Patent Publication Number: US-10317015-B2

Title: Light module with self-aligning electrical and mechanical connection

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit and priority of U.S. Prov. App. Ser. No. 62/207,303 (filed Aug. 19, 2015) by Michael Joye entitled “Light emitting diode lamps and related methods.” 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
     Not applicable. 
     REFERENCE TO AN APPENDIX SUBMITTED ON A COMPACT DISC AND AN INCORPORATED BY REFERENCE OF THE MATERIAL ON THE COMPACT DISC 
     Not applicable. 
     STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR 
     Reserved for a later date, if necessary. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of Invention 
     The present application is in the field of light emitting diode (LED) lamps and related methods. 
     Background of the Invention 
     An LED is a two-lead semiconductor light source. LEDs have become widespread for use in lighting applications because LEDs are favorably smaller in size, lower in power consumption, longer in life, and offer quicker response speeds than alternative incandescent or fluorescent light sources. Although better than alternative light sources, LED lamps can be inefficient, where in some cases, 80% to 85% of input power is converted to heat rather than light. This inefficiency can result in heat buildup and, if the heat is not dissipated effectively, light emitting intensity and service life of the LED light source are reduced significantly. 
     LED lamps or light bulbs are assemblies with an LED light source for use in lighting fixtures and other lighting applications. A traditional (prior art) LED bulb or lamp is an MR-16 high power LED lamp.  FIG. 1A  is a prospective view of a typical MR-16 high powered LED lamp bulb  10 .  FIG. 1B  is a side view of the MR-16 high powered LED lamp bulb  10  of  FIG. 1A .  FIG. 1C  is an exploded view of the MR-16 high powered LED bulb of  FIGS. 1A and 1B . Referring to  FIG. 1A through 1C , and  FIG. 1C  in particular, a traditional MR-16 LED bulb  10  comprises a housing  11 , a base  12 , a driver circuit and pins  13 , LED light source(s)  14 , wiring  15 , printed circuit board (“PCB”) for the LED(s)  16 , a lens and/or optic  17 , and a retainer ring  18 . Typically, the LED light source(s)  14  is(are) secured to the PCB  16  and both (a) mechanically connected to the base  12  and (b) electrically connected to the driver and pins  13  via the wires  15  and screws  19 . In use, the light source(s)  14  emit(s) light whenever the driver and pins  13  are electrically connected to a power source (not shown). The lens and optics  17  may be used to focus light emitted from the light source(s)  14  and the snap retainer ring  18  can secure the lens/optics  17  in place. Such traditional LED bulbs are tedious to assemble because, among other reasons, (a) the wiring  15  must be soldered or otherwise connected to the driver and pins  13  and LED light source(s)  14 ; the PCB  16  must be screwed into the base and housing via a screw driver; and, usually a spanner wrench and other special purpose tools must be had for dismantling and reassembling an LED lamp. 
     Another embodiment of typical LED lamps are generally shown and described by U.S. Pat. App. Pub. 2008/0174247 (published Jul. 24, 2008) by Yu et al. Referring to  FIG. 1  of Yu et al. (reproduced as  FIG. 1D  in this specification), a traditional MR-16 LED bulb  10  comprises a housing  11 , a base  12 , driver and pins  13 , an LED light source  14 , wiring  15 , insulation  16 , a lens/optic  17 , and a cover  18 . Yu et al., ¶[0007]. Typically, the LED light source  14  is secured to the insulation  16  and both (a) mechanically connected to the base  12  and (b) electrically connected to the driver and pins  13  via the wires  15 . Id. In use, the light source  14  emits light whenever the driver and pins  13  are electrically connected to a power source (not shown). Id. The lens/optic  17  may be used to focus light emitted from the light source  14  and the cover  18  can secure the lens/optic  17  in place. Such traditional LED bulbs are tedious to assemble because, among other reasons, the wiring  15  must be soldered or otherwise connected to the driver and pins  13  and LED light source  14 . 
     Traditional LED lamps, like the MR-16 lamp, have also not adequately addressed the heat-dissipation problems associated with LED light sources. For instance, heat cannot be effectively dissipated from the LED light source in a traditional bulb because the LED is positioned on insulation or a PCB. As discussed above, heat build-up can degrade the LED and, if the LED is damaged, it is more cost effective and time-efficient to replace the entire lamp than tediously replace the LED. Likewise, when failure of driver circuitry or driver components occurs, these are equally difficult and impractical to replace. Thus, an improved LED lamp is needed that effectively dissipates heat from the LED light source and/or that allows damaged LED light sources and/or damaged driver circuitry to be easily replaced. All of these problems render such MR-16 bulbs unserviceable. 
