WO2012006515A1

WO2012006515A1 - Led lamp driver package method and apparatus

Info

Publication number: WO2012006515A1
Application number: PCT/US2011/043343
Authority: WO
Inventors: Michael Miskin
Original assignee: Lynk Labs, Inc.
Priority date: 2010-07-08
Filing date: 2011-07-08
Publication date: 2012-01-12

Abstract

An LED driver package, the LED driver package having a lamp base having two conductive voltage input terminals for connecting to a lamp socket. At least partially housed within the lamp based is an LED driver circuit having at least two voltage input terminals electrically connected to the two conductive voltage input terminals of the lamp base and at least two voltage output terminals. The at least two voltage output terminals of the LED circuit are configured such that the output terminals are accessible for electrical connectivity outside of the lamp base.

Description

ATTY DOCKET NO.: LYN 101078PCT

LED Lamp Driver Package Method And Apparatus

RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 61/362,375 filed July 8, 2011 , the contents of which are fully incorporated herein by reference.

TECHNICAL FIELD

[0002] The present invention generally relates to light emitting diodes ("LEDs") for AC operation. The present invention specifically relates to lamp bases housing LED power supply packages for LED lamps.

BACKGROUND OF THE INVENTION

[0003] Field of the Invention

[0004] The present invention generally relates to light emitting diode ("LED") lamps.

The present invention specifically relates to LED driver packages for LED lamps. This invention comprises apparatus on the one hand providing a driver incorporated into a device which permits a prepackaged driver to be connected to any form of connection to an AC power supply (such as wwedge or screw type connectors to the power supply) and any chosen LED and a cover for the LED (such as a clear cover), in other words a method of packaging LED drivers and/or power supplies "LED drivers" specifically for use with LED lamps.

[0005] Description of the Related Art

[0006] LEDs are semiconductor devices that produce light when a current is supplied to them. LEDs can be driven with AC or DC voltages based on the LED circuit design. Based on the LED circuit design being AC or DC, LED drive methods typically used are constant voltage AC or DC, constant current and pulsed AC or DC. Examples of such AC LED circuit designs may be found in, for example, U.S. Patent No. 7,489,086 or U.S. Publication No. 2009/0174337 both to Miskin et al.

[0007] Historically, drivers and/or power supplies have been made with various components that are placed on circuit boards with LEDs or separately from the LEDs. The LED drivers and/or power supplies that are packaged separately of the LEDs are packaged within a package that provides at least a first set of leads for connectivity to the input voltage source to ATTY DOCKET NO.: LYN 101078PCT the driver circuitry and at least a second set of leads for connectivity to the voltage source output of the LED driver circuitry. It is also common for wire connectors to be used in place of these leads for the voltage source input and output connectivity to the LED driver.

[0008] LEDs continue to be used more and more in LED lamps. The basic design of an

LED lamp includes an LED package. The LED package can be comprised of a single LED package or several LED packages mounted to a circuit board, chip on board "COB", or other form of LED package. In many cases all of these can be referred to as an LED package, an LED array, an LED light module, an LED assembly and/or an LED light engine "LED package". The LED package is mounted to a heat sink and the heat sink is then mounted to a dielectric component that is often connected to a standard lamp base in one form or another. The dielectric component can be plastic, ceramic, coated and/or treated metal and/or other form of dielectric material. A power supply is then integrated into a cavity extending in the heat sink and the dielectric component connected to the lamp base. The dielectric component may be typically inserted between the standard lamp base can be any legacy lamp base. The lamp base and dielectric component and heat sink are then joined together with the LED driver between them. The LED package is mounted to the heat sink on the opposing side or the heat sink and dielectric component. Wires are fed from the LED package through the heat sink for connectivity to the LED driver package prior to final assembly of the heat sink and dielectric component. The lamp base may be connected to the dielectric before or after this stage of assembly, but is always a separate component from dielectric component and from the LED driver package. Meaning, the LED lamp base, the LED driver and the dielectric component are all separate components in the assembly process of the LED lamp. The LED package and the heat sink are also additional separate components. It is also common to add a reflector and/or lens cover over the LED package based on the design requirements of the LED lamp further adding additional components in the assembly of the LED lamp. An exemplary embodiment of such a device may be seen in FIG. 1.

