Claims:1. A light emitting diode (LED) device (100, 200) comprising:
a fixture body (102) having receptacle with a base (104), the base (104) comprising:
at least two key holes (110-1, 110-2) formed at diamtrically opposite ends of the base (104) for receiving heads of screws fixedly mounted on a surface of a mounting structure; and
at least three alignment holes (112-1, 112-2, 112-3) formed at even distance from each other around the boundary of the base (104) for receiving corresponding at least three alignment legs (114-1, 114-2, 114-3) of a diffuser (114) to releasable mount the diffuser (114) on the fixture body (102).

2. The light emitting diode (LED) device (100, 200) as claimed in claim 1, wherein the diffuser (114) is having one of a parabolic shape or a square shape.

3. The light emitting diode (LED) device (100, 200) as claimed in claim 1, wherein the base (104) comprising at least three stands (118-1, 118-2, 118-3) formed around a central portion of the base (104) to mount a metal core printed circuit board (MCPCB) (106, 206).

4. The light emitting diode (LED) device (100, 200) as claimed in claim 3, wherein the MCPCB (106, 206) is one of a driver based MCBCP (206) or a hybrid driver based MCPCB (106).

5. The light emitting diode (LED) device (100, 200) as claimed in claim 4, wherein the MCPCB (106, 206) comprises a dielectric layer for transmission of heat.
6. The light emitting diode (LED) device (100, 200) as claimed in claim 5, wherein the base (104) comprising a central recess (116) to accommodate electronic components, including driver (108), of the MCPCB (106).

7. The light emitting diode (LED) device (100, 200) as claimed in claim 4, wherein the hybrid driver based MCPCB (206) comprising a child printed circuit board (MCPCB) (208) connected through soldering to the MCPCB (206) in a U-shaped locking orientation through a slot provided on the surface of the MCPCB (206).

8. The light emitting diode (LED) device (100, 200) as claimed in claim 7, wherein the MCPCB (208) comprises metal oxide varistor (MOV) embedded on the surface of the MCPCB (208).

9. The light emitting diode (LED) device (100, 200) as claimed in claim 7, wherein the MCPCB (208) comprises a wire wound resistor (WWR) embedded on the surface of the MCPCB (208).

10. The light emitting diode (LED) device (100, 200) as claimed in claim 7, wherein AC components are embedded on the CPCB (208). , Description:TECHNICAL FIELD
[0001] The present disclosure, in general, relates to a light emitting diode (LED) device and, in particular, relates to a light emitting diode (LED) device with mounting system enabling mounting of the LED device on different structures.
BACKGROUND
[0002] Light-emitting diode (LED) devices are more efficient than most forms of widely used lamps, for example, incandescent, high-intensity discharge (HID) light sources, and the like. One advantage of using LED devices is that LEDs are more efficacious than incandescent light and more efficacious than some fluorescent and low wattage HID light sources. Another advantage of LED device usage is that the LEDs may be configured as low voltage, low energy devices. Another advantage of the LED devices is that of the longer life when compared to other light forms.
[0003] Presently, the LED devices are generally manufactured integrally in the manufacturing of traditional ceiling lamp or dome lamp or different kind of wall lights or other, which are available in different mounting system availability (various mounting arrangement) and application of uses, which thus can be directly used after plugging into electric supply. If the ceiling LED device or dome LED device is damaged, the ceiling LED device is replaced with a new ceiling LED device only while the dome LED device is replaced with a new dome LED device only. Accordingly, the entire LED device has to be replaced, which results in a large loss, reduces the service life of the LED device, and leads to waste.
[0004] Further, the cost of the ceiling LED device or the dome LED device or the like in the production process is increased, and disassembly and assembly are not convenient.
[0005] TECHNICAL PROBLEM: A technical problem that can be formulated from the above mentioned state of the art can be formulated by those skilled in the art as how to improve the assembly convenience of the ceiling LED device or dome LED device or the like. Also, there is a need to develop a reduced or improved mounting system to fit in almost every standard junction box available in the market.
