Omnidirectional flexible light emitting device

Abstract

An omnidirectional light emitting device is provided. An example device includes a flexible substrate (102) having a substrate length, a first substrate surface (1022), and a second substrate surface (1024). The flexible substrate is configured to be flexibly twisted about a longitudinal axis parallel to the substrate length. The example device also includes a plurality of LED packages (104) disposed on the first substrate surface (1022). Each LED package of the plurality of LED packages (104) is configured to emit light outwardly from the flexible substrate (102).

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Patent Application Serial No. 16 / 983,747, filed August 3, 2020, entitled “OMNIDIRECTIONAL FLEXIBLE LIGHTEMITTING DEVICE”, the contents of which are incorporated herein by reference in their entirety. Technical Field Background Technology

[0004] Light-emitting devices can include light-emitting diodes (LEDs). LEDs (also referred to herein as light-emitting diodes) are semiconductor devices that emit light when an electric current passes through them. Light is produced when particles carrying an electric current (such as electrons and holes) bind to the semiconductor material of the semiconductor device. LEDs are described as solid-state devices, unlike other lighting technologies that use heated filaments or gas discharges as light sources (such as incandescent lamps, halogen lamps, and fluorescent lamps).

[0005] LEDs are widely used in lighting applications in residential and commercial structures. Compared to traditional lighting (such as incandescent and fluorescent lamps), LED bulbs are more efficient. Most of the energy in an LED is converted into light, with a small amount of energy generating heat.

[0006] Traditional filament-type lighting devices using LEDs typically have LEDs mounted on one side of the filament. This single-sided configuration of traditional LED filaments results in poor light distribution. To overcome this problem, conventional solutions have increased the number of LED filaments mounted in the lighting device and / or employed transparent or semi-transparent filament substrates.

[0007] Through the efforts, originality, and innovations put forward, many shortcomings of such systems have been addressed by developing solutions according to embodiments of the present invention, many of which are described in detail herein. Summary of the Invention

[0008] Various embodiments relate to light-emitting devices configured to provide omnidirectional light output. In some embodiments, the light-emitting device includes a flexible substrate having a substrate length, a first substrate surface, and a second substrate surface. In embodiments, the flexible substrate is configured to twist and / or rotate about a longitudinal axis. In embodiments, the light-emitting device further includes a plurality of LED packages disposed on the first substrate surface. In some embodiments, the plurality of LED packages are configured to emit light outward from the flexible substrate.

[0009] In some embodiments, the flexible substrate may be configured to be permanently flexible. In some embodiments, the flexible substrate is configured to twist and / or rotate within the range of 0° to 90°, 90° to 180°, or 180° to 360°. In some embodiments, the flexible substrate is configured to radiate heat.

[0010] In some embodiments, the flexible substrate of the light-emitting device may further include a circuit board. In some embodiments, the circuit board includes a first side and a second side. In some embodiments, the flexible substrate of the light-emitting device further includes a plurality of LED packages disposed on the first side and / or electrically and mechanically coupled to the first side. In some embodiments, the flexible substrate of the light-emitting device further includes a plurality of leads / traces disposed on or electrically and mechanically coupled to the first or second side of the circuit board, and electrically coupled to the plurality of LED packages. In some embodiments, the flexible substrate further includes a driver circuit disposed on or electrically and mechanically coupled to the first or second side of the circuit board. In some embodiments, the driver circuit is electrically coupled to the plurality of leads / traces on the circuit board.

[0011] In some embodiments, the plurality of LED packages include phosphor-based LED packages. Furthermore, in some embodiments, the flexible substrate has a color matching the phosphor color of the phosphor-based LED package. In some embodiments, the plurality of LED packages are configured to emit blue light.

[0012] In some embodiments, the substrate width and the width of at least one LED package are the same. In some embodiments, the flexible substrate comprises polyamide. In some embodiments, the substrate width is 1 mm to 2 mm, and the substrate length is 5 cm.

[0013] Various embodiments of a lighting device configured to provide omnidirectional light output are provided. In these embodiments, the lighting device may include a transparent housing. In some embodiments, the transparent housing may be configured to house a light-emitting device. In some embodiments, the transparent housing may be configured to protect the integrity of the light-emitting device housed therein. For example, in various embodiments, the transparent housing may be infused with a gas that helps to suppress the introduction of moisture and / or other contaminants into the transparent housing. For example, for this purpose, the transparent housing may be infused with dry air or an inert gas.