     One attempt to meet the aforementioned need is disclosed by Yu et al. Specifically, Yu et al. discloses, with reference to Yu et al.&#39;s FIGS. 2 (reproduced as  FIG. 2  in this document), an LED lamp  20  with an LED light source  27 , a housing  21 , heat-dissipation glue  23 , a circuit board  24 , and a femininely threaded adapter  26 . Id., ¶[0020]. The LED light source  27  is a threaded cylinder wherein the threads  271  are a negative electrode for the LED and the base of the cylinder is a positive electrode for the LED. Id., ¶[0024]. The circuit board  24  features pins  25  and a positive contact point  241 . As disclosed by Yu et al., the circuit board  24  and adapter  26  are glued, via the heat-dissipation glue  23 , into the bottom of the housing  21  so that the circuit board  21  is underneath the adapter  26 . Id. ¶[0021]. When so assembled, the LED light source  27  may be threaded, via its negative electrode  271 , into the adaptor  26  until its positive electrode contacts the positive contact point  241  of the circuit board  24 . Id., ¶[0021]. In this design: (a) heat may be transferred to the ambient environment via the mechanical contacts between the LED light source  27 , adapter  26 , circuit board  24 , glue  23 , and the housing  21 ; and (b) the LED light source  27  may be readily replaced via unscrewing the component  27  from the adapter  26 . 
     Although an improvement to traditional LED lamps, the lamp disclosed by Yu et al. has various limitations. For instance, the threading of a small LED light source into an equally small adapter can be tedious and requires tools. In addition, a glue gun may be required in the assembly of the lamp. Furthermore, machining the threads for the LED light source and adapter of Yu et al.&#39;s lamp requires exact tolerances or else the assembly cannot be constructed. Additionally, when a driver component or components fail, replacement is difficult since the driver  24  is glued into the housing  21  and may also require unsoldering and re-soldering of wires to effect such replacement. Finally, Yu et al.&#39;s LED lamp accomplishes heat transfer to the ambient environment via the conduction of heat through the interface of several components of the lamp, which is less efficient than conductive heat transfer through the interface of two or less components of the lamp. Thus, a need still exists for LED lamps that effectively dissipate heat from an LED light source and that allow damaged LED light sources and drivers to be easily replaced. 
     SUMMARY OF THE INVENTION 
     It is an objective of this disclosure to describe an LED lighting module (including but not limited to lamps, light bulbs, or light fixtures) with (i) rapidly replaceable LED light source units, (ii) rapidly replaceable driver circuitry, and (iii) efficient heat dissipation. An aspect of the rapid replaceability of the disclosed light source is self-registration of the source&#39;s light elements, electronic drive components, and heat sources respectively relative to the optical, power leads or pins, and heat sink components of a lamp or other lighting device. It is yet another object of the present application to meet the aforementioned needs without any of the drawbacks associated with apparatus heretofore known for the same purpose. It is yet still a further objective to meet these needs in an efficient and inexpensive manner. 
     In view of the foregoing, disclosed is an LED lighting module with (i) rapidly replaceable LED light source units (ii) rapidly replaceable driver circuitry, and (iii) efficient heat dissipation. In a most general preferred embodiment, an LED lighting module comprises: an LED light source, driver board, and heat dissipation elements that each respectively self-register relative to optical lenses, power leads or pins, and/or heat sink components of a lamp or other lighting device. Preferably, self-registration may be accomplished via at least one of (a) corresponding geometries between the various components of the LED lighting device, (b) power transmission regions, areas or zones on the LED lighting module that interface with power leads or pin(s) of the lamp or lighting device, or (c) thermal conduction regions, areas or zones that interface with heat dissipation elements of the lamp or lighting device. Suitably, coupling of the LED lighting module and the lamp or lighting device components may be accomplished via screw-fit, snap-fit, twist-lock-fit, press-fit or any other mechanical coupling mechanism or technique. Corresponding geometries could mean that the LED module and relevant components of the lamp or lighting device are round, disc, conical or cylindrical, square, cube, triangular, or any other cooperating geometries. 
