Abstract:
A lamp having a front and rear orientation, comprising: (a) a body containing at least one light emitting diode (LED); (b) an electrical connector for operatively providing power to said LED, said electrical connector being rearward of said body and defining a connection plane between said electrical connector and said body, said electrical connector being configured for electrical connection to an electrical interface; and (c) at least one heat sink in thermal communication with at least one of said LED or said driver, said at least one heat sink having a rearward portion extending rearward from said connection plane and enveloping at least a portion of said electrical connector.

Description:
FIELD 
       [0001]    This disclosure relates to the field of illumination products and more particularly to techniques for designing an LED lamp electrical connector disposed within a heatsink cavity. 
       BACKGROUND 
       [0002]    Use of LED lamps in retrofit and other illumination product settings has been on the increase. Lighting applications that have traditionally deployed incandescent lamps are now suited for retrofit placement and/or design-in of LED lamps. LED lamps are often accompanied with a heatsink that is designed to distribute heat away from the light-emitting components that can get hot during normal operation. Unfortunately, some applications are demanding with regard to the quantity and shape of any assembly (e.g., LED emitter, heatsink, mating hardware, electrical connector, etc.). In some cases LED lamps cannot be retrofitted with or into conventional electrical connectors simply due to the shape, size and configuration of the LED heatsink. More particularly, many applications have height requirements that preclude use of conventional LED heatsink mating. What is needed is a technique or techniques to produce an LED lamp electrical connector that is disposed within a heatsink cavity. Often the configuration results in better performance thanks to a shape-optimized heatsink and often the configuration results in a shorter overall length of the assembly (e.g., the configuration when the lamp is mounted for use in the intended application). 
         [0003]    Legacy approaches are deficient, at least to the extent that they fail to achieve the advantages and/or capabilities of the herein-disclosed techniques for LED lamp electrical connector disposed within a heatsink cavity. Therefore, there is a need for improvements. 
       SUMMARY 
       [0004]    The present disclosure provides an improved method, system, and computer program product suited to address the aforementioned issues with legacy approaches. More specifically, the present disclosure provides a detailed description of techniques used in methods, systems, and computer program products for LED lamp electrical connector disposed within a heatsink cavity. The claimed embodiments address the problem of legacy electrical connector configurations. More specifically, some claims are directed to approaches for reconfiguring the heatsink to accept at least a portion of the lamp electrical connector into a cavity within the heatsink, which claims advance the technical fields for addressing the problem of legacy electrical connector configurations together with a compatible lamp and heatsink consumes too much physical space, as well as advancing peripheral technical fields. Some claims improve the functioning of multiple systems within the disclosed environments. 
         [0005]    In a first aspect, apparatus used in a lighting systems are provided, the apparatus comprising an electrical connector member, at least a portion of which is electrically an LED emitter; and a heatsink thermally coupled to the LED emitter, wherein the heatsink at least partially surrounds the electrical connector member. 
         [0006]    Further details of aspects, objectives, and advantages of the disclosure are described below and in the detailed description, drawings, and claims. Both the foregoing general description of the background and the following detailed description are exemplary and explanatory, and are not intended to be limiting as to the scope of the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The drawings described below are for illustration purposes only. The drawings are not intended to limit the scope of the present disclosure. 
           [0008]    FIG.  1 A 1  compares a stacking electrical connector with a LED lamp electrical connector disposed within heatsink cavity. 
           [0009]    FIG.  1 A 2  exemplifies a fold-around heatsink with an LED lamp electrical connector disposed within the heatsink cavity, according to an embodiment. 
           [0010]    FIG.  2 A 1  compares a hanging stacking electrical connector situated within a pendant luminaire. 
           [0011]    FIG.  2 A 2  exemplifies a hanging fold-around heatsink situated within a pendant luminaire, according to an embodiment. 
