Structures for LED Light Bulbs

Abstract

A lighting structure for holding light-emitting-diodes (“LEDs”) of an LED light bulb, wherein said lighting structure is in a grid form with a plurality of openings therein and having one or more locations for interconnecting LED lighting components disposed on said lighting structure, wherein the grid having a number of pre-selected intersections forming the grid, and wherein a number of pre-selected intersections is in proportion with the amount of desired ventilation and the number of LEDs generating the pre-determined amount of light. The lighting structure can be made from printed-circuit-board material and the openings of the grid can be in one of the following shapes: square, rectangular, circular, and oval.

Description

FIELD OF INVENTION

The present disclosure generally relates to structures for LED light bulbs, and, more particularly, to structures for LED light bulb that are conducive to heat dissipation.

BACKGROUND

LED light bulbs are generally comprised of one or more LED dies configured on a circuit board and the circuit board is then placed in a light bulb. The light bulb can then be secured into a light bulb socket or a lighting fixture. Prior art LED light bulbs are typically large in size with many design elements (e.g. copper fins or aluminum fins) providing for the dissipation of heat. While these design elements are essential for heat dissipation, they increase manufacturing cost of the light bulb as well as the weight of the light bulb (thereby increasing their shipping cost). This is a problem for LED light bulbs designed to replace traditional incandescent light bulbs because many LED dies (or a few large LED dies) would be needed to generate sufficient amount of luminance to replace the traditional incandescent light bulb. But in operation, these LED dies would generate a tremendous amount of heat, and if the amount of heat is not properly managed, the light bulb could malfunction or become a fire hazard. It is therefore desirable to have a structure for LED light bulbs that would be efficient in heat dissipation and would have a low manufacturing cost.

SUMMARY OF THE INVENTION

An object of the present disclosure is to provide a LED light bulb conducive to heat dissipation.

Another object of the present disclosure is to provide a lighting structure that has low manufacturing cost.

Briefly, a lighting structure for holding LEDs of a LED light bulb is disclosed, wherein said lighting structure is in a grid form with a plurality of openings therein and having one or more locations for interconnecting LED lighting components disposed on said lighting structure, wherein the grid having a pre-selected number of intersections forming the grid, and wherein the number of pre-selected intersections is in proportion with the amount of desired ventilation and the number of LEDs generating the pre-determined amount of light. The lighting structure can be made from printed-circuit-board material and the openings of the grid form can be in one of the following shapes: square, rectangular, circular, and oval.

An advantage of the present invention is that it provides for a LED light bulb that is conducive to heat dissipation.

Another advantage of the present invention is that it provides a lighting structure that has low manufacturing cost.

DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, aspects, and advantages of the disclosed can be better understood from the following detailed description of the disclosed embodiment when taken in conjunction with the accompanying drawings in which:

FIG. 1 a illustrates a view of an embodiment of a light bulb;

FIG. 1 b illustrates a side view of an embodiment of a light bulb showing in one respect that the driver bracket is a flat piece;

FIG. 1 c illustrates a view of an embodiment of a light bulb where the dome is attachable and detachable;

FIG. 2 a illustrates a top view of an embodiment of a light bulb, showing the socket, the driver bracket, the lighting bracket, and the lighting structure;

FIG. 2 b illustrates a bottom view of an embodiment of a light bulb, showing the lighting structure, the lighting bracket, among other aspects;

FIG. 2 c illustrates an angled view of an embodiment of a light bulb, showing the socket, the driver bracket, the lighting bracket, and the lighting structure;

FIGS. 3 a-3c illustrate an assembly of the driver circuit with the conductive spring and the conductive hook;

FIGS. 4 a-4c illustrate the insertion of the driver circuit board into the holder of a light bulb;

FIGS. 4 d-4f illustrate the attachment of the lighting structure to the driver circuit board;

FIG. 5 a shows a stamped copper frame for the lighting structure of the disclosed embodiments;

FIG. 5 b shows a stamped copper frame encapsulated in a plastic package;

FIG. 5 c shows another embodiment of the encapsulated copper frame of the disclosed embodiments;

