Patent Publication Number: US-2011050133-A1

Title: LED Lamps with Packaging as a Kit

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Ser. No. 61/237,686, entitled “LED Lamps with Packaging as a Kit,” filed by Grajcar, et al. on Aug. 28, 2009, the entire contents of which are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     Various embodiments relate generally to lighting systems that include light emitting diodes (LEDs), and some embodiments relate to LED lamp packaging. 
     BACKGROUND 
     LEDs are widely used device capable of illumination when supplied with current. Typically, an LED is formed as a semiconductor diode having an anode and a cathode. In theory, an ideal diode will only conduct current in one direction. When sufficient forward bias voltage is applied between the anode and cathode, conventional current flows through the diode. Forward current flow through an LED may cause photons to recombine with holes to release energy in the form of light. 
     The emitted light from some LEDs is in the visible wavelength spectrum. By proper selection of semiconductor materials, individual LEDs can be constructed to emit certain colors (e.g., wavelength), such as red, blue, or green, for example. 
     In general, an LED may be created on a conventional semiconductor die. An individual LED may be integrated with other circuitry on the same die, or packaged as a discrete single component. Typically, the package that contains the LED semiconductor element will include a transparent window to permit the light to escape from the package. 
     SUMMARY 
     Apparatus and methods for re-usable packaging of a lighting product include providing a container body to receive an electric lamp and a cover that can be repeatedly sealed and unsealed to the container. In an illustrative example, the lamp may be an AC LED lamp substantially located within the container body by a lamp locating feature on a bottom interior surface of the container body. In some embodiments, an interior surface of the lid may provide a projecting feature configured to positively retain the lamp in the lamp locating feature when the lid is installed on the container body. In various embodiments, the container body and the container lid may advantageously provide a protective package that may be sold as a kit, and may further provide a durable and reusable general purpose container system that may, for example, substantially reduce an environmental footprint associated with lamp packaging. 
     In some examples, apparatus and associated methods may involve an LED lamp assembly, alone or in a reusable package as a kit. In an illustrative example, a re-usable container with a screw-on lid may contain an LED lamp. In some examples, the container may be transparent and permit visual inspection of the LED lamp assembly from 360 degrees in a plane. The container may, in some examples, be formed substantially primarily from recycled materials. Various embodiments of the container may be stackable with similar containers for ready display on a retail shelf, for example. 
     Various embodiments may achieve one or more advantages. For example, some embodiments may substantially reduce cost, size, component count, weight, and/or improve reliability of a LED packaged for retail sale. Various embodiments may achieve significant reductions in carbon footprint and waste stream, hazardous chemical use, and/or life cycle energy consumption. For example, packaging may be readily re-used as a container for a wide variety of small items. In some examples, one or more components of a packaged kit may be substantially biodegradable. 
     In some embodiments, an LED lamp may be advantageously constructed for improved thermal management performance and features, reduced manufacturing complexity and cost, and/or reduced component count. In particular examples, and without limitation, an LED lamp may be in a GU  10  or a PAR  30  form factor. 
     The details of various embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1-9  depict construction and arrangement of an exemplary LED lamp in a GU  10  form factor. 
         FIGS. 10-13  depict exemplary packaging and an LED lamp in GU  10  form factor arranged as a kit. 
         FIGS. 14-20  depict construction and arrangement of an exemplary LED lamp in a PAR  30  form factor. 
         FIGS. 21-24  depict exemplary packaging and an LED lamp in PAR  30  form factor arranged as a kit. 
     
    
    
     Like reference symbols in the various drawings indicate like elements. 
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
       FIGS. 1-9  depict construction and arrangement of an exemplary LED lamp in a GU  10  form factor.  FIGS. 1-2  show perspective views of an exemplary LED lamp  100 . The lamp  100  includes a base  105 , a pair of terminals  110 , a body  120 , and a lens  125 . The body  120  and the lens  125  define a light chamber in which an LED may be disposed. When the pair of terminals are coupled to an electric power source (e.g., AC, DC voltage or current), the LED may respond by generating light. A reflector in the body  120  may generally direct the light from the LED substantially outward from the lens  125 . 
