U.S. patent application number 13/832878 was filed with the patent office on 2014-04-17 for lighting device with integrally molded base and associated methods.
This patent application is currently assigned to LIGHTING SCIENCE GROUP CORPORATION. The applicant listed for this patent is LIGHTING SCIENCE GROUP CORPORATION. Invention is credited to Mark Penley Boomgaarden, Eric Holland, Rick LeClair, Ricardo Romeu.
Application Number | 20140104858 13/832878 |
Document ID | / |
Family ID | 50475157 |
Filed Date | 2014-04-17 |
United States Patent
Application |
20140104858 |
Kind Code |
A1 |
Holland; Eric ; et
al. |
April 17, 2014 |
LIGHTING DEVICE WITH INTEGRALLY MOLDED BASE AND ASSOCIATED
METHODS
Abstract
A lighting device includes a body defining a circuitry chamber
and including an integrally molded base. The lighting device may
also include a light source carried by the body and an electrical
contact carried by the body. The lighting device may further
include a driver circuit in electrical communication with the light
source and the electrical contact. The driver circuit and/or the
electrical contact may be integrally connected to the body. A
method aspect of the invention is for assembling a lighting device.
The method may include integrally forming the base and the body to
define an integrally molded base, integrally connecting the driver
circuit and/or the electrical contact to the body and fixedly
attaching the light source to the body. The method may further
include positioning the light source in electrical communication
with the driver circuit and positioning the electrical contact in
electrical communication with the driver circuit.
Inventors: |
Holland; Eric; (Indian
Harbour Beach, FL) ; Boomgaarden; Mark Penley;
(Satellite Beach, FL) ; LeClair; Rick; (Melbourne,
FL) ; Romeu; Ricardo; (Melbourne, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LIGHTING SCIENCE GROUP CORPORATION |
Satellite Beach |
FL |
US |
|
|
Assignee: |
LIGHTING SCIENCE GROUP
CORPORATION
Satellite Beach
FL
|
Family ID: |
50475157 |
Appl. No.: |
13/832878 |
Filed: |
March 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61715075 |
Oct 17, 2012 |
|
|
|
Current U.S.
Class: |
362/369 ;
29/825 |
Current CPC
Class: |
F21Y 2103/33 20160801;
F21V 19/001 20130101; F28F 3/02 20130101; Y10T 29/49002 20150115;
Y10T 29/4935 20150115; F21V 29/773 20150115; Y10T 29/49117
20150115; F21K 9/90 20130101; F21K 9/232 20160801; F21Y 2115/10
20160801; B23P 15/26 20130101 |
Class at
Publication: |
362/369 ;
29/825 |
International
Class: |
F21K 99/00 20060101
F21K099/00 |
Claims
1. A lighting device comprising: a body defining a circuitry
chamber and including an integrally molded base; and a light source
carried by the body; an electrical contact carried by the body; and
a driver circuit in electrical communication with the light source
and the electrical contact; wherein at least one of the driver
circuit and the electrical contact are integrally connected to the
body.
2. The lighting device according to claim 1 wherein at least one of
the driver circuit and the electrical contact are integrally
connected to the body by at least one of molding and overmolding so
as to be integrally molded with the body.
3. The lighting device according to claim 1 wherein the integrally
molded base is formed into a standard light socket base selected
from the group consisting of an Edison base, a bayonet base, a
double contact bayonet base, a bi-pin, a bi-post, a wedge, and a
GU10 turn and lock base.
4. The lighting device according to claim 1 wherein a spring clip
is fixedly attached to at least one of the body, the integrally
molded base, the electrical contact, the light source, and the
driver circuit.
5. The lighting device according to claim 4 wherein the spring clip
is in electrical communication with at least one of the driver
circuit and the electrical contact.
6. The lighting device according to claim 1 wherein at least one of
the integrally molded base and the body are at least one of a
material selected from a group consisting of a material having a
thermal conductivity.gtoreq.150 Watts per meter-Kelvin; a material
having a thermal conductivity.gtoreq.200 Watts per meter-Kelvin;
aluminum; an aluminum alloy; a magnesium alloy; a metal loaded
plastics material; a carbon loaded plastics material; a thermally
conducting ceramic material; an aluminum silicon carbide material;
and a plastic.
