Waterproof light bulb assembly
12535206 ยท 2026-01-27
Inventors
Cpc classification
F21V31/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/238
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/232
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2115/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F21V31/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/232
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/238
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A waterproof light bulb assembly implements a plurality of light emitting diodes (LEDs) for use in light fixture in an outdoor or wet environment. The light bulb assembly includes a clear plastic bulb shell which used a threaded portion to mate to a bulb cap. The bulb cap includes a passage to receive a light emitting assembly having a direct current (DC) connector. The light emitting assembly includes the plurality of LEDs and a printed circuit board. The light bulb assembly also includes a lens assembly that is located above and cover the light emitting assembly. The lens assembly includes lens in a shape of upside-down pyramid seated on a top of a hollow cylinder. The hollow cylinder is inserted into the bulb cap and covers the light emitting assembly. The lens is configured to reflect and refract a light beam emitted from the light emitting assembly.
Claims
1. A waterproof light bulb, comprising: a clear plastic bulb shell having a threaded portion corresponding to a first mating part; a bulb cap to fit into the first mating part of the clear plastic bulb shell and having a passage centered therewithin; a light emitting assembly having a direct current (DC) connector to fit through the passage within the bulb cap, wherein the light emitting assembly includes a printed circuit board connected to the DC connector, and a plurality of LEDs (light emitted diodes) configured on the printed circuit board to face upwards from the printed circuit board; and a lens assembly located on a top of the light emitting assembly, including: a lens having a cut-edged top surface, and a peak centered with respect to the cut-edged top surface and positioned to point towards the light emitting assembly; and a hollow cylinder supporting the lens, wherein the lens is inserted on a top of the hollow cylinder, and a height of the hollow cylinder is determined based on a focal distance between the lens and the light emitting assembly, the lens is configured to reflect and refract a light emitted from the light emitting assembly.
2. The waterproof light bulb of claim 1, wherein the light emitting assembly further includes a switching (LC) circuit configured on the printed circuit board configured to regulate an amount of heat generated by the light emitting assembly.
3. The waterproof light bulb of claim 1, wherein the light emitting assembly is seated on the bulb cap, and a part of the hollow cylinder of the lens assembly is inserted into the bulb cap to cover the light emitting assembly.
4. The waterproof light bulb of claim 1, wherein the lens is in a shape of an upside-down pyramid.
5. The waterproof of light bulb of claim 1, wherein a lower part of the hollow cylinder is narrower than a rest of the hollow cylinder and a diameter of the lower part is smaller than that of the rest of the hollow cylinder, wherein the lower part of the hollow cylinder is configured to be inserted into the bulb cap.
6. The waterproof light bulb of claim 1, wherein a size of the plastic bulb shell corresponds to an amount of heat generated by the light emitting assembly.
7. The waterproof light bulb of claim 1, wherein the bulb cap includes a second mating part to fit into the first mating part of the plastic bulb shell, and wherein the second mating part includes a tapered portion extending into the plastic bulb shell.
8. The waterproof light bulb of claim 1, wherein the DC connector includes a cylindrical portion and an extension portion that extends beyond a bottom surface of the bulb cap.
9. The waterproof light bulb of claim 2, wherein the light emitting assembly includes a diode to regulate current within the switching circuit.
10. The waterproof light bulb of claim 1, wherein the light emitting assembly includes an integrated circuit to regulate current within the light emitting assembly.
11. A waterproof light bulb assembly, comprising: a clear plastic bulb shell having a threaded portion corresponding to a first mating part; a bulb cap to fit into the first mating part of the clear plastic bulb shell and having a passage centered therewithin; a light emitting assembly having a direct current (DC) connector to fit through the passage within the bulb cap, wherein the light emitting assembly includes: a printed circuit board to fit into a step of the bulb cap and connected to the DC connector, a plurality of light emitting diodes (LEDs) configured on the printed circuit board to face upwards from the printed circuit board, and a switching (LC) circuit configured on the printed circuit board configured to regulate an amount of heat generated by the light emitting assembly; a lens assembly located on a top of the light emitting assembly, the lens assembly including: a lens having a cut-edged top surface and a peak centered with respect to the cut-edged top surface and positioned to point towards the light emitting assembly; and a hollow cylinder supporting the lens, wherein the lens is inserted on a top of the hollow cylinder, and a height of the hollow cylinder is determined based on a focal distance between the lens and the light emitting assembly, the lens is configured to reflect and refract a light emitted from the light emitting assembly; and a socket having an interior threaded portion to receive the threaded portion of the plastic bulb shell, the socket including a female connector to receive the DC connector, and an O-ring positioned in the female connector to engage the DC connector.
