Patent Publication Number: US-11396982-B2

Title: Light bulb apparatus

Description:
RELATED APPLICATION 
     The present application is a continued application of U.S. patent application Ser. No. 16/439,705. 
    
    
     FIELD 
     The present invention is related to a light bulb apparatus, and is more particularly related to a light bulb apparatus with a flexible filament. 
     BACKGROUND 
     Light emitting diode (LED) light bulbs have advantages over traditional lighting solutions such as incandescent and fluorescent lighting because they are more durable, use less energy, operate longer, and may be controlled to deliver light of various colors. Therefore LED light bulbs with flexible filaments are becoming more popular as replacements for older lighting systems. 
     A traditional way to produce the light bulb with a flexible filament is to provide a few fixation rings on a central support of the light bulb, manually bend the flexible filament to pass through each of the fixation rings, and then fix the flexible filament. Such design requires a lot of manual work, so the production efficiency is low and the workmanship quality cannot be assured. 
     SUMMARY OF INVENTION 
     One objective of the invention is to provide a light bulb apparatus with a flexible filament; the new design proposed by the present disclosure includes a novel expanding structure to help improve the production efficiency and quality, and also reduce the manufacturing cost of the light bulb apparatus. 
     To achieve such objective, according to some embodiments of the present disclosure, the light bulb apparatus includes a light bulb shell, a bulb head, and a heat sink cup. The heat sink cup has a first end and a second end. The first end of the heat sink cup is connected to the light bulb shell, and the second end of the heat sink cup is connected to the bulb head. The light bulb apparatus includes a flexible filament for emitting light, and a central support. The flexible filament has a first terminal and a second terminal. The central support provides a first electrode electrically connected to the first terminal of the flexible filament, and provides a second electrode electrically connected to the second terminal of the flexible filament. The light bulb apparatus further includes an expanding structure and a driver module. The expanding structure is mechanically coupled to the central support, and includes a plurality of holding portions for holding the flexible filament. The driver module is electrically connected to the bulb head and the central support for providing electrical power to the first electrode and the second electrode of the central support. 
     In some embodiments, the expanding structure includes two bending strips symmetrically or asymmetrically arranged with respect to a central axis of the central support. And each of the bending strips has a plurality of concave portions as the holding portions to hold the flexible filament. The concave portions may be substantially U-shaped, C-shaped, or G-shaped. 
     In another embodiment, the expanding structure includes a plurality of support rods arranged along a central axis of the central support. Each of the support rods has a first end mechanically coupled to the central support, and has a second end extending outward from the central support to hold the flexible filament. The second ends of the support rods may be substantially U-shaped, C-shaped, or G-shaped. 
     In another embodiment, the expanding structure includes a block-shaped pillar having a concave slot. The concave slot is spiral on the surface of the block-shaped pillar for holding the flexible filament. The expanding structure may be made of metal, ceramic, glass, or plastic material. The block-shaped pillar may be hollow or solid inside. 
     In another embodiment, the expanding structure includes a plurality of support boards. Each of the support boards has a plurality of concave portions as the holding portions to hold the flexible filament. The concave portions may be substantially U-shaped, C-shaped, or G-shaped. 
     In some embodiments, the central support and the expanding structure may be made of a same material and may be integrally formed. 
     In some embodiments, the light bulb apparatus includes at least two flexible filaments connected in series or in parallel. The two flexible filaments may emit light of different colors or different color temperatures. 
     In some embodiments, the holding portions include a blocking structure for preventing the flexible filament from falling out of the holding portions. For example, the holding portions may be G-shaped for preventing the flexible filament from falling out of the holding portions. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       For a better understanding of the present disclosure, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings listed below. It is noted that these drawings are for illustration of preferred embodiments only and should not be regarded as limiting. 
         FIG. 1  is a perspective view of a light bulb apparatus according to a first embodiment of the present disclosure. 
         FIG. 2  illustrates the exploded view of the light bulb apparatus according to the first embodiment. 
         FIG. 3  illustrates the exploded view of the expanding structure and some components of the first embodiment. 
         FIG. 4  illustrates an assembly view of the expanding structure and the components in  FIG. 3  in the first embodiment. 
         FIG. 5  illustrates an assembly view of the expanding structure and some components according to a second embodiment of the present disclosure. 
         FIG. 6  illustrates an assembly view of the expanding structure and some components according to a third embodiment of the present disclosure. 
         FIG. 7  illustrates an assembly view of the expanding structure and some components according to a fourth embodiment of the present disclosure. 
         FIG. 8  illustrates an assembly view of the expanding structure and some components according to a fifth embodiment of the present disclosure. 
         FIG. 9  illustrates an assembly view of the expanding structure and some components according to a sixth embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit or define the scope of the disclosure. 
