Patent Publication Number: US-10774994-B2

Title: Spotlight apparatus and manufacturing method thereof

Description:
FIELD OF INVENTION 
     The present invention is related to a spotlight apparatus and manufacturing method thereof and more particularly related to a LED spotlight apparatus and manufacturing method thereof. 
     BACKGROUND 
     Spotlight devices are widely used in various areas, including to better show a painting or a portion of a dinner table. However, spotlight devices usually takes higher price and thus making them less adopted than needed. Current spotlight devices usually have more complicated structures and thus make them having higher cost. 
     Therefore, it would be a technical challenge to design a simpler structure of spotlight device and would be even better if heat dissipation and assembling factors are also considered in such design. 
     SUMMARY OF INVENTION 
     According to a first embodiment of the present invention, a spotlight apparatus has a LED plate, a lens plate, a cup body and a driver plate. 
     The LED plate has a plurality of LED modules, a metal plate and two connectors. The plurality of LED modules and the two connectors are mounted on the metal plate. The LED modules may each be a single LED chip or multiple LED chips formed as a module. 
     A lens plate has a central lens and a plurality of micro optical structures around the central lens. Different lens plate may be prepared for generating spotlight apparatuses with different light beam characteristics while the other components kept unchanged. 
     Therefore, a detachable connection structure like screw or clips may be designed so that users may change a different lens plate to fit their needs. For example, a user may buy such spotlight apparatus with a number of lens plates with different central lens settings. The user may replace the default lens plate with another lens plate, e.g. to emit a more wide light beam or a narrower light beam. In addition, different colors of lens plate may be designed so that users may change a different color filter to affect the light beam from such spotlight apparatus. 
     The cup body has a dome portion, a tube portion and a bottom portion. The dome portion and the tube portion are manufactured together as a single body. The lens plate is fixed to a top peripheral end of the dome portion of the cup body. The LED plate is disposed inside the dorm portion so that a portion of light emitting from the LED modules running through the central lens of the lens plate to form a focus light beam and another portion of light emitting from the LED modules running through the plurality of micro optical structures to form soft light. The plurality of micro optical structures may be designed to diffuse the light or made of tiny cave, blocks or dots. The central lens may also be made of multiple lens structures instead of a single lens. 
     The driver plate contains driver circuits, two output terminals and two input terminals. 
     The two metal pins are integrated to the bottom portion of the cup body. The two input terminals of the driver plate are inserted into the two metal pins and the two output terminals connected to the LED plate. 
     In a specific example, there is a neck portion between the dorm portion and the tube portion. There is a first distance between where the LED plate is disposed and the neck portion. There is a second distance between the top peripheral and the neck portion. The first distance is smaller than half of the second distance and larger than one fourth of the second distance. 
     In another specific example, there are diffusion optical structures formed on the dorm portion and the tube portion, e.g. to increase overall light output and to prevent visual exposing of the components of the spotlight apparatus. 
     In another specific example, the two metal pins have openings respectively for receiving the two input terminals of the driver plate. In other words, the two input terminals may not need to be welded but just plugged into the metal pins. This helps significant decrease manufacturing cost. 
     In another specific example, the two metal pins are metal hollow tubes. For example, the two metal pins are cylinder shape with central opening. 
     In another specific example, a portion of the input terminals of the driver plate is deformed when the input terminals are inserted into the openings of the two metal pins to keep better connection between the input terminals and the two metal pins. The input terminal may be made with elastic metal so that when the input terminals are plugged into the metal pins, the input terminals has form changing and increasing force to fix to the metal pins. 
     In another specific example, the two metal pins are molded with the bottom portion of the cup body. For example, the metals are not connected to the bottom portion of the cup body by screw structures. Instead, the metal pins are placed in a molding device while molding the bottom portion of the cup body. 
     In a specific example, the dome portion, the tube portion and the bottom portion of the cup body are together formed with Polycarbonate (PC) material as a single body. Please note that other plastic or material may be adopted if they allow light to go through. 
     In another specific example, the two metal pins are inserted in a molding device when the molding device is used for produce the cup body so that the two metal pins are molded with the bottom portion of the cup body. 
     In a specific example, the lens plate is made of Polycarbonate material as a single body. In other words, the cup body and the lens plate may be made of same PC material thus making the overall cost even lower. 
     In a specific example, the tube portion of the cup body has a track trench for guiding and inserting the driver plate. With such design, the driver plate may be reliably fixed to the tube portion of the cup body. 
     In a specific example, the driver plate has a base plate with metal material for heat dissipation. For example, the base plate may be made of aluminum. 
     To further increase heat dissipation, heat dissipation gel may be applied between the track trench and the driver plate to enhance heat dissipation. 
