U.S. patent application number 13/613687 was filed with the patent office on 2013-03-21 for light emitting assemblies and portions thereof.
The applicant listed for this patent is Joseph B. Thompson. Invention is credited to Joseph B. Thompson.
Application Number | 20130069103 13/613687 |
Document ID | / |
Family ID | 43305665 |
Filed Date | 2013-03-21 |
United States Patent
Application |
20130069103 |
Kind Code |
A1 |
Thompson; Joseph B. |
March 21, 2013 |
Light Emitting Assemblies And Portions Thereof
Abstract
Apparatus may be provided including a high power light emitting
diode (LED) unit, at least one printed circuit board, and an
interfacing portion of a heat sink structure. The high power LED
unit includes at least one LED die, at least one first lead and at
least one second lead, and a heat sink interface. The at least one
printed circuit board includes a conductive pattern configured to
connect both the at least one first lead and the at least one
second lead to a current source. The interfacing portion of the
heat sink structure is that portion through which a majority of
heat of the heat sink interface is transmitted. The interfacing
portion is directly in touching contact with a majority of a heat
transfer area of the heat sink interface.
Inventors: |
Thompson; Joseph B.; (Orange
Beach, AL) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Thompson; Joseph B. |
Orange Beach |
AL |
US |
|
|
Family ID: |
43305665 |
Appl. No.: |
13/613687 |
Filed: |
September 13, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12561955 |
Sep 17, 2009 |
8269248 |
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13613687 |
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12396460 |
Mar 2, 2009 |
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12561955 |
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Current U.S.
Class: |
257/99 |
Current CPC
Class: |
F21V 29/86 20150115;
H05K 2201/09027 20130101; H05K 3/3431 20130101; F21Y 2115/10
20160801; F21V 19/0055 20130101; H01L 2224/73265 20130101; H05K
3/325 20130101; F21K 9/00 20130101; H05K 2201/10106 20130101; H05K
1/189 20130101; F21V 29/70 20150115; F21V 29/89 20150115; H01L
33/62 20130101; H01L 33/64 20130101; F21V 19/004 20130101; H01L
2224/48091 20130101; H01L 2924/00014 20130101 |
Class at
Publication: |
257/99 |
International
Class: |
H01L 33/62 20060101
H01L033/62; H01L 33/64 20060101 H01L033/64 |
Claims
1. Apparatus comprising: a high power light emitting diode (LED)
unit including at least one LED die, including at least one first
lead and at least one second lead, and including a heat sink
interface, the heat sink interface being electrically isolated from
both the at last one first lead and the at least one second lead;
at least one printed circuit board including a conductive pattern
configured to connect both the at least one first lead and the at
least one second lead to a current source; and an interfacing
portion of a heat sink structure through which a majority of heat
of the heat sink interface is transmitted, the interfacing portion
being directly in touching contact with a majority of a heat
transfer area of the heat sink interface.
2. The apparatus according to claim one, wherein the heat sink
interface includes a thermal pad of a surface mount LED.
3. The apparatus according to claim 1, wherein the heat sink
interface includes a metal substrate connected directly to the LED
die via a low thermal resistance connection.
4. The apparatus according to claim 1, where the at least one
printed circuit board includes a flex circuit.
5. The apparatus according to claim 1, wherein the at least one
printed circuit board includes a single layer flex circuit.
6. The apparatus according to claim 1, wherein the interfacing
portion of the heat sink structure includes a heat spreader.
7. The apparatus according to claim 1, wherein the majority of heat
transfer area includes all of the heat transfer area of the heat
sink interface.
8. The apparatus according to claim 1, wherein the interfacing
portion is directly in touching contact with the majority of heat
transfer area of the heat sink interface via a reflow solder
connection.
9. The apparatus according to claim 1, wherein the interfacing
portion is directly in touching contact with the heat transfer area
of the heat sink interface via thermal epoxy.
10. The apparatus according to claim 1, wherein the interfacing
portion is directly in touching contact with the majority of a heat
transfer area of the heat sink interface via thermal tape.
11. The apparatus according to claim 1, further comprising a biaser
configured to resiliently apply a biasing force causing the
interfacing portion and the heat transfer area of the heat sink
interface to be forced with continuous pressure to remain in
touching contact with each other.
