GB2499783A - LED lamp having shell structure - Google Patents

LED lamp having shell structure Download PDF

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Publication number
GB2499783A
GB2499783A GB1202942.7A GB201202942A GB2499783A GB 2499783 A GB2499783 A GB 2499783A GB 201202942 A GB201202942 A GB 201202942A GB 2499783 A GB2499783 A GB 2499783A
Authority
GB
United Kingdom
Prior art keywords
shell
circuit board
shell portions
light emitting
emitting devices
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB1202942.7A
Other versions
GB201202942D0 (en
GB2499783B (en
Inventor
Nigel Alastair Dent
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Zeta Controls Ltd
Original Assignee
Zeta Controls Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Zeta Controls Ltd filed Critical Zeta Controls Ltd
Priority to GB1202942.7A priority Critical patent/GB2499783B/en
Publication of GB201202942D0 publication Critical patent/GB201202942D0/en
Publication of GB2499783A publication Critical patent/GB2499783A/en
Application granted granted Critical
Publication of GB2499783B publication Critical patent/GB2499783B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20—Light sources comprising attachment means
    • F21K9/23—Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20—Light sources comprising attachment means
    • F21K9/23—Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • F21K9/232—Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/90—Methods of manufacture
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/83—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks the elements having apertures, ducts or channels, e.g. heat radiation holes
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00—Electroluminescent light sources
    • H05B33/10—Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V17/00—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages
    • F21V17/10—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening
    • F21V17/16—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening by deformation of parts; Snap action mounting
    • F21V17/164—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening by deformation of parts; Snap action mounting the parts being subjected to bending, e.g. snap joints
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Optics & Photonics (AREA)
  • Manufacturing & Machinery (AREA)
  • Fastening Of Light Sources Or Lamp Holders (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

An electric lamp 10 comprises a plurality of electrically-powered light sources 34 (such as LEDs); at least one electrical connector 54 electrically connected to the light sources; and a structure to which the light sources are mounted with different orientations and to which the connector(s) is/are mounted. The structure has the form of a shell 100 and is assembled from a plurality of separately formed shell portions 88,90. A method of manufacture of the lamp comprising the steps of: providing at least two shell portions and a circuit board 92; assembling the shell portions and the circuit board so that the shell portions are mechanically connected to each other to form a hollow shell, the circuit board is contained within the shell, and an electrical input to the circuit board is externally accessible; attaching a plurality of light emitting devices to the shell; and electrically connecting the light emitting devices to the circuit board.