FIG. 6 illustrates one placement of LED dies on the lighting structure where such LED dies are connected view a wire to positive and negative terminals;

FIGS. 7 a-7e illustrate another embodiment of a light bulb where the direction of the light is at an angle;

FIG. 8 illustrates an alternate embodiment of a light bulb where the light structure (grid) is held by a four prong holder;

FIG. 9 illustrates yet another embodiment of a light bulb in where the lighting structure (grid) is circular in shape and is held by several prongs;

FIG. 10 illustrates still yet another embodiment of a light bulb where the lighting structure (grid) is substantially rectangular in shape;

FIG. 11 illustrates still yet another embodiment of a light bulb where the lighting structure (grid) is substantially rectangular in shape and is held in place by two side prongs;

FIG. 12 illustrates still yet another embodiment of a light bulb where the lighting structure (grid) is substantially circular in shape with a half dome;

FIG. 13 a illustrates another embodiment of the lighting structure that is substantially square in shape; and

FIG. 13 b illustrates a cross section of the lighting structure showing the copper frame being sandwiched between the plastic packaging.

FIG. 14 illustrates an alternate frame of the lighting structure having a plurality of holes;

FIG. 15 illustrates yet another alternate frame of the light structure having a plurality of holes and LED disposed thereon;

DETAILED DESCRIPTION OF THE EMBODIMENTS

In the following detailed description of the embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration of specific embodiments in which the disclosure may be practiced.

Referring to FIG. 1a, an embodiment in the form of a light bulb 8 is illustrated, comprising of a screw head 10, a driver bracket 12, a lighting bracket 14, a dome 16 and a first contact 18 and a second contact 20. The first contact 18 and the second contact 20 are for receiving power from a power source. The screw head 10 is provided to be insertable into traditional light bulb sockets. In this embodiment, the screw head 10, the driver bracket 12, and the lighting bracket 14, along with the dome 16 form the light bulb 8. Referring to FIG. 1b, a side view of the embodiment is presented where the driver bracket 12 is shown here as a flat piece holding the lighting bracket 14. Referring to FIG. 1c, the dome 16 can be a simple snap on piece to the lighting bracket 14.

FIG. 2 a illustrates a top view of the embodiment in the form of a light bulb where the screw head 10 holds the driver bracket 12 and the driver bracket 12 holds the lighting bracket 14, and the lighting bracket 14 holds a lighting structure 22 in place. FIG. 2b illustrates a bottom view (looking from the bottom toward the top) of the light bulb. Here, it is shown that the lighting bracket 14 holds the lighting structure 22 in place, and the light structure 22 is in the form of a plurality of struts in a first direction and a plurality of intersecting struts in a second direction substantially forming a grid.

Note that a number of LED dies can be placed on the lighting structure, for example, at the intersecting points of the struts forming the grid (or thereabout). The number of LED dies disposed on the light structure would correspond to the desired luminance for the light bulb. The spacing between the struts can be designed and calculated as a function of (i) the amount of heat generated by each LED die, and (ii) the desired amount of heat dissipation in respect of the surrounding LED dies. Other considerations such as the melting point of the surrounding material or the maximum desired temperature can also be taken into consideration (among other considerations).

The spacing between the LED dies and the size of the openings created by the struts will determine whether heat can be properly dissipated. This is an important consideration since improper spacing and/or opening size can result in undesirable high concentration of heat which can become a safety hazard. If the number of LED dies that can be safely placed on the light structure exceeds the size of the lighting structure, additional LED dies can be placed in other manners. For example, the additional LED dies can be placed on a second lighting structure that is secured either above or below the first lighting structure. Here, the opening of the lower lighting structure can be designed to allow for the maximum amount of light to shine through from the LED dies of the upper lighting structure; and the LED dies can be evenly distributed on both the upper and the lower lighting structures. Another example for the placement of additional LED dies is to have a single lighting structure but to have posts (of desired heights) extending perpendicular from the lighting structure; and the additional LED dies can be placed on the posts.