           [0012]    FIG.  3 A 1  exemplifies a electrical connector-in-heatsink configuration. 
           [0013]    FIG.  3 A 2  exemplifies a electrical connector-recessed-in-heatsink, according to some embodiments. 
           [0014]      FIG. 4A  is an emitter-side sectional view of a LED lamp electrical connector disposed within a heatsink cavity, according to some embodiments. 
           [0015]      FIG. 4B  is a connector-side sectional view of a LED lamp electrical connector disposed within a heatsink cavity, according to some embodiments. 
           [0016]      FIG. 4C  is an exploded view of a LED lamp electrical connector disposed within a heatsink cavity, according to some embodiments. 
           [0017]      FIG. 5A  depicts an assembly including an LED lamp electrical connector disposed within a heatsink cavity, according to some embodiments. 
           [0018]      FIG. 5B  depicts an assembly including a luminaire connected to a LED lamp electrical connector disposed within a heatsink cavity, according to some embodiments. 
           [0019]      FIG. 5C  depicts a wall alcove for receiving a luminaire connected to a LED lamp electrical connector disposed within a heatsink cavity, according to some embodiments. 
           [0020]      FIG. 6  presents a selection of lamp shapes corresponding to known-in-the-art standards. The aforementioned lamps are selected embodiments of lamps that conform to fit with any one or more of a set of mechanical and electrical standards. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Some embodiments of the present disclosure address the problem of legacy electrical connector configurations where a compatible lamp and heatsink consumes too much physical space. Some embodiments are directed to approaches for reconfiguring the heatsink to accept at least a portion of the lamp electrical connector into a cavity within the heatsink. More particularly, disclosed herein and in the accompanying figures are exemplary environments, methods, and systems for designing LED lamp electrical connector disposed within a heatsink cavity. 
         [0022]    LED lighting systems are everywhere, yet many lighting applications have height requirements that preclude use of conventional LED heatsink mating. What is needed is a technique or techniques to produce an LED lamp electrical connector that is disposed within a heatsink cavity. 
         [0023]    Some of the terms used in this description are defined below for easy reference. The presented terms and their respective definitions are not rigidly restricted to these definitions—a term may be further defined by the term&#39;s use within this disclosure. 
         [0024]    The term “exemplary” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion. 
         [0025]    As used in this application and the appended claims, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless specified otherwise, or is clear from the context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A, X employs B, or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. 
         [0026]    The articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or is clear from the context to be directed to a singular form. 
         [0027]    Reference is now made in detail to certain embodiments. The disclosed embodiments are not intended to be limiting of the claims. 
         [0028]    FIG.  1 A 1  compares a stacking electrical connector  1 A 100  with a LED lamp electrical connector disposed within heatsink cavity. 
         [0029]    As shown in FIG.  1 A 1 , the stacking electrical connector comprises a heatsink that mates against a lamp base. In this configuration, the height of the assembly is at least the combination of the height of the lamp base plus the height of the heatsink. In some cases, the resulting height is too high for a particular application, thus exemplifying the need for improvements. One such improvement involves design of a heatsink that folds around a electrical connector so as to reduce the total height of the combination of the height of the lamp base plus the height of the heatsink. 
         [0030]    FIG.  1 A 2  exemplifies a fold-around heatsink  1 A 200  with an LED lamp electrical connector disposed within the heatsink cavity. 
         [0031]    As shown in FIG.  1 A 2 , the fold-around heatsink comprises a heatsink that folds-around or wraps-around one or more components of a lamp (e.g., a electrical connector component, a driver housing, a lamp base component). The driver or drivers can be implemented using any known-in-the art technique. In particular, drivers are configured or configurable to accommodate driver a range of different voltages (e.g., 12V, 100V, 120V, 230V, 277V, etc.). 
         [0032]    FIG.  2 A 1  compares a hanging stacking electrical connector  2 A 100  situated within a pendant luminaire. 
