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Light Engine For and Method of Simulating A Flame Us10240736
Light Engine For and Method of Simulating A Flame Us10240736
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U . S . Patent Mar . 26 , 2019 Sheet 2 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 3 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 4 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 5 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 6 of 92 US 10 ,240, 736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 7 of 92 US 10,240,736 B2
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U . S . Patent Mar . 26 , 2019 Sheet 8 of 92 US 10 ,240, 736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 9 of 92 US 10 ,240, 736 B2
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U . S . Patent Mar . 26 , 2019 Sheet 11 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar . 26 , 2019 Sheet 12 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar . 26 , 2019 Sheet 13 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar . 26 , 2019 Sheet 14 of 92 US 10 ,240 ,736 B2
Power module
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U . S . Patent Mar. 26 , 2019 Sheet 16 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 17 of 92 US 10 ,240,736 B2
LED 129 Rög 31R LED130
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U . S . Patent Mar. 26 , 2019 Sheet 18 of 92 US 10 ,240, 736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 19 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar . 26 , 2019 Sheet 20 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar . 26 , 2019 Sheet 21 of 92 US 10 ,240 ,736 B2
(Sequences 1 -19)
Sequence
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U . S . Patent Mar. 26 , 2019 Sheet 22 of 92 US 10 ,240 ,736 B2
(Sequence 1 ) (Sequence 10 )
1TT1T1
2 3 4 2 3 4 12 3 4 2 3 4 3 4 2
5 6 7 5 16 7 5 6 7 5 6 5 6
|8 9 10 8 9 10 8 9 10 8 8
NN 12 13 NN 12 13 NN 12 13 11 | 12 | 13 | 11 | 12 13 11 12 13
148 14 15 16 1 5 | 14 | 15 | 16 | 14 | 15 | 16 | 14 | 15 | 16 |
(Sequence 11)
(Sequence 2 )
4
|2 |3 |4 2 13 14 1 2 3 4 6 7 6 6 7
5 6 7 5 6 7 5 6 7 8 9 10 | 8 9 | 10 8 9 10
8 | 9 | 10 | 8 9 10 8 9 10 11 | 12 | 13 | 11 | 12 | 13 | 11 | 12 13
123 1213 1213 14 | 15 | 16 | 14 | 15 | 16 14 | 15 | 16
14 15 16 14 15 | 16 | 14 | 15 | 16 (Sequence 12 )
(Sequence 3 )
4 1 2 4 1 2 4
12 3 4 2 3 4 12 3 4 5 6 7 5 7 5 6 7
5 6 7 5 6 7 5 6 7 8 9 10 8 9 10 8 9
NN 12 13 12 13 NN 12 13
| 11 | 12 | 13 | 11 | 12 | 13 | 11 12 13 14 | 15 | 16 | 14 | 15 | 16 | 14 15 16
14 15 16 14 | 15 | 16 | 14 15 16 (Sequence 13 )
(Sequence 4 )
2 3 4 2 3 4 12 3
| 2 |342 342 34 5 16 17 5 6 7 5 6 7
S65656 8 9 10 8 | 9 | 10 8 9 10
SUNNOSSO NONNON ANNUNNI
11 12 13 11 | 12 | 13 11 12 13 14 | 15 | 16 | 14 | 15 | 16 14 15 16
14 15 16 14 | 15 | 16 14 15 16 (Sequence 14 )
(Sequence 5 ) | 11TT1T1
1TT1TT1T ] 12 3 4 12 3 4 12 3 4
232 A 23 5 6 7 5 6 7 5 6
NI 9 9 NO9 NON
8 9 10 8 9 10 | 8 9 10 | 11 13 11 12 13 11 13
11 | 12 | 13 | 11 | 12 | 13 | 11 | 12 13 14 15 16 14 15 16 14 15 16
14 15 16 14 15 16 14 15 16 (Sequence 15 )
(Sequence 6 ) 1
12 3 4 12 3 4 12 3 4
12 3 4 2 3 2 3 4 6 7 6 7 5 6 7
M 7 5 MV 75 7 IS AANG . NON
8 9 10 8 9 10 8 9 10 | 11 | 12 | 13 | 11 | 12 | 13 | 11 | 12 | 13 |
SIN 12 13 NN 12 13 NN 12 13 14 15 16 14 15 16 14 15 16
| 14 | 15 | 16 | 14 | 15 16 14 15 16 (Sequence 16 )
(Sequence 7 ) 1 1
3 4 3 4 3 47
2 NI2 2 N 5 6 7 5 7 5 6 7
5 6 5 16 MAN 5 6 M 8 MIN 10 8 10 8 10
8 9 10 8 9 10 8 9 10 11 | 12 11 12 11 12 N
12 13 12 13 11 12 13 14 15 16 14 | 15 | 16 14 15 16
14 15 16 14 15 16 14 15 16 (Sequence 17 )
( Sequence 8 )
1 1 34 34 34
2 3 4 1 2 3 4 12
16 17 15 16 17 1 5 6 7 18 19 10 8 9 10 1 8 9 10
9 10 8 9 10 8 99 10 | 11 | 12 13 | 11 | 12 13 11 | 12 130
11 MAR 11MWV 11 AllNEWS | 14 | 15 | 16 | 14 | 15 | 16 14 15 16
14 | 15 | 16 | 14 15 16 14 15 16 (Sequence 18 )
(Sequence 9 )
11 2 3 4 2 3 4 12 13 14
12 13 14 12 13 14 12 13 14 5 6 7 5 6 7 5 6 7
56 1756 1756 17 8 9 10 8 9 10 8 9 10
SOON ON 910 W 12 M 12 MIN 12 M
11 12 13 11 | 12 | 13 | 11 | 12 13 14 15 16 14 15 | 16 14 15 16
(Sequence 19 )
| 14 | 15 | 16 | 14 | 15 | 16 | 14 15 | 16 |
2 2 4 12
56 756 17 15 16 177
8 9 10 8 9 7 10 18 19 | 10
IN 13 12 113 12 :13
14 15 16 14 15 16 14 15 16
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U . S . Patent Mar. 26 , 2019 Sheet 23 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 24 of 92 US
US 10 ,240,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 26 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 27 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar . 26 , 2019 Sheet 28 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 29 of 92 US 10,240,736 B2
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U . S . Patent Mar . 26 , 2019 Sheet 30 of 92 US 10 ,240 , 736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 31 of 92 US 10 ,240 ,736 B2
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U . S . Patent Mar. 26 , 2019 Sheet 33 of 92 US 10 ,240 ,736 B2
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US 10 ,240 ,736 B2
LIGHT ENGINE FOR AND METHOD OF to simulate flames at or in the panel or screen . This is a
SIMULATING A FLAME two - dimensional solution which , again , works against real
ism in the simulation . Some solutions play either a simula
CROSS -REFERENCE TO RELATED tion or actual video of flames on a digital display .Again, this
APPLICATIONS 5 is two dimensional .
