Patent Abstract:
A device comprising a bottom portion providing a first contact and a second contact via an outer surface, an inner surface is conductive with the outer surface. The device comprises a bottom pressure pin, within the bottom portion, connected to the first contact and a top portion rotatably fixed to the bottom portion and comprising first and second connectors functionally exposed therethrough. The device comprises a printed circuit board (PCB), within the bottom portion, providing a first route to the first connector and a second route to the second connector. The PCB is fixably attached to the electrical connectors and the first route continuously contacts with the bottom pressure pin. The device comprises a radial pressure pin, fixably connected to the second route, that provides continuous connection with the second contact through the bottom portion&#39;s inner surface. A method of assembly of the device and a kit comprising the device.

Full Description:
TECHNICAL FIELD 
     The present invention relates to lighting systems and, more particularly, to LED-based bulb kit. 
     BACKGROUND 
     Lighting systems have evolved over the years with different technological advents. One of the latest evolutions is based on Light Emitting Diode (LED) technology. High power LEDs present a good ratio of lumens per power unit and provide an alternate solution to conventional incandescent technology, which tend to have a shorter lifespan (e.g., 10 to 50 times shorter than properly driven high power LEDs). 
     Providing a replacement technology for a product as widely used as incandescent light bulbs presents many challenges. Because of the market maturity, a viable solution needs to be compatible with already adopted form factors. Yet, the constraints of LED-based products trigger different requirements. 
     The present invention addresses the compatibility between LED-based products and different form factors used with conventional technology. 
     SUMMARY 
     A first aspect of the present invention is directed to a device comprising a bottom portion and a top portion rotatably fixed to the bottom portion. The bottom portion provides at least a first external electrical contact point below the bottom portion and a second external electrical contact point through an outer surface of the bottom portion. A bottom pressure pin is positioned within the bottom portion and electrically connected to the first contact point (e.g., soldered). An inner surface of the bottom portion is electrically conductive with the outer surface (i.e., second contact point). The top portion comprises a first electrical connector and a second electrical connector, both connectors being functionally exposed therethrough. A printed circuit board (PCB) is positioned within the bottom portion. The PCB provides a first connection route in electrical connection with the first electrical connector and a second connection route in electrical connection with the second electrical connector. The PCB is soldered to the first and second electrical connectors thereby fixably attaching the top portion and the PCB. The first connection route is in continuous electrical contact with the bottom pressure pin. A radial pressure pin is fixably connected (e.g., soldered) to the PCB&#39;s second connection route. The radial pressure pin provides continuous electrical connection with the second contact point through the bottom portion&#39;s inner surface. 
     The continuous electrical connection between the PCB&#39;s first connection route and the bottom pressure pin, and the continuous electrical connection between the bottom portion&#39;s inner surface and the radial pressure pin, are maintained while the top portion is rotated over the bottom portion. 
     The radial pressure pin may be a spring loaded connector that can vary in length to maintain the continuous electrical connection with the inner surface. Likewise, the bottom pressure pin may be a spring loaded connector that can vary in length to maintain the continuous electrical connection with the PCB&#39;s first connection route. Optionally, the spring loaded connector used may have been designed for electronic programming equipment or test equipment. The bottom pressure pin may contact with the PCB&#39;s first connection route at a central connection point of the PCB. 
     The first and second connectors may be compatible with a wedge connector and a G4 connector through the top portion. The bottom portion&#39;s outer surface may be shaped as a bayonet lamp cap or a screw lamp cap. 
     A second aspect of the present invention is directed to a kit of parts for providing a replacement light bulb. The kit comprises a swivel adaptor, in accordance with the first aspect of the present invention as described above, and a Light Emitting Diode (LED)-array printed circuit board (PCB) compatible with the first and second connectors of the swivel adaptor. The LED-array PCB may provide a wedge or G4 connector. The LED-array PCB may also be flat. 
     A third aspect of the present invention is directed to a method for assembling a swivel adaptor. The method comprises soldering a bottom pressure pin to form an external bottom contact point of a lamp cap, wherein the bottom pressure pin is positioned within the lamp cap. the method also comprises soldering a radial pressure pin on a radial contact point of a printed circuit board (PCB), wherein the PCB has a central contact point. A first connector is soldered to the PCB in electrical connection to the central contact point and a second connector is soldered to the PCB in electrical connection to the radial contact point. The method also comprises fixably inserting the first and second connectors within a swivel top thereby allowing the connectors to be functionally exposed through the swivel top. The method further comprises inserting the PCB, attached to the swivel top, within the lamp cap whereby the bottom pressure pin contacts the central contact point of the PCB and the radial pressure pin contacts the inner surface of the lamp cap. The swivel top rotatably snaps on the lamp cap. 