         [0033]    As shown in FIG.  2 A 1 , the hanging stacking electrical connector comprises a legacy stacking electrical connector  1 A 100 . As indicated, the light-emitting surfaces of the LED lamp are disposed deeply downward in the pendant. Use of such a legacy stacking electrical connector  1 A 100  sometimes has the result that an LED lamp cannot be retrofitted. What is needed is a way to bring the light-emitting surfaces of the LED to the same height as were the light-emitting surfaces of the legacy lamp being replaced. Such a configuration is given in FIG.  2 A 2 . 
         [0034]    FIG.  2 A 2  exemplifies a hanging fold-around heatsink  2 A 200  situated within a pendant luminaire. 
         [0035]    As shown in FIG.  2 A 2 , the hanging fold-around heatsink comprises a wrap-around or fold-around heatsink. Since the electrical connector is recessed into the cavity of the shown heatsink, the light-emitting surfaces of the LED are brought to the same height as were the light-emitting surfaces of the legacy lamp being replaced. 
         [0036]    FIG.  3 A 1  exemplifies a electrical connector-in-heatsink  3 A 100  configuration. 
         [0037]    As shown in FIG.  3 A 1 , the electrical connector-in-heatsink includes connector pins that protrude beyond the envelope of the heatsink. Presence of such a protrusion further exacerbates the problem of the height of the assembly. One possible improvement is to recess the connector (and pins), and to wrap the fins of the heatsink around the connector and pins. 
         [0038]    FIG.  3 A 2  exemplifies a electrical connector-recessed-in-heatsink  3 A 200 . 
         [0039]    As shown in FIG.  3 A 2 , the electrical connector-recessed-in-heatsink is in a configuration that reduces the height of the assembly by more than 50%. 
         [0040]      FIG. 4A  is an emitter-side sectional view  4 A 00  of a LED lamp electrical connector disposed within a heatsink cavity. 
         [0041]    As shown in  FIG. 4A , the emitter-side sectional view includes a notches  495  (see shown notch  495   1 ). The notch is also visible on the connector-side sectional view  4 B 00  (see shown notch  495   2 ). In cases when the heatsink folds around the lamp base, notches facilitate alignment of the lamp base pins to the electrical connector terminals. The notches are aligned with the pinch for easier insertion. 
         [0042]      FIG. 4B  is a connector-side sectional view  4 B 00  of a LED lamp electrical connector disposed within a heatsink cavity. 
         [0043]      FIG. 4C  is an exploded view  4 C 00  of a LED lamp electrical connector disposed within a heatsink cavity. 
         [0044]    The exploded view includes the show components. Item  485  serves the purpose of easier insertion through terminal-to pin alignment. The item  485  includes an aspect of a conical shape and operates guide while installing the lamp. The shape and protrusions directs the pins to the terminals. 
         [0045]      FIG. 5A  depicts an assembly  5 A 00  including an LED lamp electrical connector disposed within a heatsink cavity. 
         [0046]    As shown in  FIG. 5A , the assembly comprises an apparatus having a electrical connector member  501 , at least a portion of which is electrically an LED emitter  504 . The apparatus further comprises a heatsink  502  that is thermally coupled to the LED emitter wherein a portion of the heatsink surrounds the electrical connector member. The apparatus shown also has a lens  506 . 
         [0047]      FIG. 5B  depicts an assembly  5 B 00  including a luminaire connected to a LED lamp electrical connector disposed within a heatsink cavity. 
         [0048]      FIG. 5C  depicts a wall alcove  5 C 00  for receiving a luminaire connected to a LED lamp electrical connector disposed within a heatsink cavity. 
         [0049]    Any of the constituent components (e.g., component  482 , component  486 , component  487 , component  483 , component  488 , component  481 , component  489 , component  484 , etc.) can be used to form a sighting system (e.g., a lamp, a luminaire, etc.). 
         [0050]    It should be noted that there are alternative ways of implementing the embodiments disclosed herein. Accordingly, the embodiments and examples presented herein are to be considered as illustrative and not restrictive, and the claims are not to be limited to the details given herein, but may be modified within the scope and equivalents thereof. 
         [0051]      FIG. 6  presents a selection of lamp shapes corresponding to known-in-the-art standards. The aforementioned lamps are selected embodiments of lamps that conform to fit with any one or more of a set of mechanical and electrical standards. Table 1 gives standards (see “Designation”) and corresponding characteristics. 
         [0000]    
       