[0014] In some embodiments, the lighting device may include a base for electrical coupling to a lighting socket. In some embodiments, the lighting device may include a light-emitting device. In some embodiments, the light-emitting device is electrically coupled to the base and housed within a transparent housing. In some embodiments, the light-emitting device includes a flexible substrate having a substrate length, a substrate width, a first substrate surface, and a second substrate surface. In some embodiments, the flexible substrate is configured to twist and / or rotate about a longitudinal axis parallel to the substrate length. In some embodiments, a plurality of LED packages are disposed on the first substrate surface. In some embodiments, each LED package includes an LED package width and is configured to emit light outward from the flexible substrate.

[0015] In the embodiments, the plurality of LED packages include phosphor-based LED packages.

[0016] In one embodiment, the flexible substrate has a color that matches the phosphor color of the phosphor-based LED package.

[0017] In some embodiments, the substrate width and the width of each LED package are the same.

[0018] In one embodiment, the base includes an Edison-type base.

[0019] In this embodiment, the base includes a G4 type base.

[0020] In one embodiment, the base includes a G6.35 type base.

[0021] In one embodiment, the base includes a G6.35 type base.

[0022] In this embodiment, the base includes a G9 type base.

[0023] In some embodiments, the base is mechanically and / or electrically coupled to the circuit board of the light-emitting device in some embodiments, thereby providing current to the light-emitting device.

[0024] This invention does not attempt to represent any specific innovation, embodiment, or example, as it is commercially viable. Furthermore, this invention is not intended to represent any essential elements of an innovation, embodiment, or example, or to limit the scope of the subject matter of this disclosure.

[0025] The innovations, embodiments, and / or examples found in this disclosure are not exhaustive, but rather describe the basic meaning of the subject matter. Therefore, one use of this content is as a prelude to the detailed description that follows. Attached Figure Description

[0026] The following detailed description, accompanying drawings, and appended claims illustrate the inventiveness, embodiments, and / or examples of the claimed invention and their advantages. All drawings are for illustrative purposes only, illustrating the inventiveness, embodiments, and / or examples of the claimed invention, and do not limit the scope of the claimed invention. These drawings are not necessarily drawn to scale, but are only a portion of the disclosure.

[0027] In the accompanying drawings, similar parts or features may have reference symbols of the same or similar designation form (e.g., alphanumeric symbols, such as reference numerals) and may represent similar or equivalent functions. Furthermore, various parts of the same type can be distinguished by a hyphen following the reference designation and a second designation used to differentiate between similar parts. If only the first reference designation is used in the specification, the description applies to any similar parts having the same first reference designation, regardless of the second reference designation. These drawings are briefly illustrated below.

[0028] Figure 1A , Figure 1B and Figure 1C This is a top view of an exemplary flexible substrate configured according to embodiments of the present disclosure;

[0029] Figure 2A This is a top view of the rotation range of an exemplary flexible substrate configured according to an embodiment of the present disclosure;

[0030] Figures 2B-2C This is a perspective view of the rotation range of an exemplary flexible substrate configured according to embodiments of the present disclosure;

[0031] Figure 3 This is a perspective view of an exemplary flexible substrate configured according to embodiments of the present disclosure;

[0032] Figure 4 An exemplary lighting device according to an embodiment of the present disclosure is shown; and

[0033] Figures 5A-5B This is a perspective view showing a flexible substrate according to various embodiments of the present disclosure. Detailed Implementation

[0034] This disclosure describes various embodiments more fully with reference to the accompanying drawings. It should be understood that some, but not all, embodiments are shown and described herein. In fact, embodiments can take many different forms, and therefore this disclosure should not be construed as limiting itself to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The same numerals always refer to the same elements.

[0035] The light-emitting device according to this disclosure offers greater functionality than conventional lighting devices. Conventional lighting devices employing flexible substrates typically have a first flexible substrate mounted on a second substrate. The second substrate is usually complex in shape. Due to the different compositions of the first and second substrates, this non-uniform arrangement of the substrates contributes to deformation, breakage, delamination, etc.

[0036] The light-emitting device according to this disclosure can employ a single, twistable substrate. Therefore, the light-emitting device according to this disclosure eliminates the need for a second substrate, reduces manufacturing costs, and provides greater functionality.

[0037] Furthermore, the twistable substrate according to this disclosure can be configured into various shapes as needed. This adaptability provides greater functionality and light scattering than conventional designs. For example, the twistable substrate according to this disclosure can be configured to substantially define a spiral shape. The twistable substrate of various embodiments can then be configured, for example, to include a plurality of LEDs and suspended between support wires, thereby overcoming the drawbacks of conventional LED filament devices.