       FIG. 3A  depicts an exemplary LED arranged on a printed circuit board (PCB) assembly that may form part of a light engine in the lamp  100 . A sub-assembly  300  includes an LED package  305  and a substrate  310 . The substrate  310  may include driver circuitry and/or connections to a power source, for example, to form a light engine. In an illustrative example, the substrate  310  may include circuitry that may cooperate with the LED  305  to operate as a light engine. In some examples, the substrate  310  may provide substantial thermal conduction from the LED package  305  to a heat spreading element. In an illustrative example, the substrate  310  may include a metallic layer to provide substantially low thermal impedance to promote heat conduction. Some embodiments may implement the assembly  300  using a printed circuit board (PCB) with an aluminum backing as the substrate  310 . The PCB may, for example, include metal (e.g., copper) area fills and or traces to make surface mount connection to terminals or heat conduction pads of the LED package. The metal fills may provide a substantially reflective surface to promote reflection of light in the light chamber toward the lens  125 . 
     The depicted substrate  310  in this example includes a pair of cut-outs  315 . In some examples, the cut-outs  315  may provide a channel to route electrical connections between the LED package  305  and a driver circuit and/or power source, for example. In some implementations the cut-outs  315  may receive fasteners (e.g., screws, clips, rivets) to mount the assembly  300  to the base  105 . 
       FIG. 3B  shows an exemplary apparatus  350  to make thermal connection between a heat spreading element (not shown) and a bottom portion of the LED package. Examples of a heat spreading element in thermal communication with the exemplary apparatus  350  are described with reference to, for example, at least  FIG. 5 . Referring to  FIG. 1 , the depicted apparatus  350  may further make electrical connection between the LED package  305  and the terminals  110  in the base  105 . 
     A flex circuit in this example provides electrical connection between the terminals  110  and electrical terminals of the LED package  305 . The apparatus  350  includes a flex circuit formed by an insulative film  355  with a proximal set of contacts for making electrical connection to terminals of the LED package  305 , a conductive layer  360  to provide electrical current paths from the proximal set of contacts to a distal set of contacts on the film  355 , and a second insulating film  365  opposite the film  355 . The distal set of contacts may make electrical interface to, for example, a driver circuit in the base  105 , for example, or directly to a connector interface to the input terminals  110 . The distal set of contacts may be inserted through a slot (not shown) in the substrate  310 , which slot may be located between the cutouts  315  and along a peripheral region of the substrate  310 . 
     In some embodiments, a portion of the flex circuit assembly ( 355 - 365 ) may be toroidal or other shape that defines an aperture under the LED package  305 . The aperture receives a raised central portion of a metal slug  370 , as shown in the depicted example, which may make substantial thermal contact or be in substantial thermal communication to a bottom surface of the LED package. Heat energy may transfer from the LED package to, for example, fastening hardware (e.g., screws, clips) that make direct contact with the metal slug. Heat energy may be transferred from the LED via the metal slug to a thermally conductive shell, as depicted in one embodiment in  FIG. 5 . The thermally conductive shell may serve to substantially spread heat energy as a heat sink for the LED. 
       FIG. 4  depicts a partially assembled lamp, including the sub-assembly  300  installed in the base  105 . Within the base  105 , electrical connection may already be made between the LED package  305  and the terminals  110 . In some embodiments, such as those of  FIG. 3B , for example, assembly may not require soldering operations to make electrical connections between the LED package  305  and the pair of terminals  110 . 
       FIG. 5  depicts an exemplary assembly  500  to provide thermally controlled operation of the LED lamp, for example, using a shell  505  formed into a generally parabolic shape. In some implementations, the shell  505  may be thermally conductive, anodized, and/or stamped metal (e.g., aluminum), for example. In some examples, the shell  505  has, as in the depicted example, a substantial number of perforations arranged in an array to permit airflow to the reflector. The apertures in the shell  505  are arranged to admit air flow from substantially any radial direction, which may promote convective flow in a wide range of orientations of the lamp (e.g., downlight, wall wash, horizontal orientations, etc. . . . ). The shell  505  may provide both substantially reduced thermal impedance, considering convective air flow to transfer heat independent of radial orientation of the lamp, which in turn may advantageously promote efficient performance as heat spreader to transfer heat away from LED. 
