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Lamp device and method to retrofit a lighting fixture

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Title: Lamp device and method to retrofit a lighting fixture.
Abstract: A device and method for retrofitting a light fixture from use with a lamp socket that employs an incandescent or metal halide lamp, to use with another lamp assembly. The lamp fixture has a collar with a base and an annular outer wall extending out from the base. The LED lamp device includes a neck base having an annular outer wall having a shaped outside surface that is placed into direct surface contact with the inner surface of the annular outer wall of the collar, to establish an effective heat-transferring interface. The shaped outer surface of the neck base provides proper fitting of the LED lamp device into the lighting fixture, and provides a heat-transferring interface over substantially all of the outer surface of the neck base, to dissipate heat away from the LED module. Aluminum material provides high thermal conductivity, light weight, availability, and low cost. ...


Browse recent Mcdermott Will & Emery patents - Washington, DC, US
Inventor: John D. Boyer
USPTO Applicaton #: #20110044049 - Class: 362287 (USPTO) - 02/24/11 - Class 362 


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The Patent Description & Claims data below is from USPTO Patent Application 20110044049, Lamp device and method to retrofit a lighting fixture.

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FIELD OF THE INVENTION

In one aspect, the disclosure is related to lighting. More specifically, the disclosure is directed to retrofitting existing lighting fixtures.

BACKGROUND OF THE INVENTION

Outdoor lighting has evolved over the years from the earliest use of incandescent lamps, through the use of fluorescent, high intensity discharge (HID), and mercury-vapor lamps, and more recently to light emitting diode (LED) lamps. LED lamps offer several advantages, including improved quality, performance, lifespan and cost, and their use and popularity have been growing. LED lighting also provides, and has the potential for further providing, reduced power consumption per unit lumen.

One drawback of LED lighting systems is the cost and inconvenience of removing conventional, non-LED-based light fixtures and installing new light fixtures that are design and optimized for LED-based lamps. To defray this expense, attempts have been made to retrofit, or force-fit, LED lamp technology into non-LED lamp fixtures. Examples include the incorporation of LED lamps inside and on the outside surface of “bulb” style lamps, with threaded electrical connections so that the LED bulb lamp can be screwed into a conventional socket.

An alternative means for retrofitting LED lamps into a conventional light fixture is to replace both the conventional bulb and the electrical socket with an LED lamp assembly which incorporates or is augmented with a suitable power and control systems for LED service. Nevertheless, such retrofitting efforts often fail to address one or more of the functional differences characteristic of LED lamps. In particular, LED lamps are sensitive to heat generated by the LED itself, and may lose efficiency unless the heat and local temperature increases are minimized. LED lamps are also well known to emit light in a lambertian distribution, whereas most conventional incandescent and fluorescent lamps emit a spherical light pattern. Positioning and controlling the light emitted from an LED requires a different technique than the light from a conventional lamp. Furthermore, typical power converters that convert off-line (110-377V AC) to 24V, constant current to drive the LEDs, are bulky and do not conveniently install into such socket-type light fixtures.

SUMMARY

OF THE INVENTION

In one aspect, the disclosure relates to a device and method for retrofitting a light fixture from use with a lamp socket that employs a conventional incandescent or metal halide lamp powered by off-line voltage, to use with a light emitting diode (LED)-based lamp assembly. The conventional non-LED lamp fixture is of a type having a collar that has a base and an annular outer wall extending out from the base. The base of the lamp fixture is securable to a structure, such as a pole, canopy, or wall. The LED lamp device has an annular outer wall having a shaped outside surface that is placed into direct surface contact with the inner surface of the annular outer wall of the collar, to establish an effective heat-transferring interface between the LED lamp device and the collar, and a means for affixing an LED module comprising at least one LED.