     Optionally, the radial pressure pin may be a spring loaded connector that can vary in length to maintain a continuous electrical connection with the inner surface during rotation of the swivel top over the lamp cap. Likewise, the bottom pressure pin may also optionally be a spring loaded connector that can vary in length to maintain a continuous electrical connection with the PCB&#39;s central contact point during rotation of the swivel top over the lamp cap. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features and exemplary advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the appended drawings, in which: 
         FIG. 1A ,  FIG. 1B ,  FIG. 1C  and  FIG. 1D  herein referred to concurrently as  FIG. 1  are perspective views of an exemplary light bulb casing in accordance with the teachings of the present invention; 
         FIG. 2  is a view of an exemplary kit of parts in accordance with the teachings of the present invention; 
         FIG. 3  is a perspective view of an exemplary kit of parts comprising a swivel adaptor and a wedge LED-array in accordance with the teachings of the present invention; 
         FIG. 4  is an exploded perspective view of an exemplary swivel adaptor in accordance with the teachings of the present invention; 
         FIG. 5A  and  FIG. 5B  herein referred to concurrently as  FIG. 5  are perspective views of exemplary spring loaded connectors in accordance with the teachings of the present invention; 
         FIG. 6  is a perspective view of an exemplary assembled inner printed circuit board in accordance with the teachings of the present invention; and 
         FIG. 7  is a flow chart of an exemplary method of assembling a swivel adaptor in accordance with the teachings of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Reference is now made to the drawings, in which  FIGS. 1A ,  1 B,  1 C and  1 D, herein referred to concurrently as  FIG. 1 , show a perspective view of an exemplary light bulb casing  100  in accordance with the teachings of the present invention. The light bulb casing  100  is shown with a bayonet light bulb socket  110 A for receiving a bayonet conventional light bulb (not shown). The bayonet light bulb socket  110 A has its L-shaped slots  120 A substantially aligned with the vertical axis of the light bulb casing  100 .  FIG. 1  also shows other bayonet light bulb socket  110 B and  110 C having their respective L-shaped slots  120 B ad  120 C aligned differently with reference to the light bulb casing  100 . 
     The light bulb casing  100  could also comprise a wedge bulb socket  130  capable of receiving G4 light bulb (not shown) or a wedge shape circuit (not shown). The wedge shaped circuit is a flat shape that receives an array of high power LEDs on its face and electronic components to drive the LEDs on its back. The wedge shape circuit is meant to advantageously replace a conventional light bulb in the light bulb casing  100 . 
     The wedge bulb socket  130  and the bayonet light bulb socket  110 A-C are two common form factors. A provider of replacement LED bulb or Original Equipment Manufacturer (OEM) LED bulb has a market advantage if its product or kit is able to fit into these two common form factors. Minimising the number of LED circuits in a product line of LED bulbs is also advantageous. As can be appreciated from  FIG. 1 , however, there are different angles to the slots  110 A-C, making production of a single product or kit addressing the two common form factors difficult. 
       FIG. 2  shows a kit  200  of parts that can be sold to address the need for a unique product compatible with the different exemplified form factors of the light bulb casing  100 . It contains a wedge-compatible connector  210 , a bayonet-compatible connector  220  and a LED-array  230 . The connectors  210  and  220  are meant to be connected in one of the sockets  110 A-C or  130  in the light bulb casing  100 . A two-wire connector  240  of the wedge-compatible connector  210  or the bayonet-compatible  220 , in turn, connects to a mating two-wire connector  250  of the LED-array  230 . The LED-array  230  is meant to be fastened (e.g., glued with double face tape) within the light bulb casing  100 . 
     There are a number of issues with the kit  200 , some of which are listed hereinafter. For instance, the LED-array  230  is difficult to fasten within the light bulb casing  100 . The light bulb casing  100  usually presents a concave back surface, which makes proper adherence of the LED-array  100  more difficult. It is also difficult to properly fasten the LED-array  230  within the light bulb casing  100  for a period of time that matches the expected long lifespan of the LED-array  230 . Trying to re-fasten or replace the LED-array  230  is also made difficult by the residues from previous fastening attempts. Alignment of the LED-array  230  is also limited by the back surface of the light bulb casing  100 , which has not been designed for this purpose. Another disadvantage of the kit  200  is the required wires, which are difficult to maintain within the light bulb casing  100  without interfering with light emitted by the LED-array  230 . Heat dissipated by the LED-array  230  may also cause problems to the wires. 
