(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2006/0109661 A1
`(43) Pub. Date: May 25, 2006
`
`Coushaine et al.
`
`US 20060109661A1
`
`(54) LED LAMP \VITH LEDS ON A HEAT
`CONDUCTIVE POST AND METHOD OF
`MAKING THE LED LAMP
`
`(76)
`
`Inventors: Charles M. Coushaine. Rindge. NH
`(US): Thomas Tessnow. Weare. NH
`(US); Fred Peterson. Sanbomton. NH
`(US); Kim Albright. Warner. NH (US);
`Florence Taitel. Hooksett. NH (US):
`Howard Eng. Hancock. NH (US)
`
`Correspondence Address:
`YOUNG & THOMPSON
`745 SOUTH 23RD STREET
`2ND FLOOR
`ARLINGTON, VA 22202 (US)
`
`(21) Appl. No.:
`
`10/993,436
`
`(22)
`
`Filed:
`
`Nov. 22. 2004
`
`Publication Classification
`
`(51)
`
`Int. (:1.
`(2006.01)
`£le 29/00
`(52) U.S.Cl.
`.............................................................. 362/373
`
`(57)
`
`ABSTRACT
`
`A lamp. and a method of assembling the lamp. includes a
`heat sink. a heat conductive post extended longitudinally
`from the heat sink where the post has longitudinal faces that
`each has a longitudinally extending slot therein. a metal clad
`circuit board slid into each slot so that each circuit board is
`
`in thermal conununication with the post where each circuit
`board has an exterior surface with an LED thereon. and a cap
`on top of the post where the cap abuts lateral end surfaces
`of the circuit boards. The cap may hold the circuit boards in
`their respective slots.
`
`
`
`

`

`Patent Application Publication May 25, 2006 Sheet 1 of 6
`
`US 2006/0109661 A1
`
`
`
`FIG. 1
`
`

`

`Patent Application Publication May 25, 2006 Sheet 2 of 6
`
`US 2006/0109661 A1
`
`
`
`

`

`Patent Application Publication May 25, 2006 Sheet 3 of 6
`
`US 2006/0109661 A1
`
`FIG. 3
`
`24
`
`&§\\\\\\\\\\\\\\\\\\\\\\\\§\\\§\\Aa.
`\pl[IlllllilJl/Il/I/I/IAI/fll/ll
`
`‘
`
`
`/W
`
`
`
`\\\ ' '_\\\\\\\\\\\\\ \\\
`
`$7///
`\
`
`\III.I.
`
`
`
`
`w§§§§§§§§
`r/-VII/l//”I”/”l|’/’.”/I/””’llxA
`
`sA
`////////////J
`
`yv
`
`'64
`
`76
`
`
`
`
`
`
`
`
`

`

`Patent Application Publication May 25, 2006 Sheet 4 of 6
`
`US 2006/0109661 A1
`
`
`
`

`

`Patent Application Publication May 25, 2006 Sheet 5 of 6
`
`US 2006/0109661 A1
`
`LIGHT
`
`
`
`

`

`Patent Application Publication May 25, 2006 Sheet 6 of 6
`
`US 2006/0109661 A1
`
`2.2
`
`'3
`.'
`l——_—'/'
`
`/
`
`/
`
`«{7}:
`
`1
`
`IE
`
`70
`
`Fl 99
`
`