         
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                 Base Diameter 
                   
                 IEC 60061-1 
               
               
                 Desig- 
                 (crest of 
                   
                 Standard 
               
               
                 nation 
                 thread) 
                 Name 
                 Sheet 
               
               
                   
               
             
             
               
                 E05 
                 05 mm 
                 Lilliput Edison Screw (LES) 
                 7004-25 
               
               
                 E10 
                 10 mm 
                 Miniature Edison Screw (MES) 
                 7004-22 
               
               
                 E11 
                 11 mm 
                 Mini-Candelabra Edison Screw 
                 (7004-06-1) 
               
               
                   
                   
                 (mini-can) 
               
               
                 E12 
                 12 mm 
                 Candelabra Edison Screw (CES) 
                 7004-28 
               
               
                 E14 
                 14 mm 
                 Small Edison Screw (SES) 
                 7004-23 
               
               
                 E17 
                 17 mm 
                 Intermediate Edison Screw (IES) 
                 7004-26 
               
               
                 E26 
                 26 mm 
                 [Medium] (one-inch) Edison 
                 7004-21A-2 
               
               
                   
                   
                 Screw (ES or MES) 
               
               
                 E27 
                 27 mm 
                 [Medium] Edison Screw (ES) 
                 7004-21 
               
               
                 E29 
                 29 mm 
                 [Admedium] Edison Screw (ES) 
               
               
                 E39 
                 39 mm 
                 Single-contact (Mogul) Giant 
                 7004-24-A1 
               
               
                   
                   
                 Edison Screw (GES) 
               
               
                 E40 
                 40 mm 
                 (Mogul) Giant Edison Screw 
                 7004-24 
               
               
                   
                   
                 (GES) 
               
               
                   
               
             
          
         
       
     
         [0052]    Additionally, the base member of a lamp can be of any form factor configured to support electrical connections, which electrical connections can conform to any of a set of types or standards. For example, Table 2 gives standards (see “Type”) and corresponding characteristics, including mechanical spacing between a first pin (e.g., a power pin) and a second pin (e.g., a ground pin). 
         [0000]    
       
         
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 2 
               
               
                   
               
               
                   
                   
                 Pin Center 
                 Pin 
                   
               
               
                 Type 
                 Standard 
                 to Center 
                 Diameter 
                 Usage 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 G4 
                 IEC 60061-1 
                 4.0 
                 mm 
                 0.65-0.75 
                 mm 
                 MR11 and other small halogens of 
               
               
                   
                 (7004-72) 
                   
                   
                   
                   
                 5/10/20 watt and 6/12 volt 
               
               
                 GU4 
                 IEC 60061-1 
                 4.0 
                 mm 
                 0.95-1.05 
                 mm 
               
               
                   
                 (7004-108) 
               
               
                 GY4 
                 IEC 60061-1 
                 4.0 
                 mm 
                 0.65-0.75 
                 mm 
               
               
                   
                 (7004-72A) 
               
               
                 GZ4 
                 IEC 60061-1 
                 4.0 
                 mm 
                 0.95-1.05 
                 mm 
               
               
                   
                 (7004-64) 
               
               
                 G5 
                 IEC 60061-1 
                 5 
                 mm 
                   
                   
                 T4 and T5 fluorescent tubes 
               
               
                   
                 (7004-52-5) 
               
               
                 G5.3 
                 IEC 60061-1 
                 5.33 
                 mm 
                 1.47-1.65 
                 mm 
               
               
                   
                 (7004-73) 
               
               
                 G5.3-4.8 
                 IEC 60061-1 
               
               
                   
                 (7004-126-1) 
               
               
                 GU5.3 
                 IEC 60061-1 
                 5.33 
                 mm 
                 1.45-1.6 
                 mm 
               
               
                   
                 (7004-109) 
               