Some flame-effect lights use solid - state sources such as
This application is a continuation of U .S . application Ser. LEDs which have a smaller form factor and improved
No . 15 /583,612 , filed on May 1 , 2017 , which is a divisional effective lives over sources like incandescent sources. In
application of U .S . application Ser. No. 15/090 ,179, filed on some cases , they can also represent energy savings . Further
Apr. 14 , 2016 , now U .S . Pat. No. 9,689,544 , issued on Jun . 10 more , driving them to different intensities that can change
27 , 2017 and claims priority to China patent application quickly is possible . However, again , with regard to special
numbers 201510152837 . 2 and 201520282857 .7 , both filed lighting effects such as flame simulation , the state - of -the -art
May 5 , 2015 , each of which is incorporated by reference in has concentrates on 2D solutions or utilizing rotating optical
its entirety herein .
devices relative the sources.
BACKGROUND OF THE INVENTION It can therefore be seen that a number of factors go into
the design of lighting which attempts to simulate a flame or
A . Field of the Invention flames . Examples can include realism of simulation , cost of
The present invention relates to lighting and , in particular, materials and components, operating costs , durability , and
to apparatus, systems, and methods for producing lighting 20 flexibility in how many forms they can take and how many
and lighting effects that simulate the appearance of a flame different applications they can be used . Some of these
or flames. factors are antagonistic with one another, making it even
B . Problems in the Art more difficult to reach good solutions.
Artificial lighting continues to advance . The advent of For example , the combination of lights and moving parts
solid -state light sources such as LEDs has spurred further 25 may help simulate the look of flames , but can add capital and
innovation . operating costs . It can also create noise which can be
The design of light sources for illumination purposes antithetical to realistic simulation or to the consumer of such
occupies a substantial amount of the marketplace . Use of devices.
artificial light for particular lighting effects is another major The repeating patterns of most simulated flames take two
commercial area . 30 dimensional forms, which allows viewers to know or per
One particular area for lighting effects involves simula - ceive that they are looking at a simulated flame.
tion of the appearance of flames . There has been a long - felt The inventor has therefore found there is room for
need for the same. This comes from both safety concerns improvement in the state -of-the -art.
associated with real flames in such things as candle -based
fixtures , gas lamps, or wood burning or gas flame fireplaces, 35 SUMMARY OF THE INVENTION
as well as consumer - driven desire for the aesthetic and
ornamental appearance of flames . It is therefore a principle object, feature , aspect, or advan
One attempt at simulated candle flames uses an incan - tage of the present invention to provide an apparatus , a
descent single -candle - flame-sized bulb with multiple fila system , and method which improves over or solves prob
ments. A circuit switches between the filaments to simulate 40 lems and deficiencies in the state -of- the - art. Further objects ,
a jumping candle flame. However, they have had limited features , aspects , and advantages of the invention include
success in the marketplace . It is difficult to produce a apparatus, systems, or methods which :
realistic flame simulation . It is also difficult to expand the a . provide a more realistic flame simulation ;
effect beyond the single bulb . b . provide more of a 3D solution that provides a similar
Bigger systems utilize such things as steady -state light 45 3D and even stereoscopic effect when viewed from multiple
sources but with moving or rotating mirrors , reflectors , or directions ;
lenses . They are relatively complex . They involve the cost c . can be used in a wide variety of lighting applications;
and complexity of moving parts and , again , have limited d . is relatively economical regarding both capital and
success in realistic simulation . operating costs over a typical effective life span ;
Attempts at using artificial light sources for log - fire flame 50 e . provides the opportunity for a relatively long typical
simulation in such application as fireplaces also have limi- effective life span ;
tations. Some are essentially or predominantly two -dimen - f. can be implemented in a variety of form factors ;
sional in the sense the simulation is in a vertical plane across g . can include a stand - alone light engine module that can
a length and height in the fireplace . This might be deemed be used in a variety of standard light fixture bulb electrical
sufficient by some because most viewing -angles of a fire - 55 sockets, or can be integrated or built- in to a fixture ;
place are towards perpendicular to that plane . Such two - h . can be designed to create a variety of lighting effects ;
dimensional solutions lack realistic simulation , particularly i. can be essentially silent during operation ;
for shallower viewing angles relative that vertical plane . j. is aesthetically pleasing;
Some use lights and mechanical devices. One example is a k . is relatively noncomplex without moving mechanical
fan to blow illuminated red and /or yellow silk ribbons 60 parts ;
vertically . The waving of the ribbons is intended to provide 1. generates a relatively small amount of heat;
the flame simulation . This has limited three - dimensional m . has potential for long operating life ;
effect and limited realism . It also creates noise and addi n . can be made durable and robust for a variety of
tional electrical power consumption over and above just environments of use including indoors , outdoors, and even
lights . Some fireplace attempts utilize light sources (incan - 65 underwater ;
descent or LED ) to illuminate or edge - light a flat panel or 0 . can be used alone or with surrounding optical surfaces
screen . The lights can be varied in intensity or color to try or fixtures , and can be used in combinations.
