Lamp seat for a light emitting diode and capable of heat dissipation, and method of manufacturing the same

• US 8,053,787 B2
• Filed: 11/21/2007
• Issued: 11/08/2011
• Est. Priority Date: 06/28/2007
• Status: Active Grant

• Current Assignee: Wen-Chin Shiau
• Original Assignee: Wen-Chin Shiau
• Inventors: Shiau, Wen-Chin
• Primary Examiner(s): Pham; Thanh V
• Assistant Examiner(s): Ligai; Maria
• Application Number:
  US11/944,328
• Publication Number:
  US 20090001558A1
• Time in Patent Office: 1,448 Days
• Field of Search: 257/E33.057, 257/699, 257/698, 257/700, 257/712, 257/E33.066, 257/E33.075, 257/81, 257/82, 438/122
• US Class Current: 257/81
• CPC Class Codes: F21L 4/027 the light sources being a LED
• CPC Class Codes: F21V 29/74 with fins or blades
• 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: 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 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H05K 1/056 the metal substrate being covered by an organic insulating layer
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/445 having insulated holes or insulated via connections through the metal core

Abstract

A lamp seat includes a metal substrate having opposite first and second surfaces, first and second conductive patterns formed on the first surface, and third and fourth conductive patterns formed on the second surface and connected respectively and integrally to the first and second conductive patterns. A heat-conductive first insulating layer is disposed between the metal substrate and each of the first, second, third and fourth conductive patterns. A heat-conductive second insulating layer is formed over the first insulating layer such that corresponding parts of the first and second conductive patterns are exposed outwardly of the second insulating layer for electrical connection with positive and negative electrodes of a light emitting diode, respectively.

Claims

1. A lamp seat adapted for a light emitting diode, comprising:

a metal substrate having opposite first and second surfaces and formed with first and second through holes that extend from said first surface to said second surface and that are spaced apart from each other, said metal substrate further having first and second annular surrounding walls that define said first and second through holes, respectively;

a heat-conductive first insulating layer having first, second and third layer portions that are formed respectively over said first and second surfaces and said first annular surrounding wall of said metal substrate;

first and second conductive patterns formed on said first layer portion of said first insulating layer;

third and fourth conductive patterns formed on said second layer portion of said first insulating layer;

a first conductive layer disposed in said first through hole in said metal substrate, formed over said third layer portion of said first insulating layer, and interconnecting integrally and electrically said first and third conductive patterns;

a second conductive layer disposed in said second through hole in said metal substrate, formed on said second annular surrounding wall of said metal substrate, and interconnecting integrally and electrically said second and fourth conductive patterns; and

a heat-conductive second insulating layer having first and second openings and formed over said first layer portion of said first insulating layer such that corresponding parts of said first and second conductive patterns are exposed respectively via said first and second openings and are adapted to be connected electrically and respectively to positive and negative electrodes of the light emitting diode;

a heat-conductive third insulating layer formed over said second annular surrounding wall of said metal substrate such that said third insulating layer is sandwiched between said second annular surrounding wall of said metal substrate and said second conductive layer, and interconnects integrally said first and second layer portions of said first insulating layer; and

a heat-conductive fourth insulating layer formed over said second layer portion of said first insulating layer such that a portion of said third conductive pattern and a portion of said fourth conductive pattern are exposed outwardly of said fourth insulating layer without extending through said fourth insulating layer, are spaced apart from said first and second through holes in said metal substrate and are adapted for heat transmission and electrical connection with an external power source.

2. The lamp seat as claimed in claim 1, wherein said metal substrate is made of aluminum.

3. The lamp seat as claimed in claim 1, wherein said first, second, third and fourth conductive patterns, and said first and second conductive layers are made of copper.

4. The lamp seat as claimed in claim 1, wherein said first and second insulating layers are made of epoxy resin.

5. The lamp seat as claimed in claim 1, wherein said exposed portion of said third conductive pattern is circular and is disposed at a central portion of said second surface of said metal substrate.

6. The lamp seat as claimed in claim 5, wherein said exposed portion of said fourth conductive pattern is ring-shaped and is disposed around said exposed portion of said third conductive pattern.

7. The lamp seat as claimed in claim 1, further comprising two conductive pads disposed respectively in said first and second openings in said second insulating layer and connected electrically and respectively to said corresponding parts of said first and second conductive patterns such that the positive and negative electrodes of the light emitting diode are connected electrically and respectively to said first and second conductive patterns via said conductive pads.