[0038] Conventional devices are typically manufactured so that the flexible substrate emphasizes the shape of a standard (e.g., Edison-style) light bulb. This conventional design is flawed because it leads to a suboptimal arrangement of the LEDs within the bulb. On the other hand, the flexible substrate according to this disclosure is inherently more geometrically efficient.

[0039] The basic helical configuration of the above example allows for more efficient arrangement of LEDs within the bulb. This is because the geometry of the helix ensures that a portion of the light emitted from each LED maintains a constant angle with the flexible substrate itself. Therefore, more light from multiple LEDs can be emitted outward from the light-emitting device; less light can be wasted. The flexible substrate according to this disclosure can be configured in various other regular and irregular shapes. For example, while maintaining flexibility and geometric efficiency, the flexible substrate according to this disclosure can include a helical or coil shape.

[0040] The light-emitting device according to embodiments of the present disclosure overcomes further light distribution defects of conventional light-emitting devices. Conventional lighting devices employing LED filaments typically have the LED disposed on one side of the filament. LEDs are “directional” light sources (e.g., LEDs are inherently configured to emit light in a specific and unidirectional direction). Therefore, due to this unidirectional configuration, conventional lighting devices produce poor omnidirectional light emission. This directional defect is overcome by using a twistable / rotatable substrate with LEDs disposed thereon, as the flexible substrate itself facilitates indicating the direction of light emission. Therefore, the light-emitting device according to the present disclosure achieves better, more omnidirectional light emission compared to conventional lighting devices.

[0041] Furthermore, conventional lighting devices must employ transparent or translucent filament substrates to compensate for their unilateral configuration. By employing a twistable substrate, the light-emitting device according to this disclosure can be configured to have an opaque substrate or otherwise less transparent / translucent substrate. Therefore, the light-emitting device according to embodiments of this disclosure can provide users with a greater degree of aesthetic choice.

[0042] In view of the foregoing, it may be desirable to configure a light-emitting device according to embodiments of the present disclosure, thereby employing two or more flexible substrates. The light-emitting device according to the present disclosure can employ multiple flexible substrates and still achieves improved omnidirectional light emission compared to conventional lighting devices.

[0043] Figure 1A , Figure 1B and Figure 1C This is a top view of an exemplary flexible substrate 102 configured according to embodiments of the present disclosure. In embodiments, the flexible substrate 102 may include a substrate length, a substrate width, a first substrate surface 1022, and a second substrate surface (not shown). In embodiments, the flexible substrate 102 may be configured to be twistable and / or rotatable about a longitudinal axis parallel to the substrate length. The flexible substrate 102 of some embodiments includes materials that facilitate the twisting / rotation of the flexible substrate 102, including but not limited to plastics and polyamides. In embodiments, a plurality of LED packages 104 may be disposed on the first surface 1022 of the flexible substrate 102. The LED packages 104 of some embodiments may have an LED package width and be configured to emit light outward from the flexible substrate 102. The plurality of LED packages 104 may be electrically connected in series with each other. Figure 1A A first LED package width configuration is shown, where the LED package width is smaller than the substrate width. (Example) Figure 1B As shown, in some embodiments, the width of the LED package can be equal to or very close to the width of the substrate, so that the flexible substrate 102 blocks as little light as possible.

[0044] In embodiments, the flexible substrate 102 may be configured to radiate heat. That is, in some embodiments, the flexible substrate 102 may include a material suitable for withstanding the heat generated by the plurality of LED packages 104. In embodiments, the plurality of LED packages 104 may include phosphor-based LED packages. In some embodiments, the phosphor-based LED packages 104 may be configured to emit blue light. Furthermore, in embodiments, the flexible substrate 102 may have a color matching the phosphor color of the phosphor-based LED packages 104 to camouflage the flexible substrate 102. The flexible substrate 102 may be configured to be opaque or may be somewhat opaque. The flexible substrate 102 may be configured with metal contacts for soldering to support wires. The metal contacts of the flexible substrate 102 may include electrical contact pads for mechanical and electrical connections. In embodiments, the flexible substrate 102 may include polyamide. In embodiments, the substrate width and the width of each LED package may be the same width, such that the flexible substrate 102 blocks as little light as possible. In embodiments, the substrate width of the flexible substrate 102 may be 1 to 2 millimeters, and the substrate length of the flexible substrate 102 may be 5 centimeters.