       FIGS. 1 to 4  illustrate the first embodiment of the present disclosure. In the first embodiment, the light bulb apparatus  100  includes a light bulb shell  1 , a bulb head  7 , and a heat sink cup  6 . The heat sink cup  6  has a first end and a second end. As shown in  FIG. 1  and  FIG. 2 , the first end of the heat sink cup  6  is connected to the light bulb shell  1 , and the second end of the heat sink cup  6  is connected to the bulb head  7 . The bulb head  7  may be a traditional Edison bulb head configured to receive external power source for the light bulb apparatus  100 . 
     Refer to  FIG. 2 . The light bulb apparatus  100  includes a flexible filament  2  and a central support  4 . The flexible filament  2  includes one or more LED chips for emitting light. The flexible filament  2  has a first terminal and a second terminal, and the central support  4  provides a first electrode  41  electrically connected to the first terminal of the flexible filament  2 , and provides a second electrode  42  electrically connected to the second terminal of the flexible filament  2 . The first electrode  41  and the second electrode  42  are physically located away from each other. 
     The light bulb apparatus  100  further includes an expanding structure  3  and a driver module  5 . The expanding structure  3  is mechanically coupled to the central support  4 , and includes a plurality of holding portions for holding the flexible filament  2 . The driver module  5  includes a driver circuit board and electrical components arranged on the driver circuit board. The driver module  5  is electrically connected to the bulb head  7  and the central support  4 , and the driver module  5  is capable of providing electrical power to the first electrode  41  and the second electrode  42  of the central support  4 . The first electrode  41  and the second electrode  42  may be made of metal material. The bulb head  7  includes a metal tip  71  located distal to the heat sink cup  6 . The bulb head  7  and the metal tip  71  work together to receive external power for the light bulb apparatus  100 . 
     In this embodiment, the central support  4  extends and a part of the central support  4  is located inside the light bulb shell  1 , so the flexible filament  2  could be physically located inside the light bulb shell  1 . 
     Refer to  FIG. 3  and  FIG. 4 . In this embodiment, the expanding structure  3  includes two bending strips  31  symmetrically arranged with respect to a central axis  9  of the central support  4 . The two bending strips  31  are mechanically coupled to the central support  4 . Each of the bending strips  31  has a plurality of concave portions  35  as the holding portions to hold the flexible filament  2 . The flexible filament  2  is bent to spiral along a central axis  9  of the central support and is held and fixed by the concave portions  35 . The concave portions  35  are substantially U-shaped in this embodiment so as to properly hold and fix the flexible filament  2 . Comparing to a traditional way which includes bending the filament to pass through the fixation rings, the new way proposed by the present disclosure is more efficient and reliable, and may reduce the manufacturing cost and improve the production quality. 
     In this embodiment of the present disclosure, the central support  4  has a horn-type bottom. The horn-type bottom is connected to the light bulb shell  1  by high melting-point soldering, and the flexible filament  2  is sealed inside the light bulb shell  1 . There may be heat dissipation gas filled inside the light bulb shell  1  so as to improve the heat dissipation of the light bulb apparatus  100 . The heat dissipation gas may be helium, or a combination of helium and oxygen. The central support  4  and the heat sink cup  6  may be connected to each other by glue, by buckles, or by screw thread. The heat sink cup  6  may be made of plastic material. The heat sink cup  6  and the light bulb shell  1  may be connected to each other by glue. 
     In this embodiment, the first terminal of the flexible filament  2  is soldered to the first electrode  41 . Then the flexible filament  2  is bent to spiral and to be held by the concave portions  35  of the expanding structure  3 . And then the second terminal of the flexible filament  2  is soldered to the second electrode  42 . In another embodiment, the flexible filament  2  may be first bent to spiral and to be held by the concave portions  35  of the expanding structure  3 . And then the first terminal and the second terminal of the flexible filament  2  are soldered to the first electrode  41  and the second electrode  42  respectively. 
     In this embodiment, the bending strips  31  may be made of metal, plastic, or glass material. If the bending strips  31  are made of metal material, the bending strips  31  may be connected to the central support  4  by plug/socket and soldering. If the bending strips  31  are made of plastic or glass material, the bending strips  31  may be connected to the central support  4  by plug/socket and glue. In another embodiment, there may be more than two bending strips  31 , for example, there may be four or six bending strips  31  used in the light bulb apparatus  100 . 
     Refer to  FIG. 5 , which illustrates a second embodiment of the present disclosure. The second embodiment is similar to the first embodiment, but the two bending strips  31  are mechanically coupled to the first electrode  41  and the second electrode  42 . The bending strip  31  may be made of metal, plastic, or glass material. With the arrangement proposed by the second embodiment, the cost for installing the bending strips  31  may be reduced, and it may be more convenient for soldering or gluing the bending strips  31  to the first electrode  41  and the second electrode  42 . 