       FIGS. 6-7  depict further assembly of the shell  505  coupled to a exemplary reflector  605  and the base  105 . In an illustrative example, the reflector  605  may be adhesively-coupled to a distal end of the shell  505 . In some other examples, the reflector  605  may include one or more snap features to engage and retain contact with the distal end of the shell  505 . For purposes of explanation, the assembly  300  and lens are not shown to reveal further detail an interior volume of the base  105 . 
     In the depicted assembly  600 , the shell  505  includes a pair of mounting tabs  610  that are substantially coplanar and bent toward an interior volume of the shell  505 . A corresponding pair of threaded cylinders  615  that are integral to the base  105  each have a threaded aperture in register with an aperture on the corresponding mounting tabs  610 . In a complete example assembly, one or two screws may be inserted through cut-outs  315  in the substrate  310  and through the above-mentioned apertures in tabs  610  to engage threads in the cylinders  615 . Thus, one or two screws may be used to securely assemble together the assembly  300 , the base  105 , and the shell  505  to form a light engine. 
       FIG. 7  shows a perspective view of an exemplary sub-assembly that includes the reflector  605 , the shell  505 , and the assembly  300  with the LED package  305 . 
       FIG. 8  depicts an exemplary lens coupled to the assembly  300 . As depicted, a lens  805  may be formed of a substantially transparent plastic or glass material having a substantially uniform index of refraction. In some implementations, the lens  805  may be formed with a gradient index of refraction (GRIN) lens that may form a desired beam pattern. The lens  805  may include features that provide substantial diffusion, which may advantageously yield a more uniform light distribution. 
       FIG. 9  shows a side elevation of an example sub-assembly that includes a reflector coupled to a transparent lens. A depicted assembly  900  includes the LED package  305  in the assembly  300 , which is mounted to the base  105  having terminals  110 . The reflector  605  provides a substantially reflective surface around and extending beyond a distal end of the lens  805 . In some embodiments, the reflector  605  may help to generally redirect light near the distal end of the lens  805  out of the light chamber. To aid understanding, the shell  505  that generally provides a substantial heat sink is removed to reveal arrangement of the interior features. 
       FIGS. 10-13  depict exemplary packaging and an LED lamp in GU  10  form factor arranged as a kit. In various examples, the kit may include a re-usable container with a lid, operable as a package for an energy efficient lamp. The container may be re-used for various applications after the lamp has been removed. In some examples, the package may be employed to protectively contain a used lamp for transport to a waste processing facility. 
     In an illustrative example, the package may house a mercury-free LED lamp during warehousing, distribution, and retail sale operations. For example, the containers containing the LED lamps may be stacked vertically on a retail shelf, permitting customers to view the LED lamp from all sides through the transparent container walls. The LED lamp may be removed from the container to replace a mercury-containing bulb, such as a fluorescent bulb, for example. To protect the mercury-containing bulb against breakage, the fluorescent bulb may be protectively stored in the container and sealed with the lid resealed until removed at a hazardous waste facility. 
     The kit includes an exemplary annular ring forming an integral bottom locating feature, which may may be seen from  FIGS. 11-12 . These locating features may substantially promote localization of the terminal posts  110 , which extend from the base  105  of the LED lamp. 
       FIG. 11  depicts an exemplary kit with a transparent container body and opaque lid, showing a view of a locating feature on the bottom of the container. As depicted, a resealable lid  1105  is sealably engaged to a container body  1110 . The container body  1110  and the lid  1105  cooperate to locate a lamp  1115 . An orientation of the lamp  1115  is generally controlled, in part, by an annular ring locating feature  1120  that encircles a pair of terminals of the lamp  1115 . 
