Patent Publication Number: US-2013229103-A1

Title: Adjustable beam lamp

Description:
This application is a continuation of co-pending U.S. patent application Ser. No. 12/679,843, filed Mar. 24, 2010, which is a National Stage Application of PCT/US2009/043999, filed May 14, 2009, and which claims the benefit of U.S. Provisional patent application Serial No. 61/053,512, filed May 15, 2008, and which applications are incorporated herein by reference. To the extent appropriate, a claim of priority is made to each of the above disclosed applications. 
    
    
     FIELD OF THE INVENTION 
     The instant invention relates to a need for a lighting lamp configured to handle several applications, wherein the lighting lamp is configured to be adjusted so as to facilitate generation of light ranging from a wide beam flood to a narrow beam spot. 
     BACKGROUND OF THE INVENTION 
     Today, when visiting a retail establishment that offers lighting lamps for sale, a consumer will see a wide variety of pars and reflector lamps that all have various beam spreads, light output and wattage concerns. There is a need for a lighting lamp configured to handle several applications, wherein the lighting lamp is configured to be adjusted so as to facilitate generation of light ranging from a wide beam flood to a narrow beam spot. 
     In recent years, improved light emitting diodes (LEDs) have become available that produce relatively high intensities of output light. These higher power LEDs, for example, have enabled use of LEDs in light fixtures and the like. The improving capability of LEDs and the decreasing cost of the LEDs is making LED based lighting a viable alternative to more traditional lighting, such as incandescent and fluorescent lights, and will soon allow LED lighting to surpass such older technologies and will likely be surpassed itself in the future. Regardless of the light emitting technology utilized, a selectively adjustable lighting lamp that adjusts beam patterns to suit the application provides utility to the user. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting and non-exhaustive embodiments are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
         FIG. 1  depicts a perspective view of a first embodiment of the present invention in medium Flood mode; 
         FIG. 2  depicts a sectional view of a completed assembly of an embodiment of a first embodiment of the present invention; 
         FIG. 3  depicts an exploded view of a completed assembly of a first embodiment of the present invention; 
         FIG. 4  depicts a top view of outer die cast heat sink showing internal aperture detail that mates to the LED heat sink assembly; 
         FIG. 5  depicts an exploded view of the LED, driver and socket assembly of a first embodiment of the present invention; 
         FIG. 6  depicts an exploded view of a completed assembly of a first embodiment of the present invention; 
         FIG. 7  depicts a side view of a first embodiment of present invention in Flood mode; 
         FIG. 8  depicts a side view of a first embodiment of the present invention illustrating the adjustment rings slidably engaged to adjust the lighting mode; 
         FIG. 9  depicts an exploded side view of the LED, driver and socket assembly of an embodiment of a first embodiment of the present invention; 
         FIG. 10  depicts an exploded view of a completed assembly of a second embodiment of the present invention including an extruded aluminum housing heat sink; 
         FIG. 11  depicts an exploded view of the LED, driver and socket assembly of a second embodiment of the present invention including an extruded aluminum housing heat sink; 
         FIG. 12  depicts a top view of outer die cast heat sink showing internal aperture detail that mates to the LED an extruded aluminum housing heat sink; 
         FIG. 13  depicts a side view of a second embodiment of present invention including an extruded aluminum housing heat sink illustrating the spot mode of operation; 
         FIG. 14  depicts a side view of a first embodiment of the present invention including an extruded aluminum housing heat sink illustrating the flood mode of operation; 
         FIG. 15  depicts a sectional view of a third embodiment of the present invention; and 
         FIG. 16  depicts a top view of a third embodiment of the present invention. 