     Alternatively, heat dissipation glue may be applied between the track trench and the driver plate to enhance heat dissipation and connection reliability between the track trench and the driver plate. 
     In a specific example, the lens plate has a transparent hollow cup facing the LED modules. 
     According to another embodiment of the present invention, a method for manufacturing a spotlight apparatus has following steps. 
     Two metal pins are placed in a molding device. 
     A cup body is formed with the molding device. The cup body has a dorm portion, a tube portion and a bottom portion. In addition, the two metal pins are molded with the bottom portion. 
     A driver plate is placed in the cup body so that two input pins of the driver plate are inserted into the two metal pins. 
     A LED plate is mounted on the driver plate so that two output terminals of the driver plate are electrically connected to the LED plate. 
     A lens plate is placed to a top peripheral end of the dome portion of the cup body. 
     In a specific example of the method, the cup body is made of Polycarbonate material. 
     In a specific example of the method, the tube portion of the cup body has a track trench for guiding and inserting the driver plate. 
     In a specific example of the method, the metal pins two metal pins are two metal hollow tubes, and the two input terminals of driver plate are inserted into the two metal hollow tubes. 
     In a specific example of the method, the lens plate has a central lens and a plurality of micro optical structures so that a portion of light emitting from the LED plate running through the central lens of the lens plate to form a focus light beam and another portion of light emitting from the LED plate running through the plurality of micro optical structures to form soft light. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  illustrates an exploded diagram of components of a spotlight apparatus embodiment according to the present invention. 
         FIG. 2A  illustrates an embodiment of a lens plate. 
         FIG. 2B  illustrates side view of  FIG. 2A . 
         FIG. 3  illustrates a cup body embodiment. 
         FIG. 4  illustrates a diagram of metal pins and input terminals. 
         FIG. 5  is a side view of the spot light embodiment of  FIG. 1  when the spotlight is assembled. 
         FIG. 6  is a flowchart for illustrating a method for manufacturing a spotlight apparatus. 
     
    
    
     DETAILED DESCRIPTION 
     Please refer to  FIG. 1  and  FIG. 5 .  FIG. 1  illustrates an exploded diagram of components of a spotlight apparatus.  FIG. 5  illustrates a side view of cross-sectional diagram of the components of  FIG. 1  when they are assembled together. 
     The spotlight apparatus has a LED plate  103 , a lens plate  101 , a cup body  105 , a driver plate  104 , a pair of screws  102  for fixing the components. 
     The LED plate  103  has a plurality of LED modules, a metal plate and two connectors. The plurality of LED modules and the two connectors are mounted on the metal plate. The LED modules may each be a single LED chip or multiple LED chips formed as a module. 
     Please refer to  FIG. 2A  and  FIG. 2B , which illustrate a lens plate example. In  FIG. 2A  and  FIG. 2B , the lens plate is a circular shape and has a central lens  201  and a plurality of micro optical structures  202  around the central lens. Micro optical structures are patterns including concave or other structure that may guide or change light paths to achieve certain optical effect.  FIG. 2B  is a side view of  FIG. 2A . The lens plate  20  has a transparent hollow cup  203  structure for guiding light entering the central lens  201 . The central lens  201  may be made of a single lens or multiple lens that generates the effect of creating a spotlight beam. 
     Different lens plate may be prepared for generating spotlight apparatuses with different light beam characteristics while the other components kept unchanged. 
     Therefore, a detachable connection structure like screw or clips may be designed so that users may change a different lens plate to fit their needs. For example, a user may buy such spotlight apparatus with a number of lens plates with different central lens settings. The user may replace the default lens plate with another lens plate, e.g. to emit a more wide light beam or a narrower light beam. In addition, different colors of lens plate may be designed so that users may change a different color filter to affect the light beam from such spotlight apparatus. 
     Please refer back to  FIG. 1 . The cup body  105  has a dome portion  1051 , a tube portion  1053  and a bottom portion, which facing to and integrated with two metal pins  1054 . The dome portion  1051  and the tube portion  1053  are manufactured together as a single body. The lens plate  101  is fixed to a top peripheral end of the dome portion  1051  of the cup body  105 . The LED plate  103  is disposed inside the dorm portion  1051  so that a portion of light emitting from the LED modules running through the central lens of the lens plate  101  to form a focus light beam and another portion of light emitting from the LED modules running through the plurality of micro optical structures to form soft light. The plurality of micro optical structures may be designed to diffuse the light or made of tiny cave, blocks or dots. The central lens may also be made of multiple lens structures instead of a single lens. 
     The driver plate  104  contains driver circuits, two output terminals and two input terminals. 
     The two metal pins  1054  are integrated to the bottom portion of the cup body  105 . The two input terminals  1041  of the driver plate  104  are inserted into the two metal pins  1054  and the two output terminals  1042  connected to the LED plate  103 . 