       FIG. 3  shows a kit  300  of parts that can be sold to address the need for a unique product compatible with the different exemplified form factors of the light bulb casing  100 . It contains a swivel adaptor  310  and a wedge LED-array  390 . The swivel adaptor has a top portion opened to receive the wedge LED-array  390  and a bottom portion  312  compatible with a bayonet light bulb socket. The wedge LED-array  390  is adapted to fit into a wedge socket as the socket  130  exemplified in  FIG. 1 . Skilled persons will readily understand that the swivel adaptor  310  may be produced or manufactured by itself and could also be sold separately from the wedge LED-array  390 . For instance, if other products compatible with the swivel adaptor  310  become available in the market, it may be useful to offer the swivel adaptor on its own rather than only in the kit  300 . 
     The swivel adaptor  310  can be inserted in a bayonet light bulb socket such as the sockets  110 A-C exemplified in  FIG. 1 . In order to receive the wedge LED-array  390  in all the exemplified sockets  110 A-C, the top portion  322  needs to be rotatable from the bottom portion  312 . 
       FIG. 4  shows an exploded perspective view of the swivel adaptor  310 . The bottom portion  312  exemplified on  FIG. 4  is a standard BA15S lamp cap. A bottom pressure pin  314  is inserted in the bottom portion and soldered in the lamp cap whereby connectivity of the bottom pressure pin  314  is made with the central external connector of the lamp cap. The bottom pressure pin  314  exemplified on  FIG. 4  is a spring loaded connector shown in greater detail on  FIG. 5A . The bottom pressure pin  314  of  FIG. 5A  is 0.575″ long when fully extended and is capable of being compressed up to 0.055″. The bottom pressure pin  314  of  FIG. 5A  has been originally designed for equipment used in test equipment or board to board interconnections or electronic programming equipment or others similar applications. The bottom pressure pin  314  of  FIG. 5A  is one example of a pressure pin that presents required conductivity characteristics. The bottom pressure pin  314  allows, as will be apparent hereinbelow, increased tolerancing in the assembly of the swivel adaptor  310 . 
     An inner printed circuit board (PCB)  316  is provided to fit within the bottom portion  312 .  FIG. 6 , hereinafter concurrently referred to with  FIG. 4 , shows the assembled inner PCB  316 . The PCB  316  presents a central contact point  605  that is meant to be in contact with the bottom pressure pin  314  once the PCB  316  is inserted in its position within the bottom portion  312 . The PCB  316  also presents at least one radial contact point  610 . The radial contact point  610  is adapted to receive a radial pressure pin  318  that extends beyond the diameter of the PCB  316 . For instance, the radial pressure pin  318  may be soldered to the PCB  316 . The radial pressure pin  318  exemplified on  FIG. 4  is a spring loaded connector shown in greater detail on  FIG. 5B . The radial pressure pin  318  is 0.137″ long when fully extended and is capable of being compressed up to 0.039″. Once the PCB  316  is inserted in its position within the bottom portion  312 , the radial pressure pin  318  is in contact with the inner surface of the bottom portion  312  whereby connectivity is ensured between the external surface of the bottom portion  312  and the radial contact point. The radial pressure pin  318  of  FIG. 5B  has been originally designed for equipment in test equipment or board to board interconnections or electronic programming equipment or others similar applications. The radial pressure pin  318  of  FIG. 5B  is one example of a pressure pin that presents required conductivity characteristics. The radial pressure pin  318  allows, as will be apparent hereinbelow, increased tolerancing in the assembly of the swivel adaptor  310 . 
     The PCB  316  presents a first connection route  615  from the central contact point  605  to a first soldering point  625  adapted to receive a first connector  320  and also presents a second connection route  620  from the radial contact point  610  to a second soldering point  630  adapted to receive a second connector  321 . The connectors  320  and  321  are adapted to fixably fit within the top portion  322  in order to maintain the PCB  316  and the top portion  322  together. The position of the connectors  320  and  321  within the top portion  322  allows the wedge LED-array  390  to be connected to the PCB  316 . 