     
    
    
     SUMMARY 
     A lamp device having first and second ends comprising a lens positioned on a first end of the lamp and a socket positioned on a second end of the lamp. The lamp is configured with a parabolic reflecting surface lining the interior side walls of at least a portion of the top portion of the lamp and an array of LEDs or other light emitting source positioned within that the top portion of the lamp. The array of LEDs or other light emitting sources are operatively connected to the socket in order to receive power. The lamp is configured to facilitate movement of the lamp components so that the LEDs or other light emitting source positioned within that the top portion of the lamp may be moved closer to and further away from the lamp lens in order to shorten or lengthen the focal point of the light beam created by the array of LEDs or other light emitting source. In one embodiment, the lamp may be configured to facilitate movement of the array of LEDs or other light emitting device closer to and further away from the lens in order to shorten or lengthen the focal point of the light beam created by the array of LEDs or other light emitting source. Alternatively, the LEDs or other light emitting device may be stationary and the lens may be moved closer to or further away from the LEDs or other light emitting source. 
     DETAILED DESCRIPTION 
     The present invention is a lighting lamp configured such that the light emitting source within the lamp is adjustable between a plurality of positions in order to increase or decrease the distance between the light emitting source and at least a portion of a lens. It is contemplated that the lens may be comprised of glass, plastic or any other material that may be used in the creation of a lens. The light emitting source may take on any of the myriad of light emitting configurations, including incandescent lighting devices, fluorescent lighting devices, and LEDs. The configuration of the lens and lamp housing in embodiments of the invention include a plurality of configurations that may resemble currently available configurations wherein some embodiments may include a lens portion and some may not. In embodiments including a lens portion, the lens may comprise any of a plurality of lens configurations, including but not limited to clear and diffused lenses having varying thickness, shape and size, depending on the application. 
     One embodiment of the present invention is a lamp that utilizes LED&#39;s in a chip format on a circuit board as the light emitting source. The LEDs run at elevated voltages, which thereby cause the LEDs to output elevated levels of light. The lamp is configured to allow for the adjustment of the focal length of the optical system of the lamp and thereby the beam pattern. By adjusting the focal length, the distance between the lens and the focal point measured along the optical axis of the lamp, the light beam pattern may be varied within a range beginning with a wide beam flood to a narrow beam spot. Lamps configured in accordance with the disclosed embodiments of the present invention facilitate adjustment of the focal length of the lamp by configuring at least the light-emitting portion of the lamp for movement within a reflector assembly. The lamp is comprised of an LED driver or other light emitting device and socket assembly, a lens, heat sink, parabola reflector and a beam adjustment assembly. The LED driver or other light emitting device and socket assembly is comprised of at least an LED platen or other light emitting device operatively connected to a driver circuit board, a standard Edison type screw-in base, and extruded aluminum heat sink housing. The lamp is configured for movement of the LED platen closer to or further away from the lens, which in some embodiment may be configured to focus light emitted by the LEDs and in another embodiment diffuse the light emitted by the LEDS. 
     A first embodiment of a lamp configured to allow for the adjustment of the lamp&#39;s focal length, in order to facilitate various beam spreads, is illustrated in  FIG. 1-9 .  FIG. 1  illustrates an assembled view of an LED type lamp  100 . As illustrated, the LED lamp  100  is comprised of an outer casing  124 , configured to also function as a secondary heat sink, a focal length adjustment assembly  122 , an adapter  120  configured to attach the LED driver assembly to the standard Edison type screw-in base  110 , and a lens  190  fittingly connected as a cap onto the outer casing  124 .  FIG. 2  illustrates an assembled sectional view of the LED lamp  100 , showing the standard Edison type screw-in base  110  an adapter  120  configured to attach the array of LEDs  186 , positioned on the LED platen  180 , and driver circuitry  170  to the standard Edison type screw-in base  110 . As illustrated, a focal length adjustment assembly  122 , which in the embodiment illustrated is a rotating ring configured with adjustment prongs  126  and  128  for shortening or lengthening the focal point of the light beam created by the array of LEDs  186 . 
