Circuit board mount for LED light

• US 9,072,171 B2
• Filed: 08/24/2012
• Issued: 06/30/2015
• Est. Priority Date: 08/24/2011
• Status: Active Grant

• Current Assignee: Ilumisys Incorporated (Altair Engineering Incorporated)
• Original Assignee: Ilumisys Incorporated (Altair Engineering Incorporated)
• Inventors: Simon, David L.
• Primary Examiner(s): DZIERZYNSKI, EVAN P
• Application Number:
  US13/593,994
• Publication Number:
  US 20130050999A1
• Time in Patent Office: 1,040 Days
• Field of Search: 362/218, 362/249.01, 362/249.02, 362/217.1
• US Class Current: 1/1
• CPC Class Codes: F21K 9/278 Arrangement or mounting of circuit elements integrated in the light source
• CPC Class Codes: F21V 19/005 by permanent fixing means, e.g. gluing, riveting or embedding in a potting compound
• 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: H05K 1/0203 Cooling of mounted components H05K1/0272 takes precedence
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/0061 onto a metallic substrate, e.g. a heat sink heat sinks for electric apparatus H05K7/20
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.

Abstract

An LED-based light for replacing a conventional fluorescent light in an existing fixture is disclosed. The LED-based light includes an elongated housing, a heat sink extending substantially the length of the housing and having at least one integral retaining portion and a circuit board positioned on the heat sink and having a plurality of LEDs mounted thereon, wherein the at least one integral retaining portion is configured to secure the circuit board to the heat sink.

Claims

1. An LED-based light for replacing a conventional fluorescent light in a light fixture comprising:

an elongated housing;

a heat sink extending substantially the length of the housing and having a substantially flat first surface and at least one integral retaining portion; and

a circuit board having a first side and an opposing second side having a plurality of LEDs mounted thereon, the circuit board positioned on the heat sink with substantially all of the first side overlying the first surface of the heat sink, wherein the at least one integral retaining portion is crimped to the circuit board to engage the first side with the first surface of the heat sink and secure the circuit board to the heat sink.

2. The LED-based light of claim 1, wherein the at least one integral retaining portion extends over and is crimped to the second side of the circuit board.

3. The LED-based light of claim 1, wherein the at least one integral retaining portion extends substantially the length of the heat sink.

4. The LED-based light of claim 3, wherein the at least one integral retaining portion is crimped to the circuit board along substantially the length of the heat sink or at a plurality of distinct locations along the length of the heat sink.

5. The LED-based light of claim 1, wherein the at least one integral retaining portion includes a plurality of integral retaining portions crimped to the heat sink and wherein the plurality of integral retaining portions are substantially evenly spaced along the length of the heat sink.

6. The LED-based light of claim 1, wherein the at least one integral retaining portion includes first and second integral retaining portions outboard of the first surface and extending substantially the length of the heat sink and wherein the circuit board is positioned on the heat sink between the first and second integral retaining portions.

7. The LED-based light of claim 6, wherein the first and second retaining portions are each crimped to the circuit board along substantially the length of the heat sink.

8. The LED-based light of claim 6, wherein the first and second retaining portions are each crimped to the circuit board at a plurality of distinct locations along the length of the heat sink.

9. The LED-based light of claim 1, further comprising:

a pair of end caps disposed on opposite ends of the housing.

10. The LED-based light of claim 1 wherein the housing is tubular and substantially all of the heat sink and circuit board are disposed within the housing.

11. A method of manufacturing an LED-based light comprising:

positioning the first of two opposing sides of a circuit board including at least one LED onto a substantially flat first surface of an elongate heat sink having an integral retaining portion such that substantially all of the first side of the circuit board overlies the first surface of the heat sink; and

crimping the retaining portion into engagement with the circuit board to engage the first side of the circuit board with the first surface of the heat sink and fix the position of the circuit board on the first surface of the heat sink.

12. The method of claim 11, further comprising

attaching a lens including a light transmitting portion to the heat sink, with the light transmitting portion at least partially enclosing the at least one LED, to at least partially complete a housing for the LED-based light;

and

attaching a connector configured for engagement with a light fixture to the housing.

13. The method of claim 11, wherein crimping the retaining portion further comprises crimping the retaining portion into engagement with the circuit board along substantially the length of the heat sink.

14. The method of claim 11, wherein crimping the retaining portion further comprises crimping the retaining portion into engagement with the circuit board at a plurality of distinct locations along the length of the heat sink.

15. The method of claim 11, wherein the heat sink has a plurality of integral retaining portions substantially evenly spaced along the length of the heat sink, and wherein crimping the retaining portion further comprises crimping each of the plurality of integral retaining portions into engagement with the circuit board.

16. An LED-based light comprising:

a circuit board having a first side and an opposing second side;

at least one LED mounted on the second side of the circuit board;

a heat sink for the at least one LED, the heat sink defining a substantially flat first surface and a heat dissipating area opposite the first surface, the circuit board positioned on the heat sink with substantially all of its first side overlying the first surface of the heat sink, the heat sink having at least one integral retaining portion crimped to the circuit board to engage the first side of the circuit board with the first surface of the heat sink and secure the circuit board to the heat sink; and

at least one connector configured for engagement with a light fixture.

17. The LED-based light of claim 16, wherein the at least one integral retaining portion is crimped to the circuit board substantially continuously along the circuit board or at a plurality of distinct locations along the circuit board.

18. The LED-based light of claim 16, wherein the at least one integral retaining portion includes a plurality of evenly spaced integral retaining portions crimped to the circuit board.

19. The LED-based light of claim 16, further comprising:

a lens with a light transmitting portion, the lens attached to the heat sink, with the light transmitting portion at least partially enclosing the at least one LED.

20. The LED-based light of claim 16, further comprising:

an elongate tubular housing for the circuit board, the at least one LED and the heat sink, the housing including a lens with a light transmitting portion at least partially enclosing the at least one LED, wherein the at least one connector includes a pair of bi-pin connectors attached at opposite ends of the housing.