Description

-1 -TITLE
Method of manufacture of electric lamps DESCRIPTION
This invention relates to a method of manufacture of electric lamps. The invention was conceived while developing a 'low-energy' replacement for a conventional 60 Watt general lighting service ('GLS') tungsten-filament light bulb. However, the invention is also applicable to other types of electric lamp.
5 It is well known that the light-producing efficiency of tungsten-filament bulbs is low and that light-emitting diodes ('LEDs') can nowadays be produced having a far higher light-producing efficiency. However, despite producing significantly less heat than a tungsten filament bulb having the same light output, it is very important that the junction temperature of an LED is maintained below a limit value, otherwise the LED will immediately blow. 10 Furthermore, even if an LED is operated with its junction below its limit temperature, its life expectancy decreases with increasing operating temperature. Moreover, the light-producing efficiency of LEDs decreases with increasing operating temperature.
It is also well known that a GLS bulb has a fairly uniform light radiation pattern over a very large angle, for example from 0 to 150 degrees or more relative to the axis of the bulb. By 15 contrast, LEDs generally have a far smaller radiation angle unless special optics are provided. Furthermore, the light output from commonly-available single high-power LEDs is substantially less than from a 60 Watt tungsten-filament bulb.
One way of emulating a GLS tungsten-filament using LED technology would therefore be to mount a number of LEDs in a cluster with the LEDs pointing in different directions. 20 However, mounting the LEDs in a cluster increases the difficulty in dissipating heat from the LEDs so as to keep their junction temperatures low. Also, mounting a large number of LEDs in a cluster so that they face in different directions creates manufacturing difficulties.
An aim of the present invention, or at least of specific embodiments of it, is to produce an electric lamp that can have its light emitting devices mounted in an arrangement that can 25 emulate a GLS light bulb and yet enables the lamp to be manufactured simply and inexpensively.
-2 -
In accordance with a first aspect of the present invention, there is provided a method of manufacture of an electric lamp comprising the steps of: providing at least two shell portions and a circuit board; assembling the shell portions and the circuit board so that the shell portions are mechanically connected to each other to form a hollow shell, the circuit board is contained 5 within the shell, and an electrical input to the circuit board is externally accessible; attaching a plurality of light emitting devices to the shell; and electrically connecting the light emitting devices to the circuit board. As in the case of the embodiment of the invention that will be described below, the shell may have an approximately pear-shaped outline, with one of the shell portions being approximately hemispherical and forming the blunt end of the pear shape, and 10 the other shell portion forming the remainder of the pear shape.
The attaching step preferably involves attaching a respective plurality of the light emitting devices to each of the shell portions. The light emitting devices may be arranged in any suitable arrangement on the pear-shaped shell, but it has been found that by mounting five light emitting devices symmetrically around the axis of the pear shape and having their primary axes 15 inclined towards the blunt end of the pear shape, and by mounting a further five light emitting devices symmetrically around the axis of the pear shape and having their primary axes inclined away the blunt end of the pear shape, a very satisfactory light distribution can be achieved.
In order to facilitate the electrical connection of the light emitting devices to the circuit board, the method preferably further includes the step of fitting at least one electrical 20 distribution device to at least one of the shell portions, and the electrically-connecting step preferably comprises electrically connecting the electrical distribution device(s) to the circuit board and to the light emitting devices.
The light emitting devices may be soldered to the distribution device, but in order to facilitate automated assembly the distribution device and the light emitting devices preferably 25 have complementary push-fit electrical connecting elements. More preferably, the connecting elements have barbed features so that they can be readily connected during manufacture, but cannot be readily disconnected.
The step of mechanically connecting the shell portions together may include the step of deforming locking elements of the shell portions into locking engagement, the locking elements 30 being disposed inside the shell and being deformed by at least one tool inserted through at least one aperture in the shell. Alternatively or additionally, the shell portions may be bonded together.
- 3 -
The shell portions may be formed by die casting metal, or by pressing and forming sheet metal. In either case, the metal is preferably aluminium alloy.
The method may further include the steps of: providing a connector cap having at least two electrical terminals; mechanically connecting the connector cap to one of the shell portions;
5 and electrically connecting the electrical terminals to the circuit board. Alternatively, one of the shell portions may be formed with a connector cap having at least two electrical terminals, and the method may further include the step of electrically connecting the electrical terminals to the circuit board.
In accordance with a second aspect of the invention, there is provided an electric lamp 10 manufactured by the method of the first aspect of the invention.
A specific embodiment of the present invention will now be described, purely by way of example, with reference to the accompanying drawings, in which:
Figure 1 is an exploded isometric view of an electric lamp;
Figure 2 is an isometric view of the lamp partly assembled; and
15 Figure 3 is an isometric view of the lamp fully assembled.
Referring to the drawings, an electric lamp 10 is shown, emulating a conventional GLS bulb. As shown in Figure 1, the main components of the bulb 10 are a base shell half 88, a top shell half 90, a bayonet or Edison screw (BC or ES) connector cap 54, a printed circuit board 92 populated with various electrical components 37, a pair of wire guides 94,96, ten LEDs 34 20 and a plug 98. Interconnecting wires between the circuit board 92 and the LEDs 34 are not shown in the drawings.