US 10 ,240 ,736 B2
In one aspect of the invention , an apparatus according to shape. Small groups of LEDs are spaced from each other
the present invention comprises a light engine in a self around the top of the array . Sets of LEDs are sequential
contained housing . The light engine includes a base with an activated at varying levels and times between bottom and
electrical interface , an interior three - dimension form factor top of the array , starting more at the bottom and moving or
carrier, a plurality of solid -state light sources distributed 5 traveling to the top to simulate the leaping of flames.
over at least a substantial portion of the carrier , a cover that In another aspect of the invention simulation of the flame
at least substantially surrounds the carrier and light sources effect involves a timing and sequencing of a three -dimen
and includes at least some light transmissive portions, and a sional array of LEDs or other individual light sources in a
control circuit for driving the light sources according to a manner which is repeating but gives the appearance of
predetermined regimen . In some embodiments the cover 10 randomness . One way this can be done is by staggering
may be transparent. In some it may be translucent or on -off sequences in different levels from top to bottom
partially light transmissive. In some embodiments theremay around the three - dimensional shape but in a type of jumping
not be a cover. The cover can enhance optical effects of a up and down as it appears to rise and jump to the topmost
simulated flame. Furthermore , in some cases there can be a portion . After looking at the bulb for several hours , the
cover over the LEDs (which could be transparent but might 15 lighting pattern seems to be rotating around the three dimen
be translucent ) and then a second cover or shroud over the sional surface . This gives the appearance of a random
first cover and LEDs (which could be translucent butmight nonrepeating pattern of the LEDs being turned on and off.
not be). In this manner the LEDs could be protected by the In another aspect more than one set of light sources in a
first cover and then their light output could be manipulated three - dimensional configuration could be nested or distrib
by the second cover or shroud . In one example a translucent 20 uted on the same three -dimensional shape and have inde
second cover or shroud could diffuse the light output so that pendent timing and sequencing. Such a plural combination
individual LED output would not be seen , to promote the could further enhance the appearance of randomness or
simulation of a flame. nonrepeating flame effect for a more realistic effect. In one
In one example , the light engine has a universal threaded embodiment this could simply involve plural sets of light
base that can interface with standard electrical light bulb 25 sources each having its own dedicated timing circuit for
sockets. The housing is integrated to enclose the light on -off control but programmed to be different than the other
sources and light generated from the light sources can issue sets in one or more of position , timing, or other parameters
in directions all around the housing . The interior carrier can such as color of the light sources or output distribution
be a flexible circuit board in a 3D shape . A translucent patterns .
shroud covers the carrier and its light sources . The light 30 These and other objects, features, aspects and advantages
engine and housing can occupy at least substantially on the of the invention will become more apparent with reference
order of the same space as mass-marketed light bulbs . to the accompanying specification and claims.
However, it is to be understood it can be scaled up or down
according to need or desire. In another embodiment of the BRIEF DESCRIPTION OF THE DRAWINGS
apparatus, the light engine can take a variety of different 35
three -dimensional form factors . It may or may not have an The patent or application file contains at least one drawing
outer cover. In some possible forms, just the set of light executed in color. Copies of this patent or patent application
sources , and their control lighting sequence and timing , can publication with color drawing ( s ) will be provided by the
be utilized . In many embodiments , an outer cover can U . S . Patent Office upon request and payment of the neces
enhance the simulation of the appearance of a flame. In one 40 sary fee .
form the outer cover or shroud is translucent and in the form FIG . 1A is a perspective view of a light engine module
of hammered or frosted glass . according to one exemplary embodiment of the invention .
The carrier presents a three -dimensional shape supporting FIG . 1B is a side elevation of FIG . 1A .
a plurality of light sources distributed at least around a FIG . 1C is a top plan view of FIG . 1A .
substantial portion of it . The light sources have the capabil- 45 FIG . 1D is a bottom plan view of FIG . 1A .
ity of being driven individually or in groups according to a FIG . 2A is a side elevation of a light fixture according to
certain preprogrammed regimen . The regimen actuates the one exemplary embodiment of a system according to the
light sources in a fashion that simulates jumping flames from present invention that could utilize the light engine of FIG .
viewing angles all around the 3D shape. 1A and showing its connection to standard household elec
A system according to the present invention includes a 50 tricity diagrammatically .
light engine such as described above in combination with a FIG . 2B is a side elevation of an alternative embodiment
light fixture . The light fixture can include a variety of form of a light fixture that could use the light engine of FIG . 1A .
factors , including different architectural styles. A few non - FIG . 2C is another possible fixture embodiment that could
limiting examples are lantern - style and pendant- light- style . use the light engine of FIG . 1A .
