing portion 107 in relation to that of the light transmissive portion in such ways as better heat dissipation and rigidity but potentially loses field angle.
In some embodiments, the reinforcing portion 107 includes a plurality of protruding parts. In other embodiments, a plurality of protruding parts are disposed on the surface of the LED light strip 2 that is not covered by the LED light assembly. Like fins on a heatsink, the protruding part boosts heat dissipation by increasing the surface area of the reinforcing portion 107 and the LED light strip 2. The protruding parts are disposed equidistantly, or alternatively, not equidistantly.
Staying on
In an alternative embodiment, the dividing line 104 is spaced apart from the line H-H. For example, when the dividing line 104 is below the line H-H, the upper segment, which encompasses the light transmissive portion, has a greater area than the lower segment, which encompasses the reinforcing portion. The lamp tube, which includes an enlarged light transmissive portion, is thus configured to achieve a field angle wider than 180 degrees; however, other things equal, the lamp tube surrenders some heat dissipation capability, structural strength or both due to a diminished reinforcing portion 107. By contrast, the lamp tube 1 has an enlarged reinforcing portion 107 and a diminished light transmissive portion 105 if the dividing line rises above the line H-H. Other things equal, the lamp tube 1, now having an enlarged reinforcing portion 107, is configured to exhibit higher heat dissipation capability, structural strength or both; however, the field angle of the lamp tube 1 will dwindle due to diminished dimensions of the light transmissive portion 105.
The LED tube lamp is configured to convert bright spots coming from the LED light source into an evenly distributed luminous output. In an embodiment, a light diffusion layer is disposed on an inner surface of the lamp tube 1 or an outer surface of the lamp tube 1. In another embodiment, a diffusion laminate is disposed over the LED light source 202. In yet another embodiment, the lamp tube 1 has a glossy outer surface and a frosted inner surface. The inner surface is rougher than the outer surface. The roughness Ra of the inner surface is, preferably, from 0.1 to 40 μm, and most preferably, from 1 to 20 μm. Controlled roughness of the surface is obtained mechanically by a cutter grinding against a workpiece, deformation on a surface of a workpiece being cut off or high frequency vibration in the manufacturing system. Alternatively, roughness is obtained chemically by etching a surface. Depending on the luminous effect the lamp tube 1 is designed to produce, a suitable combination of amplitude and frequency of a roughened surface is provided by a matching combination of workpiece and finishing technique.
In alternative embodiment, the diffusion layer is in form of an optical diffusion coating, which is composed of any one of calcium carbonate, halogen calcium phosphate and aluminum oxide, or any combination thereof. When the optical diffusion coating is made from a calcium carbonate with suitable solution, an excellent light diffusion effect and transmittance to exceed 90% can be obtained.
In alternative embodiment, the diffusion layer is in form of an optical diffusion coating, which is composed of any one of calcium carbonate, halogen calcium phosphate and aluminum oxide, or any combination thereof. When the optical diffusion coating is made from a calcium carbonate with suitable solution, an excellent light diffusion effect and transmittance to exceed 90% can be obtained.
In the embodiment, the composition of the diffusion layer in form of the optical diffusion coating includes calcium carbonate, strontium phosphate (e.g., CMS-5000, white powder), thickener, and a ceramic activated carbon (e.g., ceramic activated carbon SW-C, which is a colorless liquid). Specifically, such an optical diffusion coating on the inner circumferential surface of the glass tube has an average thickness ranging between about 20 to about 30 μm. A light transmittance of the diffusion layer using this optical diffusion coating is about 90%. Generally speaking, the light transmittance of the diffusion layer ranges from 85% to 96%. In addition, this diffusion layer can also provide electrical isolation for reducing risk of electric shock to a user upon breakage of the lamp tube 1. Furthermore, the diffusion layer provides an improved illumination distribution uniformity of the light outputted by the LED light sources 202 such that the light can illuminate the back of the light sources 202 and the side edges of the bendable circuit sheet so as to avoid the formation of dark regions inside the lamp tube 1 and improve the illumination comfort. In another possible embodiment, the light transmittance of the diffusion layer can be 92% to 94% while the thickness ranges from about 200 to about 300 μm.