     The top portion  322  exemplified on  FIG. 4  is a molded plastic part that is adapted to snap onto the bottom portion  312  and allows the wedge LED-array  390  to be inserted therein. The plastic part is dimensioned so that, once assembled, detaching the bottom portion  312  from the top portion  322  is made difficult, but the bottom portion  312  and top portion  322  are rotatable over one another. The radial pressure pin  318  and the bottom pressure pin  314  ensure continuous electrical connectivity of the PCB  316  and the electric contacts of the bottom portion  312 , even during rotation of the top portion  312  relative to the bottom portion  322 . The pressure pins  314  and  318  are meant to adapt to the variations in the assembly of the top portion  322  (e.g., its positioning over the bottom portion  312 ) and for the expected tolerancing of the dimensions of the bottom portion&#39;s  312  inner surface. 
     As can be appreciated, the swivel adaptor provides electrical connectivity between its external first contact and the first connector via the bottom pressure pin and the PCB. The swivel adaptor also provides electrical connectivity between its outer surface and the second connector via the radial pressure pin and the PCB. 
     It should be noted that no internal wires interfere with the rotation and that the described solution provides for complete rotations, which is of particular relevance if the wedge LED-array  390  is polarized. However, it should be recognized that various means could be used to limit the rotation without affecting the teachings of the present invention. 
     It will be readily understood by skilled persons that the invention is not limited to the use of a bayonet lamp cap BA15S as exemplified. Other bayonet lamp caps (not shown) of various dimensions (e.g., BA15 (BA15S, BA15D, BAY15D, BAU15S, BAZ15D), BA9S, BA20S, BA20D, BA7S, etc.) could be used in accordance with the teachings of the present invention by adapting the dimensions of the other components (e.g., the pressure pins  314  and  318  and the top portion  312 ). Other types of lamp caps (e.g., E5, E10, E11, E12, E14, E17, E26/27, E39/40; MR11, MR16; G4, GU5.3, GY6.35, G9; T10, T20, T25 etc.) of various dimensions could also be used to match different socket types that present a similar limitation in terms of alignment of the lamp cap once positioned within the lamp socket. Skilled readers will recognize that, in a lamp cap that would present an irregular inner surface, the radial pressure pin may need to be dimensioned differently and/or means to limit rotation may be required. 
     Skilled persons will also recognize that other length-adjusting components could be used instead of the exemplified pressure pins  314  and  318 . While there exist advantages in reusing existing pressure pins as shown in  FIG. 5 , specific pins (not shown) could also be designed for the same purpose of increasing tolerancing in the assembly of the swivel adaptor  310 . 
     The illustrated solution uses the wedge LED-array  390 , but skilled persons will recognise that conventional (e.g., wedge (T10, T20, T25), G4, GU5.3, GY6.35, G9, etc.) bulbs (not shown), while they may not take advantage of the solution, still remain compatible with the present invention. It will also be recognized that other directional LED-arrays (not shown) using other connection type than a wedge connector could also be used (e.g., G4, GU5.3, GY6.35, G9, etc.). Likewise, the wedge LED-array  390  does not need to be flat as shown, but could present other configurations that are advantaged by proper directional alignment. The light bulb casing  100  has been used to illustrate the context of use of the present invention. Skilled person will recognise that the present invention is capable of being used and adapted as necessary to different contexts benefiting from directional alignment of connectors (e.g., for lighting applications in recreational vehicles, emergency lamps, reading lamps, car and trailer taillight, projector lamps, etc.) without departing from the teachings of the present invention. 
       FIG. 7  shows an exemplary assembling method  700  for the swivel adaptor  310 . A bottom pressure pin is soldered  710  to form an external bottom contact point of a lamp cap. The bottom pressure pin is positioned within the lamp cap. A radial pressure pin is soldered  720  on a radial contact point of a printed circuit board (PCB). The PCB has a central contact point. A first connector and a second connector are soldered  730  to the PCB. The first connector is in electrical connection to the central contact point and the second connector is in electrical connection to the radial contact point. The first and second connectors are fixably inserted  740  within a swivel top thereby allowing the connectors to be functionally exposed through the swivel top. The PCB is inserted  750  within the lamp cap whereby the bottom pressure pin contacts the central contact point of the PCB and the radial pressure pin contacts the inner surface of the lamp cap. The swivel top rotatably snaps on the lamp cap. It should be appreciated that the steps of the exemplary assembling method may not be performed in the same order as exemplified on  FIG. 7 . 
     The description of the present invention has been presented for purposes of illustration but is not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments were chosen to explain the principles of the present invention and its practical applications and to enable others of ordinary skill in the art to understand the invention in order to implement various embodiments with various modifications as might be suited to other contemplated uses. Drawings are not necessarily drawn to scale.

Technology Classification (CPC): 5