7. The lighting device according to claim 1 wherein the light
source comprises a light emitting diode (LED).
8. A lighting device comprising: a body defining a circuitry
chamber and including an integrally molded base; a light source
carried by the body; an electrical contact carried by the body; and
a driver circuit in electrical communication with the light source
and the electrical contact; wherein the driver circuit and the
electrical contact are at least one of molded and overmolded to the
body so as to be integrally molded with the body; wherein a spring
clip is fixedly attached to at least one of the body, the
integrally molded base, the electrical contact, the light source,
and the driver circuit; and wherein the spring clip is in
electrical communication with at least one of the driver circuit
and the electrical contact.
9. The lighting device according to claim 8 wherein the integrally
molded base is formed into a standard light socket base selected
from the group consisting of an Edison base, a bayonet base, a
double contact bayonet base, a bi-pin, a bi-post, a wedge, and a
GU10 turn and lock base.
10. The lighting device according to claim 8 wherein at least one
of the integrally molded base and the body is at least one of a
material selected from a group consisting of a material having a
thermal conductivity.gtoreq.150 Watts per meter-Kelvin; a material
having a thermal conductivity.gtoreq.200 Watts per meter-Kelvin;
aluminum; an aluminum alloy; a magnesium alloy; a metal loaded
plastics material; a carbon loaded plastics material; a thermally
conducting ceramic material; an aluminum silicon carbide material;
and a plastic.
11. The lighting device according to claim 8 wherein the light
source comprises a light emitting diode (LED).
12. A method for assembling a lighting device, the lighting device
having a body defining a circuitry chamber and having a base and an
electrical contact, a light source carried by the body and a driver
circuit carried within the circuitry chamber, the method comprising
the steps of: integrally forming the base and the body to define an
integrally molded base; integrally connecting at least one of the
driver circuit and the electrical contact to the body; fixedly
attaching the light source to the body; positioning the light
source in electrical communication with the driver circuit; and
positioning the electrical contact in electrical communication with
the driver circuit.
13. The method according to claim 12 wherein integrally forming the
base and the body comprises forming the base and the body as a
single integral member.
14. The method according to claim 12 wherein integrally connecting
at least one of the driver circuit and the electrical contact to
the body comprises at least one of molding and overmolding at least
one of the driver circuit and the electrical contact to the
body.
15. The method according to claim 12 further comprising fixedly
attaching a spring clip to at least one of the body, the integrally
molded base, the electrical contact, the light source, and the
driver circuit.
16. The method according to claim 12 further comprising
electrically coupling a spring clip to at least one of the light
source, the driver circuit, and the electrical contact.
17. The method according to claim 12 wherein attaching the light
source comprises at least one of molding and overmolding the light
source to the body.
18. The method of claim 12 wherein the integrally molded base is at
least one of a material selected from a group consisting of a
material having a thermal conductivity.gtoreq.150 Watts per
meter-Kelvin; a material having a thermal conductivity.gtoreq.200
Watts per meter-Kelvin; aluminum; an aluminum alloy; a magnesium
alloy; a metal loaded plastics material; a carbon loaded plastics
material; a thermally conducting ceramic material; an aluminum
silicon carbide material; and a plastic.
19. The method according to claim 12 wherein the integrally molded
base is formed into a standard light socket base selected from the
group consisting of an Edison base, a bayonet base, a double
contact bayonet base, a bi-pin, a bi-post, a wedge, and a GU10 turn
and lock base.
20. The method according to claim 12 wherein the light source
comprises at least one light emitting diode (LED).
Description
RELATED APPLICATIONS
[0001] This application is related to U.S. Provisional Patent
Application Ser. No. 61/715,075 titled Lighting Device with
Integrally Molded Cooling System and Associated Methods filed Oct.
17, 2012, the content of which is herein incorporated by reference
in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the fields of lighting
devices and, more specifically, to the design and manufacture of
integrally molded base systems for lighting devices, and associated
methods.
