LED strip light lamp assembly

• US 8,305,225 B2
• Filed: 02/14/2006
• Issued: 11/06/2012
• Est. Priority Date: 02/14/2005
• Status: Expired due to Fees

• Current Assignee: Truck-Lite Company LLC (Truck-Lite Holdings 2 Corp.)
• Original Assignee: Truck-Lite Company LLC (Truck-Lite Holdings 2 Corp.)
• Inventors: Hefright, Craig, DiPenti, Timothy, Kolstee, Todd
• Primary Examiner(s): Swarthout, Brent
• Application Number:
  US11/354,598
• Publication Number:
  US 20060202850A1
• Time in Patent Office: 2,457 Days
• Field of Search: 34081545-81574, 340/693.5, 362/362, 362/253, 362/459, 362/487, 362/498, 362/545, 362/546, 315/159
• US Class Current: 340/815.45
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs
• CPC Class Codes: B60Q 1/32 for indicating vehicle sides , e.g. clearance lights
• 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 4/20 with light sources held by or within elongate supports
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/89 Metals
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G09F 13/22 electroluminescent electroluminescent light sources per se H05B33/00
• CPC Class Codes: H05K 1/056 the metal substrate being covered by an organic insulating layer
• CPC Class Codes: H05K 1/095 for polymer thick films, i.e. having a permanent organic polymeric binder

Abstract

A lamp assembly to be incorporated into or positioned on a truck'"'"'s existing support structure comprising: a heat sink; an electrically insulating dielectric coating disposed on the heat sink; a plurality of circuit traces disposed on the dielectric coating; a plurality of LEDs disposed on and electrically connected to one another by the dielectric coating; and a cover disposed substantially over and protecting the heat sink, the dielectric coating, the circuit traces, and the LEDs. The LEDs are spaced apart at intervals to provide general illumination. The cover can be clear or be solid and have a plurality of apertures, each corresponding to one LED, and can further include a lens over the apertures.

Claims

1. A low profile lamp assembly at least partially housed within a vehicular support structure for illuminating with minimal glare an interior space at least partially defined by said support structure, said lamp assembly comprising:

a heat sink;

an electrically insulating dielectric coating disposed on said heat sink;

a plurality of circuit traces disposed on said dielectric coating;

a plurality of light emitting diodes spaced apart and electrically connected to one another by said plurality of circuit traces, each light emitting diode of said plurality of light emitting diodes;

emitting light in a distribution pattern having a higher intensity central portion and a lower intensity wide angle peripheral portion; and

a cover disposed substantially over and protecting said heat sink, said dielectric coating, said plurality of circuit traces, and said plurality of light emitting diodes, said cover including at least one aperture corresponding to at least one light emitting diode of said plurality of light emitting diodes;

wherein said at least one light emitting diode of said plurality of light emitting diodes is recessed behind said at least one aperture within said cover such that a gap exists between the at least one light emitting diode and said aperture in said cover, said at least one aperture being positioned in order to reduce glare such that said higher intensity central portion of light emitted from said at least one light emitting diode passes unobstructed through said at least one aperture and said lower intensity wide angle peripheral portion of light emitted by said at least one light emitting diode is directed toward an inner surface of the cover, said lamp assembly adapted to be electrically connected to a power source.

2. The lamp assembly of claim 1, wherein said heat sink is made of a material selected from a group consisting of aluminum, aluminum alloys, steel, stainless steel, copper, and combinations thereof.

3. The tamp assembly of claim 1, wherein said dielectric coating is a polymer/ceramic blend.

4. The lamp assembly of claim 1, wherein said dielectric coating is applied with a thixotropic material by screen printing.

5. The lamp assembly of claim 1, wherein said dielectric coating is between approximately one thousand microns and approximately ten microns thick.

6. The lamp assembly of claim 1, wherein said plurality of circuit traces are formed by a method selected from a group consisting of painting and dipping.

8. The lamp assembly of claim 1, wherein said plurality of circuit traces are comprised of a polymeric material having metal particles dispersed therein.

9. The lamp assembly of claim 8, wherein said polymeric material is selected from a group consisting of epoxy and phenolic resin.

10. The lamp assembly of claim 8, wherein said metal particles dispersed in said polymeric material are selected from a group consisting of silver, gold, copper, silver, nickel, and alloys thereof.

