LED lighting assembly

• US 6,974,234 B2
• Filed: 12/09/2003
• Issued: 12/13/2005
• Est. Priority Date: 12/10/2001
• Status: Expired due to Fees

• Current Assignee: Robert D. Galli
• Original Assignee: Robert D. Galli
• Inventors: Galli, Robert D.
• Primary Examiner(s): Husar, Stephen
• Assistant Examiner(s): Han, Jason
• Application Number:
  US10/731,392
• Publication Number:
  US 20040114393A1
• Time in Patent Office: 735 Days
• Field of Search: 362/373, 362/92, 362/555, 362/800, 362/294, 362/311, 362/191, 362543-545
• US Class Current: 362/294
• CPC Class Codes: F21L 4/027 the light sources being a LED
• CPC Class Codes: F21V 15/01 Housings, e.g. material or assembling of housing parts F21V15/02 takes precedence housings forming signs or letters G09F13/04
• CPC Class Codes: F21V 29/74 with fins or blades
• 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 5/04 of lens shape
• CPC Class Codes: F21V 7/0091 using total internal reflection
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

The present invention provides a lighting head assembly that incorporates a high intensity LED package into an integral housing for further incorporation into other useful lighting devices. The present invention primarily includes two housing components, namely an inner mounting die and an outer enclosure and an optical component for collimating and focusing the light output. The inner and outer components cooperate to retain the LED package, provide electrical and control connections, provide integral heat sink capacity. Further the integrally incorporated optical lens captures, homogenizes and transmits substantially all of the light emitted by a light source, such as a light emitting diode. The present invention transmits 85% of the light emitted by the light source and produces a uniformly illuminated circular image in the far field of the device. 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 lighting assembly comprising:

a light emitting diode package including;

a front luminescent portion having a central axis,

a mounting base,

a heat transfer plate on a rear surface of said mounting base, and

a first and second contact lead extending from the sides of said mounting base;

a heat sink assembly including;

a mounting die having a first end, a second end opposite said first end, a longitudinal axis extending between said first and second ends and an alignment guide on said first end, said mounting die being electrically conductive and thermally conductive, wherein said alignment guide positions said light emitting diode package such that said central axis of said luminescent portion is substantially aligned with said longitudinal axis of said mounting die and said heat transfer plate is in thermal communication with said mounting die; and

a lens received adjacent said luminescent portion of said light emitting diode package for directing light output from said light emitting diode package forwardly along an optical axis.

2. The light emitting diode lighting assembly of claim 1, further comprising:

an aperture in said mounting die extending from said first end of said mounting die to said second end, wherein said first contact lead of said light emitting diode is in electrical communication with said mounting die and said second contact lead of said light emitting diode extends into said aperture.

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

a circuit board mounted adjacent said second end of said mounting die, said circuit board including electrical circuit traces printed on one side thereof, said second contact lead of said light emitting diode in electrical communication with said circuit traces.

4. The light emitting diode lighting assembly of claim 3, wherein said circuit board includes control circuitry in electrical communication with said circuit traces.

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

an exterior enclosure, said exterior enclosure having a tubular outer wall, said outer wall forming a cavity for receiving and maintaining said mounting die, said light emitting diode and said lens in assembled relation; and

a power source having first and second contact leads, said first contact lead in electrical communication with said mounting die and said second contact lead in electrical communication with said circuit traces.

6. The light emitting diode lighting assembly of claim 1, said lens including, a total internal reflection collector portion, said collector portion of said lens comprising:

a rear surface;

an outer side wall; and

a cavity extending into said collector portion from said rear surface, said cavity having an inner side wall and a front wall, said front luminescent portion disposed substantially within said cavity.

7. The light emitting diode lighting assembly of claim 1, further comprising:

an exterior enclosure, said exterior enclosure having a tubular outer wall, said outer wall forming a cavity for receiving and maintaining said mounting die, said light emitting diode and said lens in assembled relation; and

means for connecting a power source having first and second contact leads with said first and second contact leads of said light emitting diode.

8. A lighting assembly comprising:

a light emitting diode package including;

a front luminescent portion having a central axis,

a mounting base,

a heat transfer plate on a rear surface of said mounting base, and

a first and second contact lead extending from the sides of said mounting base;

an interior mounting die having a first end, a second end opposite said first end and a longitudinal axis extending between said first and second ends, said interior die being electrically conductive and thermally conductive, said interior die having a recess in a first side thereof configured to receive and retain said mounting base of said light emitting diode, wherein said central axis of said luminescent portion is substantially aligned with said longitudinal axis of said interior die and said heat transfer plate is in thermal communication with said first side of said interior die, said interior die having at least one aperture therein extending from said first side of said interior die to a second side of said interior die opposite said first side, one of said contact leads of said diode extending into said aperture;

a lens for directing light output from said light emitting diode forwardly along an optical axis, said lens including, a total internal reflection collector portion, said collector having a recess therein where in said luminescent portion of said light emitting diode is received within said recess; and

an exterior enclosure, said exterior enclosure having a tubular outer wall, said outer wall forming a cavity for receiving and maintaining said interior mounting die, said light emitting diode and said lens in assembled relation.

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

a mounting board installed adjacent said second side of said interior mounting die.

10. The light emitting diode lighting assembly of claim 9, wherein said mounting board is a circuit board with electrical circuit traces printed on one side thereof, said second contact lead of said light emitting diode in electrical communication with said circuit traces.

11. The light emitting diode lighting assembly of claim 10, wherein said circuit board includes control circuitry in electrical communication with said circuit traces.

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

a power source having first and second contact leads, said first contact lead in electrical communication with said mounting die and said second contact lead in electrical communication with said second contact of said light emitting diode.

13. A light emitting diode lighting assembly comprising:

a light emitting diode having a front luminescent portion having a central axis and a mounting base, said mounting base having a heat transfer plate on a rear surface thereof and a first and second contact lead extending from the sides thereof;

a heat sink assembly, said heat sink assembly being thermally conductive, said heat sink assembly having a front surface and a rear surface, said heat sink assembly having a longitudinal axis extending from said front surface to said rear surface, an alignment guide in said rear surface thereof and an aperture extending from said alignment guide to said front surface of said heat sink, said alignment guide being configured to receive said mounting base of said light emitting diode, wherein said luminescent portion of said tight emitting diode extends through said aperture and said central axis is in substantial alignment with said longitudinal axis;

a spreader plate, said spreader plate being thermally conductive, said spreader plate in thermal communication with said heat transfer plate of said light emitting diode and said rear surface of said heat sink assembly, wherein said spreader plate retains said light emitting diode in said alignment guide and conducts heat from said light emitting diode to said heat sink assembly; and

a lens for directing light output from said light emitting diode forwardly along an optical axis, said lens including a total internal reflection collector portion at a first end thereof, said collector having a focal length and a recess therein where in said luminescent portion of said light emitting diode is received within said recess.

14. The light emitting diode lighting assembly of claim 13, further comprising:

a circuit board adjacent to said spreader plate, said circuit board in electrical communication with said first and second contact leads of said light emitting diode.

15. The light emitting diode lighting assembly of claim 13, said collector portion of said lens comprising:

a rear surface;

an outer side wall; and

a cavity extending into said collector portion from said rear surface, said cavity having an inner side wall and a front wall, said light source disposed substantially within said cavity.