[0009] It would be advantageous to provide an LED driver package that can reduce the cost and complexity of manufacturing LED lamps.

[0010] It would further be advantageous to provide an LED driver package that is a sealed single assembly comprising LED driver circuitry sealed within a package that includes a standard lamp base configuration such as a wedge base or a threaded connector and a dielectric ATTY DOCKET NO.: LYN 101078PCT component as the LED driver package. Such an LED driver package would provide all the components needed for the base of an LED lamp thereby requiring a manufacturer only to choose and add an LED circuit, heat sink, and optional lensing to be added to the lamp.

[0011] It would further be advantageous to provide an LED lamp base driver package such as this that are designed to mate with specific LED packages further simplifying the design and manufacture of an LED lamp.

[0012] The present invention is provided to solve these and other issues.

SUMMARY OF THE INVENTION

[0013] According to one aspect, the present invention is directed to an LED driver package, the LED driver package having a lamp base having two conductive voltage input terminals for connecting to a lamp socket. At least partially housed within the lamp base is an LED driver circuit having at least two voltage input terminals electrically connected to the two conductive voltage input terminals of the lamp base and at least two voltage output terminals. The at least two voltage output terminals of the LED circuit are configured such that the output terminals are accessible for electrical connectivity outside of the lamp base.

[0014] Packaging the LED driver circuit within the lamp base provides an economical package which may be integrated with any LED circuit the LED driver circuit can support. Rather than designing an entire lamp, an LED manufacturer may simply take the LED driver package, add a heat sink and any LED circuits to be driven by the LED circuit driver.

[0015] According to another aspect of the invention, the LED driver package may include at least two electrical conductors attached to the voltage output terminals of the LED driver circuit. The two electrical output conductors may form the portion of the output voltage terminals accessible for electrical connectivity on the exterior of the lamp.

[0016] According to another aspect of the invention, the LED driver package may include a dielectric mechanically connected to the lamp base. According to another aspect of the invention the dielectric layer may be used to seal the LED driver circuit entirely within the lamp base. According to another aspect of the invention the dielectric layer may house and seal a portion of the LED circuit.

[0017] According to another aspect of the invention, the at least two output voltage terminals accessible for electrical connectivity outside the lamp base extend through and beyond ATTY DOCKET NO.: LY 101078PCT the dielectric layer.

[0018] According to another aspect of the invention, the LED driver package may include more than one LED driver circuits. For example, when using two LED driver circuits, the LED package may further include a sensor connected to the output voltage terminals of the at least two LED driver circuits. The sensor may be configured to allow only one voltage output from the at least two LED driver circuits to be accessible for electrical connectivity outside the lamp base. The sensor may be further configured to connect a different LED driver circuit should the LED driver circuit providing the accessible output voltage fail to provide an output voltage to the sensor.

[0019] According to one aspect of the invention at least one driver circuit is integrated within a standard lamp base and dielectric component assembly that as an assembly form an LED driver package for LED lamps. The standard lamp base and dielectric assembly are used to encapsulate the LED driver circuitry. The standard lamp base is also used to provide direct electrical connectivity from the LED lamp power source to the voltage source input of the LED driver circuitry and is electrically connected to the LED driver circuitry. The dielectric component coupled to the standard lamp base assembly has electrical conductors passing through it with one end electrically connected to the voltage source output of the LED driver circuitry integrated within and their other end of the electrical conductors being accessible for electrical connectivity to an LED package.

[0020] According to one aspect of the invention, an LED lamp package is provided. The

LED lamp package includes a lamp base having at least two voltage source input terminals for connecting to a lamp socket. At least partially sealed and integrated within the lamp base is at least one LED driver circuit having at least two voltage input terminals and at least two voltage output terminals such that the at least two voltage input terminals of the at least one LED driver circuit are electrically connected to the at least two voltage source input terminals of the lamp base.

[0021] According to another aspect of the invention, the LED lamp package further includes at least two electrical conductors electrically connected to the voltage output terminals of the at least one LED driver circuit, the at least two electrical conductors being capable of providing voltage.

