LED lamp and method for manufacturing the same

Abstract

A light emitting diode (LED) lamp includes a lamp housing formed of a pair of housing members connected to each other in a horizontal direction. A printed circuit board (PCB) is detachably connected to an inside of the lamp housing, and includes at least one LED mounted to one surface of the PCB. A power supply unit (PSU) is electrically connected with the PCB in the lamp housing to supply power to the PCB.

Claims

1. A light emitting diode (LED) lamp comprising: a plurality of LEDs mounted to a printed circuit board (PCB); a power supply unit (PSU) connected to the PCB; and a housing comprising a pair of housing members coupled to each other to form the housing, wherein each housing member of the pair of housing members forms a single piece and each single piece includes a cover portion configured to emit light from at least one of the plurality of LEDs, a PSU receiving portion configured to receive the PSU, and a heat radiation portion disposed between the cover portion and the PSU receiving portion.

2. The LED lamp of claim 1, wherein each housing member of the pair of housing members is integrally formed by injection molding such that the cover portion, the PSU receiving portion and the heat radiation portion of each housing member form part of the single piece.

3. The LED lamp of claim 2, further comprising a housing connection member configured to conform to a shape of an end of the housing.

4. The LED lamp of claim 3, wherein a coupling direction of the pair of housing members is substantially perpendicular to a coupling direction of the housing connection member and the housing.

5. The LED lamp of claim 2, wherein at least one housing member of the pair of housing members includes a support portion to hold the PCB inside the housing.

6. The LED lamp of claim 1, wherein the pair of housing members are configured to couple to each other in a direction substantially perpendicular to a longitudinal axis of the housing.

7. The LED lamp of claim 1, wherein the PSU receiving portion is disposed below the cover portion and the heat radiation portion.

8. The LED lamp of claim 1, wherein the heat radiation portion is disposed adjacent to both the cover portion and the PCB.

9. The LED lamp of claim 1, wherein one of the pair of housing members further includes a wire passing portion connecting the cover portion with the PSU receiving portion.

10. A light emitting diode (LED) lamp comprising: a printed circuit board (PCB) having mounted thereto at least one LED; a power supply unit (PSU) connected to the PCB to supply power to the PCB; and a housing comprising a first housing member and a second housing member and having an inner space within which the PCB and the PSU are disposed, wherein each of the first and second housing members comprises: a cover portion configured to diffuse light emitted from the at least one LED; a PSU receiving portion configured to accommodate the PSU; and a heat radiation portion configured to radiate heat from the at least one LED, wherein the heat radiation portion is disposed between the cover portion and the PSU receiving portion.

11. The LED lamp of claim 10, wherein each of the first and second housing members is a single piece formed by injection molding.

12. A light emitting diode (LED) bulb comprising: a printed circuit board (PCB) having mounted thereto at least one LED; a power supply unit (PSU) electrically connected to the PCB; a housing comprising first and second housing members having substantially the same external appearances and being coupled to each other to form the housing, the housing configured to cover the PCB and the PSU; and a housing connection member configured to cover one end of the housing, wherein a direction in which the first housing member is coupled to the second housing member is substantially perpendicular to a direction in which the housing connection member is coupled to the end of the housing, wherein each of the first and second housing members comprises: a light diffusion portion configured to diffuse light emitted from at least one LED; a PSU receiving portion configured to accommodate the PSU; and a heat radiation portion disposed between the light diffusion portion and the PSU receiving portion.

13. The LED bulb of claim 12, wherein the light diffusion portion, the PSU receiving portion, and the heat radiation portion of each of the first and second housing members are integrally formed.

14. The LED bulb of claim 13, wherein at least one of the first and second housing members includes a holding portion to hold the PCB to restrict movement of the PCB within the housing.

15. The LED bulb of claim 12, wherein the PSU receiving portion is disposed below the heat radiation portion.

16. A method of manufacturing a light emitting diode (LED) lamp, comprising: placing a printed circuit board (PCB) having mounted thereto at least one LED on a first single-piece housing member of a pair of single-piece housing members respectively to form a single piece and include a cover portion configured to emit light from at least one of the plurality of LEDs and a PSU receiving portion configured to receive a PSU; placing the PSU for supplying power to the PCB on the first single-piece housing member; and coupling a second single-piece housing member of the pair of single-piece housing members to the first single-piece housing member such that the first and second single-piece housing member form a housing that accommodates the PCB and the PSU, wherein each of the first single-piece housing member and the second single-piece housing member includes a heat radiation portion disposed between the cover portion and the PSU receiving portion.