     As further illustrated in an exploded assembly view,  FIG. 3  further shows the components of the first embodiment of the LED lamp  100 . As illustrated, the top portion of the LED lamp is comprised of a lens  190 , an LED driver and socket assembly  132 , an exterior aluminum heat sink  124 , a focal length adjustment assembly  122 , collar retention ring  118  and a retention clip  116 . The LED driver and socket assembly  132  includes an LED platen  180 , comprised of an array of LEDs  186  and a heat sink back plate  188  along, with the driver circuit board (not shown) mounted perpendicular thereto (as illustrated in  FIG. 4 ) and sized to be positioned down inside of a first LED and driver board heat sink  160 . As illustrated, the first LED and driver board heat sink  160  is an extruded aluminum heat sink configured with longitudinally extending fins  162 . Over the first LED and driver board heat sink  160  and underneath the LED platen  180 , a compression spring  150  is positioned to provide linear stabilizing pressure to the socket assembly  132  that moves linearly in response to rotation of the focal length adjustment assembly  122  and engagement of adjustment prongs  126  and  128  with one of the plurality of beam adjustment notches  132 ,  134 ,  136 . 
     The LED lamp&#39;s exterior aluminum heat sink  124  is also configured with longitudinally extending fins  146  on its exterior surface and a blue parabolic reflector casting  142  along a portion of its interior surface. It is contemplated that the portion of the interior of the blue parabola surface  142  has been polished out and/or inserted with a mirrored reflector. Alternatively, commercially available methods capable of generating a smooth reflector surface  142  along the interior of the exterior aluminum heat sink  124  may be used. As illustrated in  FIG. 4 , the exterior aluminum heat sink  124  has a funnel shaped upper portion  125  wherein the walls  142  of the upper portion  125  are angled inward until the internal diameter becomes uniform beginning with a geared tooth aspect  148  within a lower portion  123 . The geared portion  148  along the interior of the lower portion of the exterior aluminum heat sink  124  perform as guiding members configured to mate with the fins  162  extending longitudinally out from the exterior of the first LED and driver board heat sink  160  as it is positioned within and slid up and down the interior of the exterior aluminum heat sink  124 . As shown in  FIG. 3 , the lower portion  123  further includes, on its exterior, a plurality of beam adjustment notches  134 ,  136 ,  138 , each configured to be engaged by first and second focal length adjustment arms  126  and  128  of the focal length adjustment assembly  122 . The focal length adjustment assembly  122  causes the focal length of the light associated with the array of LEDs  186  to be changed when one of the focal length adjustment prongs  126  and  128  engages one of the plurality of beam adjustment notches  134 ,  136 ,  138 . It is contemplated that the plurality of beam adjustment notches  134 ,  136 ,  138  may be of any number. In the present embodiment there are three, a first beam adjustment notch  134 , a second beam adjustment notch  136 , and a third beam adjustment notch  138 . As illustrated, the beam adjustment notches  134 ,  136  and  138  are configured on an end opposite the opening within the exterior aluminum heat sink  124  into which the first LED and driver board heat sink  160  is inserted. The LED driver and socket assembly  132  also includes a ceramic insulator gasket  130  sandwiched between an end of the first LED and driver board heat sink  160  and an adapter  120 . The adapter  120  is configured for attaching the LED driver assembly to a standard Edison screw base  110 . 
       FIG. 5  is an illustration of an exploded view of the LED driver and socket assembly  132 . The LED driver and socket assembly  132  includes an LED Platen  180 , comprised of an array of LEDs  186  and a heat sink back plate  188  having the driver circuit board  170  mounted perpendicular thereto and sized to be positioned down inside of the first LED and driver board heat sink  160 . As illustrated, the first LED and driver board heat sink  160  is an extruded aluminum heat sink configured with longitudinally extending fins  162 . The LED driver and socket assembly  132  further includes a compression spring  150 , a retention collar  140 , a ceramic insulator gasket  130 , an adapter  120  and a standard Edison screw base  110 . The adapter  120  is configured for attaching the LED driver assembly to the standard Edison screw base  110 . Self-tapping screws  112  and  114  attach the adapter  120  to the first LED and driver board heat sink  160 . Self-tapping screws  182  and  184  attach the LED Platen  180  to the first LED and driver board heat sink  160 .  FIG. 6  illustrates a complete exploded assembly view of the first embodiment of the LED lamp  100 . 