[0022] According to another aspect of the invention, the LED lamp package further ATTY DOCKET NO. : LYN 101078PCT includes at least one LED circuit having at least two LEDs, the at least one LED circuit having an input capable of being electrically connected to the at least two electrical conductors and utilizing the voltage output from the at least one LED driver circuit. The at least one LED circuit is configured to be removed and replaced with at least a second LED circuit if the at least one LED circuit fails after being connected to the at least two electrical conductors without the need to remove or replace any of the at least two electrical conductors, the LED driver circuit, the dielectric package or the lamp base.

[0023] Other advantages and aspects of the present invention will become apparent upon reading the following description of the drawings and detailed description of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 shows an embodiment of a prior art LED lamp;

[0025] Figure 2 shows a schematic view of a preferred embodiment of the invention;

[0026] Figure 3 shows a schematic view of a preferred embodiment of the invention;

[0027] Figure 4 shows a schematic view of a preferred embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0028] While this invention is susceptible to embodiments in many different forms, there is described in detail herein, preferred embodiments of the invention with the understanding that the present disclosures are to be considered as exemplifications of the principles of the invention and are not intended to limit the broad aspects of the invention to the embodiments illustrated.

[0029] FIG. 1 discloses a typical prior art LED lamp 10 having lamp base 12, dielectric layer 14, LED power source 16, heat sink 18, LED 20, and lens 22. As shown LED lamp 10 is packaged as a single unitary body with LED power source 16 integrated with heat sink 18 and dielectric layer 14. As described above these components are separate bodies, requiring numerous parts and simultaneous connection inasmuch as LED power source 16 must be electrically connected to lamp base 12 and housed within dielectric layer 14 and heat sink 18.

[0030] By contrast, FIGs. 2 and 3 disclose an LED driver package 120 having lamp base

122 wherein lamp base 122 includes two conductive voltage input terminals 124, 126 for connecting to a lamp socket. As shown in FIG. 2, an LED driver circuit 128 (shown in phantom) having at least two voltage input terminals 130, 132 and at least two voltage output terminals ATTY DOCKET NO.: LYN 101078PCT

134, 136 is at least partially integrated and sealed within lamp base 122. At least two voltage input terminals 130, 132 arc electrically connected to lamp base voltage input terminals 124, 126 inside lamp base 122. As shown in FIG. 2, voltage input terminals 130, 132 may be connected to lamp base voltage input terminals 124, 126 utilizing electrical connectors 138, 140, which, as should be appreciated by those having ordinary skill in the art, may be any electrical conduct capable of carrying a voltage and current. Alternatively, electrical connectors 138, 140 may be solders or welds with an electrically conductive material. Output voltage terminals 134, 136 extend above and beyond lamp base 122 so as to be accessible for electrical connectivity on the exterior of lamp base 122. In order to accommodate LED driver circuit 128, lamp base 122 may be hollow or at least partially hollow. In embodiments where lamp base 122 is partially hollow it is contemplated that a dielectric material may be incorporated into the base to isolate LED circuit driver 128 from lamp base 122, insuring that only lamp base voltage input terminals 124, 126 and LED circuit driver voltage input terminals 130, 132 are in contact.

[0031] Utilizing LED driver package 120 eliminates the necessity of having to build an entire lamp simultaneously reduces the part count required to manufacture an LED. Utilizing LED driver package 120 may have a further advantage of selective or partial replace ability with minimal effort. For example, in an LED lamp, the LED circuits providing light or the LED driver circuit driving the LED circuits providing light might fail. Having an LED driver package with an LED driver circuit within the lamp base and then connecting a heat sink, an LED circuit, and/or a lens to the LED driver package may allow for replacement of just the LED circuit (and any components connected therewith in an LED light package) or replacement of just the LED driver package, which ever has failed first. Since each are packaged separately, and as described below may be removably attached to one another, rather than take the entire lamp apart to replace a specific part, or have to purchase an entire new lamp altogether, an end user may only be required to replace the LED driver package or the LED circuit package. Enhanced replace ability may be realized when utilizing LED driver package 120 to insure maximum life for the end user of each LED driver package and LED circuit package purchased.