The shell halves 88,90 are thin-wall die-castings of aluminium. As shown in Figure 3, the shell halves 88,90 together form a pear-shaped shell 100, with the top shell half 90 being approximately hemi-spherical and forming the rounded end of the pear shape, and with the base 25 shell half 88 forming the remainder of the pear shape. The base shell half 88 has an open ended neck 102 which is fitted to the connector cap 54. Each shell half 88,90 is formed with five equiangularly-spaced flat-bottomed depressions 104 in its outer surface, with the depressions 104 in the base shell half 88 being inclined at an angle of about 45 degrees to the cap 54 end of the shell 100, and with the depressions 104 in the top shell half 90 being inclined at an angle of 30 about 45 degrees to the rounded end of the shell 100. The flat bottom of each depression 104 is
-4 -
formed with a through-hole 106 covering only a small proportion of the area of the flat bottom. Between each adjacent pair of depressions 104 in each shell half 88,90, a respective generally-triangular through-hole 108 is formed for ventilation purposes. At the rounded end of the top shell half 90A, a central through-hole 110 is also formed, for receiving the plug 98. The plug 5 98 is formed with an array of ventilation holes. Adjacent their mating edges, the shell halves 88,90 have cooperating ribs 112 which can be clinched, crimped or punched so that they interlock to hold the shell halves 88,90 together. Between the ribs 112, the mating edges are formed with notches 114 (Figure 1) which align in pairs when the shell halves 88,90 are connected together so as to form further through holes 116 (Figure 3) in the shell 100.
10 Opposite their light-emitting faces, the LEDs 34 have flat rear faces corresponding in outline to the shape of the flat bottoms of the depressions 104 in the shells 98,100. The rear faces of the LEDs 34 also have protruding electrical connectors 118 which align with the holes 106 in the depressions 104 when the LEDs are fitted to the shell 100.
The printed circuit board 92 has a pair of input terminals 120 adjacent its lower end for
15 connection to mains supply contacts of the connector cap 54. Nearer its upper end the printed circuit board 92 has a pair of output terminals 122 for connection to a series circuit of the ten LEDs. The printed circuit board 92 and its components 37 may be contrived to perform any required functions for driving the LEDs 34 including voltage step-down, current regulation, temperature compensation, flashing and dimming.
Each wire guide 94,96 is a press- or click-fit into the respective shell half 88,90 adjacent its mating edge. Each wire guide 94,96 is an annular moulded plastic part with grooves into which lengths of wire (not shown) are press-fitted. The wires of each guide 94,96 may be arranged, for example, to connect the five LEDs 34 of the respective shell half in series between a respective output terminal 122 of the printed circuit board 92 and a wire of the other guide 96,94.
In one example of a method of assembly of the lamp 10, the neck of the base shell half 88 is fitted into the connector cap 54 and is secured thereto, for example by bonding, clinching, crimping or riveting. The circuit board 92 is then inserted into the base shell half 88 and its input terminals 120 are connected to the supply contacts of the connector cap 54 by soldering.
30 Resin or silicone is then deposited into the connector cap 54 to hold the circuit board 92 steady. Each wire guide 94,96 is then press- or click-fitted to its respective shell half 88,90; the LEDs 34 are bonded by their flat rear faces to the flat bottoms of the depressions 104 with their connectors 118 protruding into the holes 106, and the wires of the wire guides 94,96 are
20
25
- 5 -
electrically connected to the LED connectors 188 by soldering. The shell halves 88,90 are then offered up to each other, and the wires of the wire guides 94,96 are connected to each other and to the output terminals 122 of the circuit board 92 by soldering. The shell halves 88,90 are then mated and mechanically fixed to each other by inserting tools into each adjacent pair of the 5 holes 116 and clinching the mating ribs 112 situated between those holes 116. The plug 98 is then fitted to the hole 110.
It will be appreciated that the shell halves 88,90 and connector cap 54 can form a very rigid structure. The flat rear faces of the LEDs 34 and the flat bottoms of the depressions 104 of the shell 100 provide a good thermal path from the LEDs 34 to the thermally conducting shell 10 100. The shell 100 has a substantial external exposed area from which heat can be dissipated. Furthermore, the shell 100 has an even greater exposed area internally, and the holes 108, 116 permit ambient air to circulate in and out of the shell 100 to cool the internal surface.
It will be appreciated that many modifications and developments may be made to the lamp 10 and its method of manufacture. For example, the final soldering stage may be carried 15 out using a soldering tool inserted through the aperture 110 in the top shell half 90 after the shell halves 88,90 have been mechanically connected together. The circuit board 92 and its components 37, and any other exposed electrical parts may be potted in resin or otherwise insulated. Barbed push-fit connections may be provided between the circuit board 92 and the connector cap 54 and/or between the wire guides 94,96 and the circuit board 92 and/or between 20 the wire guides 94,96 and the LEDs 34 so as to reduce the amount of soldering or obviate the need for any soldering. The wire guides and their wires may be replaced by conductors stamped and pressed out of sheet metal and then over-moulded with plastics material. The body of the connector cap 54 (particularly if it is an ES cap) may be insulated from the base shell half 88, for example using an insert-moulded plastic part in the cap body. Alternatively, the body of the 25 connector cap 54 (particularly if it is a BC cap) may be integrally formed with the base shell half 88.
It should be noted that the embodiment of the invention has been described above purely by way of example and that many modifications and developments may be made thereto within the scope of the present invention.
-6-

