Patent Publication Number: US-2016238199-A1

Title: Light bulb with led symbols

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/116,562, filed Feb. 16, 2015, the entire content of which is hereby incorporated by reference. 
    
    
     FIELD OF THE TECHNOLOGY 
     The present application relates to a light bulb with light-emitting diode (LED) symbols. 
     BACKGROUND 
     In old times, incandescent light bulb is a major lighting equipment. But its efficiency is low. Lots of energy is wasted in the form of heat. 
     So, the global trend of the lighting equipment is from incandescent bulb to compact fluorescent light (CFL) bulb, and then to LED bulb. However, the CFL bulb includes mercury which is toxic and LED bulb is most energy efficient. 
     Referring to  FIG. 1 , at present, most LED light bulbs are developed for general lighting purpose, where brightness is the main concern for consumers. 
     On the other hand, there are still some special designs of LED light bulbs or lighting fixtures which provide only decorative purpose, as shown in  FIG. 2 . However, their LED light sources are large, bulky and having big discrete bright spots (light glare), which make them not beautiful enough. 
     The above description of the background is provided to aid in understanding the light bulb with LED symbols, but is not admitted to describe or constitute pertinent prior art to the light bulb with LED symbols, or consider any cited documents as material to the patentability of the claims of the present application. 
     SUMMARY 
     According to one aspect, there is provided a light bulb with LED symbols which may include a light bulb shell, at least one LED light source, a driver, and an electrical connector. The LED light source may include at least one LED substrate with a plurality of LED chips mounted thereon, and the at least one LED substrate has a shape of a pattern, letter, word, logo, character or sign. The light bulb shell can be vacuum sealed so as to form a vacuum sealed chamber, which is filled with a gas having a low coefficient of viscosity and a high coefficient of thermal conductivity. The LED light source can be housed in the vacuum sealed chamber, and the LED light source may be electrically connected to the driver via a pair of electrical wires. The driver can be connected to the electrical connector. 
     The light bulb with LED symbols may further include a core column with an exhaust tube and a bracket. The bracket of the core column may be housed in the vacuum sealed chamber and may hold the pair of electrical wires for fixing the LED light source. The LED light source may include first and second electrodes which are electrically connected to the driver and the electrical connector disposed outside of the vacuum sealed chamber via the electrical wires. 
     In one embodiment, the light bulb shell is capable of transmitting light and connected to the electrical connector directly or by a connecting piece. 
     In one embodiment, each LED light source may include at least one series of LED chips connected in series or in parallel. The LED chips may be connected to the first and second electrodes at two ends of the LED light source. 
     In one embodiment, the at least one LED substrate may be transparent, semi-transparent or non-transparent, and may be made of a material selected from a group consisting of metal, soft glass, hard glass, quartz glass, transparent ceramic and plastic. 
     In one embodiment, the at least one LED substrate and the LED chips may be partly or thoroughly coated with a phosphor coating. 
     In one embodiment, the at least one LED substrate can be formed into a 3-dimensional shape. 
     In one embodiment, a plurality of the LED substrates may be connected with each other by a connector and formed into a 2-dimensional or 3-dimensional shape. 
     In one embodiment, the at least one LED substrate may include a printed circuit, such that the LED chips can be connected with each other through the printed circuit. 
     In one embodiment, the first electrode may be provided at one end of the LED substrate, and the LED substrate itself acts as the second electrode. 
     In one embodiment, the LED substrate may be transparent and the LED chips may emit 4π light. The die bonding material for bonding the LED chips to the LED substrate may be transparent. 
     In one embodiment, the pair of electrical wires may be mounted on a heat releasing part, and the heat releasing part may be connected with the light bulb shell at a lower portion thereof such that the LED light source is fixed inside the light bulb shell via the pair of electrical wires. 
     In one embodiment, the electrical connector can be any one of the electrical connectors of E40, E27, E26, E14, GU, BX, BA, EP, EX, GY, GX, GR, GZ, and G types of a conventional light bulb. 
     In one embodiment, the light bulb shell may be transparent, creamy, frosted or colored. 
     In one embodiment, a part of the light bulb shell may include a reflective layer, or a series of prisms or lens. 
     In one embodiment, the light bulb shell may have a shape selected from a group consisting of A, G, R, PAR, T, candle, P, PS, BR, ER, and BRL type. 
     According to another aspect, there is provided a method for manufacturing a light bulb with LED symbols which may include preparing an LED substrate in a shape of a symbol;
         fixing a pair of electrodes to two ends of the LED substrate;   fixing a plurality of LED chips onto the LED substrate by a die bonding material, the LED chips being connected to one another and connected to the electrodes by LED connecting wires to form an LED light source;   coating the LED substrate, the LED chips and the LED connecting wires with a photo luminescent powder layer;   connecting the electrodes to a pair of electrical wires such that the LED light source can be fixed onto the electrical wires;   forming a vacuum sealed chamber with the LED light source mounted therein, and filling the vacuum sealed chamber with a gas having a low coefficient of viscosity and a high coefficient of thermal conductivity;   connecting the electrical wires with a driver; and   connecting the driver with an electrical connector by a plurality of driver connecting wires.       