In another embodiment, the optical diffusion coating can also be made of a mixture including calcium carbonate-based substance, some reflective substances like strontium phosphate or barium sulfate, a thickening agent, ceramic activated carbon, and deionized water. The mixture is coated on the inner circumferential surface of the glass tube and has an average thickness ranging between about 20 to about 30 μm. In view of the diffusion phenomena in microscopic terms, light is reflected by particles. The particle size of the reflective substance such as strontium phosphate or barium sulfate will be much larger than the particle size of the calcium carbonate. Therefore, adding a small amount of reflective substance in the optical diffusion coating can effectively increase the diffusion effect of light.
In other embodiments, halogen calcium phosphate or aluminum oxide can also serve as the main material for forming the diffusion layer. The particle size of the calcium carbonate is about 2 to 4 μm, while the particle size of the halogen calcium phosphate and aluminum oxide are about 4 to 6 pm and 1 to 2 μm, respectively. When the light transmittance is required to be 85% to 92%, the required average thickness for the optical diffusion coating mainly having the calcium carbonate is about 20 to about 30 μm, while the required average thickness for the optical diffusion coating mainly having the halogen calcium phosphate may be about 25 to about 35 μm, the required average thickness for the optical diffusion coating mainly having the aluminum oxide may be about 10 to about 15 μm. However, when the required light transmittance is up to 92% and even higher, the optical diffusion coating mainly having the calcium carbonate, the halogen calcium phosphate, or the aluminum oxide must be thinner.
The main material and the corresponding thickness of the optical diffusion coating can be decided according to the place for which the lamp tube 1 is used and the light transmittance required. It is to be noted that the higher the light transmittance of the diffusion layer is required, the more apparent the grainy visual of the light sources is.
In an embodiment, the LED tube lamp is configured to reduce internal reflectance by applying a layer of anti-reflection coating to an inner surface of the lamp tube 1. The coating has an upper boundary, which divides the inner surface of the lamp tube and the anti-reflection coating, and a lower boundary, which divides the anti-reflection coating and the air in the lamp tube 1. Light waves reflected by the upper and lower boundaries of the coating interfere with one another to reduce reflectance. The coating is made from a material with a refractive index of a square root of the refractive index of the light transmissive portion 105 of the lamp tube 1 by vacuum deposition. Tolerance of the coating's refractive index is ±20%. The thickness of the coating is chosen to produce destructive interference in the light reflected from the interfaces and constructive interference in the corresponding transmitted light. In an improved embodiment, reflectance is further reduced by using alternating layers of a low-index coating and a higher-index coating. The multi-layer structure is designed to, when setting parameters such as combination and permutation of layers, thickness of a layer, refractive index of the material, give low reflectivity over a broad band that covers at least 60%, or preferably, 80% of the wavelength range beaming from the LED light source 202. In some embodiments, three successive layers of anti-reflection coatings are applied to an inner surface of the lamp tube 1 to obtain low reflectivity over a wide range of frequencies. The thicknesses of the coatings are chosen to give the coatings optical depths of, respectively, one half, one quarter and one half of the wavelength range coming from the LED light source 202. Dimensional tolerance for the thickness of the coating is set at ±20%.
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A dividing line 104 parallel to the line H-H is shared by the upper segment and the upper flange. In the embodiment, the dividing line sits below the line H-H. Consequently, the upper segment constitutes the majority of the hypothetical circle. The light transmissive portion 105 is thus configured to generate a field angle wider than 180 degrees. In an alternative embodiment, the dividing line sits on or above the line H-H. For example, when the dividing line rises above the line H-H, the upper segment, which encompasses the light transmissive portion, now constitutes less than half of the hypothetical circle. The lamp tube 1, which has an enlarged reinforcing portion 107, is thus configured for better heat dissipation and structural strength; however, other things equal, the lamp tube 1 loses some luminous filed due to a diminished light transmissive portion 105.
In an embodiment, a surface on which the LED light assembly sits—e.g. the upper surface of the platform—is configured to further reflect the light reflected from the inner surface of the lamp tube 1. The surface on which the LED light assembly sits is coated with a reflective layer. Alternatively, the surface is finished to exhibit a reflectance of 80 to 95%, or preferably, 85 to 90%. Finishing is performed mechanically, chemically or by fluid jet. Mechanical finishing buffs a surface by removing peaks from the surface with an abrasive stick, a wool polishing wheel or a sandpaper. A surface treated this way has a roughness Ra as low as 0.008 to 1 μm. Chemical finishing works by dissolving peaks of a surface faster than troughs of the surface with a chemical agent. Fluid jet finishing uses a high-speed stream of slurry to accurately remove nanometers of material from a surface. The slurry is prepared by adding particles such as silicon carbide powder to a fluid capable of being pumped under relatively low pressure.