[0032] Rather than extend output voltage terminals 134, 136 of LED driver circuit 128 out of and above lamp base 122, it is contemplated that at least two electrical conductors 142, 144 attach to output voltage terminals 134, 136. When utilizing electrical conductors 142, 144, it is contemplated that electrical conductors 142, 144 will form the portion of the output voltage ATTY DOCKET NO.: LYN 101078PCT terminals being accessible for electrical connectivity on the exterior of lamp base 122. Electrical conductors 42, 44 may take the form of any conductor capable of providing an output voltage from LED driver circuit 128, including but not limited to contactors, wires, or any other electrical conductor.

10033 J As shown in FIGS. 2 and 3, LED driver package 120 may further include a dielectric layer 146. Dielectric layer 146 may be integrated with lamp base 122, or alternatively may be connected to one end of lamp base 122, either mechanically or through any other means known in the art. Mechanical connection may be done using numerous methods known in the art, including but not limited to screw fitting or snap-fitting. Alternatively, dielectric layer 146 may be glued, welded, soldered or otherwise adhered to lamp base 122, or alternatively may be molded or potted within lamp base 122. In some embodiments lamp base 122 may include a dielectric layer extending from an end. In embodiments where dielectric 146 is utilized, it is contemplated that output voltage terminals 134, 136, or more preferably electrical conductors 142, 44 connected to output voltage terminals 134, 136 extend through and beyond dielectric layer 146, providing an output voltage that is accessible outside both lamp base 122 and dielectric layer 146.

[0034] As shown in FIG. 2, LED driver circuit 128 may be sealed entirely within lamp base 122. Sealing LED driver circuit 128 may be done using a separate dielectric creating a "cap" or "floor" on or in lamp base 122, or in the alternative LED driver circuit 128 may be sealed in lamp base 122 by dielectric layer 146. In alternative embodiments, like that shown in FIG. 3, LED driver circuit 128 may be partially housed, sealed, or integrated in lamp base 122 and partially housed, sealed or integrated in dielectric layer 146.

[0035] Regardless of where LED driver circuit 128 is housed, it is contemplated by the invention that one or both of lamp base 122 and dielectric layer 146 may contain a connection point or area for connecting a heat sink, an LED circuit, a lens, or any combination thereof directly to LED driver package 120. Such a connection may be a mechanical connection for connecting dielectric layer 146 to lamp base 122, including a screw fit, a press-fit, a snap-fit or any other mechanical configuration known in the art. One advantage to using a mechanical connection, like for example a screw-fit, is that it may allow for LED driver package 120 and an LED circuit or LED circuit package having an LED circuit and perhaps a heat sink and/or lens to be removably connected to LED driver package 120. Alternatively, one of lamp base 122 or ATTY DOCKET NO.: LYN 101078PCT dielectric 146 may provide a platform for welding, soldering, gluing, or otherwise adhering any of a heat sink, an LED circuit, or a lens thereto.

[0036] Though shown in FIGs. 2 and 3 as an Edison type lamp base, it is contemplated that lamp base 122 may take any lamp base form having two voltage inputs known in the art, like for example, a wedge type lamp base or a by-pin type base.

[0037] FIG. 4 shows an embodiment of the invention having LED driver package 400 having two or more driver circuits 402, 404 having housed at least partially within lamp base 406. LED driver package 400 and driver circuits 402, 404 may be configured and connected in any of the manners discussed above with respect to LED driver package 120 and LED driver circuit 128. Driver circuits 402, 404 each contain voltage output terminals 408, 410 and 412, 414 respectively. Attached across to each voltage output terminal 408, 410 and 412, 414 is sensor 416. Sensor 416 is configured to detect a voltage output from both LED driver circuits 402, 404 and allow only one voltage output to be provided for connectivity on the exterior of the lamp base, for example the voltage output of LED driver circuit 402. If LED driver circuit 402 fails, sensor 406 may be configured to prevent the supply of voltage output of LED driver circuit 402 to the exterior of lamp base 406, and instead provide the output of LED driver circuit 404. An example of such a multi-driver and sensor system may be found in International Application No. PCT/US201 1/036359 the contents of which are fully incorporated herein by reference.