BACKGROUND OF THE INVENTION
[0003] Lighting technologies such as light-emitting diodes (LEDs)
offer significant advantages over incandescent and fluorescent
lamps. These advantages include, but are not limited to, better
lighting quality, longer operating life, and lower energy
consumption. LEDs also are being designed to have more desirable
color temperatures than do traditional lamps. Moreover, LEDs do not
contain mercury or any other toxic substance. Consequently, a
market exists for LED-based lamps as retrofits for legacy lighting
fixtures.
[0004] A number of design challenges and costs are associated with
replacing traditional lamps with LED illumination devices. Some of
these design challenges include thermal management, installation
ease, and manufacturing cost control.
[0005] Compared to incandescent and fluorescent lamps, LED-based
lighting solutions have relatively high manufacturing and component
costs. These costs are often compounded by a need to replace or
reconfigure a light fixture that is designed to support
incandescent or fluorescent lamps to instead support LEDs.
Consequently, the cost of adoption of digital lighting technology,
particularly in the consumer household market, is driven by design
choices for retrofit LED-based lamps that impact both cost of
manufacture and ease of installation.
[0006] U.S. patent application Ser. No. 13/420,794 by Chang and Yen
discloses an LED light bulb comprising a light source and a
cup-shaped lamp head, with its bottom provided with a power
connector. The power connector has a screw-connection head and an
electric connection point. This system of power connector and
electric connection point may, however, be a difficult method to
maintain when manufacturing lamps with a multi-component design due
to the typically labor-intensive and error-prone conventional hand
assembly or semi-automated assembly processes employed.
[0007] Much of the cost generated by the manufacture of light
bulbs, specifically LED light bulbs, comes out of the time and
steps in the manufacturing process. Consequently lamp designs like
those described above, which feature additional assembly and parts,
suffer from unfavorable costs.
[0008] This background information is provided to reveal
information believed by the applicant to be of possible relevance
to the present invention. No admission is necessarily intended, nor
should be construed, that any of the preceding information
constitutes prior art against the present invention.
SUMMARY OF THE INVENTION
[0009] In view of the foregoing, it is therefore an object of the
present invention to provide an improved LED-based lamp for use in
a space-limited lamp enclosure, such as a can light fixture. The
LED-based lamp may comprise an integrally molded base which,
according to embodiments of the present invention, may
advantageously position an integrally molded base substantially
beneath a molded outer surface. The integrally molded base may also
advantageously include a spring clip which may be in electrical
communication with the integrally molded base and an external power
supply.
[0010] The present invention may advantageously provide an
integrally molded base for a lighting device that is designed to
operate in a space-limited fixture, and that is inexpensive to
manufacture, install, and operate. These and other objects,
features, and advantages according to the present invention are
provided by a lighting device capable of being in electrical
communication with an external power source and providing
electrical power to the power supply and at least a portion of the
lighting device.
[0011] The lighting device according to an embodiment of the
present invention may include a body, a driver circuit, a light
source, an electrical contact, a power supply, an integrally molded
base, and a heat sink that, when in an assembled configuration, may
form an integrally molded enclosure with the light source. The
light source may be a light emitting diode (LED) package. The LED
package may include an LED and a circuit board functionally coupled
to the LED. The electrical contact may comprise at least one of a
first, second, and third electrical contact.
[0012] The lighting device according to an embodiment of the
present invention may include an optic. A plurality of molded
housings may be configured to include an attaching lip and a
circuit board receiving section. The sidewalls of the plurality of
molded housings may connect to each other. The body may be
configured to include a spring clip which may be in electrical
communication with at least one of the integrally molded base and
the first electrical contact. The spring clip may be integrally
molded to the body.
[0013] The present invention may also include a method for
manufacturing any of the devices described hereinabove. The method
may include the steps of mounting the light source on the circuit
board, molding or overmolding the circuit board with the body, and
attaching the heat sink to the circuit board and the inner housing.
The method may also include molding or overmolding the heat sink
with the body, installing electrical circuitry in the outer
housing, and integrally molding or overmolding the base to the
body.