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Typically, the end cap 3 has a shape of a cylinder. The cross section of the end cap 3 thus defines a circle. Alternatively, the cross section of the end cap 3 takes an irregular shape depending on the shapes of, respectively, the light transmissive portion and the reinforcing portion and on the manner the two portions and the end cap 3 interconnect to form the LED tube lamp. Regardless of the shape of the end cap 3, the cross section of the end cap 3 encloses all or only a part of the cross section of the reinforcing portion 107 of the lamp tube 1. In the embodiment shown in
In an alternative embodiment shown in
In some embodiments, an end of the LED light assembly extends to the end cap 3 as shown in
The bracing structure 107b may is made from a metallic material or plastic material. The metallic material is a pure metal, an alloy or a combination of pure metal and alloy having differentiated stiffness. Similarly, the plastic material is a single type of plastic or a combination of plastic materials having differentiated stiffness. Specifically, the plastic lamp tube 1 may include only one bracing structure with one stiffness or two bracing structures with various stiffness.
When only one bracing structure is adopted, the material of the only one bracing structure may be metal, metal alloy, or plastic, and the ratio of the cross-sectional area of the bracing structure to the cross-sectional area of the lamp tube 1 is from 1:3 to 1:30, or most preferably, from 1:5 to 1:10.
When more than one bracing structures with different stiffness are adopted, each of the bracing structures may be made of metal, metal alloy, or plastic. In one embodiment, when two bracing structures with different stiffness are adopted, the ratio of the cross-sectional area of the bracing structure with larger stiffness to the cross-sectional area of the other bracing structure is from 0.001:1 to 100:1, and the ratio of the cross-sectional area of the bracing structure with larger stiffness to the cross-sectional area of the lamp tube 1 is from 1:20 to 1:300.
In view of the bracing structure made of metal, the cross-section of the lamp tube 1 vertically cut by a hypothetical plane shows that the hypothetical plane may include the following 1. a lamp tube made of plastic, a first bracing structure made of a metal with a first stiffness, and a second bracing structure, such as a maintaining stick, made of a metal with a second stiffness different from the first stiffness; 2. a lamp tube made of plastic and a single bracing structure made of metal and/or metal alloy; or 3. a lamp tube made of plastic, a first bracing structure made of metal, and a second bracing structure, such as a maintaining stick, made of metal alloy. Similarly, various plastics with different stiffness may be used to serve as the bracing structures mentioned above according to embodiments of the present invention. As long as the materials for the used bracing structures have different stiffness, the materials are not limited. Thus, metal or metal alloy and plastic could also be served as materials for different bracing structures without departing from the spirit of the present invention. Additionally, the bracing structure is made from a material having a greater stiffness than a material from which the light transmissive portion is made.
In some embodiments, the lamp tube includes a first end cap fixedly connecting to a first end of the lamp tube and a second end cap fixedly connecting to a second end of the lamp tube. The first end cap is dimensionally larger—e.g. from 20% to 70% larger—than the second end cap.
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In an embodiment, the lamp tube 1 further includes a ridge 235 and a maintaining stick 2351. The maintaining stick 2351 is, likewise, an elongated structure, which is unbroken from end to end, or alternatively, broken at intervals, and which fills up the space inside the ridge 235. The maintaining stick 2351 is made of thermally conductive plastic, or alternatively, metal. The metal is one of carbon steel, cast steel, nickel chrome steel, alloyed steel, ductile iron, grey cast iron, white cast iron, rolled manganese bronze, rolled phosphor bronze, cold-drawn bronze, rolled zinc, aluminum alloy and copper alloy. The material from which the maintaining stick 2351 is made is chosen to provide the LED tube lamp with a combination of heat dissipation capability and structural strength that is otherwise absent from other parts of the lamp tube 1. In an embodiment, the maintaining stick 2351 is made from a different material than a material from which the LED light strip 2 or the reinforcing portion 107 is made. For example, when the LED light strip 2 or the reinforcing portion 107 of the lamp tube 1 is made from a metal having superior heat dissipation capability but insufficient stiffness, e.g. aluminum panel, the maintaining stick 2351 is made from a metal stiffer than aluminum to supply more structural strength. The ratio of the volume of heatsinking-oriented metal to the volume of stiffness-oriented metal in a lamp tube 1 is from 0.001:1 to 100:1, or most preferably, from 0.1:1 to 10:1. The ratio of the cross-sectional area of the maintaining stick 2351 to that of the lamp tube 1 is from 1:20 to 1:100, or most preferably, from 1:50 to 1:100.