     The present embodiment includes a plurality of heat sinks as the design is configured to remove as much heat out as possible. It is contemplated that additional heat sinks and other configurations may be utilized to accomplish the objective of removing heat. The specific design illustrated herein is not set forth in a limiting sense but simply as an embodiment of a design comprising multiple heat sinks, including, LED array heat sink back plate  188 , the first LED and driver board heat sink  160  and the exterior aluminum heat sink  124 . It is also contemplated that lamp configurations that do not include LEDs as a lighting source or may not require heat reduction components may be configured without heat sink components. 
     As illustrated m  FIG. 7 , the embodiment illustrated includes a focal length adjustment assembly  122  that may be manipulated to engage one of a first, second or third beam adjustment notches  134 ,  136 ,  138  that facilitate a change of the positioning of the LED driver and socket assembly  132  within the exterior aluminum heat sink  124  between three varying heights. When the LED driver and socket assembly  132  is pushed down into the interior of the exterior aluminum heat sink  124 , the focal length adjustment assembly  122  is pushed upward past the base  110  along with a retaining ring (not shown) that engages a grooved area positioned just atop the LED driver assembly to the base  110 . The LED driver assembly  132  is retained and comprises the spring loaded assembly illustrated. As illustrated, the focal length adjustment prong  128  engages the first beam adjustment notch  134 . When a user pulls the focal length adjustment collar  122  downward and turns it slightly to the right, as illustrated in  FIG. 8 , the user may adjust the device to another index point by causing the focal length adjustment prong  128  to engage the third beam adjustment notch  138 , thereby changing the location of the array of LEDs on the LED platen  180  within the parabolic reflector. The closer the array of LEDs on the LED platen  180  are to the lens  190 , the more a flood effect is created. Conversely, the further the array of LEDs on the LED platen  180  are from the lens  190 , retracted down into the parabolic reflector assembly, the narrower the light beam output. The embodiment illustrated in  FIGS. 1-9 , is configured to facilitate three indexed focal length adjustments that provide three different locations of the array LEDs within the parabolic reflector assembly. 
     An alternative embodiment of an LED lamp utilizing LED&#39;s in a chip format on a circuit board that are run at elevated voltages is illustrated in  FIGS. 10-14 .  FIG. 10  illustrates an exploded assembly view of a second embodiment of the LED lamp  200 . As illustrated, the top portion of the LED lamp is comprised of a glass parabola  290 , an LED driver and socket assembly  232 , and an exterior aluminum heat sink  224 . The LED driver and socket assembly  232  includes an LED Platen  280 , comprised of an array of LEDs  286  and a heat sink back plate  288  having a driver circuit board (not shown) mounted perpendicular thereto (as illustrated in FIG.  11 ) and sized to be positioned down inside of an LED and driver board heat sink  260 . As illustrated, the LED and driver board heat sink  260  is an extruded aluminum heat sink having a pentagonal configuration. The LED lamp&#39;s exterior aluminum heat sink  224  has a hollow interior configuration. A first end of heat sink  224  is configured for receiving the glass parabolic envelope  290  which is seated and permanently epoxied to the interior of the exterior aluminum heat sink  224 . A second end of the exterior aluminum heat sink  224  has a pentagonal aperture sized to receive the LED driver and socket assembly  232 . The exterior aluminum heat sink  224  also serves as focal length adjustment device when it is slidingly moved up and down the LED and driver board heat sink  260  and positioned at various locations by engaging the ball detent pin  256 , which extends through the pin aperture  268  in one of the beam adjustment index apertures  262 ,  264  and  266 . Because the glass parabolic envelope  290  is attached to heat sink  224 , when heat sink  224  is slidingly moved up and down the LED and driver board heat sink  260 , it causes the focal length of the array of LEDs  186  to be changed. It is contemplated that the plurality of beam adjustment index apertures may be any number, but in the present embodiment there are three, each of which are dictated by a first beam adjustment aperture  262 , a second beam adjustment aperture  264 , and a third beam adjustment aperture  266 . An adapter  220  is configured for attaching the heat sink  260  of LED driver assembly to a standard Edison screw base  210 . 