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`
`US 2006/0 I0966 I A I
`
`May 25, 2006
`
`LED LAMP WITH LI-IDSON A HEAT
`CONDUCTIVE POST AND METHOD OF MAKING
`THE LED LAMP
`
`BACKGROUND OF THE INVENTION
`
`invention relates to a lamp and a
`[0001] The present
`method of making a lamp m which a light emitting diode
`(LED) is the light source. This application relates to copend­
`ing application Ser. No.
`IO/647,632 titled LED LAMP
`VVITH INSERTABLE
`LED
`SUBSTRATES
`AND
`METHOD OI-‘MAKING TI-IE LAMP filed on Aug. 25,
`2003 and to copending application Ser. No. 10/647,831
`titled LED LAMP WITH INSERTABLE AXIAL \VIRE­
`VVAYSAND METHOD OF MAKING THE LAMP filed on
`Aug. 25. 2003.
`
`[0002] As is known, light output of an LED depends on its
`temperature. LED temperature should be kept low to ensure
`eflicient light production Accordingly, it is beneficial to
`provide an LED lamp that includes an LED With a heat sink
`for draWing heat aWay from the LED. The LED may be
`mounted on a post where the post
`is surrounded by a
`refiector. A circuit board provides the necessary electrical
`components and connections for operating the LED. The
`above-noted related applications and U.S. Pat. No. 6,773,
`138 disclose examples of such a lamp.
`
`[0003] The arrangement of t_herellector, heat sink, circuit
`board, and post in an LED lamp and the eflicient assembly
`of tl1esecomponents l1avepresented problems for designers
`of such lamps. One of t_heproblems is l1ow to provide an
`eflicient assembly technique for connecting the LED on top
`of the post to a circuit board at a bottom of the post. In the
`assembled lamp, heat should be conducted away from the
`LED at the top of the post to the heat sink at the bottom of
`the post a11delectrical connections should be made fro111the
`circuit board at the bottom ofthe post to the I.ED at the top
`of the post. The arrangement of these components should
`facilitate automated manufacture of the lamp.
`
`SUMM_ARYOF THE INVENTION
`
`[0004] An object of the present invention is to provide a
`novel LED lamp, and a method of assembling the LED
`lamp,
`that
`includes a heat sink. a heat conductive post
`extended lo11gitudinally from the heat sink wl1ere the post
`has longitudinal faces that each has a longitudinally extend­
`ing slot therein. and a metal clad circuit board slid i11toeach
`slot so that eacl1 circuit board is in thermal communication
`With the post Where each circuit board has an exterior
`surface With an LED thereon. A cap may be provided 011top
`ofthe post abutting lateral end surfaces of the circuit boards
`to hold the circuit boards in their respective slots. The circuit
`boards may be formed from a single integral unit that has
`plural that are folded into respective slots to form the circuit
`boards. Among other features, sliding insertion of the circuit
`board i11to the slot
`in the heat conductive post and’or
`retention of the circuit board in the slot by the cap on top of
`the post and’or the folding arms of a single circuit board
`facilitate automated manufacture of the lamp.
`
`[0005] Other objects and advantages of the invention Will
`be apparent to those of skill i11the art of the present invention
`after consideration of the following drawings and descrip­
`tion of preferred embodiments.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0006] FIG. 1 is an exploded pictorial representation of a11
`embodiment of the lamp of the present invention.
`[0007] FIG. 2 is a pictorial representation of the lamp of
`FIG. l.
`
`[0008] FIG. 3 is a cross section of an embodiment of the
`lamp of the present invention.
`
`[0009] FIG. 4 is a detailed pictorial representation of the
`end of the heat conductive post to Whichthe retaining cap is
`attached.
`
`FIG. 5 is a sche111aticrepresentation ofan electrical
`[0010]
`connection between the mounting board and the base.
`
`[0011] FIG. 6 is a schematic representation of another
`electrical connection betWeen the mounting board and the
`base.
`
`[0012] FIG. 7 is a schematic representation of a further
`electrical connection betWeen the mounting board and the
`base.
`
`[0013] FIG. 8 is a pictorial representation of the lamp of
`the present invention With a refiector.
`
`[0014] FIG. 9 is a pictorial representation of a folding
`mounting board in a further embodiment of the present
`invention.
`
`DESCRIPTION OF PREFERRED
`EMBODIMENTS
`
`[0015] With reference noW to FIGS. 1-4, an embodiment
`of the la111p10 includes a heat conductive post 12 mounted
`on a heat conductive portion ofa base 14, wl1erethe post 12
`has an exterior face with a longitudinal slot 16 therem. A
`mounting board 18 is slideably disposed in the slot 16,
`Wherethe mounting board 18 has an exterior surface 20 with
`an LED 22 thereon. Aretaining cap 24 is attached to the post
`12 opposite the base 14. The mounting board 18 may have
`an intcrlercnce fit Withthe slot 16 to hold mounting board 18
`in the slot 16 and provide thermal communication betWeen
`the post 12 and the mounting board 18. Alternatively, or in
`addition, the cap 24 abuts a lateral end 26 of the mounting
`board 18 to hold (or help hold) the board 18 in the slot 16.
`
`[0016] As shoW11in FIG. 4, each slot 16 may be provided
`With a longitudinal rib 16' that presses against an interior
`surface of the respective one of the mounting boards 18 and
`longitudinal edges of the exterior surface of each of the
`mounting boards may be held by edges 16" ofthe respective
`slot to provide the mterference fit.
`
`[0017] The method of making the lamp includes the steps
`of mounting the heat conductive post 12 on the heat con­
`ductive portion of the base 14 so that the post 12 and the heat
`conductive portion of the base 14 are i11tl1em1alcommuni­
`cation. sliding the mounting board 18 into the slot 16 so as
`to place the mountmg board 18 in thermal commtmication
`With the post 12. and making the electrical coimections for
`the LED 22. The mounting board 18 may be held in the slot
`16 Withthe interference fit of the motmting board 18 and/or
`by mounting the cap 24 on the post so that the cap abuts a
`lateral end 26 of the mounting board IS.
`[0018]
`In the assembled lamp, heat is conducted away
`fron1 the LED 22 on the post 12 to the heat conductive
`
`

