Patent Publication Number: US-2011063837-A1

Title: Led array module and led array module frame

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This Application claims the benefit of U.S. Provisional Patent Application No. 61/242,880, entitled “LED Array Module and LED Array Module Frame,” filed on Sep. 16, 2009, which is expressly incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     1. Field 
     The present disclosure relates to a light emitting diode (LED) array module and, more particularly, to aspects of the LED array module and to a frame of the LED array module. 
     2. Description of Related Art 
     LEDs have been developed for many years and have been widely used in various light applications. As LEDs are light-weight, consume less energy, and have a good electrical power to light conversion efficacy, they have been used to replace conventional light sources, such as incandescent lamps and fluorescent light sources. LEDs may be utilized in an array module. 
     SUMMARY 
     In one aspect of the disclosure, an LED module frame includes a supporting member, legs, and arms. The supporting member is configured to support a reflector. The legs are coupled to the supporting member. The arms are coupled to the supporting member and extend inwardly towards an inner edge of the supporting member. Each of the arms has an attachment mechanism for attaching to an LED array. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1C  are views of an exemplary LED array module. 
         FIGS. 2A-2D  are views of an exemplary frame of the LED array module. 
         FIGS. 3A-3C  are views of additional exemplary frames. 
         FIG. 4  is a view of an exemplary LED module. 
         FIG. 5  is a view of another exemplary frame. 
         FIGS. 6A-6D  are top views of heat sinks to which the exemplary LED modules may attach. 
         FIG. 7  is a view of an exemplary array of LED modules. 
     
    
    
     DETAILED DESCRIPTION 
     Various aspects of the present invention will be described herein with reference to drawings that are schematic illustrations of idealized configurations of the present invention. As such, variations from the shapes of the illustrations as a result, for example, manufacturing techniques and/or tolerances, are to be expected. Thus, the various aspects of the present invention presented throughout this disclosure should not be construed as limited to the particular shapes of elements (e.g., regions, layers, sections, substrates, etc.) illustrated and described herein but are to include deviations in shapes that result, for example, from manufacturing. By way of example, an element illustrated or described as a rectangle may have rounded or curved features and/or a gradient concentration at its edges rather than a discrete change from one element to another. Thus, the elements illustrated in the drawings are schematic in nature and their shapes are not intended to illustrate the precise shape of an element and are not intended to limit the scope of the present invention. 
     It will be understood that when an element such as a region, layer, section, substrate, or the like, is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. It will be further understood that when an element is referred to as being “formed” on another element, it can be grown, deposited, etched, attached, connected, coupled, or otherwise prepared or fabricated on the other element or an intervening element. In addition, when a first element is “coupled” to a second element, the first element may be directly connected to the second element or the first element may be indirectly connected to the second element with intervening elements between the first and second elements. 
     Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element&#39;s relationship to another element as illustrated in the drawings. It will be understood that relative terms are intended to encompass different orientations of an apparatus in addition to the orientation depicted in the drawings. By way of example, if an apparatus in the drawings is turned over, elements described as being on the “lower” side of other elements would then be oriented on the “upper” side of the other elements. The term “lower” can therefore encompass both an orientation of “lower” and “upper,” depending of the particular orientation of the apparatus. Similarly, if an apparatus in the drawing is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The terms “below” or “beneath” can therefore encompass both an orientation of above and below. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and this disclosure. 
     As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Various aspects of an LED array module may be illustrated with reference to one or more exemplary configurations. As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other configurations of an LED array module disclosed herein. Additionally, LEDs are but one form of solid state light emitters. Thus, the exemplary configurations, described with reference to LEDs, are representative of any solid state light emitter which may be used in embodiments of the disclosure. 
     Furthermore, various descriptive terms used herein, such as “on” and “transparent,” should be given the broadest meaning possible within the context of the present disclosure. For example, when a layer is said to be “on” another layer, it should be understood that that one layer may be deposited, etched, attached, or otherwise prepared or fabricated directly or indirectly above or below that other layer. In addition, something that is described as being “transparent” should be understood as having a property allowing no significant obstruction or absorption of electromagnetic radiation in the particular wavelength (or wavelengths) of interest, unless a particular transmittance is provided. 