[0014] The method may further include molding or overmolding the
base to the body, attaching the driver circuit to the body,
attaching the first electrical contact to the body, and attaching
the light source to the body. The method may still further include
attaching the spring clip to the body, attaching the spring clip to
the base, attaching the spring clip to the first electrical
contact, and attaching the spring clip to the light source. The
method may also include attaching the spring clip to the driver
circuit, electrically coupling the spring clip and the light
source, electrically coupling the spring clip and the driver
circuit, and electrically coupling the spring clip and the first
electrical contact.
[0015] The method may also include electrically coupling the first
electrical contact and the second electrical contact, electrically
coupling the first electrical contact and the power supply, and
electrically coupling the first electrical contact and the driver
circuit. The method may further include electrically coupling the
second electrical contact and the power supply, electrically
coupling the second electrical contact and the driver circuit,
electrically coupling the power supply and the driver circuit, and
electrically coupling the light source and the driver circuit. The
method may still further include electrically coupling the third
electrical contact and the light source, electrically coupling the
third electrical contact and the power supply, electrically
coupling the third electrical contact and the driver circuit, and
attaching an optic over the inner housing opposite the light
source.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of a lighting device having an
integrally molded base system according to an embodiment of the
present invention.
[0017] FIG. 2 is a side elevation view of the lighting device
illustrated in FIG. 1.
[0018] FIG. 3 is a side sectional view of the lighting device
illustrated in FIG. 1 taken through line 3-3 in FIG. 2.
[0019] FIG. 4 is an exploded perspective view of the lighting
device illustrated in FIG. 1.
[0020] FIG. 5 is a side elevation view of an outer housing of the
lighting device illustrated in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] The present invention will now be described fully
hereinafter with reference to the accompanying drawings, in which
preferred embodiments of the invention are shown. This invention
may, however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Those of ordinary skill in
the art will realize that the following embodiments of the present
invention are only illustrative and are not intended to be limiting
in any way. Other embodiments of the present invention will readily
suggest themselves to such skilled persons having the benefit of
this disclosure. Likewise, throughout this disclosure, the present
invention may be referred to as relating to luminaires, digital
lighting, and light-emitting diodes (LEDs). Those skilled in the
art will appreciate that this terminology is only illustrative and
does not affect the scope of the invention. For instance, the
present invention may just as easily relate to lasers or other
digital lighting technologies.
[0022] Although the following detailed description contains many
specifics for the purposes of illustration, anyone of ordinary
skill in the art will appreciate that many variations and
alterations to the following details are within the scope of the
invention. Accordingly, the following embodiments of the invention
are set forth without any loss of generality to, and without
imposing limitations upon, the claimed invention.
[0023] In this detailed description of the present invention, a
person skilled in the art should note that directional terms, such
as "above," "below," "upper," "lower," and other like terms are
used for the convenience of the reader in reference to the
drawings. Also, a person skilled in the art should notice this
description may contain other terminology to convey position,
orientation, and direction without departing from the principles of
the present invention.
[0024] Referring now to FIGS. 1-5, a lighting device 100 that
includes an integrally molded base 150 according to an embodiment
of the present invention is now described in detail. Throughout
this disclosure, the present invention may be referred to as a
lighting device 100, a lighting system, an LED lighting system, a
lamp system, a lamp, a device, a system, a product, and a method.
Those skilled in the art will appreciate that this terminology is
only illustrative and does not affect the scope of the
invention.
[0025] Example methods and systems for lighting devices with an
integrally molded base 150 are described herein below. In the
following description, for purposes of explanation, numerous
specific details are set forth to provide a thorough understanding
of example embodiments. It will be evident, however, to one of
ordinary skill in the art that the present invention may be
practiced without these specific details and/or with different
combinations of the details than are given here. Thus, specific
embodiments are given for the purpose of simplified explanation and
not limitation.
[0026] Continuing to refer to FIGS. 1-5, a lighting device 100
including the integrally molded base 150 will now be discussed.