[0045] Figure 2A This is a top view of the rotation range of an exemplary flexible substrate 102 configured according to an embodiment of the present disclosure. Figures 2B-2C This is a perspective view of the rotation range of an exemplary flexible substrate 102 configured according to embodiments of the present disclosure. In embodiments, the flexible substrate 102 may be configured to be permanently flexible. That is, the flexible substrate 102 may maintain the shape into which it is twisted and / or rotated upon torque release, such that the flexible substrate 102 is twisted and / or rotated about a longitudinal axis parallel to the substrate length of the flexible substrate 102. The flexible substrate 102 may be configured to twist and / or rotate at least 360°. The exemplary flexible substrate 102 may be configured to twist and / or rotate in the range of 90° to 180°. In embodiments, the exemplary flexible substrate 102 may be configured to twist and / or rotate in the range of 180° to 360°. In embodiments, the exemplary flexible substrate 102 may be configured to twist and / or rotate in the range of 0° to 90°.

[0046] Figure 100A shows a relaxed or untwisted flexible substrate 102. When the flexible substrate 102 is relaxed, the LED package 104 is positioned facing a uniform direction. Figure 100B shows a flexible substrate 102 twisted by approximately 90°. As shown, a first subset of the LED package 104 is positioned facing a direction almost perpendicular to a second subset of the LED package 104. Figure 100C shows a flexible substrate 102 twisted by approximately 180°. An exemplary visual feature of the 180° rotation is that the second substrate surface 1024 is now visible. Furthermore, the first subset of the LED package 104 is now positioned antiparallel to the second subset of the LED package 104 (e.g., in the opposite direction).

[0047] Figure 3 This is a perspective view of an exemplary flexible substrate 102 configured according to embodiments of the present disclosure. In embodiments, the exemplary flexible substrate 102 may further include a circuit board having a first side 1022 and a second side 1024. A plurality of LED packages 104 may be disposed on the first side 1022 and / or electrically and mechanically coupled to the first side 1022. A plurality of leads / traces 302 may be disposed on the first side 1022 or the second side 1024 and / or electrically and mechanically coupled to the first side 1022 or the second side 1024, and electrically and mechanically coupled to the plurality of LED packages 104. For example, the LED packages 104 may be coupled to the first side 1022 by, for example, wire bonding or soldering. The driver circuit 304 may be any driver circuit suitable for converting a blue phosphor LED into white light with minimal energy loss as heat.

[0048] Figure 4 An exemplary lighting device 400 configured according to embodiments of the present disclosure is shown. In an embodiment, the lighting device 400 includes a transparent housing 402. In some embodiments, the transparent housing 402 may be configured to house a light-emitting device 410. In an embodiment, the lighting device 400 includes a base 404 for electrical coupling to a lighting socket. In some embodiments, the light-emitting device 410 is electrically coupled to the base 404 and housed within the transparent housing 402. The light-emitting device 410 may be mounted within the transparent housing 402 using a support wire 412. In an embodiment, the light-emitting device 410 includes a flexible substrate 102. The flexible substrate 102 may be configured with metal contact ends. The metal contact ends 413 of the flexible substrate 102 may include electrical contact pads 414 for mechanical and electrical connection between the light-emitting device 410 and the base 404 (e.g., see...). Figures 5A-5BFor example, support line 412 can be electrically and mechanically coupled to electrical contact pad 414 of flexible substrate 102. Therefore, support line 412 can couple the flexible substrate 102 of light-emitting device 410 to base 404 via electrical contact pad 414. Alternatively, flexible substrate 102 can be coupled to a support structure independent of the metal contact ends. In some embodiments, base 404 can be configured as various bulb base types (e.g., Edison type (e.g., E10, E11, E26), G4, G6.35, GY6.35, etc.). In embodiments, base 404 is mechanically and / or electrically coupled to the circuit board 102 of light-emitting device 410 in some embodiments to provide current to light-emitting device 410.

[0049] The flexibility of the flexible substrate 102 can be temporary or permanent. When the flexibility is temporary, the flexible substrate 102 is electrically and mechanically coupled to the support line 412 before applying appropriate torque to configure it in a twisted position. Alternatively, the permanent flexible substrate 102 can be configured in a twisted position before being electrically and mechanically coupled to the support line 412. For example, a mixture of phosphor and silicone / epoxy resin can be applied to the flexible substrate 102 first. The flexible substrate 102 can then be configured to rotate as desired and fixed to the support line 412 while maintaining the desired configuration. Thus, the flexible substrate 102 can permanently maintain its configuration. Alternatively, the flexible substrate 102 can include a material that is inherently conducive to maintaining permanent flexibility (e.g., copper).

[0050] Figures 5A-5B This is a perspective view showing a flexible substrate 102 according to various embodiments. Figure 5A A flexible substrate 102 with an electrical contact pad 414 is shown. Figure 5B A flexible substrate 102 is shown with metal contact terminals 413, which may or may not include electrical contact pads 414. In an embodiment, the metal contact terminals 413 may be adapted to be soldered to support lines 412.