12. Apparatus comprising: a high power light emitting diode (LED)
unit including at least one first lead and at least one second
lead, and including a heat sink interface, the heat sink interface
being electrically isolated from both the at last one first lead
and the at least one second lead; and an interfacing portion of a
heat sink structure through which a majority of heat of the heat
sink interface is transmitted, the interfacing portion being
directly in touching contact with a heat transfer area of the heat
sink interface wherein the heat sink interface includes a metal
substrate connected to the LED unit via a low thermal resistance
connection.
13. The apparatus of claim 12, further comprising at least one
printed circuit board including a conductive pattern configured to
connect both the at least one first lead and the at least one
second lead to a current source.
14. The apparatus according to claim 12, wherein the interfacing
portion is directly in touching contact with the majority of a heat
transfer area of the heat sink interface via thermal tape.
15. The apparatus according to claim 12, further comprising a
biaser configured to resiliently apply a biasing force causing the
interfacing portion and the heat transfer area of the heat sink
interface to be forced with continuous pressure to remain in
touching contact with each other
16. The apparatus according to claim 15, wherein the biaser
includes a spring clip.
17. The apparatus according claim 16, wherein the biaser includes a
plug-in receptacle including a spring configured to receive the LED
unit, whereby once the LED unit is so received, the biasing force
is automatically and continuously applied.
Description
RELATED APPLICATION DATA
[0001] This application is a continuation of U.S. application Ser.
No. 12/561,955, filed Sep. 17, 2009, which is a continuation of
U.S. application Ser. No. 12/396,460, filed Mar. 2, 2009. The
content of each of these parent applications is hereby expressly
incorporated by reference herein it its entirety.
FIELD OF DISCLOSURE
[0002] The present disclosure relates to high power light emitting
diodes assemblies including high power light emitting diodes, and
portions of such assemblies.
BACKGROUND
[0003] Traditional illumination technologies, for example,
incandescent and fluorescent lighting, are being supplanted by high
power light emitting diode structures. Light emitting diodes
(LED's) have advantages over other illumination devices because
they consume less power and last longer. In addition, they are
highly durable, and responsive. One problem associated with high
power LED's is the need to prevent the temperature in the LED die
from rising. If the temperature of the LED die is allowed to rise
above a certain threshold level, the life of the LED can be
shortened. Moreover, the lighting efficiency would be
compromised.
[0004] Another issue concerning LED lighting is the manufacturing
cost. LED lighting solutions can cost substantially more than
incandescent and fluorescent lighting solutions. Accordingly, there
is a need for new technologies that reduce or prevent heat unwanted
rises in temperature at the LED die, and that allow for LED's to be
employed in various illumination setting at reduced manufacturing
and deployment costs.
SUMMARY OF THE DISCLOSURE
[0005] In accordance with select embodiments described herein,
apparatus may be provided. The apparatus may include a particular
device, an assembly of devices, a single apparatus, or plural
apparatus. The apparatus may include a high power light emitting
diode (LED) unit, a least one printed circuit board, and an
interfacing portion of a heat sink structure. The high power LED
unit includes at least one LED die, at least one first lead and at
least one second lead, and a heat sink interface. The at least one
printed circuit board may include a conductive pattern configured
to connect both the at least one first lead and the at least one
second lead to a current source. The interfacing portion of the
heat sink structure is the portion through which a majority of heat
of the heat sink interface is transmitted. The interfacing portion
is directly in touch contact with a majority of heat transfer area
of the heat sink interface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Embodiments of the disclosure are further described in the
detailed description which follows by reference to the noted
drawings, in which like reference numerals represents similar parts
throughout the several views of the drawings, and wherein:
[0007] FIG. 1 is a block diagram of an illumination apparatus 10 in
accordance with one embodiment herein;
[0008] FIG. 2 shows an elevated perspective view of a cross section
of a LUXEON.RTM. Rebel high power surface mount LED;
[0009] FIG. 3 is an elevated cross-sectional view of a panel type
LED module;
[0010] FIG. 4 is an elevated cross-sectional view of a surface
mount LED module;
[0011] FIG. 5 is a perspective elevated view of an LED assembly in
accordance with one embodiment of the present disclosure;
[0012] FIG. 6 is an exploded view of the LED module portion of the
assembly shown in FIG. 5;
[0013] FIG. 7 is an elevated side cross-sectional view of portions
of the LED assembly shown in FIG. 5;
[0014] FIG. 8 is an elevated side cross-sectional view of the same
portions of the LED assembly shown in FIG. 7, per a different
embodiment;
[0015] FIG. 9 is a top view of a plural set of LED modules
interconnected with a printed circuit board and a heat spreader
substrate;
[0016] FIG. 10 is a top view of a flex circuit in accordance with
one embodiment of the present disclosure; and
[0017] FIGS. 11, 12, and 13 respectively show a cross section, a
top view, and a side view of a socket cover structure.