       FIG. 11  is an illustration of an exploded view of the LED driver and socket assembly  232  of the second embodiment. As illustrated, the LED driver and socket assembly  232  includes an LED Platen  280 , comprised of an array of LEDs  286  and a heat sink back plate  288  having the driver circuit board  270  mounted perpendicular thereto and sized to be positioned down inside of the LED and driver board heat sink  260 . As illustrated, the LED and driver board heat sink  260  is an extruded aluminum heat sink having a pentagonal configuration. On one of the pentagonal sides, the LED and driver board heat sink  260  includes indexing points  262 ,  264  and  266  which facilitate setting the relationship of the height of the array of LEDs in order to adjust the focal length. The LED driver and socket assembly  232  further includes an adapter  220  and a standard Edison screw base  110 . The adapter  120  is configured for attaching the LED driver assembly to the standard Edison screw base  110 . Self tapping screws  282  and  284  attach the LED Platen  280  to the LED and driver board heat sink  260  by screwing into apertures  286  and  288 . 
       FIG. 12  is a top view of a top view of the exterior aluminum heat sink  224 , illustrating the pentagonal hole in its bottom through which the LED driver and socket assembly  232  slides through. The ball detent pin  256 , configured for spring  254  retention, engages the beam adjustment index apertures  262 ,  264  and  266  to facilitate locating the relationship of the height of the array of LEDs to the glass parabola  290 . The ball detent pin  256  is held in with a retaining spring  254 . By retracting pin  256  a user may index the different adjustment index apertures  262 ,  264  and  266  on the pentagonal LED and driver board heat sink  260 . The LED driver and socket assembly  232  slides up and down through pentagonal aperture sized to receive the LED driver and socket assembly  232 . By simply pulling retracting pin  256  and either raising or lowering the LED driver and socket assembly  232  through the parabola  290  of the mirrored envelope, the focal point is changed. 
     As illustrated in  FIG. 13 , moving the LED driver and socket assembly  232  downward through the barrel of the parabolic reflector, the LED lamp  200  generates more of a spot beam pattern because the array of LEDs are positioned further away from the lens portion of the parabola  290 . And, as illustrated in  FIG. 14 , moving the LED driver and socket assembly  232  upward in the barrel of the glass parabola  290  causes the array of LEDs to be positioned closer to the lens portion of the parabola  290 , thereby creating an increased flood pattern. As illustrated, the retracting pin  256  is positioned into the third adjustment aperture  266 . 
     Another embodiment of a lamp configured to allow for the adjustment of the focal length of the lamp, in order to facilitate various beam spreads, is illustrated in  FIGS. 15 and 16 . As shown,  FIGS. 15 and 16  illustrates an assembled view of a third embodiment of an LED type lamp  300 . As illustrated, the LED lamp  300  is comprised of an outer casing  324  configured to also function as a secondary heat sink, a focal length adjustment collar  322 , an adapter  320  configured to attach the LED driver assembly to the standard Edison type screw-in base  310 , and a lens  390  fittingly connected to and positioned as a cap onto the outer casing  324 . An array of LEDs  386  are positioned on the LED platen  380 , which may be adjusted upward or downward as a result of the manipulation of the focal length adjustment collar  322 . The focal length adjustment collar  322  is a rotating ring configured with an adjustment prong  326  for shortening or lengthening the focal point of the light beam created by the array of LEDs  386 . 