12. The waterproof light bulb of claim 11, wherein the light emitting assembly is seated on the bulb cap, and a part of the hollow cylinder of the lens assembly is inserted into the bulb cap to cover the light emitting assembly.
13. The waterproof light bulb of claim 11, wherein a lower part of the hollow cylinder is narrower than a rest of the hollow cylinder and a diameter of the lower part is smaller than that of the rest of the hollow cylinder, wherein the lower part of the hollow cylinder is configured to be inserted into the bulb cap.
14. The waterproof light bulb assembly of claim 11, further comprising a mount connected to a bottom portion of the socket.
15. The waterproof light bulb assembly of claim 11, wherein the lens is in a shape of an upside-down pyramid.
16. A light emitting diode (LED) lighting device, comprising: an assembly of a light emitting module and a lens module; and a direct current (DC) connector, connected with the light emitting module and extended therefrom for connecting to a power source, wherein the light emitting module connected to the DC connector includes a printed circuit board connected to the DC connector, a plurality of LEDs configured on the printed circuit board to face upwards from the printed circuit board, and a switching (LC) circuit configured on the printed circuit board configured to regulate an amount of heat generated by the light emitting module, and wherein the lens module is located on a top of the light emitting module and is configured to cover the light emitting module, the lens module includes a lens in a shape having a cut-edged top surface and a peak centered with respect to the cut-edged top surface and positioned to point towards the light emitting module; and a hollow cylinder supporting the lens, wherein the lens is inserted on a top of the hollow cylinder, and a height of the hollow cylinder is determined based on a focal distance between the lens and the light emitting module, wherein the lens is configured to reflect and refract a light emitted from the light emitting module.
17. The LED lighting device of claim 16, further comprising a clear plastic light bulb shell for enclosing the assembly of the light emitting module and the lens module, wherein the clear plastic bulb shell has a threaded portion that corresponds to a first mating part.
18. The LED lighting device of claim 17, further comprising a bulb cap to fit into the first mating part of the clear plastic bulb shell and having a passage centered therewithin, wherein the light emitting module fits through the passage within the bulb cap.
19. The LED lighting device of claim 18, further comprising a socket having an interior threaded portion to receive the threaded portion of the plastic bulb shell, the socket including a female connector to receive the DC connector, and an O-ring positioned in the female connector to engage the DC connector.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings are included to provide further understanding of the invention and constitute a part of the specification. The drawings listed below illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention, as disclosed by the claims and their equivalents.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(15) Aspects of the invention are disclosed in the accompanying description. Alternate embodiments of the present invention and their equivalents are devised without parting from the spirit or scope of the present invention. It should be noted that like elements disclosed below are indicated by like reference numbers in the drawings.
(16) The waterproof light bulb assembly of the disclosed embodiments includes a bulb cavity configured to allow for the correct heat release provided by the plurality of LEDs. Excessive heat discharge can cause damage to the LED bulb. The LED modules inside the bulb generate heat. If there are too many LED modules, then the interior of the bulb overheats which causes the circuitry and other components within the bulb to fail. Too few modules, and the light bulb is too dim for use in an outdoor or wet environment. Further, the light bulb should resemble a conventional bulb. Thus, the disclosed embodiments provide a plurality of LED modules to emit enough light for use in chandeliers and other light fixtures but also account for the generated heat to avoid failures.
(17) It should be noted that the disclosed waterproof light bulb assembly may be used in any location, including outdoors in the rain or in inclement weather. The light bulbs do not require extensive maintenance. Unlike conventional light bulbs, the disclosed light bulbs resist corrosion from the elements and exposure. For example, a conventional upward-facing Edison light bulb may only last a short time being used outdoors before needing to be replaced. This failure rate precludes use of the Edison conventional bulb in remote or elevated locations as personnel would have to lower and replace the bulbs frequently.
(18) Although there are LED bulbs on the market, these devices do not look or illuminate like conventional incandescent light bulbs. The disclosed embodiments allow for a modern, energy efficient, all weather light bulb that is upward-facing and is cosmetically identical or looks similar to any traditional indoor candelabra light bulb. This feature may be important for set locations and the ambience being created by using a chandelier. Further, the LED light bulbs in accordance with the disclosed embodiments are applicable to wet location environments.