DETAILED DESCRIPTION
[0018] Referring to the drawings now in greater detail, FIG. 1 is a
block diagram of illumination apparatus 10. The illustrated
apparatus 10 may include a single apparatus, plural apparatus, or
an assembly of different devices. The illustrated apparatus 10
includes an LED unit 12, which includes one or more first leads 14,
one or more second leads 16 and a heat sink interface 20. The
illumination apparatus 10 further includes wire connections 18 and
a heat sink structure 22. LED unit 12 may include a single LED die,
or a plural set of LED dies. Alternatively, LED unit 12 may include
a plural set of LEDs that all form part of one integrated circuit.
LED unit 12 may further include a lens (not shown in FIG. 1) over
its LED's.
[0019] Heat sink interface 20 could be provided on the bottom, top,
and/or side of an LED module structure, or it could be provided on
more than one of the bottom, top, and each of the four sides of a
rectangular LED modular unit. The heat sink interface 20 could have
an interfacing portion that is across the entire surface of a given
side (among the bottom, top, and side sides) of LED unit 12, and
this surface area could be considered the heat transfer area of the
heat sink interface. Alternatively, the heat transfer area of the
heat sink interface 20 could be a limited region on a given side
(among the bottom, top, and side sides). Heat sink structure 22 may
include, among other elements, radiated fins, metallic or ceramic
structures that have a low thermal resistance, a heat transfer
plate or structure, and so on. The material of the heat sink
components could include any one or more of aluminum, copper, a
different metal element or alloy, or a non-metallic substance
suitable for a heat sink, e.g., ceramic.
[0020] Wire connections 18 include wire connections to one or more
operating current sources which connect the at least one first lead
14 and at least one second lead 16 to such operating current or
currents. In accordance with select embodiments herein, wire
connections 18 are implemented in the form of conductors in a
printed circuit board or a flex circuit.
[0021] LED unit 12 could include one or more LED's interconnected
in the form of an integral unit. Some examples of the types of
LED's that could be included in LED unit 12 are shown in FIGS. 2,
3, and 4.
[0022] FIG. 2 is a perspective view of a cross section of a
LUXEON.RTM. Rebel, a high power surface mount LED which is made by
Philips A version of the drawing in FIG. 2 is provided at page 12
of the Application Brief AB32, dated March 2007, provided by
Philips (pages 1-13).
[0023] The illustrated cross-sectional portion of an LED module
shown in FIG. 2 includes a cross section 30 with cut-away portions
of a commercially available high power surface mount LED for
illumination applications. The illustrated cut-away portions
include a substrate 32, a thermal pad 34, a cathode 36 (an anode,
not shown in this figure), an LED die 38, a bond layer 39, a TVS
(transient voltage suppressor) 40, an integral lens 42, and an
interconnect layer 44.
[0024] The substrate 32 is ceramic. The thermal pad 34 is
electrically isolated from cathode 36 and the anode (not shown).
The illustrated surface mount LED 30 includes a single LED die 38.
Bond layer 39 is provided to secure LED die 38 to a metal
interconnect layer 44, with a low thermal resistance bonding
material. Integral lens 42 is made of silicon.
[0025] High power surface mount LED's such as that shown in FIG. 2
may be automatically installed using automated pick-and-place
equipment and processes.
