Abstract:
An LED lamp at least includes an LED lamp set and an adjustment assembly. The LED lamp set includes an LED set and a cooling set. The LED set includes at least one LED lamp element which is replaceable individually and a holder to hold the LED lamp element. The cooling set is fastened to the holder. The adjustment assembly includes an adjustment member and an adjustment holder that contain mating engaging portions engageable with each other. The adjustment member is coupled with the adjustment holder and the LED lamp set to provide adjustment function of light illumination angle. The invention further includes an assembly dock coupled with a plurality of LED lamp sets and adjustment assemblies according to requirements to enhance expandability and usability. The structure thus formed can be assembled and disassembled easily, and also provides greater expandability, replacement capability and practicality.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to an LED lamp and particularly to an LED lamp that is expandable and replaceable. 
       BACKGROUND OF THE INVENTION 
       [0002]    With constant progress of society and advance of technology, and increasing environmental consciousness, energy saving and carbon reduction have become vital issue and goal people regard highly and struggle for in all countries around the world. 
         [0003]    Since white light LED was developed and introduced in 1990s, its merits such as sturdy and less likely to be shattered, consumed less electric power, mercury-free and eco-friendly, smaller size, applicable in low temperature environments, providing directional light, less light pollution and rich color selections and the like have make it an excellent substitute for the conventional light bulb. 
         [0004]    LED has lifespan more than fifty thousand hours and is dozen times longer than the one thousand hours of the conventional incandescent bulb and ten thousand hours of the fluorescent lamp, thus greatly reduces replacement cost of lamp sets. 
         [0005]    However, the conventional lighting fixture adopted LED lamps mostly has a plurality of LEDs directly soldered on a circuit board to form an LED module. If damage occurs, the LED cannot be replaced individually. Hence repair and maintenance cost is higher. This becomes its main disadvantage. 
         [0006]    Moreover, the conventional LED street lamp is formed by assembling the LED modules soldered on a circuit board as previously discussed, its projecting range and angle are limited. Hence its usability and applicability also leave a lot to be desired. 
         [0007]    To remedy the aforesaid drawbacks, the Applicant has submitted a novel design in U.S. patent application Ser. No. 12/558,228 entitled “Improved LED lamp electrode structure” that provides a feature and advantage of individual replacement, thus overcomes the shortcoming of the conventional LED lamp that requires replacement of the entire LED set when malfunction occurs. Therefore repairs and maintenance cost can be reduced. 
       SUMMARY OF THE INVENTION 
       [0008]    The primary object of the present invention is to overcome the disadvantage of conventional LED lamp in illumination by incorporating the concept of U.S. patent application Ser. No. 12/558,228 entitled “Improved LED lamp electrode structure” submitted by the Applicant to provide a novel LED lamp element that can be individually mounted onto a holder to form an LED lamp set to couple with an adjustment assembly with mating male and female engaging portions to provide angle adjustment function for illumination. It also can be coupled with an assembly dock to further improve applicability and practicability. 
         [0009]    To achieve the foregoing object, the invention provides an LED lamp that at least includes an LED lamp set and an adjustment assembly. The LED lamp set includes an LED set and a cooling set. The LED set includes at least one replaceable LED lamp element and a holder to hold the LED lamp element. 
         [0010]    The adjustment assembly includes an adjustment member and an adjustment holder that have mating male and female engaging portions. After the LED lamp set and the adjustment assembly are coupled, it can be swiveled 360 degrees to adjust illumination angle. It also can be coupled with an assembly dock formed and produced by molding to mate with the number of the LED lamp set and adjustment assembly to provide replacement capability and simpler installation. Thus light illumination angle can be adjusted easily and expandability and practicability are also improved. 
         [0011]    In short, the LED lamp according to the invention provides many benefits, notably: 
         [0012]    1. Simpler assembly and disassembly, and lower repairs and maintenance cost: with the LED lamp element can be replaced individually, assembly and disassembly are simpler and can be done quickly to overcome the shortcoming of the conventional LED module that requires whole set replacement. Thus time and cost of repairs and maintenance can be reduced. 
         [0013]    2. Modular and customized production: the invention provides excellent expandability and practicability, and can be fabricated in a modular fashion to meet different requirements. 
         [0014]    3. Greater applicability: with the adjustment assembly providing the mating male and female engaging portions, the LED lamp set can be coupled with the adjustment assembly to provide individual adjustment of illumination angle. By incorporating with the assembly dock, illumination range and width can be increased to meet requirements of varying installation angles. 
         [0015]    The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  is a perspective view of the invention. 
           [0017]      FIG. 2  is an exploded view of the invention. 
           [0018]      FIG. 3  is another perspective view of the invention. 
           [0019]      FIG. 4  is an exploded view of the LED lamp element. 
           [0020]      FIG. 5  is another exploded view of the LED lamp element from another angle. 
           [0021]      FIG. 6  is an exploded view of the holder. 
           [0022]      FIG. 7  is another exploded view of the holder from another angle. 