Note that although the lighting structure is shown as a grid having substantially square-shaped spacing, other configurations for the lighting structure 22 are possible. The lighting structure 22 can have a grid in diamond shapes, in circular or elliptical shapes, and in single lines of struts, or other desirable configurations as well. For example, the entire lighting structure can be a single line of strut having one or more LEDs disposed thereon; and the two ends of the strut would connect to the driver board (described below).

FIG. 2 c illustrates an angled view of the light bulb of the embodiment. Here, the screw head 10 assembled with the driver bracket 12, and the driver bracket 12 holds the lighting bracket 14 with its extended arms. The lighting bracket 14 in turn holds the lighting structure 22 with several support notches 24. It is important to note that the simplicity of this structure significantly reduces manufacturing cost, weight of the light bulb, and it maximizes heat dissipation.

FIG. 3 a illustrates a driver board 30, which can be a simple piece of board. Here, it is generally in a Y shape. For the embodiment, the driver board 30 is also a circuit board as well. The driver circuit board 30 has a number of contact points, including a contact point at 32 for accepting the conductive spring 36 and a contact point at 34 for accepting the conductive hook 38. There is also a power converter 35 for converting the received power to the proper voltage needed for the LED dies. The driver circuit board 30 has a first conductive interface 40 for conducting the circuits on the driver circuit board 30 and the lighting structure 22 and a first clip 42 for securing the driver circuit board 30 with the lighting structure 22. Likewise, it has a second conductive interface 44 for conducting the circuits on driver circuit board 30 and the lighting structure 22 and a second clip 46 for securing the driver circuit board 30 with the lighting structure 22. The first conductive interface 40 can be the positive terminal and the second conductive interface 44 can be the negative terminal. In this manner, the control circuitry on the driver circuit board 30 controls and powers the LED dies on the lighting structure 22. FIG. 3b illustrates an assembled embodiment of the driver circuit board 30 where the conductive spring 36 is attached at contact point 32 and the conductive hook 38 is attached at contact point 34. FIG. 3c illustrates a side view of the driver circuit board 30 with the conductive spring 36 and conductive hook 38 attached to the board 30. In the manner, the LED dies are electrically connected to the driver circuit board and can be operated by the circuits on the driver circuit board.

In alternative embodiments, the driver board can be designed to have one or more prongs. While FIGS. 3a-3c illustrated a two prong driver board, a single prong driver board can be designed to hold the lighting structure in place. For example, a single prong driver board can be designed to be secured to the lighting structure at a single point (e.g. at the center of the lighting structure) and thus holding the lighting structure in place.

Once the driver circuit board 30 is assembled, referring to FIG. 4a, it can be inserted into the holder 50 (comprising of the screw head 10, the driver bracket 12, and the lighting bracket 12) (see FIG. 4b), and FIG. 4c illustrates the post-assembled light bulb where the driver circuit board 30 is inserted into the holder 50 and the conductive spring 36 and the conductive hook 38 are in place in the holder. After the driver circuit board 30 is inserted into the holder 50, referring to FIG. 4d, the lighting structure 22 can be snapped into place with the driver circuit board 30 using the clips 42 and 46 (as shown in FIGS. 4e and 4f).

Referring to FIGS. 5a-5e, the steps in manufacturing the lighting structure 22 are illustrated. In manufacturing the lighting structure, referring to FIG. 5a, a method is to start with a stamped copper frame 60, and the copper frame 60 may be designed such that there may be one or more conducting areas 62 for conducting electricity and/or signals and there may be one or more dissipation areas 70, 72 for the dissipation of heat. The conducting area(s) are not necessarily conductive with the dissipation area(s). The copper frame 60 can be initially held by breakaway holders 80, 82, 84, and 86.

