COMPLETE SPECIFICATION
An LED Light Bulb with a unique Locking Ring, Aluminum Disk, and a Plastic Diffuser
combination that achieves convective cooling of the bulb in a manner as to protect the lamp
LEDs from ambient dust and flies etc. as also make the product assembly easier.
FIELD OF INVENTION
[ 001 ] The invention relates to Light Bulbs using Light Emitting Diodes (LED)s as light sources,
with a unique design to achieve convective cooling on special heat sink which is covered with
Electrically Insulating Plastic over metal heat sink while preventing the LEDs from ambient dust
and flies etc.
BACKGROUND OF THE INVENTION
[ 002 ] In most of the present day LED bulbs, the Optical diffuser covering the LEDs is made of
Glass. Plastic Diffusers are also being used, but still the existing products having the following
limitations:
a) The Glass Diffuser is more complex to manufacture and assemble
b) Glass being fragile is prone to breakage.
c) The assembly requires the Glass Diffuser to be glued to the plastic body of the bulb.
d) The current diffuser designs for convective Cooling design of older type cannot prevent
dust from entering the inside of the diffuser and gathering over the LEDs during long
usage time. A
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[ 003 J The proposed innovation uses a unique Plastic Locking Ring, Aluminum Disk, Plastic
Diffuser, Heat Sink and Plastic Base combination for achieving convective cooling of the LED
Metal Core PCB (MCPCB) in a manner as to protect the lamp LEDs from ambient dust and flies
etc. and also make the product assembly easier avoiding usage of glue for fixing the diffuser to
the bulb body.
[ 004 ] The unique Plastic Optical Diffuser locks mechanically with the Plastic Locking Ring
with the help of 3 projections. These projections ensure that the Plastic Diffuser is locked in the
right place on the locking ring, during the assembly process.
[ 005 ] The unique Aluminum Metal Disk (Item no. 3) put inside the Locking Ring is
mechanically locked with the main Plastic Body & Heat sink by use of 3 Screws. This Al Disk
not only prevents the dust or flies to enter the LED area but also supports quicker heat transfer to
the Heat & helps in optimum heat management.
PRIOR ART
[ 006] In a previously published US patent application with Number: WO 2007130358 A2,
published on Nov 15, 2007, is mentioned a Plastic LED Bulb with a plastic Diffuser Shell.
However the patent application does not feature any plastic locking mechanism as claimed in the
proposed innovation.
SUMMARY OF THE INVENTION
[ 007 ] The principle objective of the innovation is to achieve convective cooling of the bulb in a
manner as to protect the lamp LEDs from ambient dust and flies etc
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[ 008 ] Another objective of the innovation is to achieve plastic locking of the diffuser to the rest
of the bulb body and eliminating the gluing of the diffuser as in existing products, thereby
increasing the ease of product assembly.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[ 009 J The features of the invention, are detailed out in the figures, Figure 1, Figure 2, Figure 3
and Figure 4 , Figure 5
Figure 1 shows the Exploded view of Proposed LED Bulb assembly as compared to a old
conventional LED Bulb assembly
Figure 2 shows the Cross Sectional View of the Assembled Lamp where in the Al/Metal Disc,
locking ring, Diffuser, heat sink & outer plastic Body details shown.
Figure 3 shows the external view of the Assembled Lamp with convective air currents marked.
Figure 4 shows the Plastic Diffuser details showing the plastic locking projections.
Figure 5 shows the Plastic Ring where 3 projections of diffuser rests and 3 mechanical locks of
diffuser gets stuck.
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DESCRIPTION OF THE PREFFERED EMBODIMENTS
[ 009 ] Figure 1 illustrates the key components of the innovation which are as follows:
[ 010 ] Individual components of the innovation are:
1 Plastic Diffuser
2 LED MCPCB
3 Aluminum/Metal Disk
4 Plastic Ring
5 Heat sink
6 Plastic Body
[ Oil ] The function of the key components of the LED Bulb are as follows:
[ 012 ] Plastic Diffuser: In the Plastic Diffuserfl], 3 extrusion and 3 locks are provided at
60/120 Degree angle, during assembly it get locked into the plastic ring easily. If the extruded
part of diffuser is not place properly into the groove then the diffuser will get bounce back &
prevent misplacement of Diffuser locks in the locking Ring.