[0038] Sensor 416 may include any sensor, circuit, and/or switch combination known to those of ordinary skill in the art capable of detecting or sensing the output of LED driver circuits 402, 404 and blocking the outputs so only a single output is provided for connectivity outside of LED driver package 400 and/or LED base 406 so long as one of LED driver circuits 402, 404 are operational. Examples of circuits or sensors which may be used for sensor 406 include a relay circuit, a micro-controller IC, or a voltage level sensing circuit connected between the voltage output terminals 408, 410 and 412, 414 of LED driver circuits 402, 404.

[0039] In alternative embodiments, sensor 416 may include a logic gate and multiple circuits, each of the multiple circuits including an RMS converter and a window voltage comparator controlling an analog switch. Each RMS converter would receive the voltage output LED driver circuits 402, 404 and convert the output voltages to an RMS voltage. The RMS voltage may then be provided to a respective window voltage comparator, and be compared to high and low reference voltages stored in the each window voltage comparator. If the measured ATTY DOCKET NO.: LYN 101078PCT

RMS voltage is within the high or low reference range, the comparator may then close an analog switch, allowing the voltage output of LED circuits 402, 404 to proceed to the logic gate. The logic gate may then be configured to allow only one received voltage output from LED circuits 402, 404 to pass through and be provided for connectivity outside of LED driver package 400 and/or LED base 406. If the allowed voltage output from either of LED driver circuits 402, 404 fails and is not provided, the logic gate may then allow the non-allowed voltage output from LED driver circuits 402, 404 to be provided for connectivity outside of LED driver package 400 and/or LED base 406. Utilizing a logic gate receiving multiple inputs and an RMS converter and window voltage comparator has the added benefit of blocking the voltage output from either of LED driver circuits 402, 404 if the output is too high or too low, insuring maximum efficiency and stability when providing for connectivity outside of LED driver package 400 and/or LED base 406.

[0040] It is contemplated by the invention that LED driver circuits 128, 402, or 404 may provide an AC output voltage or DC output voltage. In embodiments where LED driver circuits 128, 402, or 404 output AC voltage, LED driver circuits 128, 402, 404 may of receive a first AC voltage at a first frequency at its voltage input terminals and provide a second AC voltage at a second frequency at the voltage output terminal wherein the second AC voltage is relatively constant. An example of such a driver may be found in U.S. Patent No. 7,489,086, the contents of which are fully incorporated herein by reference. Utilizing an AC voltage output may be particularly advantageous inasmuch as the LED circuit driver can be designed to be much smaller, allowing for smaller or more integrated and better sealed lamp bases, or alternatively allowing additional drivers, i.e. two or three or more, to be sealed within the lamp base as described above to insure that the LED lamp driver package 120 or 400 are driving continues to operate, even after an initial driver circuit or two fail.

[0041] In embodiments where a DC voltage is output LED driver circuits 128, 402, 404 may include a standard DC-rectifier circuit. Whether providing an AC voltage output or a DC voltage output, it is contemplated by the invention that the input voltage received at, for example, LED driver circuit voltage input terminals 130, 132 may be stepped up or down by a transfoimer located within LED driver circuit 128.

[0042] It is further contemplated by the invention that LED driver package 120 may be sold as an LED lamp package. When sold as an LED lamp package, in addition to driver ATTY DOCKET NO.: LYN 101078PCT package 120, one or more LED circuits may be included in the package. The LED circuits may be matched to LED driver package 120 and may be removably or replacably connected to LED driver package 120, enabling the one or more LED circuits to be replaced should the one or more LED circuits fail before LED driver circuit 128. Providing one or more LED circuits insures maximum efficiency of driver package 120.

[0043] While in the foregoing there has been set forth preferred embodiments of the invention, it is to be understood that the present invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. While specific embodiment have been illustrated and described, numerous modifications come to mind without significantly departing from the characteristics of the invention and the scope of protection is only limited by the scope of the accompanying Claims.

Claims

ATTY DOCKET NO.: LYN 101078PCT CLAIMS What is claimed is:

1. An LED driver package comprising:

a lamp base having two conductive voltage input terminals for connecting to a lamp socket;

at least one LED driver circuit having at least two voltage input terminals and at least two voltage output terminals,

the at least one LED driver circuit being at least partially integrated and sealed within the lamp base;

the at least one LED driver circuit including voltage input terminals electrically connected to the lamp base voltage input terminals inside the lamp base,

the at least one LED driver circuit output voltage terminals being accessible for electrical connectivity on the exterior of the lamp base.