     In a preferred embodiment, the module comprises: a base; a heat-sink housing; a light source unit, light source assembly, or a light source board with two circular power rings and a thermal conduction ring; a driver board or other electrical control module with power leads or pins and corresponding positive and negative pogo pins; wherein an electrical power connection between the light source unit/assembly/board and the driver/control module is accomplished via compressing the spring loaded pogo pins against the circular power rings; and, wherein the heat sink housing interfaces with the thermal conduction ring to accomplish a heat transfer connection between the light source unit/assembly/board and heat sink housing. Although pogo pins are preferred, any type of electromechanical contact could be used (except that plug-and-socket-type connections are less preferable). 
     A preferred embodiment of the LED lighting module minimally comprises: an LED light source assembly; power transmission ring(s); at least one thermal conduction ring; at least one electrical contact pogo pin; a base; and a housing. The pogo pins could be any type of electromechanical contact capable of accomplishing similar electromechanical functions (e.g., electrical connectivity via mechanical contact). In said preferred embodiment, the parts of the module may be connected by interfacing male and female threads and sandwich fits, with all of the inner assemblies and parts self-registering. However, other embodiments include connection of parts via snap-fit, twist-lock-fit, or press-fit, wherein the power transmission regions, areas or zones and thermal conduction regions, areas, or zones may be incorporated instead of rings. In other words, all the parts of the module may self-register, fit together, and assemble very easily, wherein the preferred embodiment utilizes round, conical, or cylindrical assemblies and units that screw and sandwich together. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Other objectives of the disclosure will become apparent to those skilled in the art once the invention has been shown and described. The manner in which these objectives and other desirable characteristics can be obtained is explained in the following description and attached figures in which: 
         FIG. 1A  is a perspective view of a prior art MR-16 lamp bulb; 
         FIG. 1B  is a side view of the prior art MR-16 lamp bulb of  FIG. 1A   
         FIG. 1C  is an exploded view of the prior art MR-16 lamb bulb of  FIGS. 1A and 1B ; 
         FIG. 1D  is a reproduction of Yu et al.&#39;s  FIG. 1 ; 
         FIG. 2  is a reproduction of Yu et al.&#39;s  FIG. 2 ; 
         FIG. 3  is a perspective view of an LED lamp  1000 ; 
         FIG. 4  is another perspective view of the LED lamp  1000 ; 
         FIG. 5  is an exploded view of the LED lamp  1000 ; 
         FIG. 6  is another exploded view of the LED lamp  1000 ; 
         FIG. 7  is a top perspective view of a driver  1400 ; 
         FIG. 8  is a top view of the driver  1400 ; 
         FIG. 9  is a bottom perspective of the driver  1400 ; 
         FIG. 10  is a side view of the driver  1400 ; 
         FIG. 10A  is a cross section of a pogo pin  1440 ; 
         FIG. 10B  is a perspective view of a driver  1400  installed in a silicone casing or base  1200 ; 
         FIG. 10C  is a side view of a driver  1400  installed in a silicone casing or base  1200 ; 
         FIG. 11  is a top perspective of a light source unit  1500 ; 
         FIG. 12  is a bottom perspective of a light source unit  1500 ; 
         FIG. 13  is a top view of a light source unit  1500 ; 
         FIG. 14  is a bottom view of the light source unit  1500 ; 
         FIG. 15  is a side view of the light source unit  1500 ; 
         FIG. 16  is an exploded view of an alternate embodiment of an LED lamp  1000  with an alternate embodiment of a driver  1900  and a power transfer disk  2000 ; 
         FIG. 17  is a perspective view of an embodiment of the driver  1900 ; 
         FIG. 18  is a side view of the embodiment of the driver  1900 ; 
         FIG. 19  is a top perspective view of the power transfer disk  2000 ; 
         FIG. 20  is a bottom perspective view of the power transfer disk  2000 ; 
         FIG. 21  is a top view of the power transfer disk  2000 ; and, 
         FIG. 22  is a side view of the power transfer disk  2000 . 
     
    
    
     It is to be noted, however, that the appended figures illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments that will be appreciated by those reasonably skilled in the relevant arts. Also, figures are not necessarily made to scale but are representative. 