       FIG. 1A  and  FIG. 1B  are perspective views of an exemplary LED array module  300 .  FIG. 1C  is a perspective exploded view of the LED array module  300 . As shown in  FIG. 1C , the LED array module  300  includes a printed circuit board  302 , a frame  304  attachable to the printed circuit board  302 , an LED array  306  attachable to the frame  304 , a removable thermal grease sheet  308  that is attached to a bottom surface of the LED array  306  and is removed prior to attaching the module  300  to a heat sink, a reflector  310  for transforming light from the LED array  306 , a cover  312  for covering the LED array  306  and the reflector  310 , and a secondary optic  314  for further transforming the light emitted from the LED array  306 . 
     Bolts  316  insert through the cover  312 , through the frame  304 , and through cutouts on the printed circuit board  302  for allowing the module  300  to attach to a heat sink. A Teflon nut  318  inserted into leg of frame  304  threads onto screw  316  holding cover  312 , reflector  310 , and frame  304  together as a subassembly. An electrical connector  320  may be coupled to the LED array  306 . The LED array  306 , reflector  310  and printed circuit board  302  are sealed within the cover  312  with the silicone o-ring  322  and a rubber grommet  324  that is insertable into a hole in the side of the cover  312 . 
       FIGS. 2A-2D  are views of the frame  304 . The frame  304  is circular and has holes  404  for attaching to the printed circuit board  302 . The frame  304  further includes legs  412  with holes  406  for allowing the cover  312  to attach to the frame  304  and for allowing both the cover  312  and the frame  304  to attach to a heat sink with the bolts  316 . The frame includes arms  408  that extend inwardly from the circular edge of the frame  304 . The arms  408  have compression feet  410  for attaching to respective holes in the LED array  306 . The length of the legs  412  and the height of the arms  408  are configured such that the attached LED array  306  extends slightly below the legs  412 . Such a configuration allows the attached LED array  306  to make full contact with a heat sink without being limited in movement by the legs  412 . 
       FIGS. 3A-3C  are views of an exemplary frame  500 . The frame  500  includes pins  414  that extend from the legs  412 . The pins  414  extend from the bottom of the legs  412  and are configured to be inserted into slots within a heat sink so that the LED array module  300  may be locked to the heat sink without the use of the bolts  316 . In such a configuration, the bolts  316  may be replaced with screws and screw holes may be provided within the frame  500  for connecting the cover  312  to the frame  500 . As shown in  FIG. 3C , in another configuration, the pins  414  may have a pressable head  415  that is biased upward by a compression spring  416 . In such a configuration, a user may press the heads  415  of the pins  414  while inserting and securing the pins  414  within respective slots of the heat sink. Once the pins are secured within the heat sink, the user may depress the heads  415  of the pins  414 . The compression springs  416  exert an upward force on the pins  414 , thus allowing the pins  414  to be locked within the slots of the heat sink. In such a configuration, the slots of the heat sink are configured such that once the pins  414  are rotated, the pins  414  are allowed to move upwardly within the slots. 
     Alternatively, tension springs may be used within the holes  406  of the legs  412  in order to apply an upward force on the pins  414 . The pins  414  may be configured to be stationary with respect to the frame  500 . In such a configuration, the user must press the heads  415  while rotating the frame  500  into a secured position with respect to the heat sink. Alternatively, the pins  414  may be configured to rotate with respect to the frame  500 . In such a configuration, the heads  415  may include grooves to allow a screwdriver to press and to rotate the pins  414  into a secured position within the heat sink. 
     Because the frame  500  is fully enclosed within the cover  312 , the pins  414  may be of such a length that the heads  415  of the pins  414  are exposed above the cover  312 . In order to maintain the seal that the cover  312  provides, the cover  312  may include a flexible, but water resistant membrane, below which rest the heads  415  of the pins  414 . In such a configuration, a user may press the membrane in order to press the heads  415  of the pins  414  in order to exert a force opposite to the force exerted by the springs. 
       FIG. 4  is a view of an exemplary LED array module  600 . The LED array module  600  includes pins  614  extending from a bottom surface. The pins  614  may be inserted into respective slots of a heat sink and may be secured to the heat sink by rotating the LED array module  600 . As shown in  FIG. 4 , the pins  614  may extend from the cover  312 . 