(19) The disclosed embodiments also allow for existing or even antique light fixtures to be retrofitted with the waterproof light bulbs. The disclosed light bulb assembly may fit different light bulb socket designs and dimensions. This benefit allows the disclosed light bulbs to fit many varieties of devices and fixtures, some of which are antiques in that they do not include the designs of modern light fixtures.
(20) The waterproof light bulb assembly in accordance with the disclosed embodiments includes LED modules as light sources and a hollow light bulb, or light bulb shell. The LED modules including a plurality of LEDs are installed in the light bulb assembly with the plurality of LEDs facing upwardly. The light bulb shell acts like that glass portion of a conventional light bulb. This appearance also is provided based on the configuration of the LED modules within the light emitting assembly. The LED light is not as soft as the light emitted in a conventional light bulb, and as the plurality of LEDs face upwardly, the LED light will shine in an upward direction. Conventionally, the light bulb shell is made frosted to let light pass through but not too frosted to diminish the lighting effects. The frosted light bulb shell helps reserving some emitting light inside of the light bulb to provide the appearance of a conventional light bulb. The disclosed embodiments provide a unique waterproof light bulb assembly in which the light bulb shell may be made of clear plastic. An additional lens is disclosed inside the light bulb shell to reflect and refract the light shone by the LED module to render the light bulb having an appearance of a conventional light bulb. In the disclosed embodiments, the bulb shell made be made of clear or frosted plastic.
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(22) Lens 122 is located above light emitting assembly 104 and is apart from assembly 104 with a distance called a focal length. To do so, lens 122 is inserted on a top of hollow cylinder 128. The height of hollow cylinder 128 is determined to ensure that the light emitted from light emitting assembly 104 will travel to lens 122 and be reflected and refracted by lens 122, thereby a light bulb appearance most simulated to the conventional light bulb are generated.
(23) A detailed view of lens assembly 120 is illustrated in
(24) Light emitting assembly 104 includes components that emit light using LED modules. Preferably, light emitting assembly 104 includes a plurality of LEDs that are oriented upwards into plastic bulb shell 102. Light emitting assembly 104 also includes circuitry and components to regulate the heat given off by the LED modules. Light bulb shell 102 also may be sized to account for the heat generated by light emitting assembly 104.
(25) Bulb cap 106 seats light emitting assembly 104 as well as mates that light bulb shell 102. Disclosed in greater detail below, bulb cap 106 is configured to resemble a conventional light bulb that is placed in a light fixture. A direct current (DC) connector of light emitting assembly 104 extends through bulb cap 106 to receive power to the circuitry and LED modules. Bulb cap 106 is fits tightly, or mates, with a portion of light bulb shell 102 to provide a waterproof seal.
(26) Lens assembly 120 is seated on the top of light emitting assembly 104 and is inserted in bulb cap 106. As describe above, lower end 130 of hollow cylinder 128 has a smaller diameter than the rest of hollow cylinder 128. Therefore, after lower end 130 of hollow cylinder 128 is inserted in bulb cap 106, the rest of hollow cylinder 128 will sit on bulb cap 106 to secure the position of lens assembly 120.
(27) Light bulb assembly 100 also includes socket 108 and mount 110. Socket 108 may receive bulb cap 106 and a threaded portion of light bulb shell 102. Socket 108 also may help attach the DC connector to a wire or power source in a secure manner. Socket 108 is secured to mount 110. Mount 110 is configured to fit light bulb assembly 100 to a variety of light fixtures.
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(29) As can be seen in
(30) Some components of socket 108 are shown in more detail. Socket 108 includes socket housing 204. Socket housing 204 includes a threaded interior portion to receive the threaded exterior portion of light bulb shell 102. Two screws 206 attach socket housing 204 to mount 110. Socket 108 also includes o-ring 202 and female connector 208. These components engage the DC connector of light emitting assembly 104, disclosed in greater detail below. Female connector 208 fits within socket housing 204.
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(32) Exterior threaded portion 302 is provided on the bottom of light bulb shell 102. Exterior threaded portion 302 is shown in greater detail by
(33) The interior of exterior threaded portion 302 may be referred to as mating part 406. Mating part 406 includes a tapered draft 408. Tapered draft 408 tapers inward along the length of mating part 406. Tapered draft 408 may tap at an angle between 0.5 to 3. Thus, the passage 410 of light bulb shell 102 to receive bulb cap 106 may get slightly thinner the further it goes towards shaped portion 301.
