SEMICONDUCTOR LIGHT SOURCE FOR ILLUMINATING A PHYSICAL SPACE INCLUDING A 3-DIMENSIONAL LEAD FRAME

• US 20100096643A1
• Filed: 04/04/2007
• Published: 04/22/2010
• Est. Priority Date: 08/24/2001
• Status: Active Grant

• Current Assignee: Satco Products Incorporated
• Original Assignee: CAO Group, Inc.
• Inventors: Cao, Densen
• Granted Patent: US 8,569,785 B2
• Time in Patent Office: Days
• US Class Current: 257/88
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• CPC Class Codes: F21K 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21Y 2107/30 on the outer surface of cylindrical surfaces, e.g. rod-shaped supports having a circular or a polygonal cross section
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/45124 Aluminium (Al) as principal constituent
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/73265 Layer and wire connectors
• 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 2924/01079 Gold [Au]
• CPC Class Codes: H01L 33/486 adapted for surface mounting
• 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

Abstract

The present invention is a semiconductor light source 100 for illuminating physical spaces including a lead frame with multiple facets 101. Each facet can have one or more semiconductor light emitting devices 108, such as LEDs, located on it. The light source is disclosed in threaded 100, surface mounted 400, and bar light 700 configurations.

Claims

1. A semiconductor light source for illuminating a physical space comprising:

a. a 3-dimensional lead frame having at least two electrodes, an anode and a cathode, the lead frame further comprising an electrically conductive and heat conductive first electrode with a bore vertically and centrally disposed throughout,

b. a plurality of facets located on said first electrode said facets being configured in different directions and to accept mounting of light emitting semiconductor chips thereon,

c. an electrically conductive second electrode with a diameter smaller than a diameter of the bore, coaxially disposed within the bore, and extending at least to a bottom of the first electrode, said second electrode having a cap on a top end with a diameter greater than a diameter of the bore, a space thereby being defined between the pin and the body,

d. an insulation layer disposed between the first and second electrodes, electrically isolating one from the other, one electrode being the cathode and another the anode, and

e. a plurality of light emitting semiconductor chips, mounted on said facets, each connected to the anode and the cathode.

6. A semi-conductor light source as recited in claim 1 further comprising an encapsulation structure covering the lead frame and chips.

7. A semi-conductor light source as recited in claim 6 wherein said encapsulation structure serves as an optical lens for light emitted by said chips.

8. A semi-conductor light source as recited in claim 6, the encapsulation structure being comprised of at least one material selected from the list of materials consisting of:

silicon, epoxy, and plastic.

9. A semi-conductor light source as recited in claim 8 wherein said encapsulation structure serves as an optical lens for light emitted by said chips.

10. A semi-conductor light source as recited in claim 1 further comprising a light conversion layer for converting light emitted by the chips to white light.

11. A semi-conductor light source as recited in claim 10 wherein said light conversion layer is a phosphor layer.

12. A semi-conductor light source as recited in claim 1 wherein said lead fame has at least one light emitting semiconductor chips mounted on at least one facet.

13. A semi-conductor light source as recited in claim 1, at least two of the semiconductor chips being arranged in an array of semiconductor chips which is operationally connected to the lead frame.

14. A semi-conductor light source as recited in claim 1 wherein the light source emits light across an arc of 360 degrees.

15. A semi-conductor light source as recited in claim 1 wherein the light source emits light across an arc of less than 360 degrees.

16. A semi-conductor light source as recited in claim 15, the arc being defined so that the light source emits light in one direction.

17. A semi-conductor light source as recited in claim 1 further comprising structure for connection to a power source.

18. A semi-conductor light source as recited in claim 17, the structure for connection to a power source being a base with mechanical means for attachment to a light socket.

19. A semi-conductor light source as recited in claim 16, the structure for connection to a power source being structure for mounting the light on a surface.

2. A semi-conductor light source as recited in claim, the bottom of the first electrode being threaded for interface with a socket structure.

3. A semi-conductor light source as recited in claim wherein the pin extends beyond the bottom of the first electrode.

4. A semi-conductor light source as recited in claim 3 further comprising a planar base upon which the lead frame is mounted.

5. A semi-conductor light source as recited in claim 4 further comprising electrodes in the planar base allowing for electrical connection to the cathode and anode.

20. A semiconductor light source for illuminating a physical space comprising a lead frame having at least two electrodes, one being a cathode and another being an anode, the lead frame further comprising:

a. a cylindrical electrode, made of a heat conductive material, having a closed first end upon which an electrical connection is attached,

b. a second electrode, insertable within the cylindrical electrode without contact between the electrodes, said second electrode having a cap with a diameter sufficient to prevent full insertion into the cylindrical electrode and an electrical connection, said second electrode also having projection through a wall of the cylindrical electrode, again without contact between the electrodes;

c. electrical insulation between the cylindrical electrodes, thereby isolating one from the other;

d. a plurality of facets located on said cylindrical electrode, said facets being configured to accept mounting of light emitting semiconductor chips thereon, and

e. a plurality of light emitting semiconductor chips mounted on said facets of said lead frame and connected electrically to the electrodes.

21. A semi-conductor light source comprising a plurality of lead frames as recited in claim 20 wherein said lead frames are configured with respect to each other to form a bar light.

22. A semi-conductor light source as recited in claim 21 further comprising an encapsulation structure over said bar light.

23. A semi-conductor light source as recited in claim 20 further comprising at least one other lead frame with a plurality of facets in operable connection to the first and having at least one LED chip on at least one facet.

24. A semi-conductor light source as recited in claim 20, at least two semiconductor chips being arranged in an array of semiconductor chips which is attached to the lead frame.