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Generally disclosed is an LED lighting module (including but not limited to lamps, light bulbs, or light fixtures) with (i) rapidly replaceable LED light source units and (ii) rapidly replaceable driver circuitry, and (iii) efficient heat transfer. An aspect of the rapid replaceability of the disclosed lighting device is self-registration of the device&#39;s heat sources (e.g., light elements, electronic drive components) relative to the optical, power leads or pins, and finally, heat sink components of the lighting device. Preferably, self-registration may be accomplished via at least one of (a) corresponding geometries between the various components of the LED lighting device, (b) power transmission regions, areas or zones on the LED lighting module that interface with power leads or pins of the lamp or lighting device, or (c) thermal conduction regions, areas or zones that interface with heat dissipation elements of the lamp or lighting device. In a preferred embodiment, the module comprises: a light source unit that is (a) thermally coupled to a heat-sink housing via a thermal conduction ring and (b) electrically coupled to a driver via compression of one or more pogo pins on the driver against one or more power rings on the light source unit. The more specific details of the disclosed module are described with reference to the attached figures. 
       FIGS. 3 and 4  are respectively top and bottom views of a lighting module  1000 .  FIGS. 5 and 6  are corresponding exploded views of the lighting module  1000  shown in  FIGS. 3 and 4 . As shown in those figures, the module  1000  comprises: a base  1200 ; insulator  1300 ; a driver board  1400 ; a light source unit  1500 ; a heat sink housing  1600 ; an optional optic  1700  (e.g., lens, refractor, waveguide, or reflector); and a retainer ring or apparatus  1800 . 
     Referring only to  FIGS. 5 and 6 , the base  1200  is defined by a cup-like portion  1210  and a plug retainer  1220  that extends from the basin of the cup like portion  1210 . As shown, the plug retainer  1220  is hollow and features an orifice  1221 . As discussed later, the orifice  1221  may suitably enable exposure of the pins  1410  of the driver  1400 . 
     Still referring to the exploded views of  FIGS. 5 and 6 , the insulator  1300  conforms or otherwise complies with the inner contours of the hollow of the plug retainer  1220  of the base  1200 . In a preferred embodiment, the insulator  1300  preferably features heat-dissipation or heat-conduction properties. In operation, the insulator  1300  is suitably configured for retaining the driver  1400  within the base  1200  so that the driver&#39;s  1400  pins  1410  are exposed at the orifice  1221  of the base  1200  (see, e.g.,  FIGS. 3 and 4 ). In one embodiment, the “insulator”  1300  may be a silicone or rubber grommet or other seal that isolates the pins  1410  from the lamp base  1200  and registers the driver  1400  within the base  1200 . 
     Yet still referring to  FIGS. 5 and 6 , the driver  1400  is shown in between the insulator  1300  and the light source unit  1500 .  FIGS. 7, 8, 9, and 10  respectively illustrate a top perspective view of the driver  1400 , a top view of the driver  1400 , a bottom perspective of the driver  1400 , and a side view of the driver  1400 . Referring to  FIGS. 7 through 10 , the driver  1400  is preferably a disk-shaped board  1420  with two electrical pins  1410  disposed on the underside of the disk  1420 . In use, the pins  1410  are ultimately for electrically contacting a power source (not shown) for providing power to the driver  1400 . Suitably, the disk  1420  further features electronics  1430  or circuitry for voltage transformation of power from the power source, wherein said electronics are in electrical communication with said pins  1410 . Finally, the disk  1420  features pogo pin electrical contact points  1440  that are in electrical contact with the electronics  1430 . The pogo pins  1440  may be located on the outer circumference of the disk  1410  and may preferably be arranged side-by-side radially in a row.  FIG. 10A  illustrates a cross section of a pogo pin  1440 . As shown, an electrical conducting pin  1441  floats atop a conductive spring  1442  within a shaft  1443  so that the pin may be compressed (e.g., like a piston) in response to a contact while, at the same time, conduct electricity. Referring back to  FIGS. 5 and 6 , the driver  1400  is attached within the basin of the cup-like portion  1210  of the base  1200  via the insulator  1300 .  FIG. 10B  is a perspective view of the driver  1400  installed in a silicone casing  1450 .  FIG. 10C  is the side view of a driver  1400  installed in a silicone casing  1450 . As shown, the spring loaded pogo pins  1440  or other electromechanical contact of the driver  1400  is positioned in the silicone casing  1450  so that the pogo pins  1440  extend out of the silicone casing  1450  while the pins  1410  extend out of the bottom of the silicone casing  1450 , and when installed, out of the base  1200  through orifice  1221 . As discussed later below, the pogo pin electrical contact points  1440  may be compressed against the light source unit  1500  so that electricity may flow to the light source unit  1500  from the power source (not shown) via the driver  1400 . 