     In a specific example, there is a neck portion  1052  between the dorm portion and the tube portion. 
     Please also refer to  FIG. 3 . There is a first distance  302  between where the LED plate  312  is disposed and the neck portion  311 . There is a second distance  301  between the top peripheral  313  and the neck portion  311 . The first distance  302  is smaller than half of the second distance  301  and larger than one fourth of the second distance  301 . For example, the first distance  302  is about ⅓ of the second distance  301 . Such arrangement makes both light efficiency and heat dissipation for leaving space for heat movement. 
     In another specific example, there are diffusion optical structures formed on the dorm portion and the tube portion, e.g. to increase overall light output and to prevent visual exposing of the components of the spotlight apparatus. 
     In another specific example, the two metal pins have openings respectively for receiving the two input terminals of the driver plate. In other words, the two input terminals may not need to be welded but just plugged into the metal pins. This helps significant decrease manufacturing cost. 
     In another specific example, the two metal pins are metal hollow tubes. For example, the two metal pins are cylinder shape with central opening. 
     In another specific example, a portion of the input terminals of the driver plate is deformed when the input terminals are inserted into the openings of the two metal pins to keep better connection between the input terminals and the two metal pins. The input terminal may be made with elastic metal so that when the input terminals are plugged into the metal pins, the input terminals has form changing and increasing force to fix to the metal pins. 
     In another specific example, the two metal pins are molded with the bottom portion of the cup body. For example, the metals are not connected to the bottom portion of the cup body by screw structures. Instead, the metal pins are placed in a molding device while molding the bottom portion of the cup body. 
     In a specific example, the dome portion, the tube portion and the bottom portion of the cup body are together formed with Polycarbonate (PC) material as a single body. Please note that other plastic or material may be adopted if they allow light to go through. 
     Please refer to  FIG. 4 , which illustrates interaction between an input terminal of a driver plate  401  and a metal pins  402 . The front end of the input terminal is inserted into a hole of the metal pins  402 . In addition, a deformation of the inserted portion of the input terminal  401  would help fixing better for the input terminal  401  and the metal pins  402 . In another specific example, the two metal pins are inserted in a molding device when the molding device is used for produce the cup body so that the two metal pins are molded with the bottom portion of the cup body. 
     In a specific example, the lens plate is made of Polycarbonate material as a single body. In other words, the cup body and the lens plate may be made of same PC material thus making the overall cost even lower. 
     In a specific example, the tube portion of the cup body has a track trench for guiding and inserting the driver plate. With such design, the driver plate may be reliably fixed to the tube portion of the cup body. 
     In a specific example, the driver plate has a base plate with metal material for heat dissipation. For example, the base plate may be made of aluminum. 
     To further increase heat dissipation, heat dissipation gel may be applied between the track trench and the driver plate to enhance heat dissipation. 
     Alternatively, heat dissipation glue may be applied between the track trench and the driver plate to enhance heat dissipation and connection reliability between the track trench and the driver plate. 
     In a specific example, the lens plate has a transparent hollow cup facing the LED modules. 
     Please refer to  FIG. 6 , which is a flowchart illustrating a method for manufacturing a spotlight apparatus that has following steps. 
     Two metal pins are placed in a molding device (step  601 ). 
     A cup body is formed with the molding device (step  602 ). The cup body has a dorm portion, a tube portion and a bottom portion. In addition, the two metal pins are molded with the bottom portion. 
     A driver plate is placed in the cup body (step  603 ) so that two input pins of the driver plate are inserted into the two metal pins. 
     A LED plate is mounted on the driver plate (step  604 ) so that two output terminals of the driver plate are electrically connected to the LED plate. 
     A lens plate is placed (step  605 ) to a top peripheral end of the dome portion of the cup body. 
     In a specific example of the method, the cup body is made of Polycarbonate material. 
     In a specific example of the method, the tube portion of the cup body has a track trench for guiding and inserting the driver plate. 
     In a specific example of the method, the metal pins two metal pins are two metal hollow tubes, and the two input terminals of driver plate are inserted into the two metal hollow tubes. 
     In a specific example of the method, the lens plate has a central lens and a plurality of micro optical structures so that a portion of light emitting from the LED plate running through the central lens of the lens plate to form a focus light beam and another portion of light emitting from the LED plate running through the plurality of micro optical structures to form soft light. 
     Please be noted that other variations based on the same inventive spirit should be regarded falling within the protection scopes of the present invention. For example, the metal pins mentioned above may be designed as screw with associated screw grooves on the bottom portion of the cup body. Other ways for integrating the metal pins with the bottom portion of the cup body may also be adopted under different design needs. 
     The embodiments mentioned above should not be interpreted as limitation for the present invention. Persons of ordinary skilled in the art would be able to create equivalent designs under protection scopes.