In some embodiments, the lamp tube 1 includes a light transmissive portion and a reinforcing portion. In other embodiments, a ridge is substituted for the reinforcing portion. Thus, in these embodiment, the lamp tube 1 includes a light transmissive portion and a ridge, but no reinforcing portion. In an improved embodiment, the lamp tube 1 further includes a maintaining stick that fills up the space inside the ridge.
The outer surface of the reinforcing portion forms an outer surface of the lamp tube 1, as the embodiments in
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The length of the reinforcing portion, on which the LED light assembly is disposed, in the vertical direction in relation to the diameter of the lamp tube depends on the field angle the lamp tube is designed to produce. In the embodiment shown in
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The position of the LED light strip 2 inside the lamp tube 1—i.e. the length of the first vertical rib 233 and the length of the second vertical rib 233—is chosen in light of a desired totality of factors such as field angle, heat-dissipating capability and structural strength. In
In an embodiment, the LED light strip is made from flexible substrate material. Referring to
In an embodiment, the LED light strip 2 further includes a protection layer over the wiring layer 2a and the dielectric layer 2b. The protection layer is made from one of solder resists such as liquid photoimageable.
In another embodiment, as shown in
In some embodiments, any type of power supply 5 can be electrically connected to the LED light strip 2 by means of a traditional wire bonding technique, in which a metal wire has an end connected to the power supply 5 while has the other end connected to the LED light strip 2. Furthermore, the metal wire may be wrapped with an electrically insulating tube to protect a user from being electrically shocked. However, the bonded wires tend to be easily broken during transportation and can therefore cause quality issues.
In still another embodiment, the connection between the power supply 5 and the LED light strip 2 may be accomplished via tin soldering, rivet bonding, or welding. One way to secure the LED light strip 2 is to provide the adhesive sheet at one side thereof and adhere the LED light strip 2 to the inner surface of the lamp tube 1 via the adhesive sheet. Two ends of the LED light strip 2 can be either fixed to or detached from the inner surface of the lamp tube 1.
In case that two ends of the LED light strip 2 are fixed to the inner surface of the lamp tube 1, it may be preferable that the bendable circuit sheet of the LED light strip 2 is provided with the female plug and the power supply is provided with the male plug to accomplish the connection between the LED light strip 2 and the power supply 5. In this case, the male plug of the power supply is inserted into the female plug to establish electrical connection.
In case that two ends of the LED light strip 2 are detached from the inner surface of the lamp tube and that the LED light strip 2 is connected to the power supply 5 via wire-bonding, any movement in subsequent transportation is likely to cause the bonded wires to break. Therefore, a preferable option for the connection between the light strip 2 and the power supply 5 could be soldering. Specifically, the ends of the LED light strip 2 including the bendable circuit sheet are arranged to pass over the strengthened transition region and directly soldering bonded to an output terminal of the power supply 5 such that the product quality is improved without using wires. In this way, the female plug and the male plug, respectively, provided for the LED light strip 2 and the power supply 5 are no longer needed.
Referring to
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In this embodiment, during the connection of the LED light strip 2 and the power supply 5, the soldering pads “b” and the soldering pads “a” and the LED light sources 202 are on surfaces facing toward the same direction and the soldering pads “b” on the LED light strip 2 are each formed with a through hole “e” as shown in
Referring to
There are at least one soldering pads “b” for separately connected to the positive and negative electrodes of the LED light sources 202. For the sake of achieving scalability and compatibility, the amount of the soldering pads “b” on each end of the LED light strip 2 may be more than one such as two, three, four, or more than four. When there is only one soldering pad “b” provided at each end of the LED light strip 2, the two ends of the LED light strip 2 are electrically connected to the power supply 5 to form a loop, and various electrical components can be used. For example, a capacitance may be replaced by an inductance to perform current regulation. Referring to
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The abovementioned through hole “e” or notch “f” might be formed in advance of soldering or formed by direct punching with a thermo-compression head during soldering. The portion of the thermo-compression head for touching the tin solder may be flat, concave, or convex, or any combination thereof. The portion of the thermo-compression head for restraining the object to be soldered such as the LED light strip 2 may be strip-like or grid-like. The portion of the thermo-compression head for touching the tin solder does not completely cover the through hole “e” or the notch “f” to make sure that the tin solder is able to pass through the through hole “e” or the notch “f”. The portion of the thermo-compression head being concave may function as a room to receive the solder ball.