     As illustrated, the top portion of the LED lamp is comprised of a lens  390 , an LED driver and socket assembly  332 , an exterior aluminum heat sink  360 , a focal length adjustment collar  322 , and a collar retention ring  320 . The LED driver and socket assembly  332  includes an LED Platen  380 , comprised of an array of LEDs  386  and a heat sink back plate  388 , with the driver circuit board (not shown) mounted perpendicular thereto and sized to be positioned down inside of driver board heat sink  360 . As illustrated, the first LED and driver board heat sink  360  is an extruded aluminum heat sink configured with longitudinally extending fins  362 . Over the top portion of the driver board heat sink  360  and underneath the LED platen  380  a compression spring  350  is positioned to provide linear stabilizing pressure between focal length adjustment collar  322  and outer casing  324  which is biased by spring  350  to allow the LED driver and socket assembly  332  to move linearly, causing the LED platen  380  to be moved closer to and/or further away from lens  390 . 
     The LED lamp&#39;s exterior aluminum heat sink  324  is also configured with longitudinally extending fins  346  on its exterior and on its interior is a plurality of conical shaped parabolic reflectors  342   a,    342   b,    342   c,    342   d,    342   e,    342   f,  each of which is approximately 25 mm in diameter and 28 mm in height and includes a blue parabolic reflector casting  344   a,    344   b,    344   c,    344   d,    344   e ,  344   f  along a portion of its interior surface. It is contemplated that the portion of the interior of the blue parabola surface,  344   b,    344   c,    344   d,    344   e,    344   f  has been polished out and/or inserted with a mirrored reflector. Alternatively, commercially available methods capable of generating a smooth reflector surfaces,  344   b,    344   c,    344   d,    344   e,    344   f  along the interior of the conical shaped parabolic reflectors  342   a,    342   b,    342   c,    342   d,    342   e,    342   f  may be used. The upper portion of the exterior aluminum heat sink  224  has a funnel shaped upper portion wherein the interior walls of the upper portion are angled inward facilitating the adjacent fitting of the plurality of conical shaped parabolic reflectors  342   a,    342   b,    342   c,    342   d,    342   e,    342   f  therein. The lower portion of the exterior aluminum heat sink  324  includes, on its exterior, a plurality of beam adjustment notches  328  each configured to be engaged by a focal length adjustment arm  326  which extends from focal length adjustment collar  322 . The focal length adjustment collar  322  causes the focal length of the array of LEDs  386  to be changed when the focal length adjustment arm  326  which extends from focal length adjustment collar  322  engages one of the plurality of beam adjustment notches  328 . Although the present embodiment illustrates five beam adjustment notches  328  on the lower portion of the exterior aluminum heat sink  324 , it is contemplated that the of plurality of beam adjustment notches  328  may be of any number. It is also contemplated that the focal length adjustment collar  322  and the exterior aluminum heat sink  324  may be configured to allow for a plurality of smaller increments that may be engaged by a sliding configuration that facilitates smaller incremental changes in the distance between the array of LEDs  386  and the lens  390 . 
     Reference may be made throughout this specification to “one embodiment,” “an embodiment,” “embodiments,” “an aspect,” or “aspects” meaning that a particular described feature, structure, or characteristic may be included in at least one embodiment of the present invention. Thus, usage of such phrases may refer to more than just one embodiment or aspect. In addition, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments or aspects. Furthermore, reference to a single item may mean a single item or a plurality of items, just as reference to a plurality of items may mean a single item. Moreover, use of the term “and” when incorporated into a list is intended to imply that all the elements of the list, a single item of the list, or any combination of items in the list has been contemplated. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the application claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the application claims if they have structural elements that do not differ from the literal language of the application claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the application claims. 
     One skilled in the relevant art may recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, resources, materials, etc. In other instances, well known structures, resources, or operations have not been shown or described in detail merely to avoid obscuring aspects of the invention. 
     While example embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise configuration and resources described above. Various modifications, changes, and variations apparent to those skilled in the art may be made in the arrangement, operation, and details of the methods and systems of the present invention disclosed herein without departing from the scope of the application claims.