The light engine can be placed inside the fixture . The fixture 55 FIG . 3 is a perspective view ofa fixture similar to FIG . 2A
may or may not have light transmissive panes . illustrating the illumination effect of a light engine such as
A method according to an aspect of the invention includes FIG . 1A inside it .
positioning a plurality of individual solid - state light sources FIG . 4A is a side elevation and exploded view of the light
in a three - dimensional array . Individual or groups of the engine of FIG . 1A .
LEDs sources are driven according to a predetermined 60 FIG . 4B is similar to FIG . 4A but from a 90 . degree .
regimen to simulate a leaping flame or flames by actuating different perspective from FIG . 4A .
LEDs according to a pre- programmed sequence. FIG . 5 is a sectional view taken along 5 -5 of FIG . 4A .
Another aspect of the invention comprises simulating a FIGS. 6A , B , and C are perspective, side elevation , and
flame effect with artificial lights by a particular repeating top plan views, respectively , of a cylindrical carrier (flexible
pattern of activation of a three -dimensional array of LEDs. 65 circuit board formed in a cylinder) of an array of plural
The array has LEDs spaced apart from each other and LEDs which can be placed inside the light engine of FIG .
populating most of the lower part of a three dimensional 1A , shown in isolation .
US 10 ,240 ,736 B2
FIGS. 6D and E are perspective and top plan views, FIG . 15 is a side elevation , partially exploded view of an
respectively , of a bottom end cap for the light engine of FIG . alternative embodiment of a light engine according to the
1A , in isolation . present invention .
FIG . 6F is a perspective view of an electrical threaded FIG . 16 is a side elevation view of a still further alterna
base for the light engine of FIG . 1A , in isolation . 5 tive embodiment of a light engine according to the present
FIG . 6G is a perspective view , in isolation , of an internal invention .
frame used in the light engine of FIG . 1A . FIGS. 17A and B are top plan assembled views and
FIG . 6H is a highly diagrammatic perspective view , in perspective exploded views, respectively , for an alternative
isolation , of a transformer for converting household line double - cylinder embodiment for LEDs and LED carriers ,
electrical voltage into a lower voltage which can bemounted 10 here plural such combinations, for a single light engine
inside the light engine on the frame of FIG . 6G . A schematic
of the circuitry inside the component, hard wires from the according to another alternative embodiment of the present
threaded base of FIG . 6F and to the circuit board of FIG . 61 invention .
are shown in ghost lines. FIGS. 18A and B are top plan and perspective views of a
FIG . 61 is a perspective view . in isolation of a circuit 15 still further star - shaped alternative embodiment for a carrier
board carrying components of controlling the LEDs in the and plural LEDs according to the invention .
light engine of FIG . 1A . FIG . 19 is a perspective view of another possible dome
FIGS. 7A , B , and C are reduced -in - scale perspective , shaped embodiment of the carrier and LEDs according to the
front elevation , and top plan views of an outer translucent present invention .
cylindrical cover, shroud, shade, or lens for the light engine 20 FIG . 20 is another potential alternative cone - shaped
of FIG . 1A , in isolation . embodiment for carrier and LEDs according to the present
FIGS. 7D , E , F , and G are perspective , bottom plan , side invention .
elevation , and top plan views of the top cover from the light FIG . 21A is a reduced scale exploded perspective view of
engine of FIG . 1A , in isolation . another exemplary embodiment according to aspects of the
FIG . 8 is a block diagram of components of the circuit 25 invention ; here a triangle - in - cross section elongated form
board of FIG . 61 for the light engine of FIG . 1A . Connection over which two curved flexible circuit boards, each carrying
to the power transformer of FIG . OH is shown in ghost lines. an array of LEDs, could be placed for use in simulating a
FIGS. 9A - D are electrical schematics of examples of the fireplace fire
types of components of FIG . 8 , including power filtering and FIG . 21 B is just the 3D shape circuit boards of FIG . 21A
voltage regulating modules (FIG . 9A ), a DMXmodule (FIG . 30 ir
9B ), a control or CPU module (FIG . 9C ), and a driver FIGS. 22A -DD are still frame stop action photographs
module (FIG . 9D ) . from a continuous video of operation of one exemplary
FIGS . 9E -G are optional features such as a speed control embodiment of a fixture similar to that of FIG . 3 with a light
( FIG . 9E ), a flame size control ( FIG . 9F ), and an infrared /
body induction module (FIG . 9G ) that could be used in the 35 engine similar to FIGS. 1A - D installed and operating under
circuitry of FIGS. 61 and 8 and shown schematically. the timing pattern at least similar to FIGS. 13 A - C .
FIG . 10 is an electrical schematic of one example of FIGS. 23A -DD are a series of still frame color stop action
circuitry of an array of plural LEDs such as could be used photos similar to FIGS . 22A -DD but with a front door to the
with the circuit components of FIGS. 9A -G . fixture open to see the light engine operating inside .