17. The method of claim 16, further comprising electrically connecting the PCB and the PSU before or after placing the PCB and the PSU to the first single-piece housing member.

18. The method of claim 17, further comprising connecting a housing connection member to the housing so as to cover one end of the housing with the housing connection member.

19. The method of claim 16, further comprising forming the first and second single-piece housing members to be substantially symmetrical to each other when coupled to each other to form the housing.

20. The method of claim 16, further comprising forming each of the first and second single-piece housing members by injection molding.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and/or other aspects, features, and advantages of the invention will become apparent and more readily appreciated from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings in which:

(2) FIG. 1 is a perspective view illustrating a light emitting diode (LED) lamp according to one embodiment of the present invention;

(3) FIG. 2 is a perspective view illustrating a housing member forming part of the lamp housing shown in FIG. 1;

(4) FIG. 3 is a diagram schematically illustrating heat radiating from a printed circuit board (PCB) mounted to the housing member shown in FIG. 2;

(5) FIG. 4 is a diagram illustrating an electrical connection between the PCB mounted to the housing member of FIG. 2 and a power supply unit (PSU);

(6) FIG. 5 is a flowchart illustrating a method of manufacturing an LED lamp according to an embodiment of the present invention;

(7) FIG. 6 is a diagram illustrating steps of the manufacturing method of FIG. 5; and

(8) FIG. 7 is a diagram illustrating an inner structure of an LED lamp according to another embodiment of the present invention.

DETAILED DESCRIPTION

(9) Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.

(10) FIG. 1 is a perspective view of an illustrative light emitting diode (LED) lamp 100 according to an embodiment of the present invention. FIG. 2 is a perspective view of an illustrative housing member included in a lamp housing 110 such as the lamp housing shown in FIG. 1. FIG. 3 is a diagram illustratively showing heat radiating from a printed circuit board (PCB) 130 mounted to the housing member of FIG. 2. FIG. 4 is a diagram illustratively showing an electrical connection between the PCB mounted to the housing member and a power supply unit (PSU) 140.

(11) As shown in FIGS. 1-4, the LED lamp 100 may include a lamp housing 110 which is shaped so as to define the external appearance of the LED lamp 100. The lamp housing 110 can be formed of two or more housing members 110a, 110b connected together through a horizontal connection. The PCB 130 is detachably connected to an inside of the lamp housing 110, and includes a plurality of LEDs 131 disposed on one surface thereof. The PSU 140 can be electrically connected to the PCB 130 inside the lamp housing 110 to supply power to the PCB 130.

(12) As will be described in detail, the structure of the LED lamp 100 may be simplified so as to reduce material costs and facilitate the assembly of component parts of the lamp.

(13) As shown in FIG. 1, the lamp housing 110 may include a pair of housing members 110a and 110b which are shaped to define the external appearance of the LED lamp 100. The housing members 110a, 110b can be connected to each other. A housing connection member 120 can then be connected to lower ends of the pair of housing members 110a and 110b, so as to hold the pair of housing members 110a and 110b connected to each other.

(14) The pair of housing members 110a and 110b are connected in a horizontal direction. That is, the pair of housing members 110a and 110b are connected together by moving the housing members towards each other in a horizontal direction or plane, wherein the horizontal direction is defined as a direction perpendicular to an axis of rotational symmetry of the LED lamp 100. When assembled together, the pair of housing members 110a and 110b form an inner space or internal volume in which the PCB 130 can be mounted and in which the PSU 140 can be inserted. Because the assembly of the elements is performed along a horizontal direction or plane, the assembly may be facilitated in comparison to other LED lamps (not shown) which rely on a vertical assembly structure.

