Method and system for attachment of light emitting diodes to circuitry for use in lighting

• US 7,677,763 B2
• Filed: 09/29/2006
• Issued: 03/16/2010
• Est. Priority Date: 10/20/2004
• Status: Expired due to Fees

• Current Assignee: Timothy Chan
• Original Assignee: Timothy Chan
• Inventors: Chan, Timothy
• Primary Examiner(s): O'Shea; Sandra L
• Assistant Examiner(s): CARTER, WILLIAM JOSEPH
• Application Number:
  US11/541,314
• Publication Number:
  US 20070025103A1
• Time in Patent Office: 1,264 Days
• Field of Search: 362/252, 362/373, 362/800, 362/249.02, 36221714-21717, 439 43- 48, 439/52, 439/53, 439113-115, 439/119, 439/151, 439207-213, 439/374, 439378-381, 439/485, 439/487, 439/515, 439525-526, 439604-606, 43962001-62002, 43962021-62025
• US Class Current: 362/249.02
• CPC Class Codes: F21V 19/0025 the fastening means engaging the conductors of the light source, i.e. providing simultaneous fastening of the light sources and their electric connections
• CPC Class Codes: F21V 19/04 with provision for changing light source, e.g. turret auxiliary devices for cleaning, placing, or removing incandescent lamps H01K3/32, fluorescent lamps H01J9/006
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2107/00 Light sources with three-dimensionally disposed light-generating elements
• 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: H01R 33/09 for baseless lamp bulb
• CPC Class Codes: H05K 2201/09472 Recessed pad for surface mounting; Recessed electrode of component
• CPC Class Codes: H05K 2201/09981 Metallised walls
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2201/10651 Component having two leads, e.g. resistor, capacitor
• CPC Class Codes: H05K 2201/10765 Leads folded back, i.e. bent with an angle of 180 deg
• CPC Class Codes: H05K 3/107 by filling grooves in the support with conductive material H05K3/045, H05K3/101, H05K3/1258 and H05K3/465 take precedence
• CPC Class Codes: H05K 3/308 Adaptations of leads connectors to printed circuits H01R12/00
• CPC Class Codes: H05K 3/325 by abutting or pinching, i.e. without alloying process; mechanical auxiliary parts therefor adaptations of leads inserted in holes for press-fit connections H05K3/308
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A method and system for attaching LEDs to circuitry which would protect the LEDs from heat damage and allows for individual LEDs to be removed.

Claims

1. An LED array comprising:

a plurality of packaged LEDs each having a first terminal and a second terminal and a heat sink slug dispose between said first terminal and second terminal; and

a multiple-LED base socket having an outer surface and a pair of electrically conductive channels formed in the outer surface;

said pair of electrically conductive channels being adapted to receive the terminals of the plurality of packaged LEDs; and

said plurality of packaged LEDs being arranged adjacent one another on the outer surface of the base socket with the first terminals of the LEDs being inserted in one of the channels of said pair of electrically conductive channels and the second terminals of the LEDs being inserted in another of the channels of said pair of electrically conductive channels, wherein said first terminal and second terminal both being outwardly biased springs each engaging a sidewall surface comprising an electrically conductive plate, wherein said heat sink slug establishes thermal contact to the outer surface of the base socket between said pair of electrically conductive channels.

2. The array of claim 1 wherein the heat sink slug establishes thermal contact to the outer surface of the base socket between said pair of electrically conductive channels with the aid of a thermal grease, a thermal tape or a thermal adhesive.

3. The array of claim 1 wherein an outer most wall of one channel and an outer most wall of the other channel of said pair of channels are angled inward toward each other.

4. The array of claim 1 wherein comprising an additional pair of trim adapted for insertion into the pair of channels after the installation of the LEDs to further secure the terminals to said pair of channels.

5. The array of claim 1 wherein the outer surface of the base socket is substantially planar and said electrically conductive channels are parallel to one another and run laterally across the upper surface between first and second ends of the base socket.

6. The array of claim 1 wherein the outer surface of the base socket is substantially planar and said electrically conductive channels are formed as substantially concentric rings.

7. The array of claim 1 wherein the outer surface of the base socket is cylindrical in shape and said electrically conductive channels are formed as peripheral rings around the cylindrical outer surface.

8. The array of claim 1 wherein the outer surface of the base socket is conical in shape and said pair of electrically conductive channels are formed in the outer surface running from an outer rim of said conical base socket towards a inner center rim of said conical base socket.

9. The array of claim 1 further comprising at least one additional pair of electrically conductive channels adapted to receive respective first and second terminals of an additional plurality of packaged LEDs.

10. The array of claim 9 wherein one of the channels of one of the pairs of electrically conductive channels is coupled to one of the channels of another of the pairs of electrically conductive channels via a conductive jumper.

11. The array of claim 1 further comprising a jumper inserted in said base socket, said jumper having first and second terminals, with the first terminal of the jumper being inserted in one of the channels of said pair of electrically conductive channels and the second terminal of the jumper being inserted in the other of the channels of said pair of electrically conductive channels.

12. The array of claim 11 further comprising a plurality of said jumpers interspersed with packaged LEDs so as to provide a desired light pattern for said array.

13. The array of claim 1 wherein the first and second terminals of at least one of said packaged LEDs comprise a pair of spring prongs formed from respective leads of said LED.

14. A packaged LED comprising a heat sink slug dispose between a first and second terminals having respective outwardly biased spring leads adapted for insertion into respective first and second conductive channels of a base socket, each of said outwardly biased spring leads engaging a conductive sidewall surface pane of said respective channels to thereby establish electrical contact between the terminals and the base socket and said heat sink slug establishing thermal contact with said base socket between said first and second conductive channels of said base socket, and a plurality of locations being arranged adjacent one another on an outer surface of the base socket for insertion of each of said outwardly biased spring leads.

15. A multiple-LED base socket for an LED array, the base socket having an outer surface and a pair of electrically conductive channels formed in the outer surface, and a thermal contact surface disposed between said pair of electrically conductive channels, with first and second electrically conductive channels of said pair of electrically conductive channels being adapted to receive respective first and second terminals of each of a plurality of packaged LEDs, wherein said first and second terminals being outwardly biased engaging an electrically conductive plate of each of said pair of electrically conductive channels and said thermal contact surface adapted to established thermal communication with a heat sink slug of each of the plurality of packaged LEDs.

16. The base socket of claim 15 wherein said pair of channels has a outer most wall of said first electrically conductive channel and a outer most wall of said second electrically conductive channel that are both angled inward toward each other.

17. The base socket of claim 15 further comprising an additional pair of trim adapted for insertion into the pair of channels after the installation of said packaged LEDs to further secure said first and second terminals to said respective channels.

18. The base socket of claim 15 wherein the outer surface of the base socket is substantially planar and said electrically conductive channels are parallel to one another and run laterally across the upper surface between first and second ends of the base socket.

19. The base socket of claim 15 wherein the outer surface of the base socket is substantially planar and said electrically conductive channels are formed as substantially concentric rings.

20. The base socket of claim 15 wherein the outer surface of the base socket is cylindrical in shape and said electrically conductive channels are formed as peripheral rings around the cylindrical outer surface.

21. The base socket of claim 15 further comprising at least one additional pair of electrically conductive channels adapted to receive respective first and second terminals of an additional plurality of packaged LEDs.