FIG . 11 is an example of how an LED array circuit of the 40
type of FIG . 10 could be produced by printing conductive DETAILED DESCRIPTION OF EXEMPLARY
traces on a flexible circuit board (here shown in plan view ). EMBODIMENTS
The LED dies could then be surface mounted to the printed
traces , and the flexible circuit board with installed LEDs A . Overview
formed into the cylinder like shown in FIGS. 6A - C . 45 For a better understanding of the invention, several
FIG . 12 is an illustration of and parameters of one examples of forms and embodiments the invention could
example of LEDs that could be used in the LED array of take are now described in detail. These are by way of
FIG . 11 for the light engine of FIG . 1A , including specifi- example only and neither inclusive nor exclusive of all
cations for tricolor ratio , chromaticity , etc . forms and embodiments the invention can take.
FIG . 13A is a diagrammatic illustration of one example of 50 Frequent reference will be taken to the drawings which
an LED array layout ( in plan view ) for a flexible printed have been summarized above. Reference numerals will be
circuit such as FIG . 11 for purposes of describing lighting used to indicate certain parts and locations throughout the
sequence of the LEDs to simulate a flame effect using LEDs drawings. The same reference numerals will be used to
oft tricolor ratios and chromaticity selections illustrated in indicate the same or similar parts or locations throughout the
FIG . 12 . 55 drawings unless otherwise indicated .
FIG . 13B is a timing diagram matched to the LED array I t is to be understood that many of the embodiments will
of FIG . 13A . As indicated it illustrates both level of driving be described in the context of what is called a light engine
of the LED ( full on or partially full on or off ) as well as ormodule that essentially has the form factor of a light bulb .
which of the LEDs at the numbered positions in FIG . 13A It has a threaded base that can be threaded into a conven
are on at what time and in what sequence . 60 tional light bulb socket to provide electrical power. There
FIG . 13C is diagrammatic representations of the LED fore, it can be substituted in virtually any light fixture that
layout of FIG . 13A at each sequence time 1 - 19 from FIG . has such a socket. It is to be understood , however, that the
13B , showing at each moment in time which LEDs would be invention can take a variety of other forms. It can be scaled
on or off and at what intensity . up or down within practical limits . It does not have to be
FIG . 14 is a set of additional possible examples of lighting 65 packaged with the threaded conventional light bulb base . A
fixtures in which the light engine of FIG . 1A could be used , different interface to electrical power and a differentmount
each shown in simplified side elevation . in a fixture are of course possible . But as will be taught by
US 10 ,240 ,736 B2
the specific embodiments that follow , basic features and As will be appreciated from FIGS. 1A -D , this configu
operating principles can be applied in a variety of other form ration allows 360 -degree light output radially relative the
factors and applications . longitudinal axis between threaded base 19 and top cap 16 .
It is to be further understood that the invention is not This light output is through an at least partially light trans
necessarily limited to solid - state light sources . Other types 5 missive ( including but not limited to completely transparent,
of sources could be driven in a similar regimen . Solid - state translucent, diffuse , colored , moire patterned , or other treat
sources themselves can vary. Examples include LEDs , ments on this lens, shroud , or cover ). That cover 12 can also
OLEDS, PLEDs, and laser diodes. They give off light by be substantially sealed relative to the other components to
solid state electroluminescence rather than thermal radiation protect interior contents from moisture, dirt and dust, or
or fluorescence . 10 other unwanted things. In this embodiment, member 12 is
It is particularly to be noted that multiple light engines, or basically a transparent cover over the LEDs to encase and
protect them .
one integrated light engine of 3D carriers of the light sources As can be further appreciated , the components can be
can be implemented in a variety of applications which may made
or may not include an enclosing fixture . One example would 15 threadedoutbase
of a variety of materials . In one example the
19 is electrically conductive and thus typically
be utilizing an embodiment of the invention to simulate metal. Other components such as the formed end 18 , top
leaping flames in a fireplace. One example is at FIGS . cover 16 , and cylindrical carrier and outer light transmissive
21A -B . This would involve designing the carrier to be cover 12 can be of electrically insulated material. One
elongated across a good portion of the fireplace . Alterna - example would be any of a variety of plastics. The designer
tively, plural light engines such as similar to those shown in 20 could select the materials according to need or desire. For
FIG . 1A could be placed in some sort of an array across that example , for indoor applications , thematerials may notneed
same space . to be as robust as for outdoors applications.
It will be appreciated that even without a translucent The shroud 12 in light engine 10 in FIGS. 1A - D alterna
cover or shroud , the light engine of FIGS . 1A - D , or other tively could be translucent. Non -limiting examples of trans
unshrouded configurations could be operated just for an 25 lucent frosted or hammered glass, oil paper, and some
aesthetically pleasing or other lighting presentation . In one plastics .
embodiment, using timing and sequencing such as will be LEDs or other light sources can be selected according to
described further below , it can give the general appearance need or desire . In this example , the LEDs can be commer
of a simulated jumping flame. The invention is not neces - cially available dies. They can be selected from a wide
sarily limited , however, to simulation of a flame. Again , it 30 variety of operating characteristics including lumen output,
could simply present a light output effect. light output distribution pattern , power requirements , color ,
B . Apparatus etc . The designer could also elect to include either a thin
1. Exemplary Embodiment Light Engine 10 layer coating that could change color of light output or other
a ) Assembled Views of Light Engine 10 Self- Contained characteristics . The designer could also elect secondary
Bulb 35 optics at each die if desired . As can be appreciated , the
With reference to FIGS. 1A - D through FIG . 15 , one designer can elect to use all the same LEDs or LEDs that
example of what would be called light engine 10 will be vary in characteristics. The designer would normally evalu
described . In this example , its form factor is larger than a ate all of those factors , including the color, light transmis
conventional threaded base light bulb . For example, it can s iveness, and other characteristics of the cover 12 , in select
have an end to end length of 220 millimeters , and a largest 40 ing the light sources .
diameter width of 90 millimeters , with a cylindrical at least The LEDs in light engine 10 are characterized in FIG . 12 ,
partially light transmissive lens 12 having approximately including size , color output, and operating requirements . It
130 millimeter length , an interior cylindrical three dimen - will be understood, however, that light source type and its
sional carrier 14 carrying plural LEDs 15 , a top cap 16 , and operating characteristics can vary according the need or
a bottom cap 18 with a threaded electrical interface 19 45 desire.