`

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`
`US 2006/0 I0966 I A 1
`
`May 25, 2006
`
`portion at the bottom of the post. Automated manufacture of
`the lamp is facilitated by sliding insertion of the mounting
`board 18 into the slot 16 and/or retention of the mounting
`board 18 in the slot 16 by the cap 24.
`[0019]
`In a more particular embodiment, the post 12 has N
`(N>2) exterior faces and a cross section that is constmit
`along a11entire length of the post, such as shown in FIGS.
`1-4. The cross section ofthe post may be other than square.
`such as a triangle, rectangle, pentagon, octagon, and the like.
`Further, the cross section may be unsymmetrical, or may be
`radially symmetrical (meaning that one face can be rotated
`X degrees and symmetrically replace another face). The flat
`sides of the post 12 and a constant cross section facilitate
`insertion of the mounting board 18. As is apparent, provid­
`ing the slot 16 with parallel sides and making the mounting
`board 18 slightly smaller than the slot 16 further facilitates
`the assembly. The post 12 may be made of extruded alumi­
`num or other suitable heat conductive material.
`
`[0020] The cap 24 preferably has the same ntunber of
`sides as the post. although other shapes are possible (e.g.,
`round) provided the cap abuts a lateral end surtace of each
`mounting board 18 When the cap 24 is to be used to hold the
`mounting board 18 in the slot 16. The cap may have a
`projection 28 that snap-fits into a corresponding cavity 30 in
`a top ofthe post 12. The cap may have a decorative color and
`shape.
`[0021] The mounting board 18 may include a first elec­
`trical circuit 42 that
`is connected to the LED (shoWn in
`dashed lines in FIG. 2 to indicate that these may be internal
`circuits) and base 14 may include a second electrical circuit
`40, Where the first and second electrical circuits are con­
`nected to each other to connect the LED to the second
`electrical circuit.
`
`[0022] Vv'iLhreference now to FIGS. 5-7, connection of
`the first and second electrical circuits to each other may be
`accomplished by one of several means for connecting the
`circuits to each other. For example, the second electrical
`circuit 40 may include plural pins 44 that extend longitudi­
`nally from the base 14, the first electrical circuit 42 may
`include plural sockets 46 that are attached to the mounting
`board 18, and respective ones of the plural pins 44 and
`sockets 46 may be joined to each other to electrically
`connect the LED to the second electrical circuit. By way of
`further example, as shown in FIG. 6, the second electrical
`circuit 40 may include a socket 48 on the base 14, the first
`electrical circuit 42 may include plural contacts 50 that fit
`into the socket 48, and the socket 48 and plural contacts 50
`may be joined to each other to electrically comiect the LED
`to the second electrical circuit. Altematively,
`the second
`electrical circuit 40 may include plural contact pads 52 on
`the base 14, the first electrical circuit 42 may include plural
`contact fingers 54 that extend from the mounting board 18,
`and respective ones of the plural contact pads 52 and plural
`contact fingers 54 may be joined to each other to electrically
`connect the LED to the second electrical circuit.
`[0023] Each mounting board 18 may include plural LEDs
`22 that are longitudinally aligned. The LEDs may be pack­
`aged dies or chip-on-board mounted. The mounting board 18
`may be a metal clad circuit board With greater rigidity than
`non-r11etalclad boards so as to provide improved themial
`communication between the LED 22 and the board 18 and
`the board 18 and the post 12. The first electrical circuit 42
`may be a printed circuit or the like.
`
`[0024] The base 14 may be a metal clad circuit board or a
`heat sink 14' (FIG. 3), or a combination. lf the base is a
`metal clad circuit board, a separate heat sink may also be
`needed. The second electrical circuit 40 may be a circuit
`board attached to the heat sink or may be circuitry on the
`heat sink. The second electrical circuit may be on either side
`of the base and may include a suitable extemal coimection
`(FIG. 3) forthe lamp that may include a connection housing
`60 and pins 61.
`
`[0025] As shown in FIGS. 3 and 8, a reflector 62 that
`reflects light from the LED 22 may be provided as part of the
`lamp. Alternatively, the post and base may be inserted into
`an existing reflector. Suitable fasteners may be provided for
`joining the base and reflector. The reflector may be parabolic
`or the like and the LED 22 may be placed 11earthe focal
`point ofthe reflector. The post may be joined to the base by
`a fastener 64 that extends through the base into a bottom of
`the post.
`
`In a further embodiment shown in FIG. 9, a
`[0026]
`motmting board 70 may be a single piece of flexible circuit
`board With plural arms 72 that are each folded at a fold line
`73 to fit into respective ones of the slots 16 of the post 12.
`Each arm 72 may have the LEDs 22 and appropriate
`electrical circuitry preassembled thereon. The center 74 of
`the mounting board 70 rests on top of the post 12 When the
`amis 72 are slid all the Way into their respective slots. The
`motmting board 70 may be provided With a suitable con­
`nection for a cap 24, which is optional in this embodiment.
`The combined pressure of the interference fit of the arms 72
`in the slots 16 holds the mounting board 70 on the post 12.
`This technique ftmher facilitates manufacture of the lamp.
`
`[0027] With reference again to FIG. 3, a more particular
`embodiment of the lamp includes a heat sink 14‘ having
`second electrical circuit 40 thereon, and a heat conductive
`post 12 extending longitudinally from the heat sink 14',
`Where tl1e post 12 has a bottom in thennal communication
`Withthe heat sink 14' and the post 12 has plural longitudinal
`faces that each has a longitudinally extending slot 16 therein
`Metal clad circuit boards 18' are each slideably arranged in
`a respective one ofthe slots so that each of the circuit boards
`18' is in thermal communication With the post 12. Each of
`the circuit boards 18' has
`a first lateral end surface 76
`abutting the heat sink 14' and/or the second electrical circuit
`40, (b) an exterior longitudinal sLu'faceWithat least one LED
`22 thereon, and (c) first electrical circuit 42 adjacent to the
`first lateral end surface of the circuit board that connects to
`the second electrical circuit. A cap 24 is provided 011a top
`of the post 12 opposite the heat sink 14', Where the cap 24
`holds each of the circuit boards 18' in a respective slot 16
`and the cap 24 abuts the lateral end surface 26 of each ofthe
`circuit boards so that each of the circuit boards 18' is
`captured between the cap 14 and one of the heat sink 14' and
`the first electrical connection 40.
`
`[0028] While embodiments of the present invention have
`been described in the foregoing specification and draWings,
`it is to be understood that the present invention is defmed by
`the following claims when read in light of the specification
`and draWings.
`
`