     The method may further include forming the LED substrate into a 3-diemnsional shape by twisting, bending or pulling. 
     Although the light bulb with LED symbols is shown and described with respect to certain embodiments, it is obvious that equivalents and modifications will occur to others skilled in the art upon the reading and understanding of the specification. The light bulb with LED symbols in the present application includes all such equivalents and modifications, and is limited only by the scope of the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Specific embodiments of the light bulb with LED symbols will now be described by way of example with reference to the accompanying drawings wherein: 
         FIGS. 1-2  show LED light bulbs of the prior art. 
         FIG. 3  shows the structure of a light bulb with LED symbols according to an embodiment of the present application. 
         FIG. 4  shows the structure of an LED light source according to an embodiment of the present application. 
         FIG. 5  is a cross sectional view of an LED chip being mounted on an LED substrate according to an embodiment of the present application. 
         FIGS. 6-7  show LED substrates having different shapes. 
         FIG. 8  shows LED light sources electrically connected to each other by connectors. 
         FIG. 9  shows the structure of a connector according to an embodiment of the present application. 
         FIG. 10  shows a light bulb with three LED light sources connect with each other by connectors according to an embodiment of the present application. 
         FIG. 11  shows the LED light source only having one electrode at one end of the LED substrate and the LED substrate acts as another electrode according to an embodiment of the present application. 
         FIG. 12  shows an LED substrate in 3-dimensional shape by twisting, bending or pulling. 
         FIG. 13  shows LED light sources electrically connected to each other by connectors, forming a three-dimensional shape. 
         FIG. 14  shows the structure of a light bulb with LED symbols according to another embodiment of the present application. 
         FIG. 15  shows a light bulb shell formed with a series of lens and a reflective layer according to one embodiment of the present application. 
         FIG. 16  shows a light bulb shell formed with a series of prisms according to one embodiment of the present application. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to a preferred embodiment of the light bulb with LED symbols, examples of which are also provided in the following description. Exemplary embodiments of the light bulb with LED symbols are described in detail, although it will be apparent to those skilled in the relevant art that some features that are not particularly important to an understanding of the light bulb with LED symbols may not be shown for the sake of clarity. 
     Furthermore, it should be understood that the light bulb with LED symbols is not limited to the precise embodiments described below and that various changes and modifications thereof may be effected by one skilled in the art without departing from the scope of the protection. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of this disclosure and appended claims. 
     In addition, improvements and modifications which may become apparent to persons of ordinary skill in the art after reading this disclosure, the drawings, and the appended claims are deemed within the scope of the protection. 
     It should be noted that throughout the specification and claims herein, when one element is said to be “coupled” or “connected” to another, this does not necessarily mean that one element is fastened, secured, or otherwise attached to another element. Instead, the term “coupled” or “connected” means that one element is either connected directly or indirectly to another element or is in mechanical or electrical communication with another element. 
     The present application is to provide a light bulb which contains light-emitting diode (LED) symbols for both general lighting and decorative purposes. As used herein, the term “symbol” includes but is not limited to pattern, letter, word, logo, character and sign. The LED symbols can be very small and can emit light continuously without any light glare. 
     As shown in  FIGS. 3-5 , according to an embodiment of the present application, the light bulb with LED symbols may include a light bulb shell  12 , a core column  14  with an exhaust tube  16  and a bracket  18 , at least one LED light source  20 , a driver  22 , and an electrical connector  24 . 
     The LED light source  20  may include at least one LED substrate  30  with a plurality of LED chips  32  mounted thereon. The LED substrate  30  may be in the shape of a pattern, letter, word, logo, character, or sign. The LED substrate  30  may be made of metal, soft glass, hard glass, quartz glass, transparent ceramic, plastic, or any other suitable material. The LED substrate  30  may be transparent, semi-transparent or non-transparent. The LED light source  20  may include a first electrode  34  and a second electrode  36 . 
     The LED light bulb shell  12  can be vacuum sealed with the core column  14  so as to form a vacuum sealed chamber, which is filled with a gas having a low coefficient of viscosity and a high coefficient of thermal conductivity. The bracket  18  and the LED light source  20  fixed thereon can be housed in the vacuum sealed chamber. 
     The LED light source  20  may be electrically connected to the driver  22  via a pair of electrical wires  26 . The driver  22  may be in turn connected to the electrical connector  24 . The electrical connector  24  may be electrically connected to an external power supply so as to light the LED light source  20 . 
     The first and second electrodes  34 ,  36  of the LED light source  20  may be connected to the core column  14  via the pair of electrical wires  26  such that the LED light source  20  can be firmly fixed onto the electrical wires  26 . The light bulb shell  12  and the core column  14  can be fused at their joining position by high-temperature heating process. Thereafter, they can be vacuum sealed so as to form the vacuum sealed chamber, and the vacuum sealed chamber can be filled with a gas having a low coefficient of viscosity and a high coefficient of thermal conductivity, e.g. He, H 2 , or a mixed gas of He and H 2 . The driver  22  may be connected to the electrical connector  24  by driver connecting wires  28 . The electrical wires  26  of the core column  14  may be connected to the driver  22 , and in turn connected to the electrical connector  24 . Finally, the electrical connector  24  can be fixed to the light bulb shell  12 . The light bulb shell  12  may be connected to the electrical connector  24  directly or by a connecting piece  25 . 