In various embodiments, the material of construction of the LED lamp device is a metal or engineering plastic having a high thermal conductivity. Metals are selected from aluminum, copper, brass, bronze, iron and steel. Aluminum is particular attractive for its high thermal conductivity, light weight, availability, and low cost. The shaped outer surface of the LED lamp device provides proper fitting of the LED lamp assembly into the lighting fixture, and provides a heat-transferring interface over substantially the entire outer surface of the adapter sleeve, to dissipate heat away from the LED module and its power and control units.

In one embodiment, the LED lamp module includes a light board 81 to which is affixed one or a plurality of LEDs, and optionally LED power and control components.

The means for affixing the LED module to the LED lamp device is generally disposed at the distal end, and a recess formed in the distal end within which the LED module is positioned. In one embodiment, a protective lens or transparent plate is positioned over the recessed LED module for protection from the environment and for personnel safety. Power wiring from the LED module to a power source is routed through openings in the LED lamp device and collar.

In another aspect, the disclosure also relates to the above-mentioned LED lamp device.

In one embodiment, the LED lamp device, and its use in a retrofitable retrofitting light fixture, can comprise an adapter sleeve having the annular outer wall with the shaped outside surface, and 2) a lamp head moveably affixed to the adapter sleeve that comprises a means for affixing the LED module. In one embodiment, the lamp head has an annular base portion having a proximal rim that associates with a shoulder on the annular wall of the adapter sleeve both to provide a broad contact interface for conducting heat through and away from the lamp head to the adapter sleeve, and to permit movement, such as rotation, of the lamp head with respect to the adapter sleeve, and more typically so that the LED module revolves around an axial centering line of the adapter sleeve. The LED module has a centerline disposed at an angle from the axial centering line of the adapter sleeve of from about 10° to about 70°.

The LED lamp device can be configured with modular design features, such that the LED lamp device of the first embodiment can also be used as the adapter sleeve, configured with the shoulder on the annular wall so that a separate lamps head can be added for modifying the direction and distribution of the LED light, as well as the appearance of the LED lamp device itself.

In another aspect, the disclosure relates to a method for retrofitting an existing lamp fixture to replace a threaded lamp socket with an LED-based lamp assembly, the lamp fixture having a collar having an annular wall with an inner wall surface, and a base to which the threaded lamp socket is secured for attaching the lamp fixture to the structure, and for communicating electrical power from an electrical power source to the threaded socket lamp. The method can include removing the threaded lamp socket from the collar; providing an LED lamp device having an annular wall having a shaped outside annular surface and an LED module; affixing the LED lamp device to the lamp fixture, wherein the shaped outside annular surface is placed into direct surface contact with the inner surface of the annular wall of the metallic collar, to establish a heat-transferring interface between the adapter sleeve and the collar, and connecting the electrical power source to the LED module.

The disclosure also relates to the ornamental shape and design of the LED lamp device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of one embodiment of a light fixture having one embodiment of a lamp with a light module.

FIG. 2 shows a sectional view of the light fixture and lamp device taken through line 2-2 of FIG. 1.

FIG. 3 shows an exploded view of the lamp device of FIG. 1.

FIG. 4 shows a perspective view of an alternative light fixture having a second embodiment of the lamp device.

FIG. 5 shows a perspective view of the lamp device of FIG. 4 isolated from the light fixture and the light module, showing a neck base and a lamp head.

FIG. 6 shows a sectional, exploded view of an embodiment of the lamp device taken through line 6-6 of FIG. 5, showing an internal bracket and bolt for associating the neck base with the lamp head.

FIG. 7 shows an exploded view of the lamp device of FIG. 5.

FIG. 8 shows a partial sectional view of the lamp device of FIG. 5 taken through line 8-8 of FIG. 5



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Previous Patent Application:
Removable attachment assembly for droplight
Next Patent Application:
Led lamp having good heat dissipating efficiency and security
Industry Class:
Illumination
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stats Patent Info
Application #
US 20110044049 A1
Publish Date
02/24/2011
Document #
12913502
File Date
10/27/2010
USPTO Class
362287
Other USPTO Classes
362294, 445/2
International Class
/
Drawings
20



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