[0026] Philips provides a recommended pad layout and PCB (printed
circuit board) design for the surface mount LED shown in FIG. 5, in
the above-identified Application Brief AB32. LED module 30 may be
fixed to a printed circuit board using a lead free reflow
technique. Meanwhile, the printed circuit board (PCB) is connected
to the thermal pad 34 of the surface mount LED 30 with
plated-through-vias in order to reduce the thermal resistance of
the assembly.
[0027] FIG. 3 is a cross-sectional elevated side view of a
panel-type LED module 50. The illustrated LED module 50 includes
one or more LED dies 52, each of which is connected to a conductive
pattern on printed circuit boards portions 56. An illustrated LED
die 52 is connected a metal substrate 62 via a thermally conductive
adhesive 58.
[0028] This LED module 50 is described in U.S. Pat. No. 7,494,250,
for example, at column 1 thereof. As described in the '250 patent,
the thermally conductive adhesive 58 includes a silver epoxy that
conducts heat. As shown in FIG. 3, an insulation colloid 60 is
provided to electrically isolate metal substrate 62 from printed
circuit board 56. The illustrated LED module 50 shown in FIG. 3
further includes wires 54 which connect the anode and cathode of
LED die 52 to corresponding conductive portions of printed circuit
board 56.
[0029] FIG. 4 is an elevated side cross sectional view of a surface
mount LED module 70. This structure is also described in the '250
patent. The surface mount LED module 70 includes one or more LED
dies 72. Each die 72 is connected to a bearing base 78 via a
thermally conductive adhesive 76. This illustrated module 70 is
also described in the '250 patent, which explains that thermally
conductive adhesive 76 includes a silver epoxy.
[0030] The illustrated bearing base 78 is bordered around its
periphery by an insulation housing 80. First and second lead frames
82 and 84 are provided which are connected to insulation housing
80. Wires 74 connect the anode and cathode respectively to the
first and second lead frames 82 and 84.
[0031] FIG. 5 is a perspective view of an LED assembly 60 includes
an LED module 61 and a LED support and heat sink housing 70. LED
module 61 may be secured to LED support and heat sink housing 70,
for example, with the use of an adhesive, or with the use of a
magnetic snap-on force created with the use of magnetic and ferrous
components, to be described further hereinbelow.
[0032] The illustrated LED module 61 includes a heat spreader
substrate 62, a cylindrical wall 64, and a transparent lens 66. A
plurality of LED modules are mounted to heat spreader substrate 62
and are housed behind transparent lens 64 inside of cylindrical
wall 64.
[0033] Heat spreader substrate 62, in the illustrated embodiment,
includes a copper plate. Cylindrical wall 64 may be metallic. In
one embodiment, cylindrical wall 64 includes a magnetic ring.
Transparent lens 66 is secured to cylindrical wall 64 with the use
of an adhesive. Cylindrical wall 64 is similarly secured to heat
spreader substrate 62 with the use of an adhesive. LED support and
heat sink housing 70, as shown in FIG. 5, may be cup-shaped. In the
illustrated embodiment, LED support and heat sink housing 70 is
metallic. It may be, for example, aluminum, a ferrous material, or
copper.
[0034] Heat spreader substrate 62 and cup-shaped LED support and
heat sink 70, when secured to each other, collectively serve as a
heat sink structure. As a further part of the heat sink structure,
a heat transfer structure 76 may be inserted inside the cylindrical
opening of cup-shaped LED support and heat sink housing 70. Heat
transfer structure 76 may include, for example, a piece of
mass-produced honeycomb aluminum cut into a desired cylindrical
shape and inserted into the cup-shaped housing 70 so that the
longitudinal axes of the hexagonal cells of the honeycomb structure
are parallel to the longitudinal axis of cup-shaped LED support and
heat sink housing 70.
[0035] In the illustrated embodiment, the honeycomb heat transfer
structure is cylindrical in shape, is in direct contact with the
inner cylindrical walls of housing 70, and has a length, in the
longitudinal direction of housing 70, that is about one third of
the length of housing 70. In the illustrated embodiment, housing 70
has a diameter of about one and a quarter inches and a length of
about two inches.
