LED lamp with radiator and method for manufacturing the same

An LED lamp includes a radiator, two caps and a light emitting module. The radiator includes a base and a plurality of fins parallel to each other extends along a face of the base, the fins are integrally formed with the base. The two caps are aligned with two opposite ends of the radiator along a longitudinal direction. The light emitting module includes several circuit boards attaching to another face of the base and a plurality of LEDs disposed on the circuit boards. The circuit boards are arranged along the longitudinal direction of the fins, the radiator is cut into pieces with different length according to the arrangement of the circuit board. The present disclosure also provides a method for manufacturing the LED lamp.

BACKGROUND

1. Technical Field

The present disclosure generally relates to a lamp with a radiator and a method for manufacturing the lamp, and more particularly to a light emitting diode (LED) lamp with a radiator and a method for manufacturing the LED lamp.

2. Description of the Related Art

An LED lamp utilizing LEDs as a source of illumination is widely used in many fields because the LEDs have features of long-term reliability, environment friendliness and low power consumption. It is well-known that a conventional lamp utilizes fluorescent lights as a source of illumination. With the development of the LED lamp, the LED lamp is intended to be a cost-effective yet high quality replacement for the conventional fluorescent lamp.

Generally, the LED lamp comprises a bracket integrally formed in a manner of metal die casting or metal extrusion by a die/mould, and a plurality of LED modules received in the bracket. The LED lamp can achieve a constant illumination intensity because a dimension of the bracket is constant. For achieving different illumination intensities according to different requirements, the dimension of the bracket has to be changed. However, a change of the die/mould for forming the bracket raises a considerable design cost burden. Furthermore, obtaining different dies/moulds with different sizes requires additional manufacture and material cost.

What is needed, therefore, is an LED lamp whose light intensity can be easily adjusted by increasing or decreasing the number of LEDs thereof for meeting different illumination demands.

DETAILED DESCRIPTION

Referring toFIG. 1, an LED lamp100in accordance with an exemplary embodiment is provided as a projection lamp. The LED lamp100includes a radiator10, two caps20attached to two opposite ends of the radiator10respectively, a light emitting module30disposed at a bottom face of the radiator10, and a power device41and two stents42disposed at a top face of the radiator10.

Referring toFIG. 2andFIG. 3, the radiator10is integrally preformed of a metal with good heat conductivity such as aluminum, copper or an alloy thereof. In this embodiment, an elongated extruded semi-finished product is cut into pieces with different lengths, and the radiator10is selected from one of the pieces. The radiator10includes a rectangular base11and a plurality of fins12disposed on a top face of the base11. The fins12are parallel to and spaced from each other.

For facilitating description, a longitudinal extending direction of the base11is defined as a longitudinal direction, and a direction parallel to the base11and vertical to the longitudinal direction is defined as a transverse direction. The base11includes a main plate111and two flanges112extending aslant downward from two opposite sides of the main plate111along the transverse direction, respectively. The two flanges112extend away from each other along the transverse direction. The flanges112also extend along the longitudinal direction and have a length identical to that of the main plate111. The flanges112are integrally formed with the main plate111to form a recess113. A plurality of through holes114is disposed uniformly on bottom sides of the flanges112.

Each of the fins12extends along the longitudinal direction. The fins12located at a middle of the radiator10are lower than other fins12to form a receiving portion121. The fins12include a first group122, a second group123located at two lateral sides of the first group122symmetrically, and a third group124located at two lateral sides of the main plate111symmetrically and covering the flanges112. The receiving portion121is defined on the first group122and between two parts of the second group123.

Also referring toFIG. 4, two fins12of the first group122have “T” shaped top ends and define a plurality of positioning holes125on the top ends. The two fins12of the first group122are spaced by other fins12of the first group122. Two pairs of fins12of the second group123located at two opposite lateral sides of the first group122have branches extending therefrom. The branches extend face to face on each pair of the fins12of the second group123. A sliding channel127is defined in each pair of the fins12of the second group123. The number of the third group124is two, and each extends upward and then outward and downward and connects a free end of a corresponding flange112to form a tube with the corresponding flange112for preventing an operator from being injured when assembling the LED lamp. Two inserting holes126are defined in bottom ends of the two fins of the first group122, respectively. Two additional inserting holes126are defined below the sliding channels127. Another two inserting holes126are defined in ends of the fins12of the third group124and located at top sides of the flanges112. The inserting holes126extend through the corresponding fin12along the longitudinal direction.

