LED lighting assembly with improved heat management

• US 7,121,680 B2
• Filed: 08/25/2004
• Issued: 10/17/2006
• Est. Priority Date: 12/10/2001
• Status: Expired due to Term

• Current Assignee: Emissive Energy Corporation
• Original Assignee: Robert D. Galli
• Inventors: Galli, Robert D.
• Primary Examiner(s): PAYNE, SHARON E
• Application Number:
  US10/925,798
• Publication Number:
  US 20050017366A1
• Time in Patent Office: 783 Days
• Field of Search: 362/202, 362/205, 362/294, 362/373, 362/545, 362/800, 361/719, 257/706, 257/712, 665/80.3, 174/16.3
• US Class Current: 362/202
• CPC Class Codes: F21L 4/027 the light sources being a LED
• 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]
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

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 assembly 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.

Claims

1. A portable flashlight assembly comprising:

at least one battery, said battery having a first and second electrical contact;

a flashlight head assembly including,

a single light emitting diode having a mounting base, said mounting base having a heat transfer plate on a rear surface thereof and a first and second contact leads extending from the sides thereof,

a mounting die, said mounting die being thermally conductive, said mounting die having a rear wall with a top surface, and

a circuit board received adjacent said top surface of said rear wall of said mounting die, said circuit board having an aperture therethrough and first and second electrically conductive contact members thereon adjacent said aperture,

said light emitting diode being received on said circuit board wherein said heat transfer plate extends through said aperture in said circuit board and is in thermal communication with said top surface of said mounting die, said first and second contact leads being positioned in electrical communication with said first and second contact members;

an exterior enclosure; and

means for selectively energizing said light emitting diode disposed between and in electrical communication with one of said contacts of said battery and said circuit board.

2. The flashlight assembly of claim 1, wherein said circuit board is formed on a flexible circuit substrate.

3. The flashlight assembly of claim 1, further comprising:

a thermally conductive interface material disposed between said thermally conductive body and said heat transfer plate.

4. The flashlight assembly of claim 3, wherein said thermally conductive material is selected from the group consisting of:

thermal grease, thermally conductive adhesive and a thermal interface pad.