Light emitting diode light bar module with electrical connectors formed by injection molding
First Claim
1. A light-emitting diode (LED) module, comprising:
- a plurality of LED dies configured to emit light;
a heat sink thermally coupled to the plurality of LED dies;
a trench extending from a first end of the heat sink to a second end of the heat sink opposite the first end; and
a connector disposed at one of the first and second ends of the trench, the connector including a plurality of conductive pins surrounded by an injection molding material.
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Accused Products
Abstract
The present disclosure relates to methods for fabricating electrical connectors of a waterproof connector-heat sink assembly of a LED light bar module using injection molding. The methods include matching the coefficient of thermal expansion (CTE) of injection molding materials for the connectors and heat sinks. A heat sink and conductor pins are inserted into an injection mold and the injection molding materials are injected into the injection mold. An integrated connector-heat sink assembly is formed when the injection molding materials of the connectors form a waterproof seal with the heat sink when the injection molding materials solidify. Placement of the heat sink and conductor pins inside the injection mold is controlled to ensure that adhesive bonding between the injection molding materials and the heat sink is stronger than a maximum shear force.
11 Citations
20 Claims
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1. A light-emitting diode (LED) module, comprising:
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a plurality of LED dies configured to emit light; a heat sink thermally coupled to the plurality of LED dies; a trench extending from a first end of the heat sink to a second end of the heat sink opposite the first end; and a connector disposed at one of the first and second ends of the trench, the connector including a plurality of conductive pins surrounded by an injection molding material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A lighting module, comprising:
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a heat sink extending in a longitudinal direction; a recessed channel running through the heat sink along the longitudinal direction; a printed circuit board (PCB) located in the recessed channel; a plurality of light-emitting diode (LED) dies located on the PCB; a male connector located in the recessed channel and coupled to a first end of the PCB, wherein the male connector includes a set of conductive pins circumferentially surrounded by a first injection molding element; and a female connector located in the recessed channel and coupled to a second end of the PCB opposite the first end, wherein the female connector includes a component containing a set of holes, wherein each of the holes is configured to mate with a respective one of the conductive pins of the male connector, and wherein the component is circumferentially surrounded by a second injection molding element. - View Dependent Claims (11, 12, 13, 14, 15, 16)
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17. A connector-heat sink apparatus of a light emitting diode (LED) light bar module comprising:
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a plurality of LED dies configured to emit radiation; a heat sink having a channel with an opening, the heat sink being thermally coupled to the plurality of LED dies and providing heat dissipation for the LED dies; and an injection-molded connector disposed in the opening of the channel to form a waterproof seal with the channel of the heat sink, wherein the injection-molded connector includes injection molding materials and a set of conductor pins surrounded radially by the injection molding materials. - View Dependent Claims (18, 19, 20)
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Specification