11. The lamp assembly of claim 1, wherein each of said plurality of light emitting diodes is selected from a group consisting of Luxeon 1 W emitter diodes, Luxeon 3 W emitter diodes, 1 W Jupiter diodes, 1 W XLamp diodes, 1 W Golden Dragon diodes, and Super-Flux HPA ⅛

W diodes.

12. The lamp assembly of claim 1, wherein each light emitting diode of said plurality of light emitting diodes is separated from each adjacent light emitting diode of said plurality of light emitting diodes by approximately one inch to six inches.

13. The lamp assembly of claim 1, wherein said cover is made of a substantially clear material selected from a group consisting of a polycarbonate and an acrylic plastic.

14. The lamp assembly of claim 1, wherein said cover is secured to said heat sink by fasteners, an adhesive, an epoxy, or a mechanical engagement selected from the group consisting of:

a snap fit, an interference fit, and a locking mechanism between two extruded shapes.

15. The lamp assembly of claim 1, wherein said cover includes a lens such that light emitted from said plurality of light emitting diodes is redirected to be more evenly distributed as it passes through said cover.

16. The lamp assembly of claim 1, wherein said support structure functions as said cover.

53. The lamp assembly of claim 1 wherein a diameter of the aperture is approximately equal to a diameter of the LED.

7. The lamp assembly of claim I wherein said plurality of circuit traces is disposed only over predetermined routes.

17. An electrically driven light emitting diode lamp assembly at least partially housed within a vehicular support structure, said lamp assembly being low profile, providing general illumination having reduced glare to an interior space at least partially defined by said vehicular support structure and comprising:

an electrically and thermally conductive and entirely metal heat sink;

an electrically insulating coating disposed over said heat sink, said coating being less than approximately one thousand microns thick;

a plurality of circuit traces disposed along said coating, said plurality of circuit traces being spaced apart to prevent electrical conduction directly between each trace of said plurality of traces;

a plurality of light emitting diodes spaced apart and electrically connected to one another by said plurality of circuit traces, each light emitting diode of said plurality of light emitting diodes;

emitting light in a distribution pattern having a higher intensity central portion and a lower intensity wide angle peripheral portion;

each light emitting diode of said plurality of light emitting diodes having at least one electrical lead for providing an electrical connection to one or more of said plurality of circuit traces and secured to one of said plurality of circuit traces via an electrically conductive adhesive layer; and

a cover being disposed substantially over and protecting said heat sink, said coating, said plurality of circuit traces, and said plurality of light emitting diodes, said cover including at least one aperture corresponding to at least one light emitting diode of said plurality of light emitting diodes;

wherein said at least one light emitting diode of said plurality of light emitting diodes is recessed behind said at least one aperture within said cover such that a gap exists between the at least one light emitting diode and said aperture in said cover, said at least one aperture being positioned in order to reduce glare such that said higher intensity central portion of light emitted from said at least one light emitting diode passes unobstructed through said at least one aperture and said lower intensity wide angle peripheral portion of light emitted by said at least one light emitting diode is directed toward an inner surface of the cover;

wherein said assembly is adapted to be electrically connected to a power source and is installed directly within said support structure to provide general illumination in a substantially uniform manner to the interior space.

18. The lamp assembly of claim 17, wherein said heat sink is made of a material selected from a group consisting of aluminum, aluminum alloys, steel, stainless steel, copper, and combinations thereof.

19. The lamp assembly of claim 17, wherein said coating is made of a polymer/ceramic blend.

20. The lamp assembly of claim 17, wherein said coating is applied with a thixotropic material by screen printing.

21. The lamp assembly of claim 17, wherein said plurality of circuit traces are formed by a method selected from a group consisting of painting and dipping.

22. The lamp assembly of claim 17, wherein said plurality of circuit traces is disposed only over predetermined routes.

23. The lamp assembly of claim 17, wherein said plurality of circuit traces are comprised of a polymeric material having metal particles dispersed therein, said polymeric material being selected from a group consisting of an epoxy and a phenolic resin, and wherein said metal particles dispersed therein are selected from a group consisting of silver, gold, copper, silver, nickel, and alloys thereof.