[0036] Housing 70 includes a base end 72, which is the end
approximate to LED module 61. Housing 70 further includes an open
end 74 which is at the end that is furthest from LED module 61.
[0037] In the event that housing 70 is made of a non-ferrous
material, for example, aluminum, a ferrous member 78 may be secured
or fixed behind base end 72, so that a magnet that is part of LED
module 61 can exert an attractive biasing force acting on ferrous
member 78, causing the interfacing portion of LED module 61 (heat
spreader substrate 62) and the heat transfer area of the heat sink
interface (i.e., base end 72) to be forced with continuous pressure
to remain touching contact with each other. In different
embodiments, different elements may be ferrous but not magnetized
while others may be magnetized--in a manner to cause the same
attractive biasing force noted above.
[0038] This magnetic connection force further causes a conductive
pattern exposed underneath substrate 62 (not shown in FIG. 5) to
come into contact with pin connectors 77 and 79 which in turn are
connected to wires that connect the LED circuitry of LED module 61
with an operating current source. In the illustrated embodiment,
outer pin connector 77 is put in contact with an annular conductive
pad and inner pin connector 79 is put in contact with a conductive
pad centered within and concentric with the annular conductive
pad.
[0039] Housing 70 may include a plurality of holes 81 throughout
the cylindrical wall thereof. This allows for air to pass into the
cavity of cup-shaped housing 70 through holes 81, as well as
through the openings within heat transfer structure 76 and the open
end 74 of housing 70.
[0040] The illustrated housing 70 may be provided with a mounting
structure 63 for purposes of mounting the resulting LED assembly 60
to some lighting fixture or in some other illumination
application.
[0041] FIG. 6 is an exploded view of the elements of the LED module
61 shown in FIG. 5. The illustrated LED module 80 as shown in FIG.
6 includes a heat spreader substrate 82 (a copper plate having a
hole 83, in the illustrated embodiment), a printed circuit board 84
(for example, a flex circuit as shown in the illustrated
embodiment), a plurality of single die LED units 86, a small
cylindrical magnet 88, a cylindrical wall or ring member 90, and a
protective transparent lens 92.
[0042] PCB 84 is secured over an opening 83 of heat spreader
substrate 82, when each of the six illustrated single LED units 86
is soldered to PCB 84 (at their anode and cathode pads) and
soldered directly to the top surface of heat spreader substrate 82
(at their thermal pads).
[0043] Each of single die LED units 86 includes, on the lower
surface thereof, a thermal pad, an anode lead, and a cathode lead.
The anode and cathode leads are soldered to corresponding
conductive pads on PCB 84, while the thermal pad is soldered
directly to heat spreader substrate 82. Cylindrical magnet 88 is
provided in the center of the resulting assembly of LED units 86,
by cementing magnet 88 at that location directly to the PCB 84.
Ring 90 is cemented to heat spreader substrate 82, in a position so
that the resulting hexagonal pattern of single die LED units 86 is
centered in relation to and concentric with the inner wall of ring
90. Protective lens 92 is also cemented to the top of ring 90.
[0044] FIG. 7 and FIG. 8 show variations of cross-sectional
portions of an LED assembly as shown in FIG. 5. One version of the
illustrated cross-section 100 is shown in FIG. 7, and another
version 100' is shown in FIG. 8.
[0045] As shown, for example, in FIG. 6, a given LED module 80 may
include six LEDs evenly spaced in a round table fashion about a
center axis. Different positioning and directional configurations
of the single die LEDs could be employed in an LED module in
accordance with other embodiments. In addition, the number of
single die LED units that are employed could be just one LED, or a
plural number of LEDs that is different than the number of LEDs
shown in the embodiments herein.
[0046] For purpose of simplification, the assembly shown in FIG. 7
only shows two single die LED units 102. Those LED units 102 are
connected using solder reflow to a flex circuit type PCB 103 as
well as to a heat spreader substrate 108. More specifically, each
of the LED units 102 has anode and cathode connection pads on the
bottom surface thereof and a thermal pad on their bottom surface.
The thermal pads are soldered directly to the top surface of heat
spreader substrate 108, while the anode and cathode pads are
soldered directly to corresponding conductive pads on PCB 103.
