Method of manufacturing a light emitting diode lighting assembly

• US 9,255,674 B2
• Filed: 10/04/2013
• Issued: 02/09/2016
• Est. Priority Date: 10/04/2012
• Status: Active Grant

• Current Assignee: Signify North America Corporation (Signify N.V.)
• Original Assignee: Once Innovations Inc. (Signify N.V.)
• Inventors: Grajcar, Zdenko
• Primary Examiner(s): DZIERZYNSKI, EVAN P
• Application Number:
  US14/046,184
• Publication Number:
  US 20140098531A1
• Time in Patent Office: 858 Days
• Field of Search: 362/198
• US Class Current: 1/1
• CPC Class Codes: F21K 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• CPC Class Codes: F21K 9/233 specially adapted for generating a spot light distribution, e.g. for substitution of reflector lamps
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 17/164 the parts being subjected to bending, e.g. snap joints
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21V 3/062 the material being plastics
• CPC Class Codes: F21V 3/10 characterised by coatings
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/22 characterised by materials, surface treatments or coatings, e.g. dichroic reflectors
• CPC Class Codes: F21Y 2101/00 Point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A method of manufacturing a light emitting diode lighting assembly that includes producing a heat sink and securing a platform assembly having a plurality of light emitting diode dies on a single plane. A bulb is formed by securing a first lens section made of a first material to a second lens section made of a second material such that only the bulb determines the lamp type of the light emitting diode lighting assembly.

Claims

1. A method of manufacturing a light emitting diode lighting assembly steps comprising:

producing a heat sink connected to a light emitting diode light source;

selecting a first lens section having a first diffusion rate and first reflection coefficient;

selecting a second lens section having a second diffusion rate and second reflection coefficient;

securing the first and second lens section together to form a bulb;

securing the first lens section to the heat sink; and

wherein only the selection of the first lens section and second lens section determines the lamp type of the light emitting diode lighting assembly.

2. The method of claim 1 wherein the bulb is frictionally secured to the heat sink.

3. The method of claim 1 wherein the first lens section has a high diffusion rate and the second lens section has a low diffusion rate.

4. The method of claim 3 wherein the first lens section has a reflection coefficient greater than 4% and the second lens section has a reflection coefficient less than 4%.

5. The method of claim 4 wherein the lamp type is omnidirectional lamp.

6. The method of claim 5 wherein the lamp type is A-19.

7. The method of claim 4 wherein the first lens section has a portion of reflective material thereon.

8. The method of claim 7 wherein the portion of reflective material is a metallic ring formed on the second lens section.

9. The method of claim 7 wherein the portion of reflective material is a plurality of spaced apart reflective particles.

10. The method of claim 1 wherein the first lens section is made of a material having a low diffusion rate and the second lens section has a reflective ring formed therein.

11. The method of claim 10 wherein the lamp type is a directional lamp.

12. The method of claim 11 wherein the lamp type is BR 20.

13. The method of claim 11 wherein the lamp type is BR 30.

14. The method of claim 10 wherein the second lens section has an outer diameter that is greater than the outer diameter of the first lens section.