(15) In addition, the pair of housing members 110a and 110b may each have an integrated structure in which each housing member is formed of a single, unitary member. In such examples, the LED lamp 100 can thus rely on a reduced number of parts for assembly. Additionally, the material costs may be reduced. For example, each member of the pair of housing members 110a and 110b may be manufactured by plastic injection molding to form a member such as the member shown in FIG. 2. In such an example, separate post-processing of the housing member is unnecessary (such as post-processing for assembling together multiple component parts of a housing member), notably in cases in which each housing member is formed of a single plastic injection molded part. Also, when plastic injection molding is used, the number of members that can be made using a same mold (e.g., a guaranteed number of shots per mold) may be increased by 3 times as compared to when die-casting is used. Furthermore, by applying plastic injection molding, an LED lamp with a pleasing aesthetic appearance can be obtained. However, the manufacturing methods used for forming the pair of housing members 110a and 110b is not limited to the injection molding methods described herein. Other manufacturing methods may also be used.

(16) The pair of housing members 110a and 110b may each include a heat radiation portion for radiating heat generated from the PCB 130. In particular, the inclusion of the heat radiation portion may enable the LED lamp 100 to function without inclusion of a separate heat sink plate commonly used in other LED lamp structures. As a result, the material cost for producing the LED lamp 100 may be reduced.

(17) A representative housing member 110a of the pair of housing members 110a and 110b is shown and described in relation to FIG. 2. As shown in FIG. 2, the housing member 110a may include a cover portion 111 (e.g., a transparent or translucent cover portion through which light produced by LEDs 131 is emitted from the lamp). The PCB 130 to which the plurality of LEDs 131 are mounted is connected at a lower end of an inner space or volume contained within the cover portion 111. The housing member 110a also includes a heat radiation portion 115 disposed at a lower end of (or below) the cover portion 111 and used to radiate the heat generated from the plurality of LEDs 131 away from the PCB 130, and a PSU receiving portion 118 disposed at a lower end of (or below) the heat radiation portion 115. The PSU 140 may be detachably connected in an inner space or volume of the PSU receiving portion 118.

(18) As shown in FIGS. 2, 3, and 4, the cover portion 111 may have a substantially hemispherical shape and include an insertion groove 112, formed on an inner wall of a lower end of the hemisphere, and configured to receive an outer circumference of the PCB 130. Accordingly, the PCB 130 may be horizontally inserted into the insertion groove 112 of the cover portion 111. Thus, a convenient connection of the PCB 130 to the housing member 110a may be achieved.

(19) The PSU receiving portion 118 forms a space in which the PSU 140, and any associated circuitry, is detachably connected. The PSU receiving portion 118 may be sized or shaped to correspond to a size or shape of the PSU 140, such that the PSU 140 can be inserted into and connected to an inside of the PSU receiving portion 118 and stably maintained in the connected state.

(20) The heat radiation portion 115 may be disposed between the cover portion 111 and the PSU receiving portion 118, and operative to radiate heat generated by the plurality of LEDs 131 to the outside, as shown by the arrows emanating out of grooves of the heat radiation portion 115 in FIG. 3.

(21) Since the heat radiation portion 115 is disposed in a space between the cover portion 111 and the PSU receiving portion 118, the heat being radiated through a bottom of the cover portion 111 may be discharged to the outside directly through the heat radiation portion 115 along arrows shown in FIG. 3, rather than being transferred to the PSU receiving portion 118 and the PSU 140 disposed in the PSU receiving portion 118.

(22) In addition, the heat radiation portion 115 is designed to provide airflow for cooling the PCT 130 and LEDs 131. As such, the PCB 130 and the plurality of LEDs 131 mounted to the PCB 130 may be cooled by the flow of air having a relatively low temperature.

(23) Thus, according to one embodiment, the housing member 110a includes the heat radiation portion 115, which allows passage of airflow between the cover portion 111 and the PSU receiving portion 118, instead of including a separate heat sink plate for heat radiation. Therefore, the heat generated from the PCB 130 (including the plurality of LEDs 131) may be efficiently absorbed by the heat radiation portion 115 and transferred outside of the LED lamp structure. Since a separate heat sink or other heat dissipating structure is unnecessary in this case, the material costs may be reduced.