Referring more specifically to FIG. 3, the lighting device 100,
according to an embodiment of the present invention, may include a
light source 110, a heat sink 132, a body 143, an integrally molded
base 150, and an optic 160. The integrally molded base 150 may be
molded during manufacturing as an integral part of the body 143.
The body 143 may comprise an inner housing 122 and an outer housing
142.
[0027] The heat sink 132 may be positioned adjacent to the light
source 110, and may abut both the inner housing 122 and the outer
housing 142. The heat sink 132 may include a plurality of fins 134.
For example, and without limitation, the heat sink 132 may present
a frustoconical cup into which the inner housing 122 may be
positioned such that the outer periphery of the inner housing 122
may contact the inner periphery of the heat sink 132. As an
alternative example, and without limitation, the plurality of fins
134 of the heat sink 132 may be configured as projecting flanges
into which the inner housing 122 may be positioned such that the
outer periphery of the inner housing 122 may make contact with the
inner periphery of the fins 134 of the heat sink 132.
[0028] The body 143 and the integrally molded base 150 may be made
by molding, overmolding, casting, or stamping of a thermally
conductive material. Materials may include, without limitation,
metals, metal alloys, carbon allotropes, ceramics, polymers,
plastics, and composite materials.
[0029] Referring now to FIG. 4, the light source 110 of the
lighting device 100 according to an embodiment of the present
invention is now discussed in greater detail. The light source 110
may include any device capable of emitting light. The light source
110 may, for example and without limitation, include incandescent
lights, halogens, fluorescents (including compact-fluorescents),
high-intensity discharges, light-emitting semiconductors, such as
light-emitting diodes (LEDs), lasers, and any other light-emitting
device known in the art. In some embodiments of the present
invention, the light source 110 may be an LED package. As
illustrated in FIG. 4, for example, the light source 110 is an LED
package, and the LED package may include an LED 112 and a circuit
board 114. The circuit board 114 may be configured to be
functionally coupled to the LED 112. In some further embodiments,
the LED package may include a plurality of LEDs and a circuit
board.
[0030] Referring now back to FIG. 3 and with continuing reference
to FIG. 4, the inner housing 122 of the lighting device 100,
according to an embodiment of the present invention, is discussed
in greater detail. The inner housing 122 may be configured to
define an interior volume 124 within a sidewall 126. In one
embodiment, the sidewall 126 may have a generally curved shape and
may be attached to an attaching lip 128 that may be configured to
receive an optic 160.
[0031] As illustrated, for example, in FIGS. 2, 3, and 4, the optic
160 may interface with the attaching lip 128 to attach to and be
carried by a cooling system 120. Specifically, the optic 160 may
form an interference fit with the attaching lip 128, the
interference fit providing sufficient strength to carry the optic
160 thereby. Optionally, the optic 160 may be attached to the
attaching lip 128 through the use of an adhesive, glue, or any
other attachment method known in the art.
[0032] The optic 160 may be configured to interact with light
emitted by the light source 110 to refract, reflect, or otherwise
redirect incident light. Accordingly, the light source 110 may be
disposed such that light emitted therefrom is incident upon the
optic 160. The optic 160 may be formed in any shape to impart a
desired refraction. In the present embodiment, the optic 160 has a
generally concave geometry. Furthermore, the optic 160 may be
formed of any material with transparent or translucent properties
that comport with the desired refraction to be performed by the
optic 160.
[0033] Additionally, in some embodiments, the optic 160 may include
a color conversion layer. The color conversion layer may be a layer
of material positioned adjacent an inner surface of the optic 160.
The color conversion layer may be configured to receive light
within a wavelength range emitted by the light source 110 and to
convert the received light into a converted light within another
wavelength range. More details regarding the color conversion layer
may be found in U.S. patent application Ser. No. 13/745,244 titled
Remote Light Wavelength Conversion Device and Associated Methods,
the content of which is incorporated herein in its entirety.