     To manufacture the LED light source  20 , the LED substrate  30  in the shape of a symbol is prepared. The electrodes  34 ,  36  may then be fixed to two ends of the LED substrate  30  by high temperature glue, plastics, sliver slurry, low melting glass or electrode connector. The LED chips  32  may be fixed onto the LED substrate  30  by a die bonding material  33  such as silicon glue, modified resin, epoxy resin or silver epoxy. The LED chips  32  can be connected to one another and connected to the electrodes  34 ,  36  by LED connecting wires  38 . The LED chips  32  can be connected in series or in parallel. Lastly, the LED substrate  30 , the LED chips  32  and the LED connecting wires  38  can be partly or thoroughly coated with a photo luminescent powder layer or a phosphor coating  35 . 
     Each LED light source  20  may include at least one series of LED chips  32  connected in series or in parallel. The LED chips  32  may be connected to the electrodes  34 ,  36  at two ends of the LED light source  20 . 
     The LED substrate  30  may include a printed circuit, such that the LED chips  32  may be connected with one another through the printed circuit. 
     The LED substrate  30  may be transparent and the LED chips  32  can emit 4π light. The die bonding material  33  for bonding the LED substrate  30  and the LED chips  32  together may be transparent. 
     As shown in  FIGS. 6-7 , the LED substrate  30 ′,  30 ″ may be of different shapes, e.g. circle, triangle, rectangle, letters, etc. 
     Apart from the integrally formed LED light source  20  in  FIGS. 4, 6 and 7 , several individual LED light sources  30   a ,  30   b ,  30   c  can be electrically connected to one another using connectors  40  and formed into a 2-dimensional shape, as shown in  FIG. 8 . 
     As shown in  FIG. 9 , the connector  40  may have a plastic (non-conductive) housing  42  and a metal core  44  inside. When the electrodes  34 ,  36  of the LED light sources  20  are plugged into the connector  40 , as shown by the arrows, they can be electrically connected to each other via the metal core  44 . 
       FIG. 10  shows a light bulb with the three LED light sources  30   a ,  30   b ,  30   c  connected together by three connectors  40 . 
     As shown in  FIG. 11 , the LED light source  20  may have the first electrode  34  provided at one end of the LED substrate  20 , and the LED substrate  30  itself can act as the second electrode. 
     As illustrated in  FIG. 12 , the LED substrate  30  can be formed into a three-dimensional shape by twisting, bending or pulling. 
     As shown in  FIG. 13 , several LED light sources  20  may be electrically connected to one another using connectors  40 , and formed into a three-dimensional shape. 
     As depicted in  FIG. 14 , according to another embodiment of the present application, the light bulb with LED symbols may include an LED light source  120  with first and second electrodes  134 ,  136  at two ends thereof, a heat releasing part  116  with a pair of electrical wires  126 , a light bulb shell  112 , a driver  122 , and an electrical connector  124 . 
     The electrodes  134 ,  136  of the LED light source  120  can be connected and firmly fixed to the electrical wires  126  of the heat releasing part  116 . The pair of electrical wires  126  may be mounted on the heat releasing part  116 . The heat releasing part  116  may be connected with the light bulb shell  112  at a lower portion thereof such that the LED light source  120  can be fixed inside the light bulb shell  112  via the pair of electrical wires  126 . 
     The heat releasing part  116  may be made of a material which has high thermal conductivity but electrically non-conductive. The driver  122  may be connected to the electrical connector  124  by driver connecting wires  128 . The electrical wires  126  of the heat releasing part  116  may be connected to the driver  122 , and in turn connected to the electrical connector  124 . Lastly, the electrical connector  124  can be connected to the light bulb shell  112  through a connecting piece  125 . 
     The electrical connector  24 ,  124  may be any one of the electrical connectors of E40, E27, E26, E14, GU, BX, BA, EP, EX, GY, GX, GR, GZ, and G types of a conventional light bulb. 
     The light bulb shell  12 ,  112  may be transparent, creamy, frosted or colored. The light bulb shell  12 ,  112  may have the shape of A, G, R, PAR, T, candle, P, PS, BR, ER, or BRL type. A part of the light bulb shell  12 ,  112  may have a reflective layer, or a series of small prisms or lens. As illustrated in  FIG. 15 , the light bulb shell  12  may be formed with a plurality of lens  50  for light refraction. A reflective layer  52  may also be formed on an inner surface of the light bulb shell  12  for reflection of light from the LED light source  20 . As illustrated in  FIG. 16 , the light bulb shell  12  may be formed with a series of prisms  54  for light refraction. 
     While the light bulb with LED symbols has been shown and described with particular references to a number of preferred embodiments thereof, it should be noted that various other changes or modifications may be made without departing from the scope of the appended claims.