`

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`
`US 2006/0 I0966 I A 1
`
`l\/lay 25, 2006
`
`We claim:
`1. A lamp comprising:
`
`a heat conductive post mounted on a heat conductive
`portion of a base, said post having an exterior face With
`a longitudinal slot therein; and
`
`a mounting board slideably disposed in said slot, said
`board having a11exterior surface With an LED thereon,
`said board being ir1thennal communication with said
`post and having a first electrical circuit for said LED.
`2. The lamp of claim 1. further comprising a cap on said
`post opposite said base, said cap abutting a lateral end of said
`board and holding said board in said slot.
`3. The lamp of claim 1, wherein said post has N (N>2) of
`the exterior face and wherein a cross section of said post is
`constant along an entire length of said post.
`4. The lamp of claim 1, wherein said base comprises a
`second electrical circuit that is connected to said first elec­
`trical circuit.
`5. The lamp of claim 4, wherein said second electrical
`circuit comprises plural
`longitudinally extended pins,
`wherein said first electrical circuit comprises plural sockets,
`and wl1erei11respective ones of said plural pins and sockets
`are joined to each other to electrically connect said LED to
`said second electrical circuit.
`6. The lamp of claim 4, wherein said second electrical
`circuit comprises a socket, wherein said first electrical
`circuit comprises plural contacts, and wherein said socket
`and plural contacts are joined to each other to electrically
`connect said LED to said second electrical circuit.
`7. The lamp of claim 4, wherein said second electrical
`circuit comprises plural contact pads, wherein said first
`electrical circuit comprises plural contact fingers, and
`wherein respective ones of said plural contact pads and
`plural contact fingers arejoined to each other to electrically
`connect said LED to said second electrical circuit.
`8. The lamp of claim 1. wherein said heat conductive post
`has plural ones of said exterior face each with a respective
`said slot and comprising plural ones of said mounting board
`each slideably disposed in a respective said slot,
`
`wherein said plural mounting boards are integrally joined
`with a center portion that rests on a top of said post, and
`wherein fold lines define a periphery of said center
`portion.
`9. The lamp of claim l. wherein said board comprises
`plural ones of said LED that are longitudinally aligned.
`10. The lamp of claim 1. further comprising a reflector
`arranged to reflect light from said LED.
`ll. A lamp comprising:
`
`a heat sink having a first electrical ccircuit thereon;
`
`a heat conductive post extending longitudinally from said
`heat sink, said post having a bottom in thermal com­
`munication with said heat sink, said post having plural
`longitudinal faces that each has a longitudinally extend­
`ing slot therein; and
`
`plural metal clad circuit boards that are each slideably
`arranged in a respective said slot so that each of said
`circuit boards is in thermal commtuiication with said
`post, each of said circuit boards having
`a first lateral
`end surface abutting one of said heat sink and said first
`electrical circuit, (b) an exterior longitudinal surface
`
`least one LED thereon, and (c) a second
`with at
`electrical circuit that connected to said LED and to said
`first electrical circuit.
`12. The lamp of claim 11, further comprising a cap 011a
`top of said post opposite said heat sink that holds each of
`said circuit boards in a respective said slot, said cap abutting
`a second lateral end surface of each of said circuit boards
`opposite said first lateral end surface so that each of said
`circuit boards is captured between said cap and one of said
`heat sink and said first electrical circuit.
`13. The lamp of claim ll, wherein each said slot corri­