OBJECTS OF THE DISCLOSURE
[0006] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed here in below.
[0007] It is a general object of the present disclosure to provide an LED device with a unique mounting system, i.e., key holes, for mounting the LED device on different structures including roof, wall, junction box, and so forth, so as to ensure a cost-effective and efficient operation of a LED device.
[0008] It is another object of the present disclosure to propose an LED device that allows the ceiling LED device or dome LED device to be conveniently installed.
[0009] It is another object of the present disclosure to propose an LED device that helps in ease of installation when an existing LED device is damaged.
[0010] It is yet another object of the present disclosure to proposed an LED device that reduces the possibility of spot formation over a diffuser in the LED device by using parabolic shape diffuser.
[0011] It is another object of the present disclosure to provide an LED device that eases in assembly of the different components of the LED device.
[0012] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.
SUMMARY
[0013] This summary is provided to introduce concepts related to LED device having multiple mounting options. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0014] The present disclosure proposes a light emitting diode (LED) device comprising a fixture body having a receptacle with a base. The base includes at least two key holes formed diametrically opposite ends of the base for receiving heads of screws fixedly mounted on a surface of a structure. Also, the base includes at least three alignment holes formed at even distance from each other around the boundary of the base for receiving corresponding at least three alignment legs of a diffuser to releasable mount the diffuser on the fixture body.
[0015] In an aspect, the diffuser is having one of a parabolic shape or a square shape.
[0016] In an aspect, the base comprising at least three stands formed at a central portion of the base to mount a metal core printed circuit board (MCPCB).
[0017] In an aspect, the MCPCB includes a dielectric layer for transmission of heat.
[0018] In an aspect, the base includes a central recess to accommodate electronic components, including driver, of the MCPCB.
[0019] In an aspect, the MCPCB is one of a driver based MCBCP or a hybrid driver based MCPCB.
[0020] In an aspect, the hybrid driver based MCPCB includes a child printed circuit board (CPCB) connected through soldering to the MCPCB in a U-shaped locking orientation through a slot provided on the surface of the MCPCB.
[0021] In an aspect, the MCPCB includes metal oxide varistor (MOV) embedded on the surface of the MCPCB.
[0022] In an aspect, the MCPCB includes a wire wound resistor (WWR) embedded on the surface of the MCPCB.
[0023] In an aspect, AC components are embedded on the MCPCB.
[0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
[0025] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
[0026] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
[0028] FIG. 1A illustrates an exploded view of the light emitting diode (LED) device, in accordance with a first exemplary embodiment of the present disclosure;
[0029] FIG. 1B illustrates an exploded view of the light emitting diode (LED) device, in accordance with a second exemplary embodiment of the present disclosure;
[0030] FIG. 2A illustrates a top view of a hybrid driver based metal core printed circuit board (MCPCB) of the light emitting diode (LED) device in accordance with the first exemplary embodiment;
[0031] FIG. 2B illustrates a top view of a driver based metal core printed circuit board (MCPCB) of the light emitting diode (LED) device in accordance with the second exemplary embodiment;
[0032] FIG. 3A illustrates a top of a fixture body of an exemplary LED device in accordance with the present disclosure;
[0033] FIG. 3B illustrates a side view of the fixture body of an exemplary LED device in accordance with the present disclosure;
[0034] FIG. 3C illustrates a bottom view of the fixture body of an exemplary LED device in accordance with the present disclosure;
[0035] FIG. 3D illustrates a top of a diffuser of an exemplary LED device in accordance with the present disclosure;
[0036] FIG. 3E illustrates a side view of the diffuser of an exemplary LED device in accordance with the present disclosure;
[0037] FIG. 3F illustrates a bottom view of the diffuser of an exemplary LED device in accordance with the present disclosure;
[0038] FIG. 4A illustrates a top view of the fixture body of an exemplary LED device in accordance with the present disclosure;
[0039] FIG. 4B illustrates a perspective view of the fixture body of an exemplary LED device in accordance with the present disclosure;
[0040] FIGS. 5A, 5B, 6A, 6B, 7A, 7B, 7C, 7D illustrate different steps of assembling the exemplary LED device in accordance with the present disclosure; and
[0041] FIG. 8A and 8B illustrate different steps of mounting the exemplary LED device in accordance with the present disclosure.