24. The lamp assembly of claim 17, wherein each of said plurality of LEDs is selected from a group consisting of Luxeon 1 W emitter diodes, Luxeon 3 W emitter diodes, 1 W Jupiter diodes, 1 W XLamp diodes, 1 W Golden Dragon diodes, and Super-FLux HPA ⅛

W diodes.

25. The lamp assembly of claim 17, wherein each light emitting diode of said plurality of light emitting diodes is separated from each adjacent light emitting diode of said plurality of light emitting diodes by approximately to one to six inches.

26. The lamp assembly of claim 17, wherein said cover is made of a substantially clear material selected from a group consisting of a polycarbonate and an acrylic plastic.

27. The lamp assembly of claim 17, wherein said cover is secured to said heat sink by fasteners, an adhesive, an epoxy, or a mechanical engagement selected from the group consisting of:

a snap fit, an interference fit, and a locking mechanism between two extruded shapes.

28. The lamp assembly of claim 17, wherein said cover includes a lens such that light emitted from said plurality of light emitting diodes is redirected to be more evenly distributed as it passes through said cover.

29. The lamp assembly of claim 17, wherein said support structure functions as said cover.

54. The lamp assembly of claim 17 wherein a diameter of the aperture is approximately equal to a diameter of the LED.

30. A low profile lamp assembly for providing reduced glare illumination, at least partially housed within an interior support structure of a truck trailer, said lamp assembly comprising:

a heat sink, said heat sink being made of an electrically and thermally conductive material;

an electrically insulating dielectric coating disposed on said heat sink, said dielectric coating being between approximately ten and one-thousand microns thick;

a plurality of circuit traces disposed on said dielectric coating;

a plurality of light emitting diodes electrically connected to each other by said plurality of circuit traces for producing a level of illumination between 50 and 200 Lux, each light emitting diode of said plurality of light emitting diodes being spaced from each adjacent light emitting diode of said plurality of light emitting diodes by approximately one to six inches, each light emitting diode of said plurality of light emitting diodes having at least one electrical lead for providing an electrical connection to one or more of said plurality of circuit traces and being secured to one of said plurality of circuit traces by an electrically conductive adhesive; and

each light emitting diode of said plurality of light emitting diodes emitting light in a distribution pattern having a higher intensity central portion and a lower intensity wide angle peripheral portion; and

a cover disposed substantially over and protecting said heat sink, said dielectric coating, said plurality of circuit traces, and said plurality of light emitting diodes;

wherein each light emitting diode of said plurality of light emitting diodes is recessed behind said cover such that a gap exists between the at least one light emitting diode and said aperture in said cover;

said at least one aperture being positioned in order to reduce glare such that said higher intensity central portion of light emitted from said at least one light emitting diode passes unobstructed through said at least one aperture and said lower intensity wide angle peripheral portion of light emitted by said at least one light emitting diode is directed toward an inner surface of the cover; and

wherein said lamp assembly is adapted to be electrically connected to a power source for providing general illumination in a substantially uniform manner to an interior of the truck trailer.

31. The lamp assembly of claim 30, wherein said heat sink is made of a material selected from a group consisting of aluminum, aluminum alloys, steel, stainless steel, copper, and combinations thereof.

32. The lamp assembly of claim 30, wherein said dielectric coating is made of a polymer/ceramic blend.

33. The lamp assembly of claim 30, wherein said dielectric coating is applied with a thixotropic material by screen printing.

34. The lamp assembly of claim 30, wherein said plurality of circuit traces are formed by painting or dipping.

35. The lamp assembly of claim 30, wherein said plurality of circuit traces is disposed only over predetermined routes.

36. The lamp assembly of claim 30, wherein said plurality of circuit traces are comprised of a polymeric material having metal particles dispersed therein, said polymeric material being selected from a group consisting of an epoxy and a phenolic resin, and wherein said metal particles dispersed therein are selected from a group consisting of silver, gold, copper, silver, nickel, and alloys thereof.

37. The lamp assembly of claim 30, wherein each of said plurality of light emitting diodes is selected from a group consisting of Luxeon 1 W emitter diodes, Luxeon 3 W emitter diodes, 1 W Jupiter diodes, 1 W XLamp diodes, 1 W Golden Dragon diodes, and Super-FLux HPA ⅛

W diodes.

