Lamp and method of producing a lamp

• US 20050285505A1
• Filed: 06/11/2003
• Published: 12/29/2005
• Est. Priority Date: 06/14/2002
• Status: Active Grant

• Current Assignee: Lednium Technology Pty Limited
• Original Assignee: Lednium Pty., Ltd.
• Inventors: Montagnat, John Albert, Jeganathan, Balu
• Granted Patent: US 7,704,762 B2
• Time in Patent Office: Days
• US Class Current: 313/500
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21Y 2107/20 on convex supports or substrates, e.g. on the outer surface of spheres
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/45144 Gold (Au) as principal constituent
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/01004 Beryllium [Be]
• CPC Class Codes: H01L 2924/01078 Platinum [Pt]
• CPC Class Codes: H01L 2924/01079 Gold [Au]
• CPC Class Codes: H01L 2924/12041 LED
• CPC Class Codes: H01L 33/62 Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
• CPC Class Codes: Y10S 362/80 Light emitting diode
• CPC Class Codes: Y10S 438/956 Making multiple wavelength emissive device

Abstract

A method of producing a lamp, including: mounting light emitting junctions in respective receptacles; mounting the receptacles on a curved support structure so as to form a three-dimensional array; and placing the light emitting junctions in electrical connection with the support structure.

Claims

1. A method of producing a lamp, including:

mounting light emitting junctions in respective receptacles;

mounting the receptacles on a curved support structure so as to form a three-dimensional array; and

placing the light emitting junctions in electrical connection with the support structure.

2. A method as claimed in claim 1, wherein the support structure includes a plurality of conductors and the method further includes forming at least one of the conductors in a curved configuration.

3. A method as claimed in claim 2, wherein at least some of the conductors are formed in a part spherical configuration.

4. A method as claimed in claim 3, wherein the at least some conductors are formed in a convex configuration.

5. A method as claimed in claim 3, wherein the at least some conductors are formed in a concave configuration.

6. A method as claimed in claim 2, in which the light emitting junctions are connected to the at least one curved conductor by intermediate conductors.

7. A method as claimed in claim 6, wherein each of the plurality of conductors is curved, one of said curved conductors being two-dimensionally curved and the rest of said curved conductors being three-dimensionally curved.

8. A method as claimed in claim 7, wherein each junction is electrically connected to two of the curved conductors.

9. A method as claimed in claim 2, wherein the junctions are electrically connected to conductors such that the current flowing in groups of junctions can be controlled separately to the current flowing in other groups of junctions.

10. A method as claimed in claim 2, wherein the junctions are connected to conductors such that the current flowing in any junction can be controlled independently of the current in every other junction.

11. A method as claimed in claim 1, wherein the receptacles are preformed cups.

12. A method as claimed in claim 11, wherein the cups function as optical guides for controlling the direction of light output from respective junctions mounted therein.

13. A method as claimed in claim 11, wherein the cups are formed in a one-dimensional or two-dimensional array and are subsequently singularised.

14. A method as claimed in claim 11, wherein the cups are mounted in respective cavities in the support structure.

15. A method as claimed in claim 14, wherein the cavities are holes extending through the support structure.

16. A method as claimed in claim 11, wherein the junctions installed in the cups are electrically connected to conductive areas, insulated from, but mounted on, a flange of each cup.

17. A method as claimed in claim 13, wherein singularised cups, with light emitting junctions attached, are packaged in tape and reel, or other, bulk packaging.

18. A method as claimed in claim 1, wherein the support structure is formed as a lead frame.

19. A method as claimed in claim 18, wherein the support structure is formed by:

(a) stamping a conductive plate in a predetermined configuration;

(b) forming cavities in a central portion of the conductive plate for receiving said receptacles; and

(c) impressing a curved configuration on said central portion.

20. A method as claimed in claim 19, wherein said central portion is separated into separate conductors before the step of impressing.

21. A method as claimed in claim 19, wherein the central portion is coated with silver or silver alloy.

22. A lamp formed in accordance with the method of claim 1.

29. A lamp as claimed in claim 22, wherein one or more of the junctions is adapted to emit light of a different color to the other junctions.