DETAILED DESCRIPTION
[0042] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0043] In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
[0044] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
[0045] The terms “comprises”, “comprising”, “includes” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device or method that includes a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.
[0046] The present disclosure aims to solve a technical problem of improving the assembly convenience of the ceiling LED device or dome LED device or the like. Also, in the state of the art, there is a need to develop a reduced or improved mounting system to fit in almost every standard junction box available in the market. To solve this issue, the present disclosure provides an LED device with a unique mounting system, i.e., key holes, for mounting the LED device on different structures including roof, wall, junction box, and so forth, so as to ensure a cost-effective and efficient operation of a LED device.
[0047] Further, in typical disc LED device provides point source light as typical beam angle of the LED device is 120 Degree. Because of the point source light, when a typical LED device is installed, one can see some dark patches and non-uniform light in some cases. To solve this issue, the present disclosure proposes to add a parabolic shape diffuser on the top of LED in special shape which helps to increase the beam angle of the LED from 120 Degree to 140-150 degrees and light is diffused thus providing more uniform light from the LED device.
[0048] FIG. 1A illustrates a light emitting diode (LED) device 100 in accordance with a first embodiment of the present disclosure, while FIG.1B illustrates a LED device 200 in accordance with a second embodiment of the present disclosure.
[0049] In first embodiment shown in FIG. 1A, the LED device 100 includes a hybrid based metal core printed circuit board (MCPCB) 106. The hybrid driver based MCPCB 106 includes a child printed circuit board (CPCB) 108 connected through soldering to the MCPCB 106 in a U-shaped locking orientation through a slot provided on the surface of the MCPCB 106. A top view of the MCPCB 106 of the LED device 100 is shown in FIG. 2A in accordance with the present disclosure. In an aspect, the MCPCB 108 includes metal oxide varistor (MOV) embedded on the surface of the MCPCB 108. In an aspect, the MCPCB 108 includes a wire wound resistor (WWR) embedded on the surface of the MCPCB 108. In an aspect, AC components are embedded on the MCPCB 108.
[0050] In second embodiment shown in FIG. 1B, the LED device 200 includes a driver based metal core printed circuit board (MCPCB) 206. The MCPCB 206 includes a driver 208 connected through wires to the MCPCB 206. A top view of the MCPCB 206 of the LED device 200 is shown in FIG. 2B in accordance with the present disclosure.
[0051] Although the LED device 100, 200 of both the embodiments are shown with disc shape, those skilled in the art can appreciate that the shape of the LED device 100, 200 should not be construed as a limitation of the subject matter of the present disclosure. Further, apart from the different types of the drivers used in the both embodiments of the LED device 100, 200, all other components are similar in both the embodiments.
[0052] For instance, the LED device 100, 200 includes a fixture body 102. A top of the fixture body 102 is shown in FIG. 3A, a side view of the fixture body 102 is shown in FIG. 3B, and a bottom view of the fixture body is shown in FIG. 3C.
[0053] Further, as shown in FIG. 4A and 4B, the fixture body 102 includes a receptacle with a base 104. The base 104 includes at least two key holes 110-1, 110-2 formed, at opposite ends, near the periphery of the base 104, for receiving heads of screws fixedly mounted on a surface of a structure. The structure may include, but not limited to, false ceiling, roof, pole, wall, inclined surface, and so forth. Apart from the key holes 110-1, 110-2 formed near the periphery of the base 104, the base 104 may include further key holes 110-3, 110-4 in the area covered by the MCPCB 106, 206.
[0054] The base 104 further includes at least three alignment holes 112-1, 112-2, 112-3 formed at even distance from each other around the boundary of the base 104 for receiving corresponding at least three alignment legs 114-1, 114-2, 114-3 of a diffuser 114 (as shown in FIG. 3D-3E) to releasable mount the diffuser 114 on the fixture body 102.