[0034] As shown in FIG. 3, the end of the inner housing 122
substantially opposite the optic 160 may be configured to define an
aperture. A circuit board receiving groove 129 may be presented as
a notch in the sidewall 126 of the inner housing 122 positioned
generally near the aperture. A circuit board 114 may be mounted in
the circuit board receiving groove 129 to form a seal. For example,
and without limitation, the interior volume 124 of the inner
housing 122 may be isolated from the environment exterior to the
lighting device 100 such that fluid from the environment is not
able to gain entry to the interior volume 124 and intermix with the
fluid contained therein. Hence, a fluid seal may be created about
the interior volume 124 of the inner housing 122.
[0035] Referring now to FIG. 5, the body 143 of the lighting device
100, according to an embodiment of the present invention, is
discussed in greater detail. The body 143 may carry at least one of
the light source 110, a driver circuit 115, the inner housing 122,
the outer housing 142, the integrally molded base 150, an
electrical contact, and a spring clip and may define a circuitry
chamber 148. The outer housing 142 of the lighting device 100 that
includes the cooling system 120 may include a head 145 and a
plurality of fin guards 147. The electrical contact may comprise at
least one of a first, second, and third electrical contact 151,
152, 153. For example, at least one of the driver circuit 115, the
heat sink 132, the integrally molded base 150, the first electrical
contact 151, and the spring clip may be integrally molded to the
body 143.
[0036] Additionally, in some embodiments, an inner surface of the
inner housing 122 that is in optical communication with the
interior volume 124 of the inner housing 122 may be generally
reflective. In some further embodiments, the inner surface of the
inner housing 122 may include a reflective layer positioned
thereupon to increase the reflectance of light incident thereupon.
Moreover, the inner surface of the inner housing 122 may be
configured to reflect light incident thereupon in the direction of
the optic 160. Furthermore, in some embodiments, the inner surface
of the inner housing may include a color conversion layer as
described hereinabove.
[0037] For example, and without limitation, the body 143 may be
formed into any tubular shape, including a circle, ovoid, square,
rectangle, triangle, or any other polygon. Referring to the
embodiment of the lighting device 100 shown in FIG. 3, the body 143
may be substantially hollow to form the circuitry chamber 148. The
circuitry chamber 148 may be configured to permit the power supply
140 and electronic control devices to be positioned therewithin.
The power supply 140 may be configured to include at least one of
the first, second, and third electrical contacts 151, 152, 153 and
the driver circuit 115. The circuitry chamber 148 may present a
void of sufficient geometry to permit electrical connectors, such
as wires, to pass therethrough from the light source 110 to the
integrally molded base 150. Those skilled in the art will
appreciate that although the integrally molded base 150 is
illustrated as being an Edison connector integrally molded into the
body 143 of the lighting device 100, the integrally molded base 150
for the lighting device 100 may be provided by any type of
connector that is suitable for connecting the lighting device to an
external power source, including, but not limited to an Edison
base, a bayonet base, a double contact bayonet base, a bi-pin, a
bi-post, a wedge, and a GU10 turn and lock base.
[0038] In order to maintain a fluid seal between the circuitry
chamber 148 and the environment external to the lighting device
100, the body 143 may further include a sealing member. The sealing
member may include any device or material that can provide a fluid
seal as described above. For example, and without limitation, the
sealing member may form a fluid seal between the body 143 and the
integrally molded base 150. Other embodiments may have the
circuitry chamber 148 disposed on other parts of the cooling system
120 and the body 143.
[0039] As perhaps best illustrated in FIG. 2, the head 145 of the
outer housing 142 may be positioned to substantially encase the
base plate 136 of the heat sink 132 between the inner housing 122
and the outer housing 142. The head 145 may have an aperture
adjacent the portion of the heat sink 132 that is in contact with
the light source 110 to permit fluid to flow unimpeded from the
interior volume 124 through the circuit board 114 and the heat sink
134 to the external environment. The head 145 may also have one or
more apertures that allow the plurality of fins 134 of the heat
sink 132 to project radially through the head 145 to expose the
plurality of fins 134 to the environment external to the lighting
device 100.