[0051] Many modifications and other embodiments will occur to those skilled in the art to which this disclosure pertains, which benefit from the teachings presented in the foregoing description and associated drawings. Therefore, it should be understood that this disclosure is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terminology is used herein, it is used only in a general and descriptive sense and not for limiting purposes.

Claims

1. A light-emitting device, comprising: A flexible substrate having a substrate length, a first substrate surface, and a second substrate surface, the flexible substrate being configured to flexibly twist about a longitudinal axis parallel to the substrate length; as well as A plurality of LED packages are disposed on the surface of a first substrate, wherein each of the plurality of LED packages is configured to emit light outward from the flexible substrate; The plurality of LED packages include phosphor-based LED packages, and the flexible substrate has a color that matches the phosphor color of the phosphor-based LED package.

2. The light-emitting device according to claim 1, wherein, The flexible substrate is configured to twist or rotate about the longitudinal axis.

3. The light-emitting device according to claim 1, wherein, The flexible substrate is configured to twist and / or rotate within one or more of the ranges of 0° to 90°, 90° to 180°, or 180° to 360°.

4. The light-emitting device according to claim 1, wherein, The flexible substrate is configured to radiate heat.

5. The light-emitting device according to claim 1, wherein, The flexible substrate further includes: A circuit board having a first side and a second side; Multiple LED packages are disposed on the first side and / or electrically and mechanically coupled to the first side; Multiple leads / traces, wherein the multiple leads / traces are disposed on one or more of the first side or the second side and / or electrically and mechanically coupled to one or more of the first side or the second side, and the multiple leads / traces are electrically coupled to the multiple LED packages; and A driver circuit is disposed on one or more of the first side or the second side and / or electrically and mechanically coupled to one or more of the first side or the second side, and the driver circuit is electrically coupled to a plurality of leads / traces of the circuit board.

6. The light-emitting device according to claim 1, wherein, The plurality of LED packages are configured to emit blue light.

7. The light-emitting device according to claim 1, wherein, Each of the plurality of LED packages includes an LED package width.

8. The light-emitting device according to claim 7, wherein, The width of the flexible substrate is equal to or greater than the width of at least one LED package, or equal to and greater than the width of at least one LED package.

9. The light-emitting device according to claim 1, wherein, The flexible substrate comprises polyamide.

10. The light-emitting device according to claim 8, wherein, The substrate has a width of 1mm to 2mm and a length of 5cm.

11. A lighting device, comprising: Transparent shell; A base electrically coupled to a lighting socket; as well as A light-emitting device, electrically coupled to the base and housed within the transparent shell, wherein the light-emitting device comprises: A flexible substrate having a substrate length, a first substrate surface, and a second substrate surface, the flexible substrate being configured to flexibly twist about a longitudinal axis parallel to the substrate length; and A plurality of LED packages are disposed on the surface of a first substrate, wherein each of the plurality of LED packages is configured to emit light outward from the flexible substrate; The plurality of LED packages include phosphor-based LED packages, and the flexible substrate has a color that matches the phosphor color of the phosphor-based LED package.

12. The lighting device according to claim 11, wherein, The base includes one or more of the following: Edison type base, G4 type base, G6.35 type base, G6.35 type base, and G9 type base.

13. The lighting device according to claim 11, wherein, The flexible substrate further includes: A circuit board having a first side and a second side; Multiple LED packages are disposed on the first side and / or electrically and mechanically coupled to the first side; Multiple leads / traces, wherein the multiple leads / traces are disposed on one or more of the first side or the second side and / or electrically and mechanically coupled to one or more of the first side or the second side, and the multiple leads / traces are electrically coupled to the multiple LED packages; and A driver circuit is disposed on one or more of the first side or the second side and / or electrically and mechanically coupled to one or more of the first side or the second side, and the driver circuit is electrically coupled to a plurality of leads / traces of the circuit board.

14. The lighting device according to claim 13, wherein, The base is mechanically and / or electrically coupled to the circuit board of the light-emitting device, thereby providing current to the light-emitting device.

15. The lighting device according to claim 11, wherein, Each of the plurality of LED packages includes an LED package width, wherein the substrate width of the flexible substrate is equal to or greater than at least one LED package width, or equal to and greater than at least one LED package width.

16. The lighting device according to claim 11, wherein, The flexible substrate is configured to twist and / or rotate within one or more of the ranges of 0° to 90°, 90° to 180°, or 180° to 360°.

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