( collectively having a length of about 65 millimeters ) (see As will be further discussed later, an internal drive circuit
dimensions in mm in FIG . 1B ). But, as mentioned , this can in light module 10 can be configured to drive the LEDs in
be scaled up or down within practical limits . It can also have a certain pattern over time. This programmed lighting regi
differing form factors . For example , the diameter could be men can take many forms.
increased relative to length . The shapes do not necessarily 50 As can be seen from FIGS. 1A - D , light engine 10 is
have to be cylindrical. In this embodiment the LED array is elongated around an axis generally between bottom cap 18
at least substantially three dimensional in that it projects and top cap 16 . Light from the sources will radiate generally
light radially around the longitudinal axis to at least a radially from and therefore be observable by persons from
substantial degree if not entirely . Another embodiment is any viewing position 360 degrees around that axis . Unlike
closer to the scale of a conventional incandescent household 55 the more 2D solutions, this promotes the perception of a real
light bulb . See FIGS . 23A -DD for an actual example . It is on flame, as a real flame typically has 3D form .
the order of 120 mm overall length , 50 mm overall width , b ) Examples of Bulb 10 in Several Styles of Light
and 70 mm from top cap to bottom of LEDs (see FIG . 13A Fixtures
for dimensions in mm of the flexible substrate 14 and LEDs FIG . 2A is a schematic illustration of a system according
5 from that embodiment). Other form factors are , of course , 60 to the present invention . The light engine 10 of FIGS. 1A - D
possible . is mounted inside a light fixture 20 which has a comple
As such , light engine 10 can be a self-contained light mentary threaded electrical socket (shown schematically in
source assembly. It can be assembled and sold as a unit. In dashed lines ). Fixture 20 includes an intermediate frame 22
this embodiment, its universal threaded base allows it to be that includes portions that are at least partially light trans
used in complementary threaded electrical sockets typical in 65 missive . In this case , light engine 10 is shown in all dashed
light fixtures that can be connected to household line elec - lines to indicate its general position inside the surrounding
trical power. fixture 20 and that light transmissive panes 24 of fixture 20
US 10 ,240 ,736 B2
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are frosted , hammered , and /or twisted or otherwise not 20 (essentially an outer translucent shroud ), with transparent
transparent. These panes essentially are an outer shroud , shroud 12 of light engine 10 inside fixture 20 , would present
cover, or lens. The observer of fixture 20 would therefore not the observer with a fuzzy 3D ball of brightness inside fixture
directly see light engine 10 . Additionally , such frosting or 20 , which is similar to an actual 3D flame. By on -off timing
texturing of the panes 24 ( see for example FIG . 3 ) would 5 of sets of LEDs in the light engine , discussed below , the
help simulate a flame-like effect from the fixture . fuzzy ball of lightwould also appear to move, shift, expand,
As discussed with regard to light engine 10 , its inner contract, and /or jump with licking flames at the top . Again ,
shroud 12 is transparent. But panes 24 on fixture 20 are a subtlety of the design of this embodiment is that the
translucent ( here hammered glass ). Therefore , an observer observer intentionally is not allowed to image the light
of just light engine 10 would not be able to image any LED 10 sources . Rather , the intentionally scattering of light from the
with clarity . Rather, the translucent outer shroud (panes 24 ) light sources (by hammered glass panes or shroud 24 ) helps
would scatter the LED light in a manner that the observer create a perception in the observer consistent with an actual
would perceive distorted and fuzzy images as the LEDs turn burning flame.
on and off in sets along the axis of the shroud. The light One aspect of certain embodiments disclosed herein is
output distribution patterns, color , intensity , and other 15 simulation of a flame. To help in understanding of one form
selected characteristics of the LEDs, in combination with the in which this is accomplished , FIG . 3 is a color photograph
optical properties of the panes 14 , would produce the of an architectural light fixture having a light engine such as
perception of a 3D flame burning inside light engine 10 . A FIGS. 1A - D inside . Light fixture 20D includes a frame 22D
subtlety of the design is that by intentionally obscuring the outside of hammered translucent glass 24D (four panes at
LEDs by hammered glass fixture panes 24 , it actually 20 each side of fixture 20D ) between a top 26D and a base 28D .
enhances the simulation of a flame. This architectural fixture can take any number of forms and
Thus, placement of light engine 10 inside a fixture with embodiments. As shown in FIG . 3, it has a light output from
frosted or hammered glass panes (such as FIG . 2A ), all four sides. The hammered glass prevents direct view of
enhances flame simulation . An observer from any available the light engine 10 or individual LEDs 15 of light engine 10 .