2. The LED driver package of claim 1 further comprising at least two electrical conductors attached to the at least one LED driver circuit output voltage terminals, the at least two electrical conductors forming the portion of the output voltage terminals being accessible for electrical connectivity on the exterior of the lamp base.

3. The LED driver package of claim 1 or 2 further comprising at least one dielectric layer, the dielectric layer being connected proximate an end of LED lamp base.

4. The LED driver package of claim 3 wherein the portion of the output voltage terminals of the at least one LED driver circuit extend through and beyond the dielectric layer.

5. The LED driver package of any one of claims 1-4 further comprising two or more LED driver circuits.

6. The LED driver package of claim 5 further comprising a sensor connected to the voltage output terminals of the two or more LED driver circuits such that the sensor is configured to detect a voltage output from both of the two or more LED driver circuits and allow the voltage output to be provided for connectivity on the exterior of the lamp base from only one of the two or more LED driver circuits.

7. The LED driver package of claim 6 wherein the sensor is further configured to connect the voltage output for connectivity on the exterior of the lamp base of a different LED driver circuit in the two or more LED driver circuits if the only one of the two or more LED driver circuits fails to provide a voltage output. ATTY DOCKET NO.: LYN 101078PCT

8. The LED driver package of any one of claims 1-7 wherein the LED driver circuit provides an AC output voltage.

9. The LED driver package of any one of claims 1-7 wherein the LED driver circuit provides a DC output voltage.

10. The LED driver package of any one of claims 1-9 wherein the lamp base is an Edison type lamp base.

1 1. The LED driver package of any on of claims 1-9 wherein the lamp base is a wedge type lamp base.

12. The LED driver package of any one of claims 1-9 wherein the lamp base is a bi-pin type base.

13. The LED driver package of any one of claims 3-12 wherein the LED driver circuit is sealed in the lamp base by the dielectric layer.

14. The LED driver package claim 13 wherein a portion of the LED driver circuit is partially integrated with the interior of the dielectric layer.

15. The LED driver package of any one of claims 1-13 wherein the LED driver circuit is sealed entirely within the lamp base.

16. The LED driver package of any one of claims 1-15 wherein at least one of the lamp base or the dielectric layer contains a mechanical connection for at least one element from the group consisting of a heat sink, an LED circuit, or a lens.

17. The LED driver package of any one of claims 1-16 wherein the lamp base further includes a dielectric material.

18. A method for constructing an LED driver package, the method comprising the steps of: integrating and sealing at least one LED driver circuit in a lamp base and a dielectric body;

connecting at least two voltage input terminals of the at least one LED driver circuit to at least two conductive voltage input terminals for the lamp base;

extending at least two voltage output terminals from the at least one driver circuit through and out of the lamp base and dielectric body in order to provide access to a voltage output outside the dielectric body and lamp base. ATTY DOCKET NO.: LYN 101078PCT

19. An LED lamp package comprising:

a lamp base having at least two voltage source input terminals for connecting to a lamp socket;

at least one LED driver circuit having at least two voltage input terminals and at least two voltage output terminals, the LED driver circuit being integrated and sealed within the lamp base wherein the at least two voltage input terminals of the at least one LED driver circuit are electrically connected to the at least two voltage source input terminals of the lamp base;

at least two electrical conductors electrically connected to the voltage output terminals of the at least one LED driver circuit, the at least two electrical conductors being capable of providing voltage;

at least one LED circuit having at least two LEDs, the at least one LED circuit having an input capable of being electrically connected to the at least two electrical conductors and utilizing the voltage output from the at least one LED driver circuit;

wherein the at least one LED circuit is matched to the at least one LED driver circuit, and the at least one LED circuit is configured to be removed and replaced with at least a second LED circuit if the at least one LED circuit fails after being connected to the at least two electrical conductors without the need to remove or replace any of the at least two electrical conductors, the LED driver circuit, or the lamp base.