38. The lamp assembly of claim 30, wherein said cover is made of a substantially clear material selected from a group consisting of a polycarbonate and an acrylic plastic.

39. The lamp assembly of claim 30, wherein said cover is secured to said heat sink by fasteners, an adhesive, an epoxy, or a mechanical engagement such as a snap lit, an interference fit, or a locking mechanism between two extruded shapes.

40. The lamp assembly of claim 30, wherein said support structure further acts as said cover, said support structure including at least one aperture corresponding to at least one light emitting diode of said plurality of light emitting diodes.

41. The lamp assembly of claim 30, wherein said cover includes a lens, such that light emitted from said plurality of light emitting diodes is redirected to be more evenly distributed as it passes through said cover.

55. The lamp assembly of claim 30 wherein a diameter of the aperture is approximately equal to a diameter of the LED.

42. A system for generally illuminating an interior space of a vehicle with reduced glare, said system comprising:

a vehicular support structure having a plurality of structural elements which at least partially define the interior space; and

a low profile lamp assembly, said lamp assembly including;

a heat sink;

an electrically insulating dielectric coating disposed on said heat sink;

a plurality of circuit traces disposed on said dielectric coating;

a plurality of light emitting diodes spaced one to six inches apart and electrically connected to one another by said plurality of circuit traces; and

each light emitting diode of said plurality of light emitting diodes emitting light in a distribution pattern having a higher intensity central portion and a lower intensity wide angle peripheral portion; and

wherein said structural elements function as a cover disposed substantially over and protecting said heat sink, said dielectric coating, said plurality of circuit traces, and said plurality of light emitting diodes,

wherein said cover has least one aperture formed therein to allow light from said plurality of light emitting diodes to be emitted so as to illuminate said interior space in a substantially uniform manner;

wherein each light emitting diode of said plurality of light emitting diodes recessed behind an aperture of the plurality of apertures within the cover such that a gap exists between the at least one light emitting diode and said aperture in said cover, each aperture being positioned in order to reduce glare such that said higher intensity central portion of light emitted from said light emitting diode passes unobstructed through said aperture and the lower intensity wide angle peripheral portion of light emitted by the light emitting diode is directed toward an inner surface of the cover;

wherein said structural elements function as a cover disposed substantially over and protecting said heat sink, said dielectric coating, said plurality of circuit traces, and said plurality of light emitting diodes,

wherein said cover having said at least one aperture formed therein allows light from said plurality of light emitting diodes to be emitted so as to illuminate said interior space in a substantially uniform manner.

43. The system of claim 42, wherein said lamp assembly is adapted to be electrically connected to a power source within a truck.

44. The system of claim 42, wherein said heat sink is made of a material selected from a group consisting of aluminum, aluminum alloys, steel, stainless steel, copper, and combinations thereof.

45. The system of claim 42, wherein said dielectric coating is made of a polymer/ceramic blend.

46. The system of claim 42, wherein said dielectric coating is applied with a thixotropic material by screen printing.

47. The system of claim 42, wherein said dielectric coating is between approximately ten and one-thousand microns thick.

48. The system of claim 42, wherein said plurality of circuit traces are formed by painting or dipping.

49. The system of claim 42, wherein said quality of circuit traces is disposed only over predetermined routes.

50. The system of claim 42, wherein said plurality of circuit traces are comprised of a polymeric material having metal particles dispersed therein, said polymeric material being selected from a group consisting of an epoxy and a phenolic resin, and wherein said metal particles dispersed therein are selected from a group consisting of silver, gold, copper, silver, nickel, and alloys thereof.

51. The system of claim 42, wherein each of said plurality of LEDs is selected from a group consisting of Luxeon 1 W emitter diodes, Luxeon 3 W emitter diodes, 1 W Jupiter diodes, 1 W XLamp diodes, 1 W Golden Dragon diodes, and Super-FLux HPA ⅛

W diodes.

52. The system of claim 42, wherein said lamp assembly further includes a lens so that light emitted from said plurality of light emitting diodes is redirected to be more evenly distributed.

56. The lamp assembly of claim 42, wherein a diameter of the aperture is approximately equal to a diameter of the LED.