Led array vehicle lamp
First Claim
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1. A lamp assembly, comprising:
- a housing defining an inner surface;
a light transmissive window member on said housing, wherein said housing inner surface and said window member form a space therebetween;
at least one light emitting unit mounted to a front face of a circuit board member located within said space, wherein said light emitting unit also emits heat; and
,a formable thermally conductive medium located within said space, said medium including a formable matrix material having a first coefficient of thermal conductivity and a suspended material comprising heat conductive particles suspended in said matrix material, said particles having a second coefficient of thermal conductivity which is higher than said first coefficient of thermal conductivity, wherein said thermally conductive medium conducts heat emitted from the light emitting unit out of the lamp assembly; and
,wherein said circuit board member is substantially fully embedded in said formable thermally conductive medium having said formable matrix material formed in contact with said light emitting unit and formed in contact with said circuit board member along said front face thereof and formed in contact with said circuit board member along said back face thereof and formed in contact with said inner surface of said housing.
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Abstract
A lamp, such as for truck trailers and/or tractors, is provided with LEDs mounted to a circuit board placed in a housing. The LEDs and circuit boards are fully embedded in a resin material cured with thermally conductive particles suspended therein for conducting excess heat to the outer aluminum housing and the outer environment. The lens cover has a series of parallel, elongated lens ribs providing constant optics while allowing additional LEDs to be positioned in a row behind a lens rib. The LED circuit board has large traces to enhance heat dissipation.
514 Citations
25 Claims
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1. A lamp assembly, comprising:
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a housing defining an inner surface; a light transmissive window member on said housing, wherein said housing inner surface and said window member form a space therebetween; at least one light emitting unit mounted to a front face of a circuit board member located within said space, wherein said light emitting unit also emits heat; and
,a formable thermally conductive medium located within said space, said medium including a formable matrix material having a first coefficient of thermal conductivity and a suspended material comprising heat conductive particles suspended in said matrix material, said particles having a second coefficient of thermal conductivity which is higher than said first coefficient of thermal conductivity, wherein said thermally conductive medium conducts heat emitted from the light emitting unit out of the lamp assembly; and
,wherein said circuit board member is substantially fully embedded in said formable thermally conductive medium having said formable matrix material formed in contact with said light emitting unit and formed in contact with said circuit board member along said front face thereof and formed in contact with said circuit board member along said back face thereof and formed in contact with said inner surface of said housing. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A lamp assembly, comprising:
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a housing defining an inner surface having a bottom and side walls extending therefrom; a light transmissive window member on said housing, wherein said housing inner surface and said window member form a space therebetween; a row of light emitting units mounted to a carrier located within said space, said row being generally parallel with said light transmissive window member; an elongated lens rib along said window member and running along and in front of said row of light emitting units, said lens rib having a generally circular curvature when viewed in cross-section and further having said curvature remain generally constant along at least portions of said lens rib to allow selective positioning of said light emitting units at various locations along said elongated lens rib with substantially constant optics by said elongated lens rib; a formable thermal conductive medium including heat conductive particles encapsulated therein located within said space, wherein said carrier is at least partially embedded in said formable medium and said medium is bonded to said inner bottom surface of said housing. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 25)
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22. A method for making a lamp assembly, comprising the steps of:
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providing a housing; positioning a circuit board having a plurality of light emitting diodes mounted thereto in said housing; filling at least a portion of said housing with an initially fluid material in contact with said circuit board; solidifying said initially fluid material into a solid material bonded to said housing and having said circuit board embedded therein, said solid material including heat conductive particles for conducting heat generated from said light emitting diodes away from said circuit board; and
,placing a light transmissive window member onto said housing and over said light emitting diodes. - View Dependent Claims (23, 24)
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Specification