Connector devices, systems, and related methods for connecting light emitting diode (LED) modules

• US 9,316,382 B2
• Filed: 01/31/2013
• Issued: 04/19/2016
• Est. Priority Date: 01/31/2013
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Rowlette, John R.
• Primary Examiner(s): Lee, Diane
• Assistant Examiner(s): Wolford, Naomi M
• Application Number:
  US13/756,005
• Publication Number:
  US 20140213094A1
• Time in Patent Office: 1,174 Days
• US Class Current: 1/1
• CPC Class Codes: F21V 19/0035 the fastening means being capable of simultaneously attaching of an other part, e.g. a housing portion or an optical component
• CPC Class Codes: F21Y 2101/00 Point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing

Abstract

Connector devices, systems, and related methods for connecting light emitting diode (LED) modules to thermal substrates and/or optical elements are disclosed. In some aspects, a connector device can include a connector body having a first side configured to engage an LED module and a second side configured to engage an optical element for mechanically coupling the LED module to the optical element. The connector device can further include a housing configured to receive a portion of an electrical wire for electrically coupling the LED module to the electrical wire. A connector system can include an annular body defining an opening and at least one LED module disposed in a portion of the connector. The connector can be configured to cover a portion of the LED module and leave another portion of the LED module exposed or visible.

Claims

1. A connector device for securing a light emitting diode (LED) module that comprises a plurality of separate and individual light emitters, the connector device comprising:

a connector body comprising a first side configured to engage the LED module to hold the LED module in place against a first surface, and a second side configured to engage an optical element for mechanically coupling the LED module to the optical element;

the connector body being configured to receive a portion of an electrical wire, whereby engagement of the LED module by the first side of the connector body also electrically couples the LED module to the electrical wire; and

the connector body comprising an opening extending between the first surface on the first side and a second surface on the second side, wherein a plurality of tabs extend from the second surface and are disposed above the second surface and above the opening for engaging the optical element.

2. The connector device of claim 1, wherein the optical element comprises a diffusing bulb.

3. The connector device of claim 1, wherein the optical element comprises a reflector.

4. The connector device of claim 1, wherein the optical element comprises a diffusing lens.

5. The connector device of claim 1, wherein the optical element is configured to slide over the tabs extending from the second side of the connector body.

6. The connector device of claim 1, wherein the connector body comprises an annular ring.

7. The connector device of claim 6, wherein a portion of the annular ring is configured to cover one or more electrical components disposed on the LED module.

8. The connector device of claim 1, wherein the connector body comprises one or more raised contact portions on the first side of the connector body for engaging the LED module.

9. The connector device of claim 1, wherein the connector body contacts the LED module in only three points.

10. The connector device of claim 1, wherein the connector body contacts the LED module in only two points.

11. The connector device of claim 1, wherein the connector body contacts the LED module in more than three points.

12. The connector device of claim 1, further comprising at least one side opening for receiving the wire, wherein the at least one side opening is disposed in a lateral side wall between the first surface and the second surface.

13. The connector device of claim 1, wherein the connector body is reflective.

14. The connector device of claim 1, wherein the connector body comprises plastic or ceramic.

15. The connector device of claim 1, wherein the connector body comprises a reflective coating.

16. The connector device of claim 1, wherein the connector body is configured to engage a thermal substrate.

17. The connector device of claim 1, wherein the connector body comprises a thermally conductive material.

18. The connector device of claim 17 wherein the connector body comprises plastic.

19. The connector device of claim 17 wherein the connector body comprises metal.

20. A connector device for securing a light emitting diode (LED) module, the connector device comprising:

a connector body comprising a first side configured to engage the LED module, the connector body comprising a centrally disposed opening extending between a planar upper surface and a planar lower surface; and

a plurality of tabs extending above the planar upper surface and above the opening for engaging an optical element.

21. The connector device of claim 20, further comprising one or more raised contact portions disposed along the first side of the connector body, wherein the connector body is configured to physically contact the LED module only at the one or more raised contact portions and wherein the one or more raised contact portions are spaced apart at regular intervals about the opening of the connector body.

22. The connector device of claim 20, wherein the optical element comprises a diffusing bulb.

23. The connector device of claim 20, wherein the optical element comprises a reflector.

24. The connector device of claim 20, wherein the optical element comprises a diffusing lens.

25. The connector device of claim 20, wherein the optical element is configured to slide over tab portions extending from the connector body.

26. The connector device of claim 20, wherein the connector body contacts the LED module at only three contact portions.

27. The connector device of claim 20, wherein the connector body contacts the LED module at only two contact portions.

28. The connector device of claim 20, wherein the connector body is reflective.

29. The connector device of claim 20, wherein the connector body comprises plastic or ceramic.

30. The connector device of claim 20, wherein the connector body comprises a reflective coating.

31. The connector device of claim 20, wherein the connector body is configured to engage a thermal substrate.

32. The connector device of claim 20, wherein the connector body is configured to cover electrical components of the LED module.