               
                 GX5.3 
                 IEC 60061-1 
                 5.33 
                 mm 
                 1.45-1.6 
                 mm 
                 MR16 and other small halogens of 
               
               
                   
                 (7004-73A) 
                   
                   
                   
                   
                 20/35/50 watt and 12/24 volt 
               
               
                 GY5.3 
                 IEC 60061-1 
                 5.33 
                 mm 
               
               
                   
                 (7004-73B) 
               
               
                 G6.35 
                 IEC 60061-1 
                 6.35 
                 mm 
                 0.95-1.05 
                 mm 
               
               
                   
                 (7004-59) 
               
               
                 GX6.35 
                 IEC 60061-1 
                 6.35 
                 mm 
                 0.95-1.05 
                 mm 
               
               
                   
                 (7004-59) 
               
               
                 GY6.35 
                 IEC 60061-1 
                 6.35 
                 mm 
                 1.2-1.3 
                 mm 
                 Halogen 100 W 120 V 
               
               
                   
                 (7004-59) 
               
               
                 GZ6.35 
                 IEC 60061-1 
                 6.35 
                 mm 
                 0.95-1.05 
                 mm 
               
               
                   
                 (7004-59A) 
               
               
                 G8 
                   
                 8.0 
                 mm 
                   
                   
                 Halogen 100 W 120 V 
               
               
                 GY8.6 
                   
                 8.6 
                 mm 
                   
                   
                 Halogen 100 W 120 V 
               
               
                 G9 
                 IEC 60061-1 
                 9.0 
                 mm 
                   
                   
                 Halogen 120 V (US)/230 V (EU) 
               
               
                   
                 (7004-129) 
               
               
                 G9.5 
                   
                 9.5 
                 mm 
                 3.10-3.25 
                 mm 
                 Common for theatre use, several 
               
               
                   
                   
                   
                   
                   
                   
                 variants 
               
               
                 GU10 
                   
                 10 
                 mm 
                   
                   
                 Twist-lock 120/230-voltMR16 halogen 
               
               
                   
                   
                   
                   
                   
                   
                 lighting of 35/50 watt, since mid-2000s 
               
               
                 G12 
                   
                 12.0 
                 mm 
                 2.35 
                 mm 
                 Used in theatre and single-end metal 
               
               
                   
                   
                   
                   
                   
                   
                 halide lamps 
               
               
                 G13 
                   
                 12.7 
                 mm 
                   
                   
                 T8 and T12 fluorescent tubes 
               
               
                 G23 
                   
                 23 
                 mm 
                 2 
                 mm 
               
               
                 GU24 
                   
                 24 
                 mm 
                   
                   
                 Twist-lock for self-ballasted compact 
               
               
                   
                   
                   
                   
                   
                   
                 fluorescents, since 2000s 
               
               
                 G38 
                   
                 38 
                 mm 
                   
                   
                 Mostly used for high-wattage theatre 
               
               
                   
                   
                   
                   
                   
                   
                 lamps 
               
               
                 GX53 
                   
                 53 
                 mm 
                   
                   
                 Twist-lock for puck-shaped under- 
               
               
                   
                   
                   
                   
                   
                   
                 cabinet compact fluorescents, since 
               
               
                   
                   
                   
                   
                   
                   
                 2000s 
               
               
                   
               
             
          
         
       
     
         [0053]    The list above is representative and should not be taken to include all the standards or form factors that may be utilized within embodiments described herein. In particular, lamps can also have not-yet-defined shapes and electrical connector types (e.g., mini USB). Embodiments of the present disclosure in the form of lamp applications using not-yet-defined shapes and electrical connector types are reasonable and contemplated. 
         [0054]    In the foregoing specification, the disclosure has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the disclosure. For example, the above-described process flows are described with reference to a particular ordering of process actions. However, the ordering of many of the described process actions may be changed without affecting the scope or operation of the disclosure. The specification and drawings are, accordingly, to be regarded in an illustrative sense rather than in a restrictive sense.