Method and apparatus for providing an omni-directional lamp having a light emitting diode light engine
First Claim
1. A method of manufacturing a light emitting diode (LED) lamp, comprising:
- providing first and second light engines each including;
a substrate comprising a transparent or translucent thermally conductive material,a plurality of LED semiconductor devices mounted to the substrate,a plurality of conductive traces formed over the substrate to electrically interconnect each of the plurality of LED semiconductor devices, andconductive leads connected to the substrate for supplying electrical energy to the plurality of LED semiconductor devices;
providing a thermally conductive rod including a circular first end and a flattened second end with a distance between opposing parallel sides of the flattened second end less than a diameter of the circular first end and a face of the flattened second end perpendicular to a length of the thermally conductive rod;
mounting the first and second light engines respectively over the opposing parallel sides of the flattened second end of the thermally conductive rod;
forming a heatsink by an extrusion, molding, stamping, or die casting process to provide a fin structure for dissipating heat energy;
inserting the diameter of the circular first end of the thermally conductive rod into an opening in the heatsink; and
mounting an optical housing to the heatsink and disposed over the face of the flattened second end such that the first and second light engines are suspended within the optical housing.
1 Assignment
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Accused Products
Abstract
An LED lamp includes a light engine. The light engine includes a substrate including a transparent or translucent thermally conductive material, a plurality of LED semiconductor devices mounted to the substrate, a plurality of conductive traces formed over the substrate to electrically interconnect each of the plurality of LED semiconductor devices, and conductive leads connected to the substrate for supplying electrical energy to the plurality of LED semiconductor devices. The substrate of the light engine may include an aluminum nitride (AlN), or diamond film material. A thermally conductive rod is connected to the light engine. A heatsink is formed by an extrusion or die casting process. The heatsink includes a fin structure for dissipating heat energy into the environment. The thermally conductive rod and the heatsink are thermally connected. An optional optical envelope is mounted to the heatsink. The optional optical envelope is disposed over the light engine.
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Citations
27 Claims
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1. A method of manufacturing a light emitting diode (LED) lamp, comprising:
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providing first and second light engines each including; a substrate comprising a transparent or translucent thermally conductive material, a plurality of LED semiconductor devices mounted to the substrate, a plurality of conductive traces formed over the substrate to electrically interconnect each of the plurality of LED semiconductor devices, and conductive leads connected to the substrate for supplying electrical energy to the plurality of LED semiconductor devices; providing a thermally conductive rod including a circular first end and a flattened second end with a distance between opposing parallel sides of the flattened second end less than a diameter of the circular first end and a face of the flattened second end perpendicular to a length of the thermally conductive rod; mounting the first and second light engines respectively over the opposing parallel sides of the flattened second end of the thermally conductive rod; forming a heatsink by an extrusion, molding, stamping, or die casting process to provide a fin structure for dissipating heat energy; inserting the diameter of the circular first end of the thermally conductive rod into an opening in the heatsink; and mounting an optical housing to the heatsink and disposed over the face of the flattened second end such that the first and second light engines are suspended within the optical housing. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method of manufacturing a light emitting diode (LED) lamp, comprising:
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providing a light engine including a substrate and a plurality of LEDs mounted to the substrate; forming a fluorescent or phosphorous material over or within the substrate; providing a thermally conductive structure including a circular first end and a flattened second end with a distance between opposing parallel sides of the flattened second end less than a diameter of the circular first end; mounting the light engine to the flattened second end of the thermally conductive structure; providing a heatsink including a fin structure for dissipating heat energy; inserting the diameter of the circular first end of the thermally conductive structure into an opening in the heatsink; and mounting an optical housing to the heatsink such that the light engine and the flattened second end of the thermally conductive structure opposite the circular first end are suspended within the optical housing. - View Dependent Claims (8, 9, 10, 11, 12)
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13. A method of manufacturing a lamp, comprising:
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providing a light source including a substrate; forming a fluorescent or phosphorous material over or within the substrate; providing a thermally conductive structure including a circular first end and a flattened second end with a distance between opposing parallel sides of the flattened second end less than a diameter of the circular first end; mounting the light source to the flattened second end of a thermally conductive structure; providing a heatsink for dissipating heat energy; inserting the diameter of the circular first end of the thermally conductive structure into an opening in the heatsink; and mounting an optical housing to the heatsink such that the light source is suspended within the optical housing. - View Dependent Claims (14, 15, 16, 17)
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18. A light emitting diode (LED) lamp, comprising:
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a light engine including a substrate and a plurality of LEDs mounted to the substrate; a thermally conductive structure including a circular first end and a flattened second end connected to the light engine with a distance between opposing parallel sides of the flattened second end of the thermally conductive structure less than a diameter of the circular first end; a heatsink including a fin structure for dissipating heat energy and with a diameter of the circular first end of the thermally conductive structure inserted into an opening in the heatsink; and an optical housing mounted to the heatsink and disposed over the flattened second end of the thermally conductive structure. - View Dependent Claims (19, 20, 21, 22)
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23. A method of manufacturing a light emitting diode (LED) lamp, comprising:
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providing a light engine including a substrate and a plurality of LEDs mounted to the substrate; providing a thermally conductive structure including a circular first end and a flattened second end with a distance between opposing parallel sides of the flattened second end less than a diameter of the circular first end; mounting the light engine over the thermally conductive structure; providing a heatsink including an opening extending from a first surface of the heatsink to a second surface of the heatsink opposite the first surface; inserting the diameter of the thermally conductive structure into the opening in the heatsink; and mounting an optical housing to the first surface of the heatsink with the light engine suspended within the optical housing. - View Dependent Claims (24, 25, 26, 27)
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Specification