           [0023]      FIG. 8  is a sectional view of the LED lamp element and holder in a coupled condition. 
           [0024]      FIG. 9  is a perspective view of a radiation fin of the invention. 
           [0025]      FIG. 10  is a front view according to  FIG. 9 . 
           [0026]      FIG. 11  is a perspective view of another radiation fin of the invention. 
           [0027]      FIG. 12  is a front view according to  FIG. 11 . 
           [0028]      FIG. 13  is an exploded view of the adjustment assembly of the invention. 
           [0029]      FIG. 14  is a sectional view of the adjustment assembly of the invention. 
           [0030]      FIG. 15  is another exploded view of the adjustment assembly from another angle. 
           [0031]      FIG. 16  is an exploded view of another adjustment assembly coupled with the radiation fin in  FIG. 11 . 
           [0032]      FIG. 17  is a perspective view of the assembly dock of the invention. 
           [0033]      FIG. 18  is another perspective view of the assembly dock of the invention from another angle. 
           [0034]      FIG. 19  is an exploded view of an embodiment of the invention with three LED lamp sets and adjustment assemblies coupled with an assembly dock. 
           [0035]      FIG. 20  is a perspective view of an embodiment of the invention with three LED lamp sets and adjustment assemblies coupled with an assembly dock. 
           [0036]      FIG. 21  is an exploded view of another embodiment of the invention incorporating with U.S. patent application Ser. No. 12/558,228 entitled “Improved LED lamp electrode structure” submitted by the Applicant. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0037]    Please refer to  FIGS. 1 through 5 , the present invention provides an LED lamp  1  which at least includes an LED lamp set  2  and an adjustment assembly  3 . The LED lamp set  2  includes an LED set  4  and a cooling set  5 . 
         [0038]    The LED set  4  includes at least one LED lamp element  41  and a holder  42 . The LED lamp element  41  includes: 
         [0039]    a light bulb  43  which is an LED lighting element; 
         [0040]    a coupling boss  44  which has a clamp  441  at an upper side to hold the light bulb  43 , a lower end formed external threads  442  on the periphery, a first trough  443  inside, and two first electrode passages  444  and  445  on the periphery thereof; 
         [0041]    two first conductive elements  45  are respectively formed in a column which can be bendable; the two first conductive elements  45  have upper ends running through the first electrode passages  444  and  445  to form electric connection with the light bulb  43 ; 
         [0042]    a lamp shade  46  which has a second trough  461  with internal threads formed therein and an opening  462  in the center of the bottom run through by the coupling boss  44  for fastening therewith; 
         [0043]    a lamp shell  47  which has external threads  471  screwed with the second trough  461  of the lamp shade  46  to form coupling therewith; and 
         [0044]    a wiring member  48  which is held in the first trough  443  of the coupling boss  44  and has two second electrode passages  481  and  482  close to the axis and periphery thereof run through by the two first conductive elements  45 . 
         [0045]    The LED lamp element  41  further includes two second conductive elements  49  formed in columns with upper ends fastened to lower ends of the first conductive elements  45  and lower ends formed respectively a flange  491 . 
         [0046]    For assembly, clip the light bulb  43  in the clamp  441  of the coupling boss  44  with the two first conductive elements  45  running through the first electrode passages  444  and  445  to form electric connection with the light bulb  43 ; after the coupling boss  44  is run through and fastened to the opening  462  of the lamp shade  46 , screw the lamp shell  47  and lamp shade  46  together with the lower ends of the two first conductive elements  45  running through the second electrode passages  481  and  482  and dispose the wring member  48  in the first trough  443  of the coupling boss  44 ; and connect the upper ends of the two second conductive elements  49  to the lower ends of the two first conductive elements  45  to finish assembly of the LED lamp element  41 . 
         [0047]    Referring to  FIGS. 2 ,  4 , and  6  through  8 , the holder  42  includes a board  420 , and also at least one socket  421 , at least one base board  422  and at least one buffer  423 . The board  420  is formed integrally through aluminum extrusion and has at least one aperture  424  to hold the socket  421  and a plurality of second fastening holes  425  and third fastening holes  426  to fasten the cooling set  5  and adjustment assembly  3 . The socket  421  is held in the aperture  424  on the board  420  and includes a third trough  427  with a screw hole formed therein and through holes  428  at the bottom run through by external power cords (not shown in the drawings). The base board  422  is a printed circuit board held in the third trough  427  of the socket  421  and has two electrode circuits  4221  and  4222  respectively formed in the center and periphery and connected to the mating flanges  491  of the two second conductive elements  49 . The buffer  423  is made of silica gel and interposed between the third trough  427  and the base board  422  to provide cushion during assembly, and has two apertures  429  run through by two external power cords (not shown in the drawings). 