(24) As shown in FIGS. 2, 3, and 4, the housing member 110a may further include a connection unit 150 for interconnecting the cover portion 111 and the PSU receiving portion 118 with the heat radiation portion 115 disposed therebetween.

(25) The connection unit 150 may include a wire passing portion 151 connecting the cover portion 111 with a center of the PSU receiving portion 118. The wire passing portion 151 can include a through hole or other opening for passing a power line 141 to connect the PCB 130 with the PSU 140, and a vent hole forming portion 155 for connecting the cover portion 111 with an outer part of the PSU receiving portion 118. As shown, the vent hole forming portion 155 can provide a vent hole for providing airflow in a space between the cover portion 111 and the outside.

(26) The power line 141 may be disposed within, and pass through, the wire passing portion 151, such that one end of the power line 141 is connected to a lower end of the PCB 130 while an opposite end of the power line 141 is connected to the PSU 140. The power line 141 and the outside may be isolated from each other by the wire passing portion 151. Accordingly, the wire passing portion 151 may provide electrical isolation of the power line 141 from the outside of the LED lamp structure, notably in cases in which the circuitry is not otherwise isolated.

(27) As shown in FIG. 1, a plurality of vent hole forming portions 155 may be formed along outer parts of the cover portion 111 and the PSU receiving portion 118. The plurality of vent hole forming portions 155 may stably connect the cover portion 111 and the PSU receiving portion 118 to each other, with the heat radiation portion 115 interposed therebetween. Heat can be radiated away and cool air may be introduced through a space defined by the plurality of vent hole forming portions 155. Therefore, the heat generated by the plurality of LEDs 131 may be efficiently dissipated and the PCB and LEDs may thus be cooled.

(28) As shown in FIG. 1, the housing connection member 120 may be connected at one end (e.g., a lower end) of the pair of housing members 110a and 110b. In one example, the housing connection member 120 is connected at an end of members 110a and 110b in which the PCB 130 (including the plurality of LEDs 131) and the PSU 140 are mounted, and the housing connection member 120 is used to stably maintain the pair of housing members 110a and 110b in their connected configuration. For the purpose of stably maintaining the members connected, a male screw thread may be formed on an outer surface of one end of the pair of housing members 110a and 110b, while a female screw thread is formed inside (or on an inside surface of) the housing connection member 120 so as to be engaged with the male screw thread when the parts are assembled. Therefore, the housing connection member 120 may be easily connected to or separated from the pair of housing members 110a and 110b.

(29) However, the structure and the connection system of the pair of housing members 110a and 110b and the housing connection member 120 are not limited to the aforementioned description. Other shapes and connection structures may be used. In addition, a housing member (not shown) may be manufactured to include a socket portion shaped similarly to the housing connection member 120, for example. In such an example, a housing connection member may or may not be separately provided.

(30) Thus, the LED lamp 100 according to one illustrative embodiment of the present invention is configured such that the lamp housing 110 is integrally formed with the cover portion 111 and the heat radiating structure. Therefore, a number of parts may be reduced compared to comparable LED lamp structures and also the material costs may be reduced. Additionally, since the various parts of the LED lamp 100 are designed to be connected together along a horizontal direction, the ease of assembly of the lamp is improved.

(31) Hereinafter, an illustrative method for manufacturing the LED lamp 100 according to an embodiment of the present invention is described with reference to FIGS. 5 and 6.

(32) FIG. 5 is a flowchart illustrating a method of manufacturing an LED lamp according to one embodiment of the present invention. FIG. 6 is a diagram illustrating sequential processes forming part of the manufacturing method of FIG. 5.

(33) As shown in FIG. 5, the method for manufacturing the LED lamp 100 may include a step 501 for mounting or connecting the PCB 130, on which the plurality of LEDs 131 are mounted, to the cover portion 111 of one housing member 110a. In a second step 503, the PSU 140 is mounted or connected to the PSU receiving portion 118 of the one housing member 100a. Next, in step 505, the PCB 130 is connected or mounted to the PSU 140 using the power line 141 placed within the housing member 110a. In step 507, the other housing member 110b is connected to the one housing member 110a by assembling the housing members together in a horizontal direction. Finally, in step 509, the housing connection member 120 is mounted or connected to the pair of housing members 110a and 110b once they are connected with each other.