(34) Referring back to
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(36) Bulb cap 106 also includes connector passage 506. Connector passage 506 receives DC connector 304 of light emitting assembly 104. Connector passage 506 may be formed by inner casing 508. Inner casing 508 extends from bottom surface 502 into the interior of bulb cap 106. Inner casing 508 also fits DC connector 304 and may be circular. Connector passage 506 also includes a receiving area 510 to receive part of female connector 208 and O-ring 202 that engages DC connector 304.
(37) Bulb cap 106 also includes mating part 512 that acts as a side surface. Mating part 512 engages mating part 406 of light bulb shell 102. Mating part 512 also tapers inward at a tapered draft 514. Like tapered draft 408, the surface may taper at an angle of 0.5 to 3 in order to fit within light bulb shell 102. This configuration allows bulb cap 106 to be press fit into light bulb shell 102. Alternatively, these two components may be sonic welded together. The components form a water barrier for the interior of light bulb 200. Light bulb 200 may be waterproof within up to 10 feet of water.
(38) Bulb cap 106 also includes interior space 514. Interior space 514 is a hollow portion that surrounds inner casing 508. Hollow portion 514 allows mating part 512 to press inwards to press fit into light bulb casing 102. It also helps reduce the weight associated with bulb cap 106. At the top of mating part, or side surface, 512 is step 516. Step 516 is configured to receive part of light emitting assembly 104, as disclosed below.
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(40) Various components to provide light and regulate current are placed on printed circuit board 602. These components are placed on a top side 607 of printed circuit board 602 opposite DC connector 304. LED modules, or LEDs, 608 provide light within light bulb 200. LEDs 608 may be high powered LEDs that provide white light. LEDs 608 may operate at 380 lumens. Preferably, light emitting assembly uses a plurality of LEDs 608. For example, two LEDs may be used. LEDs 608 are configured to face upwards, or perpendicular, from printed circuit board 602. Thus, LEDs 608 emit light into light bulb shell 102. This configuration differs from known light bulbs using LEDs that are oriented in a strip within the bulb shell.
(41) LEDs 608 may be extreme high powered LEDs. The disclosed LEDs may have a viewing angle of 135 degrees. They also may have a thermal resistance, junction to solder point, of 1.8 C./W. They also may have a temperature coefficient of voltage of 5.6 mV/ C. They also may have an ESD withstand voltage of 8000 V. They also may have a DC forward current of 1050 mA and a reverse voltage of 5 V. The disclosed LEDs also may have a forward voltage of 11.2-11.9 V at 350 mA, 85 C. The LED junction temperature may be about 150 C.
(42) Light emitting assembly 104 also includes circuit components to provide a switching circuit that regulates current and heat within light bulb 200. This feature allows light bulb 200 and light emitting assembly 104 to operate for extended periods without damaging the components therewithin. The switching, or LC, circuit includes inductor 610 and capacitor 612. The switching circuit also may include resistor 614 to modulate how much current is provided to the circuit. The switching circuit acts as an electrical resonator to store energy oscillating at a switching frequency of the circuit. By using the switching circuit, heat generated by light emitting assembly 104 may be regulated so that it does not interfere with the operations of light bulb 200.
(43) Inductor 610, capacitor 612, and resistor 614 are placed on printed circuit board 602 along with LEDs 608. Light emitting assembly 104 also includes integrated circuit 616 which handle current regulation with logic and diode 618 also to regulate current within the components. Diode 618 may be in series with inductor 610 and capacitor 612. Diode 618 may configure the circuit to flow in one direction, preferably to LEDs 608. Integrated circuit 616 may be a lighting driver and use its logic also to regulate current within light emitting assembly 104. Diode 618 and integrated circuit 616 are placed on printed circuit board 602. Preferably, all these circuit components are positioned in the plane.
(44) In some embodiments, the components of light emitting assembly 104 may have values. For example, resistor 614 may have a resistance of 1.5 ohms. Capacitor 612 may have a capacitance of 4.7 uF and may be a multilayer ceramic capacitor. Inductor 610 may be a fixed inductor having an inductance of 47 uH at 710 mA and a DC resistance of 491 mOhms. Integrated circuit 616 may be a LED light driver operating as buck LED driver for 6-60V and 1 A. DC connector 304 may be a DC power connector having the dimensions of 3.51.1 mm and is a power plug spring type with groove. Diode 618 may be a Schottky diode operating at 1 A and 40V.