         [0048]    After assembly of the holder  42  is finished, the LED lamp element  41  is screwed in the third trough  427  of the socket  421  through the external threads  442  of the coupling boss  44 , and the flanges  491  of the second conductive elements  49  form electric connection with the two electrode circuits  4221  and  4222  of the base board  422  held in the third trough  427 . The buffers  423  provide cushion during screwing to prevent damage of the elements caused by excessive forces. The two external power cords (not shown in the drawings), after run through the two through holes  428  of the socket  421  and apertures  429  of the buffers  423 , form electric connection with the base board  422  by soldering. 
         [0049]    The cooling set  5  is coupled with the LED set  4 , referring to  FIGS. 2 ,  6 , and  9  through  12 , and at least includes a radiation fin  51  formed integrally through aluminum extrusion in a rhombic or arched shape to evenly disperse heat of the LED lamp element  41  to ambient air in the event that an air fan system is absent. The radiation fin  51  has a plurality of fastening holes (not shown in the drawings) formed at two sides thereof mating the second fastening holes  425  of the board  420  to be fastened therewith through fastening elements such as screws (not shown in the drawings). The radiation fin  51  and holder  42  are interposed by an airflow passage communicating two sides thereof to facilitate cooling. 
         [0050]    The cooling set  5  further includes a casing  52  and a side cap  53  (referring to  FIG. 2 ). The casing  52  is located above the radiation fin  51  to facilitate cooling, dust-fending and raindrop-guarding. The side cap  53  has a plurality of first air vents  531  on the periphery and covers one side of the airflow passage to prevent entering of insects and the like into the air passage that might impact cooling effect. 
         [0051]    The adjustment assembly  3  is coupled with the LED set  4  and cooling set  5 , referring to  FIGS. 2 ,  7 , and  13  through  16 . It at least includes an adjustment member  31  and an adjustment holder  32 . The adjustment member  31  is located at one side of the airflow passage which is formed by coupling the holder  42  and the radiation fin  51 , and has a plurality of second air vents  311  on the periphery to facilitate air ventilation and an orifice  312  in the center run through by the external power cords (not shown in the drawings), and also has an anchor portion  313  extended from one side entering into one side of the airflow passage to fasten the LED set  4 , and can be fastened to the third fastening holes  426  of the board  420  through fastening elements (not shown in the drawings) such as screws. The adjustment member  31  has a cylindrical adjustment stem  314  extended from another side to form a mating male and female engaging structure with the adjustment holder  32 . The adjustment stem  314  has a teeth-shaped male engaging portion  315  close to an inner side thereof and an annular groove  316  on the circumference close to an outer side thereof to be wedged and butted by an anchor element  317  such as a screw. 
         [0052]    The adjustment holder  32  is a female engaging structure mating the adjustment stem  314 , and includes a teeth-shaped female engaging portion  321  inside, a first fastening hole  322  and a plurality of second fastening holes  323  on an outer side. The first fastening hole  322  corresponds to the annular groove  316  of the adjustment stem  314 . When the adjustment stem  314  is inserted into the adjustment holder  32 , the male engaging portion  315  and the female engaging portion  321  are engaged. The anchor element  317  runs through the first fastening hole  322  to butt the annular groove  316  to form a firm coupling of the adjustment member  31  and adjustment holder  32 . The second fastening holes  323  are used to fasten the assembly dock (referring to  FIG. 19 ). 
         [0053]    After the adjustment assembly  3  and LED lamp set  2  are assembled, if adjusting light illumination angle is desired, unfasten the anchor element  317  to disengage the male engaging portion  315  and the female engaging portion  321 ; turn and adjust the engaging angle between them until reaching a desired angle, and engage the male engaging portion  315  and the female engaging portion  321  again and fasten them together through the anchor element  317 . Then light illumination can be achieved as desired. 
         [0054]    Refer to  FIGS. 17 through 20  for the LED lamp  1  of the invention that further includes an assembly dock  6  which can be coupled with a plurality of LED lamp sets  2  and adjustment assemblies  3  according to requirements, and can be fabricated through a molding process. In this embodiment, three sets of the LED lamp sets  2  and adjustment assemblies  3  are provided. The assembly dock  6  has a cavity  61  at a rear end formed at an inclined angle according to requirements. The adjustment holders  32  of the adjustment assembly  3  are held and coupled in the cavity  61 . The cavity  61  has an upper and lower end that have respectively a plurality of third fastening holes  611  formed thereon to receive fastening elements  612  such as screws to fasten to the second fastening holes  323  of the adjustment holders  32  to form secure coupling. The assembly dock  6  has a hole  62  at the front end to couple with an electric wire pole or lamp pole (not shown in the drawings) to mount the assembled LED lamp  1  thereon. 
         [0055]    Refer to  FIG. 21  for another embodiment of the invention. The LED set  4  includes at least one LED lamp element  41   a  and a holder  42 . The LED lamp element  41   a  adopts the structure disclosed in U.S. patent application Ser. No. 12/558,228 entitled “Improved LED lamp electrode structure” submitted by the Applicant. The holder  42  includes a board  420  with apertures  424  formed thereon to hold the LED lamp element  41   a , and is fastened through fastening elements  613  such as nuts to form secure coupling between the LED lamp element  41   a  and board  420 .