Lamp and method of producing a lamp

• US 7,704,762 B2
• Filed: 06/11/2003
• Issued: 04/27/2010
• Est. Priority Date: 06/14/2002
• Status: Active Grant

• Current Assignee: Lednium Technology Pty Limited
• Original Assignee: Lednium Technology Pty Limited
• Inventors: Montagnat, John Albert, Jeganathan, Balu
• Primary Examiner(s): Huynh; Andy
• Assistant Examiner(s): HO, HOANG QUAN TRAN
• Application Number:
  US10/487,040
• Publication Number:
  US 20050285505A1
• Time in Patent Office: 2,512 Days
• Field of Search: None
• US Class Current: 438/28
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21Y 2107/20 on convex supports or substrates, e.g. on the outer surface of spheres
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/45144 Gold (Au) as principal constituent
• CPC Class Codes: H01L 2224/48091 Arched
• 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 2924/01004 Beryllium [Be]
• CPC Class Codes: H01L 2924/01078 Platinum [Pt]
• CPC Class Codes: H01L 2924/01079 Gold [Au]
• CPC Class Codes: H01L 2924/12041 LED
• 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
• CPC Class Codes: Y10S 362/80 Light emitting diode
• CPC Class Codes: Y10S 438/956 Making multiple wavelength emissive device

Abstract

A method of producing a lamp, including: mounting light emitting junctions in respective receptacles; mounting the receptacles on a curved support structure so as to form a three-dimensional array; and placing the light emitting junctions in electrical connection with the support structure.

Claims

1. A method of producing a lamp, including:

forming, from an electrically conductive material, a plurality of electrically conductive receptacles;

forming, from an electrically conductive material, an electrically conductive non-planar support structure divided into mutually spaced portions, the portions having a three-dimensional array of recesses or through holes therein, the recesses or through holes being configured to receive and support the electrically conductive receptacles;

mounting light emitting junctions in the electrically conductive receptacles;

mounting the electrically conductive receptacles with light emitting junctions mounted therein in respective ones of the recesses or through holes in the mutually spaced portions of the non-planar electrically conductive support structure so as to form a three-dimensional array of electrically conductive receptacles in electrical connection with the mutually spaced portions of the non-planar electrically conductive support structure, each of the electrically conductive receptacles being supported by a corresponding one of the mutually spaced portions of the non-planar electrically conductive support structure; and

forming electrical connections between the light emitting junctions and the mutually spaced portions of the non-planar electrically conductive support structure;

wherein each of the light emitting junctions includes two electrical contacts of opposite electrical polarities, one of the electrical contacts being directly electrically connected to the portion of the electrically conductive support structure that supports the light emitting junction, and the other of the electrical contacts being directly electrically connected to another of the portions of the electrically conductive support structure so that electrical current flows through the supporting portions of the non-planar electrically conductive support structure to supply power to the light emitting junctions.

2. A method as claimed in claim 1, wherein each of the receptacles is asymmetrical, the light emitting junctions being mounted in the electrically conductive receptacles in a selected orientation relative to the asymmetry to facilitate the formation of electrical connections to electrical contacts of the light emitting junctions.

3. A method as claimed in claim 1, including forming electrical connections between the junctions mounted in the receptacles and the receptacles prior to the receptacles being mounted on the electrically conductive support structure.

4. A method as claimed in claim 3, wherein each of the receptacles includes an electrically conductive body and at least one electrically conductive contact attached to, but electrically insulated from, the body of the receptacle.

5. A method as claimed in claim 4, wherein said forming of electrical connections between the junctions mounted in the receptacles and the receptacles includes forming electrical connections between the junctions and the electrically conductive contacts attached to, but electrically insulated from, the bodies of the receptacles.

6. A method as claimed in claim 5, wherein said forming of electrical connections between the junctions mounted in the receptacles and the receptacles includes forming electrical connections between the junctions mounted in the receptacles and the bodies of the receptacles.

7. A method as claimed in claim 6, wherein each of the receptacle bodies includes a generally concave portion having a planar base to which corresponding light emitting junctions are mounted, and a flange to which the corresponding at least one electrically conductive contact is mounted, an electrical insulator being disposed between the flange and the at least one electrically conductive contact.

8. A method as claimed in claim 7, wherein each receptacle is supported on the electrically conductive support structure by its flange.

9. A method as claimed in claim 6, wherein the step of forming electrical connections between the light emitting junctions and the electrically conductive support structure includes forming electrical connections between the electrically conductive support structure and the electrically conductive contacts attached to, but electrically insulated from, the bodies of the receptacles.

10. A method as claimed in claim 1, wherein the mutually spaced portions of the support structure are curved.

11. A method as claimed in claim 10, wherein the curved portions of the support structure are collectively dome-shaped.

12. A method as claimed in claim 10, wherein the curved portions of the support structure are collectively substantially part spherical.