The design of conducting areas and the design of the dissipation areas may depend on the number LED dies to be placed on the lighting structure and the configuration of the LED dies on the lighting structure. For example, as illustrated by FIG. 5a, this copper frame 60 is designed to have one main conducting area 62 because there will be many LED dies substantially placed all over on the conducting area 62 (see FIG. 6 for the placement of the LED dies for this particular configuration). For this particular configuration, there are two dissipation areas, 70 and 72, for the dissipation of heat, where these dissipation areas, 70 and 72, are not electrically connected to the conducting area 62. If the number of dies being placed on the copper frame 60 changes, the size(s) of the conducting area(s) and the size(s) of the dissipation area(s) can be configured accordingly.

Referring to FIG. 5b, after the copper frame 60 is stamped, a packaging material (e.g. plastic packaging) can be applied over the copper frame. FIG. 5b illustrates one side of the lighting structure 22 in which the copper frame 60 is covered by a plastic packaging. Please note that although the plastic packaging 90 is shown to substantially cover the entire copper frame 60, the amount of coverage can be designed as desired to offer desired structure support as well as heat dissipation. The positive and negative terminals of the lighting structure can also be marked accordingly.

FIG. 5 c shows that after the encapsulation of the copper frame 60, a reflective substance can be placed on the plastic packaging to help reflect the light.

FIG. 6 illustrates one placement of LED dies 100 on the lighting structure 22 where the LED dies 100 are electrically connected via a wire 110 that, in this particular configuration, connects all the LED dies in a planned path on the lighting structure 22. There are many configurations possible here, depending on the number of LED dies. The LED dies can also be connected serially or in parallel. The dies can also be placed at the intersections of the grid or along a strut.

FIGS. 7 a-7e illustrate another embodiment of the light bulb. Here, the direction of the light and the light bulb itself are at an angle. FIG. 7a illustrates a view from the bottom of the light bulb, FIG. 7b illustrates a view from the screw-end, FIG. 7c illustrates a side view, FIG. 7d illustrates a front view, and FIG. 7e illustrates a top view. Other than the orientation between the direction of the light and the light bulb itself, the designs and operation of the light bulb can be substantially similar to the description provided above.

FIG. 8 illustrates an alternate embodiment of a light bulb where the light structure (grid) is held by a four prong holder and the lighting structure grid is substantially square in shape. FIG. 9 illustrates yet another embodiment of a light bulb in where the lighting structure (grid) is circular in shape and is held by several prongs. FIG. 10 illustrates still yet another embodiment of a light bulb where the lighting structure (grid) is substantially rectangular in shape and is held in place by four prongs with one prong on each side. FIG. 11 illustrates still yet another embodiment of a light bulb where the lighting structure (grid) is substantially rectangular in shape and is held in place by two side prongs where the grid can rotate to direct the light. FIG. 12 illustrates still yet another embodiment of a light bulb where the lighting structure (grid) is substantially circular in shape with a half dome and the lighting structure is held in place by three prongs.

FIG. 13 a illustrates another embodiment of the lighting structure that is substantially square in shape. FIG. 13b illustrates a cross section of the lighting structure showing the copper frame being sandwiched between the plastic packaging material.

FIG. 14 illustrates yet another embodiment of the lighting structure 120 where the lighting structure has a plurality of rectangular or squared shaped openings 122. The LEDs may be placed anywhere on the lighting structure. Two of more lighting structures can also be stacked using a pre-determined distance between the two lighting structures. In this manner, more LEDs can be placed for a LED light bulb and ventilation can also be better distributed.

FIG. 15 illustrates still yet another embodiment of the lighting structure 130 where the lighting structure 130 has a plurality of circular openings 132 disposed therein. The LEDs 134 may be disposed on the lighting structure 130 and in one embodiment between the circular openings. At two ends of the lighting structure 130, there are contact points 136 and 138 attached to the lighting structure 130 and wires 140 and 142 can be attached to the contact points 136 and 138 to power the LEDs. The lighting structure 130 can be made from a variety of materials.

In one embodiment, the lighting structure is made from a printed circuit board (“PCB”) material, where the PCB can connect the LEDs of the lighting structure. The circular openings on the PCB are either punched out or drilled out. The grid form of the lighting structure can have a number of pre-selected intersections forming the grid, and the number of pre-selected intersections is determined in proportion with an amount of desired ventilation and a number of LEDs on the lighting structure generating a desired amount of light. Two or more lighting structures can also be stacked at a predetermined distance in order to place more LEDs. The stacked lighting structures can be of different shapes and sizes and can be orientated to allow a maximum amount of light to pass through from the light generated by LEDs on one lighting structure through the other lighting structure.