       FIG. 6  illustrates a third embodiment of the present disclosure. In the third embodiment, the expanding structure  3  includes a plurality of support rods  32  arranged along the central axis  9  of the central support  4 . The support rods  32  are spaced an equal distance apart from each other on the surface of the central support  4 . Each of the support rods  32  has a first end mechanically coupled to the central support  4 , and has a second end extending outward from the central support  4  to hold the flexible filament  2 . The second ends of the support rods may be bent into substantial U-shape or C-shape, with the open ends of the U-shape or the C-shape facing toward the central axis  9  of the central support  4 . It is noted that since the open ends of the U-shape or the C-shape face toward the central axis  9  of the central support  4 , the open ends could not be shown in  FIG. 6 . 
     In the third embodiment, the support rods  32  may be made of metal, plastic, or glass material. With such arrangement, the material required for composing the expanding structure  3  may be reduced, and the process for installing the expanding structure  3  may also be simplified. In this embodiment, there are at least two groups of support rods  32  arranged parallel to each other so as to properly support the flexible filament  2 . The support rods  32  may be connected to the central support  4  by soldering, glue, or screw-thread. 
       FIG. 7  illustrates the fourth embodiment of the present disclosure. The fourth embodiment is similar to the first embodiment shown in FIG.  4 , but the bending strips  31  are asymmetrically arranged with respect to the central axis  9  of the central support  4 . The bending strips  31  may be made of metal, plastic, or glass material. In this embodiment, the bending strips  31  are arranged surrounding the central axis  9  of the central support  4  as a circle. In this embodiment, there may be an odd number, for example three or five, of bending strips  31  used in the light bulb apparatus  100 . 
       FIG. 8  illustrates the fifth embodiment of the present disclosure. In the fifth embodiment, the expanding structure  3  includes a block-shaped pillar  33  having a concave slot  35 . The concave slot  35  is arranged spiral on the surface of the block-shaped pillar  33  for holding the flexible filament  2 . The block-shaped pillar  33  may be hollow inside, so the overall weight of the light bulb apparatus  100  could be reduced. The block-shaped pillar  33  may also be solid inside. The block-shaped pillar  33  may be made of metal, ceramic, glass, or plastic material. Preferably, the block-shaped pillar  33  may be made of transparent glass or plastic material. The block-shaped pillar  33  may be installed onto the central support  4  by glue. 
     Refer to  FIG. 9 , which shows the sixth embodiment of the present disclosure. In the sixth embodiment, the expanding structure  3  includes a plurality of support boards  34 . Each of the support boards  34  has a plurality of concave portions  35  at its edge area as the holding portions to hold the flexible filament  2 . The concave portions  35  may be substantially U-shaped or C-shaped. In this embodiment, there are four support boards  34  arranged in the shape of a cross. The support boards  34  may be made of metal, ceramic, glass, or plastic material. Preferably, the support boards  34  are made of transparent glass or plastic material. The support boards  34  are connected to the central support  4  by soldering or glue. In another embodiment, there may be three, five, or six support boards  34  used in the light bulb apparatus  100 . 
     In some embodiments, the central support  4  and the expanding structure  3  may be made of a same material and may be integrally formed. In this way, the manufacturing cost for the light bulb apparatus  100  may be further reduced. 
     In the above embodiments, the holding portions are substantially U-shaped or C-shaped. The size of the open ends of the U-shapes or the C-shapes should be suitable to properly hold and fix the filament  2 . In some other embodiments, the holding portions may further include a blocking structure so as to prevent the flexible filament  2  from falling out of the holding portions. For example, the holding portions may be G-shaped, so the holding portions would include a blocking structure to properly prevent the flexible filament  2  from falling out of the holding portions. 
     In some embodiments, the light bulb apparatus  100  may include two or more flexible filaments  2  connected in parallel. Accordingly, there are two or more sets of the first electrodes  41  and the second electrodes  42 , with each set of the first electrode  41  and the second electrode  42  electrically connected to one of the flexible filaments  2 . Each of the flexible filaments  2  includes one or more LED chips capable of emitting light. With such arrangement, if one flexible filament  2  fails, the other ones may continue to provide lighting. 
     Alternatively, each of the flexible filaments  2  may include one or more LED chips capable of emitting light of different colors (e.g., red, green, or blue . . . ) or different color temperatures (e.g., 3000K, 4500K, or 6000K . . . ). With such arrangement, the light bulb apparatus  100  may emit light of different color or different color temperature by providing power to one or a combination of the flexible filaments  2 . 
     In another embodiment, the two or more flexible filaments  2  may be connected in series. 
     In the above embodiments, the light bulb apparatus of the present disclosure includes an expanding structure having holding portions to properly hold the flexible filament. The expanding structure may be bending strips, support rods, block-shaped pillar, or support boards . . . etc. As illustrated above, the expanding structure according the present disclosure is easy to implement and install, and may be applied in various lighting apparatuses. High production quality and manufacturing efficiency of the light bulb apparatus may be achieved. 
     The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the techniques and their practical applications. Others skilled in the art are thereby enabled to best utilize the techniques and various embodiments with various modifications as are suited to the particular use contemplated. 
     Although the disclosure and examples have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the disclosure and examples as defined by the claims.