vantage point relative fixture 20 (e . g . front, left side , right 25 As is indicative in FIG . 3 , this single moment in time shows
side , and back side if exposed ) would not directly image that the light output from light engine 10 is asymmetrical
light engine 10 because panes 24 are translucent. But they and flame like in appearance . By further discussion later,
would perceive a 3D diffuse and varying light output timing and sequence control of LEDs 15 of light engine 10
through translucent panes 24 . This enhances the perception and side fixture 200 gives the appearance of a randomly
of an actual flame inside . 30 lapping or jumping flame. One example of such a timing
As can be appreciated , fixture 20 in this example of FIG . sequence is illustrated in FIGS. 13A - C . One example of
2A is one style of an architectural fixture . Its base 28 could actual operation of light engine 10 in a fixture 20 with
include a mounting interface ( screws, bolts , or otherwise ) hammered glass panes is shown in the stop action sequence
for mounting it in an upright vertical position on some of photos ( color ) at FIGS. 22A -DD and 23A -DD . These
supporting structure ( e . g . wall bracket , post, bollard , hori- 35 photographs give some better understanding of the func
zontal surface mount, or otherwise ). FIGS. 2B and C show tional and aesthetic effect of operation of that combination
just a couple of non - limiting alternative architectural styles for simulation of flame. FIGS . 22A -DD are sequential
for fixtures ( reference numerals 20B and C ). This empha - frames of a video of continuous operation of light engine 10
sizes how light engine 10 can simply be mounted into any inside the lantern - type fixture similar to FIG . 2A . They are
number of different styles of fixtures . Furthermore , it can be 40 10 second continuous operation taken at 30 frames / sec .
understood that the panes or at least partially light transmis - Therefore each frame is approximately 1 /30 .sup .th of a
sive portions 24 of any fixture could be transparent , or second . They show visually and aesthetically how operation
combination of transparent or translucent. of light engine 10 inside a fixture which itself has translucent
It is possible that panes 24 could be omitted and there be glass panes (e. g . hammered glass ), produces the simulate
simply openings in fixture frame 22 to view the light engine 45 appearance of an internal flame or flames ( see FIGS . 22A
10 . The transparent shroud 12 of light engine 10 would allow DD ). The sequence , timing, and brightness of the lighting
some viewing angles to have a direct view of the LEDs. regimen of light engine 10 gives the appearance of flame(s )
However, if shroud 12 were made translucent, it could that jump around , flicker, build and retract, and the like. For
diffuse the LED output and help simulate a flame effect to comparison, FIGS. 23A -DD show a 10 second continuous
observers even if there were no panes in the light fixture . 50 operation of the same light engine at 30 frames / second but
Alternatively , there could be some other shroud , cover , or with a direct view of light engine 10 ( a door to one side of
lens between light engine 10 and the light fixture that could the fixture is opened so that there is no hammered glass pane
be translucent and diffuse the light engine light. between the LEDs of the light engine and the viewer). This
It can therefore be seen that a system for simulating a illustrates how timing and sequence , as well as intensity, of
flame effect can comprise the combination of one , or more , 55 the LEDs can be controlled to simulate the changing form
light engines 10 operatively mounted in any of a number of factor of a real flame as it changes size , shape , direction ,
styles of light fixtures 20 . The realism of the flame simula - color, intensity , and otherwise when burning . Note particu
tion is enhanced by placing a translucent member between larly how a substantial number of LEDs are on more
the LEDs of the light engine and viewers of the apparatus. consistently than some LEDs higher up , and that the top
In this embodiment, the light engine can simply be threaded 60 most LEDs are only flashed on at more spaced - apart times .
out and replaced when needed. But when the light engine is This simulates the jumping, leaping , or lapping of flame tips.
installed in the fixture , the aesthetic can be that of a burning The lower-most LEDs, by either the number or intensity,
gas lamp. The 3D form factor of light engine 10 furthers the tend to collectively pulse or seem to change intensity (and
simulation for virtually all viewing angles of the fixture . even color). This simulates the more steady -state combus
c ) Specific Example of Simulated Flame in One Fixture 65 tion at the base or bottom of a flame ( such as a gas flame)
FIG . 3 shows a similar fixture 20 to that of FIG . 2A . But but also how it can tend to throb or pulse . Note also how
this color photograph shows how frosted panes 24 on fixture middle to top LEDs are controlled to simulate flames
US 10 ,240 ,736 B2
11
leaping , jumping, or lapping by sequentially , at least in part, cially true when viewed from substantial distances, as light
being quickly turned on . This gives the perception of the tends to disperse with distance. Visual acuity also degrades.
simulated flames produced 360 degrees around nearer the 2 . Exploded or Isolated Views of Components of Light
bottom or base of the light engine periodically (pseudo - Engine 10
randomly ) rising in height, and then , even less frequently on 5 The internal parts in the assembly of light engine 10 are
average, turning on the very topmost spaced apart sets of illustrated in FIGS. 4A -B through 7A -D .