[0055] The alignment holes 112-1, 112-2, 112-3 may be in the form of a notch, a groove, a recess, a slot, or an aperture, and the alignment 114-1, 114-2, 114-3 may be in a form (including, but without limitation, a rail or a peg) which permits a friction fit, preferably a snug fit, to the alignment holes 112-1, 112-2, 112-3. The alignment legs 114-1, 114-2, 114-3 may have a width approximately equal to or slightly larger than the width of the alignment holes 114-1, 114-2, 114-3, such that the alignment legs 114-1, 114-2, 114-3 may fit therein in a friction fit.
[0056] In an aspect, the diffuser 114 is a parabolic shape diffuser which helps to increase the beam angle of the LED from 120 degrees to 140-150 degrees and light is diffused thus providing more uniform light from the LED device 100, 200. Although the diffuser 114 is shown as parabolic, those skilled in the art can appreciate that the diffuser 112 can have a square shape without deviating from the scope of the present disclosure.
[0057] Further, as shown in FIG. 4B, the base 104 of the fixture body 102 includes a central recess 116 to accommodate electronic components, including driver 108, 208, of the MCPCB 106, 206. Around the central recess 116, the base 104 includes at least three stands 118-1, 118-2, 118-3 to mount the MCPCB 106, 206 on the base 104. In an aspect, the MCPCB 106, 206 may include a dielectric layer for transmission of heat.
Assembling Process
[0058] First stage is to connect the driver with MCPCB. In case of the hybrid driver 108, the hybrid driver is mounted on the MCPCB 106 (FIG. 5A) and then the MCPCB 106 is mounted over the three plastic stands 118-1, 118-2, 118-3 of the fixture body 102 using hot press through electric iron (FIG. 5B). In case of driver based MCPCB 206, the driver 208 is first inserted in prescribed box, i.e., the central recess 116, (FIG. 6A) and then the MCPCB 206 is set in a position over the three plastic stands 118-1, 118-2, 118-3 with the help of hot press electric iron (FIG. 6B).
[0059] Second stage is to releasable mount the diffuser 114 on the fixture body 102 by locking the at least three alignment legs 114-1, 114-2, 114-3 of the diffuser 114 into the corresponding three alignment holes 112-1, 112-2, 112-3 formed on the base 104 of the fixture body 102 (FIG. 7A).
[0060] FIG. 7B illustrates a bottom view of the fixture body 102 with the three alignment holes 112-1, 112-2, 112-3 locked with the corresponding three alignment legs 114-1, 114-2, 114-3 of the diffuser 114. Thus, the diffuser 114 is designed in such a way to lock with fixture body 102 separately. The diffuser 114 has unique way of locking mechanism which provides accessibility to an end user to open the diffuser 114 during key holes 110-1, 110-2 mounting on structure, say roof or wall, as the diffuser 114 does not require any gluing to fix the diffuser 114 for any electric or electronic component during repair of the LED device 100, 200.
[0061] In start of all process, there will be setting for input wire 120 (FIG. 7C and 7D) to come out of housing, i.e., the central recess 116, the LED device 100, 200 has a provision to set direction of wire exist based on availability space inside junction box inside ceiling, either it may come out from side or from top of fixture body 102, or falling from the roof in market condition.
[0062] In mounting profile of the key holes 110-1, 110-2, the dimension of the mounting profile is set as per standard size available in market. With such mounting profile, the key holes 110-1, 110-2 can fit in any mounting plate available in market. Further, as shown in FIG. 8A and 8B, fitting parts or mounting plate 122 give the LED device 100, 200 flexibilities to almost fit in any junction box, the dimension of central recess 116 is set as per 2-inch standard size junction box. In an aspect, the mounting 122 can be formed from a plastic or paper like material, as the primary purpose of the mounting plate 122 to demarcate the positions of holes in the structure where the screws 126-1, 126-2 can be fixedly mounted to get engaged with the key holes 110-1, 110-2 of the fixture body 102.