(45) DC connector 304 includes tip 601. Tip 601 may be the portion of DC connector 304 that extends out from bottom surface 502 of bulb cap 106. Tip 601 may engage a power source outside light bulb 200 to receive power. DC connector 304 is insert molded or overmolded within bulb cap 106. This feature may be shown in
(46) Light emitting assembly 104 is insert molded or interference fitted within connector passage 506 using DC connector 304. This fitted piece may withstand up to 25 pounds of force. Printed circuit board 602 rests or is fitted to engage step 516 of bulb cap 106. As shown, LEDs 608 are oriented to emit light upwards and away from printed circuit board 602.
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(48) Socket 108 also includes connector portion 804. Connector portion 804 may include casings to enclose passages to fit other components of socket 108. Connector portion 804 may be thinner than socket housing 204. Connector portion 804 includes screw receiving passages 806. There may be two screw receiving passages. These receive screws 206. Connector portion 804 also includes connector passage 808 enclosed by connector casing 809. Connector portion 804 may receive female connector 208 that engages DC connector 304 of light emitting assembly 104. This connection is shown in greater detail below. Connector portion 804 also include extended part 812 that surrounds area 810 below connector passage 808. Extended part 812 by be used to align socket 108 with mount 110.
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(50) Female connector 208 includes upper section 902 and lower section 904. Upper section 902 may be received in receiving area 510. Lower section 904 may remain in socket 108. The sections are separated by depression 906. Depression 906 encircles female connector 208 and is configured to engage O-ring 202. O-ring 202 rests in depression 906 when light bulb assembly 100 is fitted together. Lower section 904 stabilizes female connector 208 within socket 108. Two parts extend from the bottom surface of lower section 904. Positive connector 908 extends from an outer boundary of lower section 904. It may be used to align female connector 208 and hold a connection to the female connector in place. Negative connector 910 may extend from the center of the bottom surface of lower section 904. Thus, connectors 908 and 910 provide the connections to a power source for light bulb assembly 100.
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(52) Mount 110 includes base 1002. Base 1002 includes hole 1004 having a border 1005. Hole 1004 and border 1005 allow mount 110 to be placed a pipe fitting. In some embodiments, hole 1004 is sized to fit a certain type of fitting. Mount 110 also includes arms 1006 that extend outwards from base 1002. Arms 1006 curve inwards as well to align holes 1008 with the bottom of socket 108. Holes 1008 receive screws 206 to secure socket 108 and mount 110 together. Arms 1006 extend from base 1002 so that one may have access to the bottom of socket 108 and to female connector 208.
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(54) It also may be shown that female connector 208 along with O-ring 202 provides a seal between socket 108 and light bulb 200. Positive and negative connectors 908 and 910, respectively, are shown extending outwards to be soldered to wires or connect to a power source for light bulb 200. All components are fitted to provide a waterproof seal that allows the disclosed waterproof light bulb assembly to be used outside and in wet conditions without exposing the circuits to the elements. Further, the light emitting assembly is configured to regulate the amount of heat generated so as to not overheat or damage the components. Once placed in the secure, waterproof fitting, the disclosed assembly does not need to be replaced or fixed for an extended period of time so that the disclosed assembly may be used in remote locations.
(55) It may be appreciated that the disclosed embodiments, including light bulb 102, waterproof light bulb assembly 100, and light emitting assembly 104 are comprised, or mostly comprised, of plastic materials. This feature is in contrast to conventional light bulbs using LEDs that are comprised, at least partially, of metal. These metal component bulbs may dissipate heat but are ill-suited for the disclosed embodiments as they are not able to withstand exposure to outdoors or wet conditions. The metal corrodes and rusts over time so that these conventional light bulbs cannot be used and causes damage to the light fixture. The disclosed embodiments, by regulating the generated heat, is able to use plastic components that can withstand outdoor and wet conditions.
(56) Further, as the light bulb assembly 100 includes a lens assembly 12 that reflects and refracts the light beam emitted from light emitting assembly 104, light bulb shell 102 does not need to made frosted and can be made of clear plastic. An upward-facing light bulb assembly that has an appearance of any traditional candelabra light bulb can thus be provided in accordance with the disclosed embodiments. The light bulb assembly of the disclosed embodiments can be used indoors and outdoors with a wet location environment.
(57) It will be apparent to those skilled in the art that various modifications and variations can be made in the disclosed embodiments of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention covers the modifications and variations of the embodiments disclosed above provided that they come within the scope of any claims and their equivalents.