Claims (11)

1. A method of manufacture of an electric lamp comprising the steps of:
providing at least two shell portions and a circuit board;
assembling the shell portions and the circuit board so that:
the shell portions are mechanically connected to each other to form a hollow shell,
the circuit board is contained within the shell, and an electrical input to the circuit board is externally accessible;
attaching a plurality of light emitting devices to the shell; and electrically connecting the light emitting devices to the circuit board.
2. A method as claimed in claim 1, wherein:
the attaching step comprises attaching a respective plurality of the light emitting devices to each of the shell portions.
3. A method as claimed in any preceding claim, wherein:
the method further includes the step of fitting at least one electrical distribution device to at least one of the shell portions; and the electrically-connecting step comprises electrically connecting the electrical distribution device(s) to the circuit board and to the light emitting devices.
4. A method as claimed in claim 3, wherein:
the distribution device and the light emitting devices have complementary push-fit electrical connecting elements.
5. A method as claimed in any preceding claim, wherein:
the step of mechanically connecting the shell portions together includes the step of deforming locking elements of the shell portions into locking engagement, the locking elements being disposed inside the shell and being deformed by at least one tool inserted through at least one aperture in the shell.
6. A method as claimed in any preceding claim, wherein:
the shell portions are formed by die casting metal.
7. A
- 7 -
method as claimed in any preceding claim, wherein:
the shell portions are formed by pressing and forming sheet metal.
8. A method as claimed in any preceding claim, further including the steps of:
providing a connector cap having at least two electrical terminals;
mechanically connecting the connector cap to one of the shell portions; and electrically connecting the electrical terminals to the circuit board.
9. A method as claimed in any preceding claim, wherein:
one of the shell portions is formed with a connector cap having at least two electrical terminals; and the method further includes the step of electrically connecting the electrical terminals to the circuit board.
10. A method of manufacture of an electric lamp substantially as described with reference to the drawings.
11. An electric lamp manufactured by a method as claimed in any preceding claim.
GB1202942.7A 2012-02-21 2012-02-21 Method of manufacture of electric lamps Expired - Fee Related GB2499783B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1202942.7A GB2499783B (en) 2012-02-21 2012-02-21 Method of manufacture of electric lamps

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1202942.7A GB2499783B (en) 2012-02-21 2012-02-21 Method of manufacture of electric lamps

Publications (3)

Publication Number Publication Date
GB201202942D0 GB201202942D0 (en) 2012-04-04
GB2499783A true GB2499783A (en) 2013-09-04
GB2499783B GB2499783B (en) 2014-07-16

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103982788A (en) * 2014-04-15 2014-08-13 绍兴炅辉电子科技有限公司 Omnidirectional LED (Light-Emitting Diode) ball lamp bulb

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6357902B1 (en) * 2000-09-25 2002-03-19 Brian Horowitz After market LED taillight bulb
US20110156584A1 (en) * 2008-08-08 2011-06-30 Solarkor Company Ltd. Led lighting device
CN202001886U (en) * 2011-01-07 2011-10-05 江苏菱安光电科技有限公司 Light emitting diode lamp bulb
US20110273885A1 (en) * 2010-04-09 2011-11-10 De Bevilacqua Carlotta Francesca Isolina Maria Led lighting device

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6357902B1 (en) * 2000-09-25 2002-03-19 Brian Horowitz After market LED taillight bulb
US20110156584A1 (en) * 2008-08-08 2011-06-30 Solarkor Company Ltd. Led lighting device
US20110273885A1 (en) * 2010-04-09 2011-11-10 De Bevilacqua Carlotta Francesca Isolina Maria Led lighting device
CN202001886U (en) * 2011-01-07 2011-10-05 江苏菱安光电科技有限公司 Light emitting diode lamp bulb

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103982788A (en) * 2014-04-15 2014-08-13 绍兴炅辉电子科技有限公司 Omnidirectional LED (Light-Emitting Diode) ball lamp bulb
CN103982788B (en) * 2014-04-15 2016-04-20 上虞富森照明电器有限公司 A kind of omnirange LED ball bulb

Also Published As

Publication number Publication date
GB201202942D0 (en) 2012-04-04
GB2499783B (en) 2014-07-16

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 20190221