[0040] In one embodiment of the invention, and as illustrated, for
example, in FIG. 3, the lighting fixture 100 may comprise the body
143, the light source 110, the first, second, and third electrical
contacts 151, 152, 153, the power supply 140, and the driver
circuit 115. The body 143 may define the circuitry chamber 148 and
include the integrally molded base 150. The light source 110 may be
carried by the body 143. Additionally, the first electrical contact
151 may be carried by the body 143. The power supply 140 may be
carried by the body 143 and may comprise the second and third
electrical contacts 152, 153. The driver circuit 115 may be in
electrical communication with the light source 110 and the third
electrical contact 153. The first electrical contact 151 may be
positioned in electrical communication with the second electrical
contact 152 and the external power source. At least one of the
driver circuit 115 and the first electrical contact 151 may be
connected to the body 143. For example, the driver circuit 115 and
the first electrical contact 151 may be positioned in the body 143
so that the driver circuit 115, the first electrical contact 151,
and the body 143 are one device.
[0041] In another embodiment, the lighting fixture 100 may comprise
the body 143, the light source 110, the first and third electrical
contacts 151, 153, the power supply 140, and the driver circuit
115. The body 143 may define the circuitry chamber 148 and include
the integrally molded base 150. The light source 110 may be carried
by the body 143. Additionally, the first electrical contact 151 may
be carried by the body 143. The first electrical contact 151 may be
positioned in electrical communication with the power supply
140.
[0042] Although only partially illustrated in FIG. 3, the third
electrical contact 153 may be positioned in electrical
communication with the power supply 140 and the driver circuit 115.
The driver circuit 115 may be positioned in electrical
communication with the light source 110 and the third electrical
contact 153. The driver circuit 115 may be at least one of molded
and overmolded to the body 143. In some embodiments, the first
electrical contact 151 may be at least one of molded and overmolded
to the body 143. Furthermore, although not illustrated, in some
embodiments, the spring clip may be fixedly attached to at least
one of the body 143, the integrally molded base 150, the first
electrical contact 151, the light source 110, and the driver
circuit 115. Additionally, the spring clip may be positioned in
electrical communication with at least one of the driver circuit
115, the first electrical contact 151, and the external power
source.
[0043] Referring to FIGS. 3 and 4, a method aspect of the present
invention is now described in greater detail. The method according
to the present invention is directed to manufacturing a lighting
device 100 that comprises the integrally molded base 150 of the
present invention being integrally molded with at least one of the
inner housing 122, the outer housing 142, and the body 143. The
method starts where the body 143 may be formed by integrally
molding the integrally molded base 150 into the body 143 which may
form a single integral member.
[0044] For example, and without limitation, at least one of molding
and overmolding of the body 143 and the integrally molded base 150
may be accomplished by any molding process known in the art,
including, but not limited to blow molding, sintering, compression
molding, extrusion molding, injection molding, matrix molding,
transfer molding, and thermoforming. At least one of the driver
circuit 115, the first electrical contact 151, the light source
110, the spring clip, and the heat sink 132 may be attached to the
body 143. Furthermore, in some embodiments, at least one of the
driver circuit 115, the first electrical contact 151, the spring
clip, and the heat sink 132 may be integrally molded to the body
143. Additionally, in some embodiments, at least one of the light
source 110, the first electrical contact 151, and the spring clip
may be electrically coupled to the driver circuit 115.
[0045] The light source 110 may be formed by mounting LEDs 112 on a
circuit board 114. Some portion of the circuit board 114 may be
overmolded with the inner housing 122 such that the circuit board
receiving groove 129 may be formed in the sidewall 126 of the inner
housing 122, and thereby used to mate the light source 110 with the
inner housing 122.
[0046] In some embodiments, the heat sink 132 may be positioned
over the inner housing 122 such that the base plate 136 of the heat
sink 132 may contact the circuit board 114 and such that the inner
periphery of the fins 134 of the heat sink 132 may contact the
outer periphery of the inner housing 122. Furthermore, some portion
of the heat sink 132 may be overmolded with at least one of the
inner housing 122, the outer housing 142, and the body 143 such
that a head 145 of the outer housing 142 may be formed to contact
the base plate 136 of the heat sink 132 opposite the inner housing
122, and such that fin guards 147 may be formed to create a channel
within which a fin 134 of the heat sink 132 may be fittedly
positioned. The fin guards 147 may connect to and mechanically
support the body 143 that may be substantially hollow to present
the circuitry chamber 148 configured to contain the power supply
140 and electronic control devices within the body 143.