`prises a longitudinal rib that presses against an interior
`surface of the respective one of said circuit boards and
`wherein longitudinal edges of the exterior surface of each of
`said circuit boards are held by edges of the respective said
`slot to hold said circuit boards in the respective said slot.
`14. The lamp of claim ll, wherein said plural circuit
`boards are integrally joined with a center portion that rests
`on a top of said post, and wherein fold lines define a
`periphery of said center portion
`15. A method of making a lamp comprising the steps of:
`
`mounting a heat conductive post on a heat conductive
`portion ofa base, the post having an exterior face with
`a longitudinal slot therein;
`
`sliding a mounting board into the slot, the board having an
`exterior surface with an LED thereon; and
`
`holding the motmting board in the slot in thermal coin­
`munication with the post.
`16. The method ofclaim 15, wherein the step of holding
`the mounting board in the slot comprises the step of mount­
`ing a cap on the post opposite the base, the cap abutting a
`lateral end of the mounting board.
`17. The method of claim 16, wherein the step of mounting
`the cap comprisese the step of press-fitting the cap into a
`fitting in the post.
`18. Tl1emethod ofclai11115, wherein the post has N (N>2)
`of the exterior face and further comprising the step of
`making a cross section of the post constant along an entire
`length of the post.
`19. The method of claim 15, wherein the post has plural
`ones of the exterior face each with a respective said slot a11d
`wherein plural ones of the mounting board are each slid in
`a respective said slot,
`
`and further comprising the steps of providing the plural
`motmting boards as an integral unit where the mounting
`boards are anns of the unit connected to a central
`portion, folding the arms at fold lines at a periphery of
`the center portion. and inserting the folded anus into
`the slots so that the center portion rests 011top of the
`post.
`20. The method of claim 15. further comprising the steps
`of providing the base with a first electrical circuit, providing
`the board with a second electrical circuit that is cormected to
`the LED, and connecting the first and second electrical
`circuits to each other
`to cormect
`the LED to the first
`electrical circuit.
`21. The method of claim 17, wherein the step of connect­
`ing said first and second electrical circuits to each other
`comprises the step of connecting a socket of the first
`electrical circuit to plural contacts of the second electrical
`circuit that are adjacent to an end of the board opposite the
`cap.
`
`

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`US 2006/0 I0966 I A 1
`
`l\/lay 25, 2006
`
`22. Thc mcthod of claim l4, furthcr comprising stcp of
`attaching a reflector that reflects light from the LED,
`23. A method of assembling a lamp comprising the steps
`
`of
`
`providing a heat sink having a first electrical connection
`thereon;
`
`attaching a heat conductive post to said heat sink, said
`post extending longitudinally from said heat sink and
`having a bottom in tl1em1alcommunication With said
`hcat sink, said post having plural longitudinal faccs
`Where each of said longitudinal faces has a longitudi­
`nally extending slot therein;
`
`sliding a respective 111etalclad circuit board into each said
`slot so that each said circuit board is in thermal com­
`munication with said post. each said circuit board
`having (a) a first lateral end surface abutting one of said
`heat sink and said first electrical cormection, (b) an
`exterior
`longitudinal
`stuface with at least one Ll-Ll.)
`thcrcon and (c) a sccond clcctrical conncction adjaccnt
`to the first lateral end s1.u"faceof said circuit board, and
`
`(d) a circuit connecting said TFD to said sccond
`elec