       FIG. 5  is a view of another exemplary frame  700 . The pins  414  may be further configured to provide an electrical power connection. In one configuration, the pins  414  each have a hole through which an insulated conductor  460  extends. In one configuration, the conductors  460  are rods. Each insulated conductor  460  is coupled to a respective conductor  470  (which may also be a rod), which extends inwardly from the frame  700  close to or in contact with a respective pad of an attached LED array  306 . In such a configuration, the arms  408  may be offset from the legs  412  by approximately 90 degrees. The conductors  460 ,  470  may be copper or another conductor. The conductors  470  may be configured to touch or to be sufficiently close to corresponding pads of an attached LED array  306 . Once the LED array  306  is attached, solder may be used to join the metal surfaces of the pads and the conductors  470 . In such a configuration, wires would not need to be bonded to the pads of the LED array  306 . In an alternative configuration, wires may be used instead of the conductors  470 . In such a configuration, the wires would be coupled to the conductors  460 . 
     As shown in  FIG. 5 , the frame  700  is configured to provide two functions: (1) a securing connection for securing the frame  700  to a heat sink or a lamp holder of any kind and (2) an automatic electrical connection once the frame  700  is secured to the heat sink. For example, this lamp holder may be similar to a twist-and-lock configuration, or bi-pin (BA). In such a configuration, replacement of an LED module  600  to a heat sink would be facilitated, as a user would not have to tighten any bolts or individually connect any power leads of the LED module. In order to prevent heat from the heat sink from affecting the conductivity of the conductors  460 , the heat sink may have an insulated member to which the pins  414  attach. 
     The frame  700  would eliminate the need for the grommet  324  (which includes holes for the electrical wiring), thus improving the seal of the cover  312  in a harsh environment. While frame  700  shows the conductors  460  extending through the legs  412  within the pins  414 , the conductors  460  may extend from another part of the frame  700  and be separate from the pins  414 . In such a configuration, the insulated member of the heat sink would include slots for both the pins  414  and the conductors  460 . The printed circuit board  302  includes holes through which both the pins  414  and the conductors  460  may extend. 
       FIGS. 6A-6D  are top views of heat sinks or lamp holders to which the LED array module  600  with the exemplary frame  700  may attach. As shown in  FIG. 6A , a heat sink  802  is configured to accept an LED array module  700  with rotatable pins  414  with an inner conductor  460  (see  FIG. 5 ). The pins  414  are inserted into slots  810  and are rotated into a locked position within corresponding inner slot  812 . The conductors  460  contact power leads  814  within the inner slots  812 . As shown in  FIG. 6B , a heat sink or lamp holder  804  is configured to accept an LED array module with rotatable pins  414  and separate conductor rods  460 . The pins  414  are inserted into the slots  810  and are rotated into a locked position within the inner slot  812 . The separate conductor rods contact the power leads  814 . As shown in  FIG. 6C , a heat sink or lamp holder  806  is configured to accept an LED array module  700  with fixed pins  414  and separate conductor rods. The pins  414  are inserted into the slots  810  and the LED array module  700  is rotated in order to position the pins  414  into a locked position within the inner slots  812 . The separate conductor rods are inserted into holes  816  and contact the power leads  814  after the LED array module  700  is fully rotated. As shown in  FIG. 6D , a heat sink or lamp holder  808  is configured to accept an LED array module  700  with fixed pins  414  with an inner conductor  460 . The pins  414  are inserted into the slots  810  and the LED module is rotated in order to position the pins  414  into a locked position within the inner slots  812 . The conductors  460  contact the power leads  814  after the LED module is fully rotated. 
     As discussed supra, the heat sink may have an insulated member to which the LED module pins  414  attach. As such, the sections of the heat sinks  802 - 808  shown with pin slots and power leads may be the insulated member. 
       FIG. 7  is a view of an array of LED array modules  900 . While the cover  312  is shown infra as circular, the cover  312  may alternatively be rectangular, hexagonal, or another suitable shape and may be configured to attach to one another, such as in a honeycomb fashion, to form the array of LED modules  900 . The connection between each of the covers  312  may be a sliding connector, a physical connector such as a screw, or a snapping mechanism similar to standard electrical connectors, but on a larger scale. 
     The various aspects of this disclosure are provided to enable one of ordinary skill in the art to practice the present invention. Modifications to various aspects of an LED array module presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be extended to other applications. Thus, the claims are not intended to be limited to the various aspects of an LED array module presented throughout this disclosure, but are to be accorded the full scope consistent with the language of the claims. All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. §112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”