Referring to
The long circuit sheet 251 may be the bendable circuit sheet of the LED light strip including a wiring layer 2a as shown in
As shown in
In the above-mentioned embodiments, the short circuit board 253 may have a length generally of about 15 mm to about 40 mm and in some embodiments about 19 mm to about 36 mm, while the long circuit sheet 251 may have a length generally of about 800 mm to about 2800 mm and in some embodiments of about 1200 mm to about 2400 mm. A ratio of the length of the short circuit board 253 to the length of the long circuit sheet 251 ranges from, for example, about 1:20 to about 1:200.
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In some embodiments, the safety switch directly—and mechanically—makes and breaks the circuit of the LED tube lamp. In other embodiments, the safe switch 334 controls another electrical circuit, i.e. a relay, which in turn makes and breaks the circuit of the LED tube lamp. Some relays use an electromagnet to operate a switching mechanism mechanically, but other operating principles are also used. For example, solid-state relays control power circuits with no moving parts, instead using a semiconductor device to perform switching.
The proportion of the end cap 3 in relation to the lamp tube 1 schematized in
In an embodiment, a first end cap of the lamp tube includes a safety switch but a second end cap does not. A warning is attached to the first end cap to alert an operator to plug in the second end cap before moving on to the first end cap.
In an embodiment, the safety switch includes a level switch. The level switch is turned on when the liquid inside is made to flow to a designated place. The end cap 3 is configured to turn on the level switch and, directly or through a relay, make the circuit only when the electrically conductive pin 301 is plugged into the socket. Alternatively, the safety switch includes a micro switch. The end cap 3 is configured to, likewise, turn on the micro switch and, directly or through a relay, make the circuit only when the electrically conductive pin 301 is plugged into the socket.
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In an embodiment, the upper portion of the actuator 332 that projects out of the housing 300 is shorter than the electrically conductive pin 301. Preferably, the ratio of the depth of the upper portion of the actuator 332 to that of the electrically conductive pin 301 is from 20% to 95%.
Having described at least one of the embodiments of the claimed invention with reference to the accompanying drawings, it will be apparent to those skills that the invention is not limited to those precise embodiments, and that various modifications and variations can be made in the presently disclosed system without departing from the scope or spirit of the invention. Thus, it is intended that the present disclosure cover modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents. Specifically, one or more limitations recited throughout the specification can be combined in any level of details to the extent they are described to improve the LED tube lamp. These limitations include but are not limited to: light transmissive portion and reinforcing portion; platform and bracing structure; vertical rib, horizontal rib and curvilinear rib; thermally conductive plastic and light transmissive plastic; silicone-based matrix having good thermal conductivity; anti-reflection layer; roughened surface; electrically conductive wiring layer; wiring protection layer; ridge; maintaining stick; and shock-preventing safety switch.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201510555543.4 | Sep 2015 | CN | national |
| 201510724263.1 | Oct 2015 | CN | national |
| 201510726484.2 | Oct 2015 | CN | national |
| 201510882517.2 | Dec 2015 | CN | national |
| 201610050944.9 | Jan 2016 | CN | national |
| 201610658402.X | Aug 2016 | CN | national |
This is a continuation application of U.S. Ser. No. 15/339,740 filed Oct. 31, 2016, which is a continuation-in-part application of the International Application PCT/CN2015/096501, with an international filing date of Dec. 5, 2015 and which claims the benefit of the following Chinese Patent Applications: CN201510555543.4 filed Sep. 2, 2015; CN 201510724263.1 filed Oct. 29, 2015; CN201510726484.2 filed Oct. 30, 2015; CN201510882517.2 filed Dec. 4, 2015; CN201610050944.9 filed Jan. 26, 2016; and CN201610658402.X filed Aug. 11, 2016, each of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15339740 | Oct 2016 | US |
| Child | 16030833 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/CN2015/096501 | Dec 2015 | US |
| Child | 15339740 | US |