       FIG. 12  shows an exemplary kit with a transparent container lid and transparent body. In this example, the lid  1105  reveals engagement among corresponding horizontally-oriented features to releasably secure the lid  1105  to the container body  1110 . 
       FIG. 13  depicts an exemplary kit with a lid ready to be assembled to the container body while containing a lamp. In a particular example,  FIG. 13  shows an exemplary package with a top locating feature  1305  that forms a centrally-located partial sphere that extends downward from a bottom surface of the lid and toward a top surface of the LED lamp. As the lid is rotatably engaged to the container body to engage corresponding substantially horizontally-oriented features, a top locating feature  1305  is advanced to a position in substantial proximity to the top surface  1310  of the LED lamp. Engagement between the top locating feature  1305  and the top surface  1310  may cooperate with containment of the terminals by the bottom locating feature  1120  (as shown in  FIG. 11 ) to substantially orient and center the lamp along a vertical central axis of the container body  1110 . 
       FIGS. 14-20  depict construction and arrangement of an exemplary LED lamp in a PAR  30  form factor.  FIGS. 14-15  particularly show respective side and bottom perspective views of an exemplary lamp compatible with, for example, PAR  30  style lamp applications. 
     In the depicted example, a lamp  1400  includes a base  1405  coupled between an electrical interface  1410  and a body. The body includes a heat spreader  1415  that couples to the base  1405  and houses components of a light engine and a light chamber. The light engine generates light that is emitted through a lens  1420 . In some The lens  1420  is secured to a distal end of the heat spreader  1415  by a securing ring  1425 , which may be rotated, in some examples, to engage locking features on the heat spreader  1415 , for example. 
       FIGS. 16-17  depict an exemplary light engine. In this example, an LED  1605  is mounted on a corresponding thermal spreading framework  1610 . Extending away from the LED  1605  is a pair of thermal fins  1615  to provide reduced thermal impedance to ambient temperature. 
     In  FIG. 17 , an example light engine  1700  includes a number of the LED  1605 , each with a thermal spreading framework  1610 , distributed in an exemplary pattern across a PCB in a substantially circular and radial pattern. Each of the LEDs  1605  is arranged on a sub-assembly that includes thermally-conductive fins  1615  that extend below the PCB to provide thermal mass and surface area in the region below the PCB. 
     Embodiments of the exemplary LED engine arrangement on a PCB are described, for example, with reference to at least FIG. 6 of U.S. Provisional Patent Application Ser. No. 61/152,670, entitled “Light Emitting Diode Assembly and Methods,” which was filed by Grajcar, Z. on Feb. 13, 2009, and the entire disclosure of which is incorporated herein by reference. 
       FIGS. 18-20  shows an exemplary electrical socket  1805  that receives electrical power to power the LEDs. In some examples, the socket  18  couples to the PCB via a wiring harness, flex circuit, or fastening hardware (e.g., screws). 
       FIG. 18  further shows an exemplary fully populated LED engine  1810  using the LEDs  1605 . The perforated shell  1815  permits substantial airflow across or around the thermally conductive fins  1615  that extend below the PCB of the light engine  1810 . The perforated shell  1815  may permit airflow that can support convective heat exchange with thermal fins  1615 , for example, with the lamp oriented in substantially any direction. In some embodiments, the light engine  1810  may provide substantial thermal coupling to a thermally conductive perforated shell  1815  by thermally conductive paths. A base connecting the shell  1815  to the socket  1805  is not shown to more clearly illustrate the components described. 
       FIG. 19  shows an exemplary intermediate assembly step in which a lens  1905  is installed on a distal end of the shell  1810 . 
       FIG. 20  shows an exemplary securing ring  2005  that may secure the lens  1905  to the lamp. 
       FIGS. 21-24  depict exemplary packaging and an LED lamp in PAR  30  form factor arranged as a kit. 