[0063] Further, the key holes 110-1, 110-2 are provided, in a direction of a central axis of the fixture body 102, with a through hole through which a mounting screw of an LED device 102, 104 passes, a side wall of the fixture body 102 is provided in such a way to match with roof/ceiling hole to allow a fastener 124-1, 124-2 (FIGS. 1A and 1B) to be inserted into the fastener hole to abut against an outer wall of the ceiling. Further, the screw 126-1, 126-2 is provided with a head away from the surface of the fixture body 102, the head of the screw has a diameter larger than the width of a key hole 110-1, 110-2 and screw thread diameter is smaller than the diameter of a circular portion of the key hole 110-1, 110-2.
[0064] Yet further, the fixture body 102 is provided with a through hole in a direction of the central axis of the fixture body 102 through which the central axis of the LED device 100, 200 passes, the fixture body 102 is connected to a LED lamp by means of the key hole 110-1, 110-2, and the fastener 124-1, 124-2 is inserted into the fastener hole to abut against an outer wall of the central axis of the LED lamp, thus the central rod of the LED lamp is fixed further by the fastener 124-1, 124-2. By the rotation of the LED device 100, 200, the screw 126-1, 126-2 is inserted into the circular portion of the key hole 110-1, 110-2 in the surface of the LED lamp, and then slides to the circular portion of the key hole 110-1, 110-2 because the diameter of the head of the screw is smaller than the diameter of the circular portion of the key hole 110-1, 110-2. Since the diameter of the head of the screw 126-1, 126-2 is larger than the width of the circular portion of the key hole, the fixture body 102 is detachably connected to the LED lamp by means of the screws 126-1, 126-2. Compared with the conventional technology, the LED device and the lamp are separated into two parts which are detachably installed, and assembly and disassembly of the fixture body 102 and the lamp may not require screwing or unscrewing of the screws 126-1, 126-2, thus the assembly and disassembly of the LED devices proposed herein are simple and quick. When damaged, the fixture body 102 can be disassembled directly from the lamp to be replaced, without requiring the overall replacement, and thus reducing the substantial loss to an end user.
[0065] The way, in which the fastener abuts against the wall of ceiling, the LED fixture through the fastener hole is not limited to the fore mentioned case. In the case that each of the outer wall of the fastener and the inner wall of the fastener hole is a surface that is smooth or has a certain roughness, the fastener is fixed by a snap fit in the case that the fastener passes through the fastener key hole to abut against the roof/ceiling of the LED fixture, and thus the whole LED fixture is connected to the roof/ceiling.
[0066] Further, in an aspect, the LED device proposed herein may include clip system for mounting in small junction box configured to attract the roof surface towards the LED fixture body and having an adjustable distance from the surface of the LED fixture body.
[0067] The diffuser and a body end connected to the fixture body. The hemisphere structure has a hollow inside configured to arrange the controller and the power supply module. The LED lamp beads are arranged on the surface of the fixture body at a position where the hemispherical structure is not located, and is arranged around the central axis of the fixture body to be uniformly distributed on the surface of the fixture body at the same side as the hemispherical structure and the diffuser.
Equivalents
[0068] An LED fixture/lamp/device including the LED fixture proposed herein are separately produced, which not only makes the installation convenient and reduces cost, but also reduces loss because the LED fixture and the LED lamp are disassembled depending on a damaged portion when the LED lamp is damaged, and then only the part including the damaged portion is replaced or maintained.
[0069] The above embodiments are described in a progressive manner. Each of the embodiments is mainly focused on describing its differences from other embodiments, and references may be made among these embodiments with respect to the same or similar portions among these embodiments.
[0070] Further, it will be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the invention and are included within its scope.
[0071] Furthermore, all examples recited herein are principally intended expressly to be only for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventor(s) to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. Also, the various embodiments described herein are not necessarily mutually exclusive, as some embodiments can be combined with one or more other embodiments to form new embodiments.
[0072] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.