[0047] It should be noted that in lieu of solder, other thermal
connection methods and substances may be employed to connect the
heat sink interface of a given LED unit and the interfacing portion
of the heat sink structure. For example, thermal epoxy or thermal
tape could be employed.
[0048] Accordingly, the thermal pads of each of the LED units 102,
which comprise the heat sink interface of those LED units, are
connected directly to an interfacing portion (heat spreader
substrate 108) of a heat sink structure. The portions of the heat
sink interface of LED units 102 that is so connected to heat
spreader substrate 108 happens to be the entire thermal pad of each
LED unit 102. It is important that the interfacing portion of the
heat sink structure (i.e., the heat spreader substrate 108 in this
embodiment) is directly in touching contact with the majority of
the heat transfer area of the heat sink interface. This "majority"
of the heat transfer area, in this embodiment, includes all of the
thermal pad which is the heat transfer area of the illustrated LED
units 102. The cathode, anode, and thermal pads of each of the
respective LED units 102, in this specific embodiment, will be
described further hereinbelow.
[0049] PCB 103 includes a conductive pattern, portions of which
include, as shown in FIG. 7, a certain conductive pattern including
exposed pads on the underneath side of PCB 103. Those conductive
portions include a center pad 110 centered on the under side
portion of PCB 103, and an annular pad 112, which surrounds center
pad 110 and is concentric with center pad 110.
[0050] As shown in FIGS. 7 and 8, heat spreader substrate 108, to
which LED units 102 (and other structure (not shown in this
figures) including a ring and an LED protective lens) are
collectively fixed, is in contact with the flat surface of base end
104 of the cup-shaped LED support 70, for example, as shown in FIG.
5. FIGS. 7 and 8 also show a side cross-sectional view of portions
of a ferrous ring member 106, that was secured to the inside of
base end 104, because the cup-shaped LED support (including base
end 104) is made, in this illustrated embodiment, of non-ferrous
aluminum. Accordingly, by providing a ferrous ring member 106, when
the LED module 61 (which includes the assembly mounted on heat
spread substrate 108) is magnetic, the magnetic force can act upon
ferrous ring member 106 to bring heat spreader substrate 108 into
secure contact with the outer surface of base end 104 of the
cup-shaped LED support.
[0051] When this secure connection happens, an insulative plug 75
is protruding upwardly through an opening in base end 104 will hold
the heads 115 and 117 of first pin 114 and second pin 116 in direct
contact with annular pad 112 and center pad 110, thereby causing an
electrical connection between wires coupled to first and second
pins 114 and 116 and the corresponding anodes and electrodes of the
set of LED units 102, by way of the conductive patterns in PCB 103.
The wires coupled to first and second pins 114 and 116 are
connected to a current source that drives LED units 102.
[0052] Per the embodiment shown in FIG. 7, PCB 103 (which in the
embodiment is a flex circuit of a thickness equal to approximately
1 mm) is simply placed on and overlaps with the cylindrical opening
of heat spreader substrate 108. Thus, it is slightly raised in
relation to the surface of heat spreader substrate 108. Thus, when
LED units 102 are connected to PCB 103 (at the anode and cathode
pads thereof) and directly to heat spreader substrate 108 (at the
thermal pads thereof), they tilt at an angle of approximately one
degree.
[0053] FIG. 8 shows an embodiment in which the tilting of LEDs 102
is not necessary. The tilting of LEDs 102 is prevented by mounting
PCB 103 within a recessed portion of heat spreader substrate
108.
[0054] FIG. 9 shows a top view of heat spreader substrate 108 shown
in FIG. 8, and of six individual LED units 102. LED units 102 are
connected using solder reflow to pads underneath the same. Those
pads to which LEDs 102 are connected on the PCB include surface
contact pads on the PCB 103.
[0055] FIG. 10 provides a top view of PCB 103 in accordance with
one embodiment. The conductive pattern includes a lower conductive
pattern (which includes center pad 200 and annular pad 202), and a
top layer conductive pattern including seven conductive portions.
