Light emitting diode module for automobile headlights and automobile headlight having the same

• US 7,128,454 B2
• Filed: 08/25/2004
• Issued: 10/31/2006
• Est. Priority Date: 07/01/2004
• Status: Active Grant

• Current Assignee: SemiLED Innovations LLC
• Original Assignee: Samsung Electro-Mechanics Co., Ltd. (Samsung Group)
• Inventors: Kim, Hyung Suk, Jeong, Young June
• Primary Examiner(s): PAYNE, SHARON E
• Application Number:
  US10/924,866
• Publication Number:
  US 20060002125A1
• Time in Patent Office: 797 Days
• Field of Search: 362/507, 362/538, 362/545, 362/800, 362/547, 362/373, 439/617, 439/611
• US Class Current: 362/507
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21S 41/143 the main emission direction of the LED being parallel to the optical axis of the illuminating device
• CPC Class Codes: F21S 41/151 arranged in one or more lines
• CPC Class Codes: F21S 45/47 Passive cooling, e.g. using fins, thermal conductive elements or openings
• CPC Class Codes: F21S 45/50 Waterproofing
• CPC Class Codes: F21V 29/74 with fins or blades
• 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 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/16225 the item being non-metallic, e.g. insulating substrate with or without metallisation
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48227 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 2924/19107 off-chip wires
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

The present invention relates to an LED module for automobile headlights. The LED module comprises a water proof structure together with a heat radiating structure in order to prevent the permeation of external moisture while efficiently radiating heat to the outside. The LED module may be combined with a lamp housing and a radiator to constitute an automobile headlight.

Claims

1. A Light Emitting Diode (LED) module comprising:

a lighting unit including an LED chip;

a module body supporting the lighting unit at a leading end and extending from the leading end to a rear end for a predetermined length, the leading end being structured to guide light from the lighting unit in an upward direction, the module body being made of a high thermal conductivity material and having a through hole extending through the length of the modular body;

a connector sealingly coupled to the rear end of the module body, the connector having a conductor inserted into and extending through the through hole in the module body for supplying external voltage to the lighting unit; and

a transparent member coupled with the leading end of the module body to seal and protect the lighting unit and a portion of the conductor exposed from the leading end of the module body from an external environment.

2. The LED module according to claim 1, wherein the module body includes:

cup part projected from an outer circumference of the leading end;

a base formed in a central portion of the cup part for guiding light from the lighting module in an upward direction; and

a through hole extending from the leading end to the rear end.

3. The LED module according to claim 2, wherein the transparent member has a lower circumference engaged with an inside wall of the cup part.

4. The LED module according to claim 1, wherein the connector includes:

a socket placed in a rear end of the connector to electrically connect the connector with an external power source; and

an insulator sheath disposed on the connector within the module body for insulating the conductor from the module body,

wherein the connector is sealed by a leading end thereof to the rear end of the module body to prevent the penetration of foreign material via the through hole toward the lighting unit.

5. The LED module according to claim 1, wherein the transparent member includes:

a transparent elastic encapsulant coupled with the leading end of the module body to seal the lighting unit and the portion of the conductor exposed from the leading end of the module body; and

a lens placed outside the transparent elastic body and coupled with the leading end of the module body to protect the transparent elastic body.

6. The LED module according to claim 1, wherein the lighting unit includes:

at least one LED chip;

a submount placed on the module body for seating the LED chip thereon, the submount having a pattern printed thereon for connection with the conductor of the connector; and

a plurality of solder bumps for attaching the LED chip on the submount and electrically connecting the LED chip with the pattern of the submount.

7. The LED module according to claim 1, wherein the lighting unit includes:

at least one LED chip;

a submount placed on the module body for seating the LED chip thereon, the submount having a pattern printed thereon for connection with the conductor of the connector; and

a plurality of wires for electrically connecting the LED chip with the pattern of the submount.

8. The LED module according to claim 2, wherein the base is formed separately from the module body.

9. The LED module according to claim 1, wherein the transparent member comprises a rigid portion and an elastic encapsulant portion.

10. The LED module according to claim 9, wherein the elastic encapsulant portion is arranged between the rigid portion and the lighting unit.

11. The LED module according to claim 9, wherein the elastic encapsulant maintains a degree of fluidity and assumes one of a post cured gel or elastomer state so as to stably protect LED and wires associated with the lighting unit.

12. The LED module according to claim 9, wherein the encapsulant portion contains one of a UV absorbent and a fluorescent material.

13. The LED module according to claim 12, wherein the fluorescent material one of adjusts the color of the light produced by the light unit or converts UV rays into white light.

14. The LED module according to claim 9, wherein the encapsulant portion is configured as a lens.

15. The LED module according to claim 1, wherein the transparent member is configured as a lens.

16. The LED module according to claim 1, further comprising:

a second through hole which extends through the module body so as to be essentially parallel to the first said through hole; and

a second connector having a conductor inserted into and extending through the second through hole, the second connector and the first said connector cooperating to supply an external voltage to the lighting unit.

17. The LED module according to claim 16, wherein the second conductor and the first said conductor are each enclosed in an insulative sheath having an essentially straight tubular configuration.

18. An automobile headlight comprising:

a Light Emitting Diode (LED) module which Includes;

a lighting unit including an LED chip;

a module body supporting the lighting unit at a leading end and extending from the leading end to a rear end for a predetermined length, the leading end being structured to guide light from the lighting unit in an upward direction, the module body being made of a high thermal conductivity material and having a through hole extending through a length of the module body;

a connector sealingly coupled to the rear end of the module body, the connector having a conductor inserted into and extending through the through hole in the module body for supplying external voltage to the lighting unit; and

a transparent member coupled with the leading end of the module body to seal and protect the lighting unit and a portion of the conductor exposed from the leading end of the module body from external environment;

a shade-shaped lamp housing for grasping the leading end of the module body, the lamp housing having a through hole for the passage of the transparent member; and

a radiator coupled around the module body to radiate heat, which is transmitted from the lighting unit via the module body, to external environment.

19. The automobile headlight according to claim 18, further comprising:

an 0-ring interposed between the lamp housing and the module body within the through hole of the lamp housing.

20. The automobile headlight according to claim 18, wherein the module body includes:

a cup part projected from an outer circumference of the leading end;

a base formed in a central portion of the cup part for guiding light from the lighting module in an upward direction; and

a through hole extending from the leading end to the rear end.

21. The automobile headlight according to claim 18, wherein the connector includes:

a socket placed in a rear end of the connector to electrically connect the connector with an external power source; and

an insulator sheath wound on the connector within the module body for insulating the conductor from the module body,

wherein the connector is sealed by a leading end thereof to the rear end of the module body to prevent the penetration of foreign material via the through hole toward the lighting unit.