23. A lamp including:

a curved electrically conductive support structure;

a plurality of receptacles mounted on the support structure so as to form a three-dimensional array; and

a plurality of light emitting junctions disposed in respective receptacles and electrically connected to the support structure.

24. A lamp as claimed in claim 23, wherein each receptacle is a cup.

25. A lamp as claimed in claim 24, wherein each cup has side walls arranged to direct light which is output from the junction, the cup further serving to dissipate heat generated from the junction, which is thermally coupled thereto.

26. A lamp as claimed in claim 24, wherein each cup further includes an electrically insulative layer, upon which is provided an electrically conductive area, to allow for electrical connection between a bonding wire of the light emitting junction mounted in the cup and an intermediate connection for coupling the junction to a conductor, for establishing a current through the light emitting junction.

27. A lamp as claimed in claim 24, wherein each cup is formed with a polarity indicator toward one side thereof for indicating the polarity of the junction disposed therein.

28. A lamp as claimed in claim 23, wherein the support structure includes a plurality of conductors, at least one conductor being curved, and the receptacles are mounted on the at least one curved conductor so that the light emitting junctions adopt a three-dimensional array.

30. A lamp as claimed in claim 28, wherein the light emitting junctions are connected to the at least one curved conductor by intermediate conductors.

31. A lamp as claimed in claim 30, wherein each of the plurality of conductors is curved, one of said curved conductors being two-dimensionally curved and the rest of said curved conductors being three-dimensionally curved.

32. A lamp as claimed in claim 31, wherein each junction is electrically connected to two of the curved conductors.

33. A lamp as claimed in claim 23, wherein the junctions are electrically connected to conductors such that the current flowing in groups of junctions can be controlled separately to the current flowing in other groups of junctions.

34. A lamp as claimed in claim 23, wherein the junctions are connected to conductors such that the current flowing in any junction can be controlled independently of the current in every other junction.

35. A lamp as claimed in claim 24, wherein the cups are mounted in respective cavities in the support structure.

36. A lamp as claimed in claim 35, wherein the cavities are holes extending through the support structure.

37. A lamp as claimed in claim 28, wherein at least some of the conductors are formed in a part spherical configuration.

38. A lamp as claimed in claim 37, wherein at least some of the conductors are formed in a convex configuration.

39. A lamp as claimed in claim 37, wherein at least some of the conductors are formed in a concave configuration.

40. A lamp as claimed in claim 23, wherein the support structure is formed as a lead frame.

41. A lamp as claimed in claim 40, wherein the lead frame is formed of copper or copper alloy.

42. A lamp as claimed in claim 41, wherein at least a part of the lead frame is coated with silver or silver alloy.

43. A lamp as claimed in claim 23, wherein the receptacles are formed of copper or copper alloy.

44. A lamp as claimed in claim 43, wherein the receptacles are coated with silver or silver alloy.

45. A lamp as claimed in claim 40, wherein the support structure is formed by:

(a) stamping a conductive plate in a predetermined configuration;

(b) coating a central portion of the conductive plate with silver or silver alloy;

(c) forming cavities in said central portion for receiving said receptacles; and

(d) impressing a curved configuration on said central portion.

46. A lamp as claimed in claim 45, wherein said central portion is separated into separate conductors before the step of impressing.

47. A lead frame for receiving a plurality of light emitting junctions to form a lamp, including:

a curved, electrically conductive support structure;

a plurality of cavities in said support structure for receiving a respective plurality of receptacles having light emitting junctions disposed therein, such that said light emitting junctions form a three-dimensional array.

48. A lead frame as claimed in claim 47, wherein the support structure is formed by:

(a) stamping a conductive plate in a predetermined configuration;

(b) forming cavities in a central portion of the conductive plate for receiving said receptacles; and

(c) impressing a curved configuration on said central portion.

49. A lead frame as claimed in claim 48, wherein said central portion is separated into separate conductors before the step of impressing.

50. A lead frame as claimed in claim 48, wherein the central portion is coated with silver or silver alloy.