Those seven conductive portions include conductive portions 204,
206, 208, 210, 212, 214, and 216. Each of those upper conductive
portions 206, 208, 210, 212, 214, and 216 includes one or more
surface contact pads. For example, conductive portion 206 includes
a conductive portion 300 that is not accessible via the surface as
well as surface accessible conductive pads 301 and 302. These
surface accessible conductive pads are areas to which the anode and
cathode conductive pads of one of the LEDs 102 are connected. The
LEDs are connected to these pads and other similar pads in order to
form a daisy chain/series connection between the LEDs.
[0056] Each of FIGS. 11, 12, and 13 show different views of a
socket cover structure in accordance with one embodiment. The
illustrated socket cover 400 includes a base 406 and a resilient
biasing member. As visible from the cross section view in FIG. 11
and the side view in FIG. 13, resilient biasing member may be
integrally formed and unitary with the enter socket cover
structure, and may supported by a vertical member 403. Socket cover
structure further includes a major opening 401, to allow for a
bubble-shaped. LED lens of a given LED unit 408 to be secured by
the resulting socket (which is formed when socket cover structure
is securely mounted to some sort of base structure).
[0057] The base structure to which a socket cover structure can be
secured can include a PCB or a flex circuit. It can also be secured
to a heat sink or a portion of a heat sink, e.g., a metallic or
ceramic planar member, at least at portions. For example, a screw
hole 402 may be provided, to allow socket cover structure to be
screwed to a base, including a metal heat sink or heat spreader
member.
[0058] As shown in FIG. 11, the resilient biasing member 404 has a
curved lip end which serves to create an apex point of the
resilient biasing force--identified by the arrow labeled "F". In
this embodiment, this apex point of the biasing force causes
pressure to be concentrated at a point on or near the edge of the
anode and cathode pads 420 of LED unit 408.
[0059] The socket created by mounting the socket cover structure
shown in FIGS. 11-13 is intended for use with high power, high
priced LEDs needing heat dissipation and replacement. A problem
exists with LEDs of this sort. There is a need for a simple
inexpensive way to use and replace basic high power LEDs. High
power LEDs need to transfer heat away from their die to maintain
maximum efficiency and life. Because the high power LED needs to be
connected to a heat dissipating device, the current state of the
art is to solder one or more LEDs on modules that provide
electrical and heat transfer functions. This module can provide all
the heat dissipation or be attached to another device to dissipate
heat. If one LED should burn out the whole module needs to be
replaced.
[0060] This embodiment makes it possible to easily change
individual LEDs by replacing the method of permanently soldering an
LED to a module with an LED socket where the LED is attached to
circuitry and heat dissipater.
[0061] A socket may be formed with the disclosed structure or
variations thereof, thereby creating a socket that: secures and
positions the LED; provides pressure to hold the LED to the heat
dissipater; allows option of inexpensive power connection via flex
circuit edge connector; allows option of having the LED heat pad
connected directly to the heat dissipating equipment instead of via
a circuit module (as in the current state of the art and described
in the Lumileds Rebel application notes); and/or allows screw,
clip, etc., reflow attachment to heatsinks and circuits.
[0062] A socket may be made from a thin flex circuit and a cover
(e.g., as shown in FIGS. 11-13) that secures and positions the LED.
The resulting socket may be placed directly on a heat dissipater.
The cover may position the LED on the circuit leads and applies
pressure to hold the LED to the electrical contacts and the LED
heat pad to the heat dissipater. Thermal grease, tape, etc. could
be used to decrease the thermal resistance of the socket. The cover
could be formed from metal clip, spring, plastic, etc.
[0063] Alternatively, a socket may be made with a circuit made from
a thicker circuit board material and embedded into the heat
dissipater so that when the LED is inserted into the socket, it's
heat pad impinges directly on the heat dissipater.
[0064] Alternatively, the socket is connected to a PCB, MCB, etc.
This module/fixture may be connected to or contains a heat
dissipater.
[0065] Alternatively, the heat dissipater could be directly applied
to the LED heat pad. The LED with heat dissipater permanently (or
otherwise) attached would then be inserted into a socket.
[0066] Alternatively, an intermediary heat transfer piece could be
applied to the LED heat pad. When the LED is inserted into the
socket the heat transfer piece would directly contact the heat
dissipater.