13. A method as claimed in claim 10, wherein the curved portions of the support structure collectively have a concave bowl-like shape.

14. A method as claimed in claim 10, wherein each of portions of the support structure is curved, one of said curved portions of the support structure being two-dimensionally curved and the rest of said curved portions of the support structure being three-dimensionally curved.

15. A method as claimed in claim 14, wherein each junction is electrically connected to two of the curved portions of the support structure.

16. A method as claimed in claim 10, wherein the electrical connections between the junctions and the portions of the support structure are configured such that the current flowing in at least one group of junctions can be controlled separately to the current flowing in at least one other group of junctions.

17. A method as claimed in claim 10, wherein the electrical connections between the junctions and the portions of the support structure are configured such that the current flowing in any junction can be controlled independently of the current in every other junction.

18. A method as claimed in claim 1, wherein the receptacles are shaped like cups or bowls.

19. A method as claimed in claim 1, wherein the receptacles have reflective sidewalls that determine the illumination provided by the lamps.

20. A method as claimed in claim 1, wherein the receptacles are mounted in respective recesses in the support structure.

21. A method as claimed in claim 1, wherein the receptacles are mounted in respective through holes extending through the support structure.

22. A method as claimed in claim 1, wherein the junctions mounted in the receptacles are electrically connected to electrically conductive areas electrically insulated from, but mounted on, a flange of each receptacle.

23. A method as claimed in claim 1, wherein the receptacles are formed in a one-dimensional or two-dimensional array and are subsequently singularized.

24. A method as claimed in claim 23, wherein singularized receptacles, with light emitting junctions attached, are packaged in tape and reel, or other, bulk packaging.

25. A method as claimed in claim 1, wherein the support structure is formed as a lead frame.

26. A method as claimed in claim 25, wherein the support structure is formed by:

stamping an electrically conductive plate in a predetermined configuration;

forming recesses or through holes in a portion of the electrically conductive plate for receiving said receptacles;

dividing at least the portion of the electrically conductive plate to form the mutually spaced portions; and

impressing a curved configuration on said portion.

27. A method as claimed in claim 26, wherein the portion is coated with silver or silver alloy.

28. A method as claimed in claim 26, wherein the curved configuration impressed on said portion is a dome shape.

29. A method as claimed in claim 28, wherein the electrically conductive support structure is substantially dome-shaped.

30. A method as claimed in claim 28, wherein the dome shape is substantially part-spherical.

31. A method as claimed in claim 1, wherein the electrically conductive receptacles and the electrically conductive support structure are configured to effectively dissipate heat generated by the light emitting junctions.

32. A lamp formed in accordance with the method of claim 1.

33. A lamp including:

a plurality of electrically conductive receptacles;

an electrically conductive non-planar support structure divided into mutually spaced portions, the portions having a three-dimensional array of recesses or through holes therein, the recesses or through holes being configured to receive and support the electrically conductive receptacles;

wherein the electrically conductive receptacles are mounted in respective ones of the recesses or through holes in the mutually spaced portions of the non-planar support structure so as to form a three-dimensional array of electrically conductive receptacles in electrical connection with the mutually spaced portions of the electrically conductive support structure, each of the electrically conductive receptacles being supported by a corresponding one of the mutually spaced portions of the non-planar electrically conductive support structure;

light emitting junctions disposed in respective ones of said electrically conductive receptacles and electrically connected to the mutually spaced portions of the electrically conductive support structure; and

electrical connections between the light emitting junctions and the mutually spaced portions of the non-planar electrically conductive support structure;

wherein each of the light emitting junctions includes two electrical contacts of opposite electrical polarities, one of the electrical contacts being directly electrically connected to the portion of the electrically conductive support structure that supports the light emitting junction, and the other of the electrical contacts being directly electrically connected to another of the portions of the electrically conductive support structure so that electrical current flows through the supporting portions of the non-planar electrically conductive support structure to supply power to the light emitting junctions.

34. A lamp as claimed in claim 33, wherein each of the receptacles is asymmetrical, the light emitting junctions being mounted in the electrically conductive receptacles in a common orientation relative to the asymmetry.

35. A lamp as claimed in claim 33, wherein each junction mounted in a receptacle is electrically connected to that receptacle by at least one electrical conductor.

36. A lamp as claimed in claim 33, wherein each of the receptacles includes an electrically conductive body to which a corresponding light emitting junction is mounted, and at least one electrically conductive contact attached to, but electrically insulated from, the body of the receptacle, the lamp including first electrical connections between the junctions mounted in the receptacles and the electrically conductive contacts, and second electrical connections between the electrically conductive contacts and the electrically conductive support structure.