The two caps20are aligned with two opposite ends of the radiator10along the longitudinal direction, respectively. The caps20are respectively engaged with two opposite ends of the radiator10. Each cap20includes a positioning plate21and a seal housing22extending upward from one end of the positioning plate21nearby the radiator10. The positioning plate21extends from the free end of the flange112and is parallel to the main plate111. A plurality of through holes211are disposed uniformly on a bottom side of the positioning plate21. A periphery of the seal housing22matches with the flanges112and the main plate111to enclose the recess113of the radiator10. Six lugs221are formed on a top side of the seal housing22corresponding to the inserting holes126. The lugs221are annular for screws inserting and extending through the inserting holes126, whereby the caps20are secured on the radiator10.

Referring toFIG. 3andFIG. 4, the light emitting module30includes a plurality of circuit boards31, a plurality of LEDs32, a plurality of lenses33each embracing an LED32, a fixed board34and a diffuser35.

Specifically, each circuit board31is attached to a bottom face of the main plate111and received in the recess113. Each circuit board31is rectangular, and a longitudinal direction of the circuit board31is vertical to the longitudinal direction of the radiator10. The plurality of LEDs21is evenly disposed at a bottom face of the circuit board31. The lens33correspondingly embraces the LED32to promote illumination effect. The fixed board34is reticular and defines a plurality of fixing holes341corresponding to the lenses33. The lens33extends through the fixing hole341. The diffuser35includes a holder351and a transparent body352latched in the holder351. The transparent body352covers the plurality of lens33. A plurality of through holes353are disposed at the holder351corresponding to the through holes114of the flanges112and the through holes211of the positioning plate21, for screws inserting through and assembling the radiator10, the caps20and the diffuser35together. A seal ring354is disposed between the holder351and the transparent body352for preventing water leakage.

The power device41is disposed on the fins12along the longitudinal direction of the radiator10. The power device41comprises a substrate411and a power source412disposed on the substrate411. The substrate411has two ends extending beyond the power source412along the longitudinal direction of the radiator10and defines a plurality of positioning holes413on the two ends respectively. The positioning holes413are corresponding to the positioning holes125located at the first group122of the fins12for screws inserting through to secure the power device41on the radiator12.

The two stents42are disposed on the fins12and located at two opposite ends of the power device41along the longitudinal direction. A side of each stent42nearby the fins12includes a fixing part421parallel to the main plate111. The fixing part421defines two through holes422corresponding to the sliding channel127of the second group123of the fins12for screws inserting through. The securing position of the stents42can be changed by sliding the screws along the sliding channel127. The LED lamp100is attached to a relative object (not shown) such as a wall by the stents42. The LED lamp100can match with different stents42to form different style lamp, such as street lamp, tunnel lamp.

The circuit boards31of the LED lamp100are disposed side by side along the longitudinal direction. In a certain application, the radiator10is extruded and cut with a longitudinal length according to the number of the circuit boards31, and then the radiator10, the caps20, the light emitting modules30, the power source and the two stents are assembled together to form the LED lamp100.

In the above LED lamp100, the radiator10is pre-extruded to form a certain length, and the radiator10is then cut into pieces with different lengths according to the arrangement of the circuit board31along the longitudinal direction of the radiator10. Thus, designing different moulds/dies to form radiators10with different sizes is not necessary. A further manufacture, design and material costs are omitted and the manufacturing process is simple and convenient for batch production.

Referring toFIG. 5, a method for manufacturing the LED lamp100is provided as follow:

Extruding to form an elongated radiator10;

Providing two caps20and a light emitting module30;

Cutting the radiator10into pieces with different lengths according to the arrangement of the light emitting module30; and

Fixing the caps20and the light emitting module30to one piece of the radiator10.

It is to be understood that the above-described embodiments are intended to illustrate rather than limit the disclosure. Variations may be made to the embodiments without departing from the spirit of the disclosure as claimed. The above-described embodiments illustrate the scope of the disclosure but do not restrict the scope of the disclosure.