[0067] Alternatively, the heat dissipater or heat transfer piece
could be directly manufactured into the LED as part of its heat pad
and this would then be inserted into the socket.
[0068] The cover and/or circuit could be attached to circuit and/or
heat dissipater using surface mount, screw down, form fit insert,
etc.
[0069] The socket could be used for a single LED or multiple
sockets could be stamped or molded into one unit. Since most LED
drivers provide a constant current, this multiple socket version
could use inserts that jumper unused sockets. For example a 6
socket unit could have 1 or more sockets jumper out if not
needed.
[0070] Advantages of providing a socket include a reduction in
production costs. Such a reduction would occur for manufacturers.
Eliminating the inclusion of expensive LEDs into modules/fixtures
(LEDs can account for 90% or more of an LED module's cost. The end
user can decide what LEDs to use at point of sale. The socket can
eliminate need for intermediary LED modules. Sockets could be added
straight to the supporting structure (for example the case of an
appliance if it can dissipate necessary heat). Sockets can
eliminates multiple versions of modules for different types of LED
light (for example warm, neutral, cool LED white light, etc.). An
LED module/fixture manufacturer can make and inventory one version
of the module/fixture instead of having a version for each type of
LED that end users may need (lumen level, color temperature, etc).
For warm, neutral, and cool white colors of light at three lumen
levels, the manufacturer would have to produce 9 different versions
of a module vs. one with the use of sockets.
[0071] Sockets can reduces cost of inventory obsolescence based on
outdated modules/fixtures because they no longer contain expensive
LEDs and because one version of module instead of multiple. They
can reduce the cost of inventory obsolescence based on out dated
LEDs for same reasons. They can also enable the use of inexpensive
FR4 boards for socket circuit providing quick prototyping. They are
easy to replace.
[0072] The smallest denominator of light gives the greatest
flexibility in design. The use of sockets results in a more
efficient heat transfer path--LED heat pad can be connected
directly to heat sink (though thermal compound) or indirectly
through one other media, state of the art and documented in Rebel
application notes transfer heat thru 3 materials before reaching
the heat sink.
[0073] For a socket on a heatsink, the LED heat pad may be
connected directly to heatsink and indirectly thru thermal
compound.
[0074] For a socketed LED on FR4 PCB module and connected to a
heatsink, The following steps may be performed. The LED heat pad
may be soldered. Solder may be applied to copper on one side of
PCB, and then thru-plated vias to opposite side of PCB to copper
heat transfer area. Copper may be applied directly to the heatsink
and indirectly through thermal compound.
[0075] The LED may be separated from the module or fixture, to
thereby reduce the inventory needed at each level of distribution
from manufacturer to end user.
[0076] Distributors and retailers likewise would only have to
inventory one version of the module or fixture instead of one for
each type of LED. The module/fixture is many times bigger than the
individual LEDS saving space. The individual LEDs can be used in
multiple fixtures from multiple vendors.
[0077] End users would have more options. End users can decide at
the retail outlet what type of light they need in the fixture. For
example, warm white LED in one application and neutral in another.
If the end user can not afford or does not need a high lumen LED
version they can opt for a lower cost lower lumen version.
[0078] Outdated module/fixture inventory is more valuable because
LED failures no longer make the module/fixture obsolescent.
[0079] End users would not be dependent on the original
module/fixture manufacturer if LED failure occurs. Very large users
of LED products, for example, militaries which could have thousands
of different kinds of modules/fixtures, could operate more
efficiently by carrying less numbers of replacements for each type
of module/fixture they use in case of LED failures. They would
carry just the LEDs instead for this type of failure, reducing cost
of inventory, and cost of logistics.
[0080] The use of sockets would result in the more efficient use of
resources, and reduces cost for the end user. When an LED fails,
the user need only replace the LED and not the entire
fixture/module.
[0081] The claims as originally presented and as they may be
amended, encompass variations, alternatives, modifications,
improvements, equivalents and substantial equivalents of the
embodiments and teachings disclosed herein, including those that
are presently unforeseen or unappreciated, and that, for example,
may arise from applicants/patentees and others.
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