[0047] For example, and without limitation, overmolding of the
inner housing 122 and the outer housing 142 may be accomplished by
any molding process known in the art, including, but not limited to
blow molding, sintering, compression molding, extrusion molding,
injection molding, matrix molding, transfer molding, and
thermoforming. The power supply 140 and other electronic circuitry
may be installed into the circuitry chamber 148 of the body 143.
The power supply 140 may include the second and third electrical
contacts 152, 153 and the driver circuit 115. The method is ended
where an optic 160 may be attached to the lighting device 100 at an
attaching lip 128.
[0048] Additionally, and without limitation, at least one of the
body 143 and the integrally molded base 150 may consist of a
material having a thermal conductivity.gtoreq.150 Watts per
meter-Kelvin; a material having a thermal conductivity.gtoreq.200
Watts per meter-Kelvin; aluminum; an aluminum alloy; a magnesium
alloy; a metal loaded plastics material; a carbon loaded plastics
material; a thermally conducting ceramic material; an aluminum
silicon carbide material; and a plastic.
[0049] Accordingly, the method of manufacture allows a manufacturer
of the lighting device 100 to advantageously mold or overmold an
integrally molded base 150 integrally into at least one of the
inner housing 122, the outer housing 142, and the body 143 in such
a way that minimizes costly and error-prone manual assembly, and
that supports a lamp design with superior manufacturing
characteristics.
[0050] The method of manufacture further allows a manufacturer of
the lighting device 100 to first mold the body 143 and the
integrally molded base 150. The power supply 140, the second and
third electrical contacts 152, 153, the circuit board 114, the
light source 110, and the driver circuit 115 may be attached to the
body 143 through an opening at either end of the circuitry chamber
148. The first electrical contact 151 may be at least one of molded
and overmolded with the body 143.
[0051] In one method embodiment, the method may be directed to
manufacturing the lighting device 100 that comprises the body 143,
the light source 110, and the driver circuit 115. The body 143 may
define the circuitry chamber 148 and may comprise the integrally
molded base 150 and the first electrical contact 151. The light
source 110 may be carried by the body 143. The driver circuit 115
may be carried within the circuitry chamber 148. The method starts
wherein the body 143 and a base may be integrally formed to define
the integrally molded base 150. At least one of the driver circuit
115 and the first electrical contact 151 may be integrally
connected to the body 143. The light source 110 may be fixedly
attached to the body 143. The light source 110 may be positioned to
be in electrical communication with the driver circuit 115. The
first electrical contact 151 may be positioned to be in electrical
communication with the driver circuit 115.
[0052] Some of the illustrative aspects of the present invention
may be advantageous in solving the problems herein described and
other problems not discussed which are discoverable by a skilled
artisan.
[0053] While the above description contains much specificity, these
should not be construed as limitations on the scope of any
embodiment, but as exemplifications of the presented embodiments
thereof. Many other ramifications and variations are possible
within the teachings of the various embodiments.
[0054] While the invention has been described with reference to
exemplary embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best or only mode
contemplated for carrying out this invention, but that the
invention will include all embodiments falling within the scope of
the appended claims. Also, in the drawings and the description,
there have been disclosed exemplary embodiments of the invention
and, although specific terms may have been employed, they are
unless otherwise stated used in a generic and descriptive sense
only and not for purposes of limitation, the scope of the invention
therefore not being so limited. Moreover, the use of the terms
first, second, etc. do not denote any order or importance, but
rather the terms first, second, etc. are used to distinguish one
element from another. Furthermore, the use of the terms a, an, etc.
do not denote a limitation of quantity, but rather denote the
presence of at least one of the referenced item.
[0055] Thus, the scope of the invention should be determined by the
appended claims and their legal equivalents, and not by the
examples given.
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