LED lamp module

• US 7,488,097 B2
• Filed: 06/26/2006
• Issued: 02/10/2009
• Est. Priority Date: 02/21/2006
• Status: Active Grant

• Current Assignee: Tall Tower Led, LLC
• Original Assignee: CML Innovative Technologies, Inc. (Lighting Holdings International LLC)
• Inventors: Reisenauer, William, Pawelko, Wojciech
• Primary Examiner(s): Lee; Jong-Suk (James)
• Assistant Examiner(s): Crowe; David R
• Application Number:
  US11/474,531
• Publication Number:
  US 20070195532A1
• Time in Patent Office: 960 Days
• Field of Search: 362/253, 362/252, 362/191, 362/249, 362/364, 362/294, 362/373, 362/646, 362/555, 362/800, 362/434, 362/227, 362/240, 257/79, 257/98, 257/99, 257/675
• US Class Current: 362/373
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• CPC Class Codes: F21K 9/68 Details of reflectors forming part of the light source
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

An LED lamp module designed to be easily retrofitted into existing incandescent based light fixtures with minimum modification is provided. The LED lamp module includes a generally circular metal core board including a first surface and a second surface; at least one LED disposed centrally on the first surface of the metal core board; and a flat annular printed circuit board including a current driver circuit for powering the at least one LED, the annular printed circuit board being disposed around the at least one LED and electrically coupled to the at least one LED, wherein the second surface of the metal core board is configured to contact a host fixture and heat generated by the at least one LED is conducted to the host fixture. The LED lamp module uses the host light fixture as a heat sink to transfer and dissipate heat to the external environment.

Claims

1. A light emitting diode (LED) lamp module comprising:

a generally circular metal core printed circuit board including a first surface and a second surface;

at least one LED disposed centrally on the first surface of the metal core printed circuit board; and

a flat annular printed circuit board including a current driver circuit for powering the at least one LED, the current driver circuit disposed along a first surface of the annular printed circuit board, the annular printed circuit board being disposed around the at least one LED and electrically coupled to the at least one LED, the first surface of the annular printed circuit board being in a face to face relationship with the first surface of the metal core printed circuit board,

wherein the second surface of the metal core printed circuit board is directly mounted in a face to face relationship with a host fixture and heat generated by the at least one LED is conducted to the host fixture via the metal core printed circuit board wherein the metal core printed circuit board is spaced apart from the annular printed circuit board by at least one electrically conductive and thermally conductive standoff, wherein the at least one electrically conductive and thermally conductive standoff electrically grounds the annular printed circuit board to the metal core printed circuit board and conducts heat generated by the annular printed circuit board to the metal core printed circuit board.

2. The LED lamp module of claim 1, wherein the second surface of the metal core board includes an aluminum backing.

3. The LED lamp module of claim 1, further comprising an optical element disposed over the at least one LED to collimate light emitting from the at least one LED wherein the optical element mates to the first surface of the metal core board.

4. The LED lamp module of claim 1, wherein the annular printed circuit board includes an inner circumference and an outer circumference, further comprising an optical element disposed over the at least one LED to collimate light emitting from the at least one LED, wherein the optical element has an outer circumference less than the inner circumference of the annular printed circuit board.

5. The LED lamp module of claim 1, wherein an outer circumference of the metal core board is substantially the same size as an outer circumference of the annular printed circuit board.

6. The LED lamp module of claim 5, wherein the metal core board is spaced apart from the annular printed circuit board by at least one standoff, wherein the outer circumference of the metal core board aligns with outer circumference of the annular printed circuit board.

7. The LED lamp module of claim 6, wherein the at least one standoff is made from electrically conducting material and electrically grounds the annular printed circuit board to the metal core board.

8. The LED lamp module of claim 1, wherein the current driver circuit includes a switching regulator for converting input voltage to constant current for powering the at least one LED.

9. The LED lamp module of claim 8, wherein the current driver circuit further includes a dimming circuit configured to provide a variable analog voltage to the switching regulator, wherein the switching regulator reduces the current to the at least one LED reducing the light output.

10. A lighting assembly comprising

a metallic host fixture comprising:

a generally cylindrical base configured to support a lighting module, the base including a flat bottom portion and a surrounding side wall; and

a generally cylindrical cover configured to be coupled to the base including a parabolic reflector extending inside the cover from a first end of the cover to a second end of the cover, the reflector terminating in an annular rim; and

the lighting module comprising;

a generally circular, flat metal core printed circuit board including a first surface and a second surface, the second surface being directly mounted in a face to face relationship to the flat bottom portion of the base of the metallic host fixture;

at least one LED disposed centrally on the first surface of the metal core printed circuit board; and

a flat annular printed circuit board including a current driver circuit for powering the at least one LED disposed along a first surface of the annular printed circuit board, the annular printed circuit board being disposed around the at least one LED and electrically coupled to the at least one LED, the first surface of the annular printed circuit board being in a face to face relationship with the first surface of the metal core printed circuit board wherein the metal core printed circuit board is grounded to the base of the metallic host fixture and is spaced apart from the annular printed circuit board by at least one electrically conductive and thermally conductive standoff, wherein the at least one electrically conductive and thermally conductive standoff electrically grounds the annular printed circuit board to the metal core printed circuit board thereby grounding the annular printed circuit board to the metallic host fixture and conducts heat generated by the annular printed circuit board to the metal core printed circuit board which is subsequently conducted to the host fixture,

wherein heat generated by the at least one LED is conducted to the metallic host fixture via the metal core printed circuit board.

11. The lighting assembly of claim 10, wherein the second surface of the metal core board includes an aluminum backing.

12. The lighting assembly of claim 10, further comprising an optical element disposed over the at least one LED to collimate light emitting from the at least one LED, wherein the optical element is configured to extend through the annular rim of the reflector.

13. The lighting assembly of claim 10, wherein the metallic host fixture acts as a Faraday shield for suppression of radiated electromagnetic interference (EMI).

14. The lighting assembly of claim 10, wherein an outer circumference of the metal core board is substantially the same size as an outer circumference of the annular printed circuit board.

15. The lighting assembly of claim 14, wherein the metal core board is spaced apart from the annular printed circuit board by at least one standoff, wherein the outer circumference of the metal core board aligns with outer circumference of the annular printed circuit board.

16. The lighting assembly of claim 15, wherein the at least one standoff is made from electrically conducting material and electrically grounds the annular printed circuit board the metal core board.