33. The connector device of claim 20, wherein the connector body comprises a thermally conductive material.

34. The connector device of claim 20 wherein the connector body comprises plastic.

35. The connector device of claim 20 wherein the connector body comprises metal.

36. A connector system for connecting a light emitting diode (LED) module to a substrate, the connector system comprising:

a connector comprising a body that defines an opening;

at least one LED module disposed in a portion of the connector, the LED module comprising;

a substrate;

one or more light emitters disposed on the substrate; and

one or more electrical components disposed on the substrate; and

wherein, when the at least one LED module is disposed in a portion of the connector, the one or more electrical components are covered and not visible and the one or more light emitters are visible through a portion of the opening; and

wherein the opening extends between a reflective, planar upper surface of the body and a parallel planer lower surface of the body, and wherein a side opening is disposed in a lateral side wall of the body between the upper surface and the lower surface, the lateral side opening being configured to receive one or more electrical components.

37. The connector system of claim 36, wherein the body is annular and covers a portion of the one or more electrical components.

38. The connector system of claim 36, wherein the LED module comprises six or more light emitters.

39. The connector system of claim 36, wherein the LED module comprises 12 or more light emitters.

40. The connector system of claim 36, wherein the LED module comprises 24 or more light emitters.

41. The connector system of claim 36, wherein the light emitters comprise LED packages.

42. The connector system of claim 36, wherein the substrate is more than 5 millimeters (mm) in diameter.

43. The connector system of claim 36, wherein the substrate is more than 25 millimeters (mm) in diameter.

44. The connector system of claim 36, wherein the substrate is more than 40 millimeters (mm) in diameter.

45. The connector system of claim 36, further comprising one or more raised contact portions that are spaced apart at regular intervals about the opening of the connector body.

46. The connector system of claim 36, wherein the LED module is disposed between the body and a thermal substrate.

47. The connector system of claim 46, further comprising a thermal interface material disposed between the LED module and the thermal substrate.

48. The connector system of claim 36, further comprising an optical element.

49. The connector system of claim 48, wherein the optical element comprises a diffusing bulb.

50. The connector system of claim 48, wherein the optical element comprises a reflector.

51. The connector system of claim 48, wherein the optical element comprises a diffusing lens.

52. The connector system of claim 48, wherein the optical element is configured to slide over tab portions extending from the body.

53. The connector system of claim 36, wherein the body contacts the LED module at only three contact portions.

54. The connector system of claim 36, wherein the connector body is reflective.

55. The connector system of claim 36, wherein the connector body comprises plastic or ceramic.

56. The connector system of claim 36, wherein the substrate of the LED module comprises alumina or aluminum nitride.

57. The connector system of claim 36, wherein the LED module comprises a micro-processor disposed on the substrate.

58. The connector device of claim 36, wherein the connector body comprises a thermally conductive material.

59. The connector device of claim 36 wherein the connector body comprises plastic.

60. The connector device of claim 36 wherein the connector body comprises metal.

61. A method of connecting a light emitting diode (LED) module to another component, the method comprising:

providing a connector with a connector body and an opening;

providing an LED module over a first side of the connector body;

positioning an optical element over a tab provided on a second side of the connector body, wherein the tab extends above the opening of the connector body; and

inserting an electrical wire into the connector body for electrically coupling the wire to the LED module.

62. The method of claim 61, wherein the connector comprises an annular shaped body defining the opening.

63. The method of claim 62, wherein providing the LED module comprises positioning a central portion of the LED module through the opening of the annular shaped body.

64. The method of claim 62, wherein a portion of the annular shaped body covers one or more electrical components disposed on the LED module.

65. The method of claim 62, wherein the LED module comprises one or more LED packages disposed over a substrate.

66. The method of claim 61, wherein the optical element comprises a reflector.

67. The method of claim 61, wherein the optical element comprises a diffusing lens.

68. The method of claim 61, wherein the optical element is configured to slide over the tab.

69. The method of claim 61, further comprising coupling the LED module to a thermal substrate.

70. The method of claim 61, further comprising applying a reflective coating over at least a portion of the connector.

71. A connector system comprising:

a light emitting diode (LED) module comprising at least one light emitter, the light emitter comprising a submount;

a connector body comprising a first side configured to engage the LED module to hold the LED module in place against a surface, a second side configured to engage an optical element, and one or more tab portions, wherein the tab portions of the connector body extend a furthest distance away from the connector body than any other portion of the connector body; and

whereby engagement of the LED module by the first side of the connector body also electrically couples the LED module to the connector device.

72. The component system of claim 71 wherein the at least one light emitter comprises at least one primary optic.

73. The component system of claim 72 wherein the connector body is engaged with the optical element as a secondary optic.