(34) First, step 501 may result in the PCB 130, on which the plurality of LEDs 131 are mounted, being mounted in the insertion groove 112 of the one housing member 110a, as shown in the top-left quadrant of FIG. 6. According to the present embodiment, the connecting of the PCB 130 to the housing member 110a may be completed by inserting the PCB 130 in the insertion groove 112 in a horizontal direction (shown as the direction of the arrow in the top-left quadrant of FIG. 6).

(35) Step 503 may be also easily performed by horizontally mounting the PSU 140 in the PSU receiving portion 118 of the one housing member 110a, as shown in the top-right quadrant of FIG. 6.

(36) After the PSU has been connected, step 505 may be performed in which the PCB 130 and the PSU 140 are electrically connected to each other using the power line 141 place within the wire passing portion 151.

(37) When the mounting of components with respect to the one housing member 110a is completed, step 507 results in the other housing member 110b being connected to the one housing member 110a (as shown in the middle-right quadrant of FIG. 6. Here, a bonding connection, a hook connection, a screw connection, or the like may be applied for connecting the pair of housing members 110a and 110b together. However, the connection method is not limited to the aforementioned examples.

(38) Finally, step 509 screw-connects the housing connection member 120 to the housing members 110a and 110b, as shown in the middle-left quadrant of FIG. 6, thereby completing manufacturing of the LED lamp 100 as shown in bottom-most quadrant of FIG. 6.

(39) As aforementioned, since the present embodiment is configured such that the other housing member 110b is horizontally connected to the one housing member 110a, the ease of assembly of the LED lamp 100 may be improved. In addition, since the PCB 130 and the PSU 140 are easily connected in the pair of housing members 110a and 110b, the structure may be simplified.

(40) FIG. 7 is a diagram illustrating an inner structure of an LED lamp according to the present invention. The features of the LED lamp shown in and described in relation to FIG. 7 may be implemented in the LED lamp 100 of FIGS. 1-6, and/or in other LED lamps.

(41) As shown in the drawing, a housing member 210a of the LED lamp may be integrally formed in the same manner as the housing member 110a of FIG. 2. A PCB 230 on which one or more LEDs 231 are mounted and a PSU 240 may be built in the housing member 210a, or assembled together as shown in FIG. 7 (and as described in relation to FIGS. 1-6). However, differently from the housing member 110a which radiates the heat generated from the LEDs 131 through the heat radiation portion 115, the housing member 210a may include not only a heat radiation portion 215 (similar to heat radiation portion 115 described above) but also a separate heat sink plate 235 detachably connected within an auxiliary insertion recess 213 formed in a lower portion of cover portion 211. Therefore, the heat radiation efficiency may be increased through the use of the separate heat sink plate 235.

(42) That is, the heat generated from the LED 231 may be absorbed by the heat sink plate 235 and, additionally, radiated through the heat radiation portion 215. Therefore, the PCB 230 may be cooled quickly and efficiently.

(43) However, as described above in relation to FIGS. 1-6, the heat sink plate 235 may be omitted so as to provide a simpler structure. For example, the PCB 230 inserted in the insertion groove 212 in FIG. 7 may instead be inserted into the auxiliary insertion groove 213 in situations in which the heat sink plate 235 is not used. Hence, the heat sink plate 235 can optionally be used, or not used.

(44) Thus, similarly to the LED lamp structure described in relation to FIGS. 1-6, the illustrative lamp structure shown in FIG. 7 may provide a simplified structure and reduced material costs by employing a housing member 210a of the integrated type. Furthermore, the heat radiation efficiency may be increased through the use of the heat sink plate 235.

(45) The above description has used directional terms (horizontal/vertical; above/below; upper/lower; etc.) to describe the relative positions of various elements as shown in the figures. It should be understood, however, that while such terms are used to describe the relative positions of elements with respect to each other, the terms do not necessarily reflect the absolute position of elements in space. For example, elements that are described as being above or below one another may be, in situations in which the LED lamp structure of FIG. 1 is turned on its side, beside each other.

(46) Although a few exemplary embodiments of the present invention have been shown and described, the present invention is not limited to the described exemplary embodiments. Changes may be made to these exemplary embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.