LEDs on the light engine to simulate flame tips every so FIGS. 4A and B show the main components of light
often . Still further, it will be appreciated that because the engine 10 in exploded form . As can be seen , threaded cap 19
LEDs are mounted on a 3D substrate , even with the fixture can be mounted on bottom cap 18 . Bracket 30 can be
door closed ( FIGS. 22A -DD ), because light from LEDs is mounted inside bottom cap and support a transformer 32 , the
emanating from around that 3D substrate helps the impres - cylindrical LED carrier 14 , the concentric cylindrical trans
sion or perception that the source of the light is 3D , that there lucent shroud or lens 12 , and a control circuit 34 . A top cap
is a ball or volume of light. This enhances simulation of a 16 can fit onto the open top of shroud 12 to complete the
real flame. For example , FIGS. 23A - DD ( fixture door open ) 16 assembled unit.
demonstrate that even a viewer directly perpendicular to one FIG . 5 is a cross-section of FIG . 4B and gives more details
side of the fixture would be in line with some LEDs on the of placement of the components inside light engine 10 .
light engine . But the viewer would be off -axis many others. a ) LED Carrier ( Flexible Circuit Board and LED Array )
Therefore , the beam axes of individual LEDs would extend FIGS. 6A - C are perspective and isometric views of LED
at various angles relative the viewer and help the 3D 20 carrier 14 . In this embodiment, carrier 14 is cylindrical in
perception . Still further, a viewer aligned with the corner of
shape (cylindrical side wall with open opposite ends ) and is
the fixture would see part of the light from the light engine populated with LED dies around its sidewall. In this embodi
inside through at least two hammered class panes 24 . This ment this 3D shape is made possible by using a flexible
helps the 3D perception . Also , in operation , light from the circuit board from the cylinder with pre - printed circuit traces
light engine would emanate in radial directions all around 25 on its outer surface . LEDs are then surface -mounted to
the vertical longitudinal axis of the light engine , so that appropriate positions in that printed circuit. FIG . 11 gives
viewers from any radial direction would have similar visual one general example of what such a printed circuit board
experience . But refraction and reflection of the hammered might look like in plan view . Flexible circuit boards are
glass panes would also contribute to somewhat random commercially available .
patterns or luminance from the fixture , which also further 30 It this specific embodiment, the LEDs 15 are populated
enhances the aesthetics and simulation . For example , some fairly evenly across most of the cylinder ' s outer surface
light from LEDs on a side of the light engine opposite the from near the bottom or bottom cap open end towards the
one viewer' s viewing direction would emanate first away top or top cap open end. Note that here several clusters of
from the viewer but could hit the inside of the hammered LEDs 15 at or near the top extend nearer the top . The
glass pane nearest to it and reflect instead of pass through 35 clusters are spaced apart circumferentially . This allows
that pane on the opposite side of the fixture . It might reflect creation of “ licking” or “ lapping” flame tips at certain areas
to one of the panes on either side of the fixture relative the of carrier 14 . This embodiment has the LEDs relatively
viewer . It could even bounce around inside the fixture . In heavily populated on the substrate , with the exception at the
any event, this type of reflected light may reach another top .
pane, including the one closest the viewer. This further 40 Spacing of LEDs 15 in this example are shown in FIG .
enhances the perception of 3D source of luminance inside 13A ( dimension numbers in mm ). Thus, the cylinder is
the fixture . As will be appreciated , this perception of a 3D relatively heavily populated with LEDs. As can be appreci
ball or body of flame will be the same or similar from all ated , the designer can adjust the spacing and alignment of
viewing directions of the fixture of FIG . 3, or FIGS. 22A - any set of LEDs. The figures give examples of such spacing
DD . 45 in proportion to the scale of the light engine or substrate . It' s
But as can further be appreciated , as an alternative, cover to be understood that the figures are not to scale . Therefore ,
or shroud 12 right at the LEDs of light engine 10 could be as shown in FIG . 1B , the height of the substrate for that
translucent (otherwise light diffusing ) and the pane or panes embodiment of light engine 10 is approximately 130 mm .
24 of light fixtures such as FIGS. 2A - C could be transparent Thus FIG . 1B shows spacing of the LEDs 15 relative to one
or missing. The viewer would not have a direct view of the 50 another for a form factor and size as dimensioned there . On
LEDs and would see a 3D source of luminance that would the other hand , FIG . 13A shows a circuit board for a light
appear to change size, shape, and nature in a random way, engine like that of FIG . 1A -D , but roughly half as big . The
including the expanding / contracting and jumping or lapping specific spacings between LEDs, as well as the consistent 51
flame tips. If the fixture has panes , even if they are trans - degree diagonal angle along which most of the LEDs are
parent, at least some of the light will bounce around (by 55 aligned , can be derived by the dimensions annotated on FIG .
reflection at the inner surface of the transparent pane or parts 13A (in mm ). Note that other figures , such as FIGS. 16
of the fixture ) or be refracted ( at both inner and outer through 21 , illustrate other potential sizes and form factors.
surfaces of the transparent pane ). This may enhance the The spacing of LEDs can vary according to need or desire .
simulation of a flame. This can help the light engine to be The designer can alternatively adopt more of the arrange
retro - fitted and used in fixtures that do not have translucent 60 ment of FIG . 13A , which is heavily populated with consis
panes, shrouds, or lens. tently arranged LEDs from bottom towards the top but ends
It is also possible that a light engine with a transparent up around the top with small separated clusters of LEDs.
shroud 12 be used in fixtures with transparent panes, This can help give the appearance of a lapping or jumping
shrouds , or lenses , or no panes, shrouds, or lenses . Operation flame. For example , simulated Christmas tree shapes (e . g .
of the light engine would still produce the pseudo -random 65 FIG . 20 ) might be a few inches tall to many feet tall .
light output which is designed to have characteristics that Likewise , some of the other shapes could be the same. Some
simulate an actual flame as described above . This is espe could be many feet tall (e.g . lawn displays or sculptures ).