[ 013 J LED MCPCB: The LED MCPCB [2] is a circular metal core PCB for mounting the
LED lamps on top surface and the bottom surface used for dissipating the excess LED heat.
[ 014 ] Aluminum/Metal Disc: The Aluminum/Metal Disc [3] together with the Plastic Locking
Ring [4] helps in holding the Aluminum/Metal Disc & also support the locking of the diffuser
after the lamp assembly is completed. This Disk has 4 holes. The center hole is for connecting the
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input wire to the LED+PCB. The 3 hole at 120 Degree are been provided to lock the LED+ PCB,
Locking Ring & the plastic Body by way of 3 screws so that the Gluing is avoided in
manufacturing process & also to prevent dust and mosquitoes to get inside the plastic diffuser.
[ 015 ] Plastic Locking Ring: A special plastic locking ring [4] holds the Aluminum/Metal
Disc [3] & also support the locking of the diffuser[l] after the lamp assembly is completed. The
top locking
Plastic Ring[4] is supported in such a fashion to leave opening on top which would help in
natural convective cooling of the heat sink which is safely housed in side the plastic Body[6]. On
top of plastic ring[4] which is having specific size of groove on which the aluminum disc [3]
rests on the ring, which in turn avoids dust to enter into diffuser [1] . The locking ring [4] is
designed in manner that it seals the LED MCPCB [2] while still maintaining the contact with the
Heat Sink [5J which is internally exposed for convective cooling for taking out the heat from the
lamp.
[ 016 ] Heat Sink: The Heat Sink [5] is a finned aluminum extruded section for convective
cooling of the LED MCPCB.
[ 017 ] Plastic Base: The Plastic Base [6] with special air vents release the heat from the heat
sink and also ensures that no metal part of the heat sink is exposed & there is no risk to user even
if the lamp is failed or electronics inside has shorted.
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(Overdrive
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CLAIMS : 1/We claim
1. An LED Light Bulb with a unique Plastic Locking Ring, Aluminum/Metal Disk, Plastic
Diffuser, Heat Sink and Plastic Base combination that achieves convective cooling of the
LED Metal Core PCB (MCPCB) in a manner as to protect the lamp LEDs from ambient
dust and flies etc. and also make the product assembly easier.
2. A Plastic Diffuser as claimed in Claim 1, which is made from optically translucent
plastic, and has 3 projections, 120 degree apart and 3 locking features 120 Degree apart,
to get locked into the plastic ring with ease during product assembly. The extruded part of
diffuser if not placed properly into the groove in the locking ring, bounces back thereby
preventing misplacement of Diffuser locks.
3. An Aluminum/Metal Disc as claimed in Claim 1, which is made of Aluminum or other
suitable metal and together with the Plastic Locking Ring helps in holding itself as also
support the locking of the diffuser after the lamp assembly is completed.
4. An Aluminum/Metal Disc as claimed in Claim 1, where the Disk has 4 holes. The center
hole is for connecting the input wire to the LED MCPCB. The 3 other holes 120 Degree
apart are provided to lock the LED MCPCB, Locking Ring & the Plastic Base by way of
3 screws so that the gluing is avoided in manufacturing process & also to prevent dust and
mosquitoes to get inside the plastic diffuser. This Alumimum/metal Disc is sized to have
tight fitment in the licking ring to seal the LED from external dust etc.
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5. A Plastic Locking Ring as claimed in Claim 1, which holds the Aluminum/Metal Disc &
also support the locking of the diffuser after the lamp assembly is completed.
6. A Plastic Locking Ring as claimed in Claim 1, which is supported in such a way as to
leave an opening on the side of the internal embedded heat sink which would help in
natural convective cooling of the heat sink which is safely housed inside the Plastic Base.
7. A Plastic Locking Ring as claimed in Claim 1, which has specific sized groove on which
the aluminum disc rests on the ring, which in turn avoids dust to enter into diffuser
8. A Plastic Locking Ring as claimed in Claim 1, which is designed in a manner that it seals
the LED MCPCB while still maintaining the thermal conductive contact with the Heat
Sink which is internally exposed for convective cooling for taking out the heat from the
lamp.
9. A Plastic Base constructed in manner as claimed in Claim 1, in with special air vents,
along with the opening on top of the plastic locking ring, release the heat from the heat
sink and also ensures that no metal part of the heat sink is exposed & there is no risk to
user even if the lamp is failed or electronics inside has shorted.