37. A lamp as claimed in claim 36, wherein each receptacle includes electrically conductive contacts attached to, but electrically insulated from, the body of the receptacle, said electrically conductive contacts of the receptacle being electrically connected to contacts of opposite polarities of the light emitting junction mounted in the receptacle.

38. A lamp as claimed in claim 36, wherein each light emitting junction includes two electrically conductive contacts of opposite polarities respectively connected to the corresponding receptacle body and to an electrically conductive contact attached to, but electrically insulated from, the body of the corresponding receptacle.

39. A lamp as claimed in claim 36, wherein each receptacle body includes a generally concave portion having a planar base to which a corresponding light emitting junction is mounted, and a flange to which the corresponding at least one electrically conductive contact is mounted, an electrical insulator being disposed between the flange and the at least one electrically conductive contact.

40. A lamp as claimed in claim 39, wherein each receptacle is supported on the electrically conductive support structure by its flange.

41. A lamp as claimed in claim 33, wherein each receptacle is shaped like a cup or bowl.

42. A lamp as claimed in claim 33, wherein each receptacle has side walls arranged to direct light output from the junction, the cup further serving to dissipate heat generated from the junction, which is thermally coupled thereto.

43. A lamp as claimed in claim 33, wherein each receptacle further includes an electrically insulating layer, upon which is provided an electrically conductive area, to allow for electrical connection between a bonding wire of the light emitting junction mounted in the receptacle and an intermediate connection for coupling the junction to a conductor, for establishing a current through the light emitting junction.

44. A lamp as claimed in claim 33, wherein each receptacle is formed with a polarity indicator toward one side thereof for indicating the polarity of the junction disposed therein.

45. A lamp as claimed in claim 33, wherein the mutually spaced portions of the non-planar electrically conductive support structure are curved.

46. A lamp as claimed in claim 33, wherein one or more of the junctions is adapted to emit light of a different color to the other junctions.

47. A lamp as claimed in claim 45, wherein the other of the electrical contacts of each light emitting junction is directly electrically connected to the another of the portions of the electrically conductive support structure by an intermediate conductor.

48. A lamp as claimed in claim 45, wherein each of the mutually spaced portions of the non-planar electrically conductive support structure is curved, one of said curved portions being two-dimensionally curved and the rest of said curved portions being three-dimensionally curved.

49. A lamp as claimed in claim 48, wherein each junction is electrically connected to two of the curved portions.

50. A lamp as claimed in claim 33, wherein the junctions are electrically connected to the mutually spaced portions of the non-planar electrically conductive support structure such that the current flowing in at least one group of junctions can be controlled separately to the current flowing in at least one other group of junctions.

51. A lamp as claimed in claim 33, wherein the junctions are connected to the mutually spaced portions of the non-planar electrically conductive support structure such that the current flowing in any junction can be controlled independently of the current in every other junction.

52. A lamp as claimed in claim 33, wherein the receptacles are mounted in respective recesses in the support structure.

53. A lamp as claimed in claim 33, wherein the receptacles are mounted in respective through holes extending through the support structure.

54. A lamp as claimed in claim 45, wherein at least some of the mutually spaced portions are formed in a part spherical configuration.

55. A lamp as claimed in claim 54, wherein at least some of the mutually spaced portions are formed in a convex configuration.

56. A lamp as claimed in claim 54, wherein at least some of the mutually spaced portions are formed in a concave configuration.

57. A lamp as claimed in claim 33, wherein the support structure is formed as a lead frame.

58. A lamp as claimed in claim 57, wherein the lead frame is formed of copper or copper alloy.

59. A lamp as claimed in claim 57, wherein at least a part of the lead frame is coated with silver or silver alloy.

60. A lamp as claimed in claim 33, wherein the receptacles are formed of copper or copper alloy.

61. A lamp as claimed in claim 60, wherein the receptacles are coated with silver or silver alloy.

62. A lamp as claimed in claim 33, wherein the mutually spaced portions of the electrically conductive support structure are collectively substantially dome shaped.

63. A lamp as claimed in claim 33, wherein the mutually spaced portions of the electrically conductive support structure are collectively substantially part-spherical.

64. A lamp as claimed in claim 33, wherein the electrically conductive receptacles and the electrically conductive support structure are configured to effectively dissipate heat generated by the light emitting junctions.

65. A lead frame for receiving a plurality of light emitting junctions to form a lamp, including:

a dome-shaped, electrically conductive support structure divided into mutually spaced portions;

a three-dimensional array of recesses or through holes in the mutually spaced portions of said electrically conductive support structure for receiving and supporting electrically conductive receptacles having light emitting junctions disposed therein to form a corresponding three-dimensional array of electrically conductive receptacles in electrical connection with the electrically conductive support structure.