While the present invention has been described with reference to certain preferred embodiments or methods, it is to be understood that the present invention is not limited to such specific embodiments or methods. Rather, it is the inventor's contention that the invention be understood and construed in its broadest meaning as reflected by the following claims. Thus, these claims are to be understood as incorporating not only the preferred methods described herein but all those other and further alterations and modifications as would be apparent to those of ordinary skilled in the art.

Claims

1. A lighting structure for a light-emitting-diode (“LED”) light bulb, wherein said lighting structure is in a grid form with a plurality of openings therein; and having one or more locations for interconnecting lighting components disposed on said lighting structure; and wherein said lighting structure having a first terminal and a second terminal for connecting to the lighting components.

2. The lighting structure of claim 1 wherein the lighting structure is made from printed-circuit-board (“PCB”).

3. The lighting structure of claim 2 wherein the plurality of openings are substantially disposed on the PCB forming a mesh structure.

4. The lighting structure of claim 1 wherein the openings of the grid form are in one of the following shapes: square, rectangular, circular, and oval.

5. The lighting structure of claim 1 wherein the grid form having a pre-selected number of intersections forming the grid.

6. The lighting structure of claim 5 wherein the pre-selected number of intersections is in proportion with an amount of desired ventilation.

7. The lighting structure of claim 5 wherein the pre-selected number of intersections is in proportion with a number of LEDs generating a pre-determined amount of light.

8. The lighting structure of claim 6 wherein the pre-selected number of intersections is further in proportion with a number of LEDs generating a pre-determined amount of light.

9. The lighting structure of claim 1 wherein two of more lighting structures are stackable at a predetermined distance and wherein light passes from one of the lighting structures through another one of the lighting structures.

10. A lighting structure for a light-emitting-diode (“LED”) light bulb, wherein said lighting structure is in a grid form with a plurality of openings therein; and having one or more locations for interconnecting lighting components disposed on said lighting structure; wherein said lighting structure having a first terminal and a second terminal for connecting to the lighting components; and wherein the lighting structure is made from printed-circuit-board.

11. The lighting structure of claim 10 wherein the openings of the grid form are in one of the following shapes: square, rectangular, circular, and oval.

12. The lighting structure of claim 10 wherein the grid form having a pre-selected number of intersections forming the grid.

13. The lighting structure of claim 12 wherein the pre-selected number of intersections is in proportion with an amount of desired ventilation.

14. The lighting structure of claim 12 wherein the pre-selected number of intersections is in proportion with a number of LEDs generating a pre-determined amount of light.

15. The lighting structure of claim 13 wherein the pre-selected number of intersections is in proportion with a number of LEDs generating a pre-determined amount of light.

16. The lighting structure of claim 10 wherein two of more lighting structures are stackable at a predetermined distance wherein light passes from the lighting components on one of the lighting structures through another one of the lighting structures.

17. A lighting structure for a light-emitting-diode (“LED”) light bulb, wherein said lighting structure is in a grid form with a plurality of openings therein; and having one or more locations for interconnecting lighting components disposed on said lighting structure; and wherein said lighting structure having a first terminal and a second terminal for connecting to the lighting components, wherein the grid form having a pre-selected number of intersections for forming the grid, wherein the pre-selected number of intersections is in proportion with an amount of desired ventilation and a number of LEDs for generating a pre-determined amount of light.

18. The lighting structure of claim 17 wherein the lighting structure is made from printed-circuit-board.

19. The lighting structure of claim 17 wherein the openings of the grid form are in one of the following shapes: square, rectangular, circular, and oval.

20. The lighting structure of claim 17 wherein two of more lighting structures are stackable at a predetermined distance wherein light passes from one of the lighting structures through another one of the lighting structures.