       FIGS. 21-22  show an exemplary top locating feature on the bottom surface of the lid. In this example, a kit  2100  includes a container  2105 , which may be sized for a PAR  30  style lamp, a lid  2110 , and a top locating feature  2115 . The locating feature  2115  may, for example, limit the vertical movement of the lamp within the package. This may advantageously prevent damage to the lamp during shipping or handling. In the depicted example, a circular feature extends downward from the bottom surface of the lid to contact or come in close proximity to a top surface (e.g., lens) of the PAR  30  lamp. The interface between the locating feature and the lamp may substantially protect the lamp from damage by distributing any vertical force of the lamp due to acceleration of the lamp toward the lid (e.g., when dropped from a shelf). 
       FIGS. 23-24  show an exemplary bottom locating feature that extends from the interior floor of the container. In this example, a container body  2105  includes a bottom locating feature  2305  configured to capture and locate at least a portion of the socket  1805  of a PAR  30  lamp, for example. The bottom locating feature  2305  may cooperate with the top locating feature  2115  and the side walls of the container body  2105  to substantially orient the lamp within the container body  2105 , and prevent substantial misalignment of the lamp. Advantageously, the features of the package may cooperate to maintain the LED lamp in a substantially vertical orientation and in a fixed position within the package. Furthermore, the locating features may advantageously promote automated packaging by providing features that simplify making reliable, automated insertions of LED lamps into such packages. 
     Although various embodiments have been described with reference to the figures, other embodiments are possible. For example, various disclosed construction features or methods may be applied to lighting or optical apparatus other than LED lamps in the GU  10  or PAR  30  form factors. 
     In various examples, a kit may include a container with a re-closeable lid and an LED lamp. In some examples, a kit may further include a set of instructions or information packet mechanically coupled to the package or the lamp. The instructions may include information about how to properly operate the lamp. By way of example, the instructions may include specifications for input power (e.g., voltage, current, or frequency), output power or intensity, lamp temperature specifications, and/or compatible fixtures for receiving the lamp. 
     Some embodiments may be constructed with a lid with a centrally recessed top surface region sized to stack with at least one similar package. For example, transparent containers may be stacked at least 5, 6, 7, 8, 9, or at least about 10 containers high to display LED lamps from any direction. Accordingly, the orientation of the package may be in any direction without obscuring the view of the lamp contained therein. 
     In various examples, at least a body of the container is partially or completely transparent to permit visual display of the LED lamp from any direction, including a full 360 degrees in a horizontal plane. In some examples, the lid of the package may further be transparent to permit inspection from the top of the package. 
     In some embodiments, implementations may be integrated with other elements, such as packaging and/or thermal management hardware. Examples of other elements that may be advantageously integrated with the embodiments described herein are described with reference, for example, to FIG. 15 in U.S. Publ. Application 2009/0185373 A1, filed by Z. Grajcar on Nov. 19, 2008, the entire contents of which are incorporated herein by reference. 
     In some examples, a top locating feature of the package may be formed from polypropylene or other suitably soft material for compression against the top of the lamp without scratching or scuffing the lens. 
     To facilitate vertical stacking of multiple container housings in some embodiments, a top exterior surface of the lids may be formed with at least an annular horizontally flat surface sized and shaped to receive and to register a corresponding annular projection on a bottom exterior surface of a container housing. The lid may include an annular ring that defines a central pocket to receive a bottom portion of the container body that is stacked on top of that lid. In some examples, a circumference of the bottom of the container housing must be at least less than an inner diameter of the upper surface of the lid. 
     In various embodiments, the packaging container may be substantially made from biodegradable materials. For example, the packaging may be made from corn starch-based materials. Some examples may include additives to the plastic to promote biodegradability. Examples of suitable materials may include ECOPURE (trademark) commercially available from Bio-Tec Environmental of Winmalee, Australia. 
     A number of implementations have been described. Nevertheless, it will be understood that various modification may be made. For example, advantageous results may be achieved if the steps of the disclosed techniques were performed in a different sequence, or if components of the disclosed systems were combined in a different manner, or if the components were supplemented with other components. Accordingly, other implementations are contemplated.