LED LIGHTING ASSEMBLY

• US 20060145180A1
• Filed: 03/13/2006
• Published: 07/06/2006
• Est. Priority Date: 12/10/2001
• Status: Active Grant

• Current Assignee: Emissive Energy Corporation
• Original Assignee: Robert D. Galli
• Inventors: GALLI, Robert D.
• Granted Patent: US 7,652,303 B2
• Time in Patent Office: Days
• US Class Current: 257/99
• CPC Class Codes: F21L 4/027 the light sources being a LED
• CPC Class Codes: F21V 23/00 Arrangement of electric circuit elements in or on lighting devices characterised by cooling arrangements F21V29/508
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/745 the fins or blades being planar and inclined with respect to the joining surface from which the fins or blades extend
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/767 the planes containing the fins or blades having directions perpendicular to the light emitting axis
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

The present invention provides a lighting head assembly that incorporates a high intensity LED package into an integral assembly including a heat sink and circuit board for further incorporation into other useful lighting devices. The present invention primarily includes a heat sink member that also serves as a mounting die and a reflector cup into which the LED package is mounted. The circuit board is placed behind the reflector cup and includes riser members that extend through holes in the rear wall of the reflector cup to facilitate electrical connections to the leads of the LED. This particular means for assembly allows the reflector cup and circuit board to cooperate to retain the LED package, provide electrical and control connections, provide integral heat sink capacity and includes an integrated reflector cup. In this manner, high intensity LED packages can be incorporated into lighting assemblies through the use of the present invention by simply installing the present invention into a housing and providing power connections thereto.

Claims

1. A light emitting diode assembly comprising:

a light emitting diode having a mounting base, an output end received on a top surface of said mounting base and a first and second contact lead extending from the sides of said mounting base;

a mounting die, said mounting die having a rear wall with a top surface, a bottom surface, a side wall extending upwardly from said top surface, said top surface and said side wall cooperating to form a cavity therein and an aperture in said rear wall extending from said bottom surface into said cavity; and

a circuit board having first and second electrical traces thereon, a top surface and a bottom surface, said top surface being received adjacent said bottom surface of said rear wall of said mounting die,

wherein said light emitting diode is affixed to said top surface of said circuit board, said first electrical lead in electrical communication with said first electrical trace and said second contact lead in electrical communication with said second electrical trace and said output end is received in said aperture such that light emitted from said output end of said light emitting diode is directed into said cavity on said mounting die.

2. The light emitting diode assembly of claim 1, said rear wall of said mounting die further comprising:

a channel extending longitudinally through said rear wall, said channel having side walls configured to receive and align said mounting base of said light emitting diode within said mounting die.

3. The light emitting diode assembly of claim 2, said rear wall of said mounting die further comprising:

a peripheral wall extending outwardly from said bottom surface of said rear wall, wherein said circuit board is received within said peripheral wall and said peripheral wall is configured to align said circuit board relative to said mounting die.

4. The light emitting diode assembly of claim 3, further comprising:

at least one opening in said peripheral wall;

at least one tab extending from a peripheral edge of said circuit board,

wherein said tab is received within said at least one opening in said peripheral wall thereby preventing rotation of said circuit board relative to said mounting die.

5. The light emitting diode assembly of claim 2, further comprising:

means for preventing said circuit board from rotating relative to said mounting die.

6. The light emitting diode assembly of claim 5, said means for preventing said circuit board from rotating comprising:

mating formations on said circuit board, said mating formations configured to engage with corresponding mating formations on said bottom surface of said rear wall of said mounting die thereby preventing rotation of said circuit board relative to said mounting die.

7. The light emitting diode assembly of claim 6, said means for preventing said circuit board from rotating comprising:

at least one tab on a peripheral edge of said circuit board, said tab configured to engage said side walls of said channel thereby preventing rotation of said circuit board relative to said mounting die.

8. The light emitting diode assembly of claim 1, wherein said mounting die is thermally and electrically conductive and said first electrical trace on said circuit board is in electrical communication with said mounting die.

9. The light emitting diode assembly of claim 8, further comprising:

a spring biased electrical contact extending from and in electrical communication with said bottom surface of said circuit board.

10. The light emitting diode assembly of claim 9, further comprising:

a power source having a first electrical contact and a second electrical contact, said first electrical contact in electrical communication with said spring biased electrical contact extending from said circuit board, said second electrical contact is in electrical communication with said mounting die.

11. The light emitting diode assembly of claim 1, wherein said cavity within said mounting die serves as a reflector cup to direct light output from said light emitting diode.

12. The light emitting diode assembly of claim 11, wherein said sidewalls of said cavity are shaped to form a parabolic reflector.

13. The light emitting diode assembly of claim 11, wherein said sidewalls of said cavity are shaped to form an ellipsoidal reflector.