     Referring again to  FIGS. 5 and 6 , the light source unit  1500  is shown between the optic  1700  and the driver  1400 .  FIGS. 11 through 15  respectively illustrate a top perspective view of the unit  1500 , a bottom perspective view of the unit  1500 , a top view of the unit  1500 , a bottom view of the unit  1500 , and a side view of the unit  1500 . As shown in those figures, the unit is a disk  1510  with (a) an LED  1520  and a thermal conduction ring  1530  on its upper surface; and (b) circular power rings  1540  on its underside surface. Optionally, the disk  1510  can also have a second thermal conduction ring on its lower surface to provide an additional thermal pathway between the disk  1510  and the top edge of the base  1200 . In a preferred embodiment, the LED  1520  is secured to the disk. Referring back to  FIGS. 5 and 6 , the light source unit  1500  is installed within the module  1000  by being sandwiched between the base  1200  and an edge  1610  of the heat-sink housing  1600  so that: the circular power rings  1540  on the underside of the disk  1510  are compressively contacting the pogo pins  1440  of the driver  1400 ; and the thermal conduction ring  1530  interfaces with the edge  1610  of the heat-sink housing  1600 . As discussed further below, the shape of the circular power rings  1540 , the compressibility of the pogo pins  1440 , and the central position of the LED  1520  allow quick assembly of the module  1000  because the light source unit  1500  may be drop-loaded into the base  1200  over the driver  1400  in any orientation and with minimal regard for misalignment tolerances during assembly while nevertheless accomplishing an electrical contact between the driver  1400  and light source unit  1500 . The thermal conduction ring  1530  and edge  1610  of the heat-sink housing  1600  too can be easily interfaced by coaxially positioning heat sink housing  1600  over the light source unit  1500  and base  1200 . It should be noted that “centrally” locating the LED  1520  does not exclusively mean the “coaxial” positioning of the LED  1520  on the disk  1510 . Instead, “centrally” means anything on top face of the disk  1510  since more than one LED light could be positioned on the disk  1510 . 
     Referring to  FIGS. 11 through 15 , the disk  1510  is suitably made of solid copper or other metal and incorporates printed circuitry and insulated thru-vias so that electricity may be passed through the disk  1510  from the circular power rings  1540  on the underside of the disk  1510  to the LED  1520  on the upperside of the disk  1510 . The solid metal disk  1510  also enables heat transfer between the LED light source  1520  and the thermal conduction ring  1530 . In a preferred embodiment, the solid copper disk  1510  is coated with an epoxy, except there is no epoxy over (1) the circular power rings  1540 , and (2) the thermal conduction ring  1530 , so that the disk can be insulated (both thermally and electrically) to guide heat transfer and electrical conduction. 
     It should be noted that the circuit/heatsink disk  1510  serves multiple, but primary two, functions: a) as a circuit board or electrical signal distributor, and b) as a thermally conductive path for heat from the LED  1520  to the lamp body  1600 . Such a disk  1510  is sometimes known as a “metallic core printed circuit board” (MCPCB). It does not have to be a round disk, but rather is round in the preferred embodiment. In other embodiments, for example, the disk  1510 , power rings  1540 , and thermal conduction ring  1530 , may be triangular, square, pentagonal, hexagonal, heptagonal, octagonal, pentagonal, decagonal, or any other symmetrical or “keyed” geometry that may be drop loaded over the driver  1400  so that the power rings  1540  or other power transfer zone(s) or region(s) self-register to contact the pogo pins  1440  of the driver  1400  and so the thermal conduction ring  1530  or other thermal transfer zones(s) or region(s) may be positioned for self-registry with the housing as discussed below. It should also be noted that the disk  1510  will distribute some heat from the LED  1520  to the lamp body  1600  almost irrespective of the material of which it is comprised, as discussed below. So, the disk  1510  need not be made of copper and instead could be made of FR4 (i.e., glass reinforced epoxy laminate sheets), FR4 with an attached heat dissipation element, a metal-clad FR4 disk or with layers of metal, a ceramic disk, any metal disk, or copper. The preferred embodiment is made of copper. 
     Referring once again to  FIGS. 5 and 6 , the heat sink housing  1600  is preferably a truncated cup shape and made of a heat conductive material (e.g., copper or other metal). Suitably, the heat sink housing  1600  features a circumferential edge  1610  on its inside. In use, the housing base  1200  and heat sink housing  1600  are configured to screw or thread together, or otherwise fit together (e.g., snap-fit, threaded-lock-fit, press-fit) so that the light source unit  1500  is sandwiched between the base  1200  and an edge  1610  of the heat-sink housing  1600  whereby: the circular power rings  1540  on the underside of the disk  1510  are compressively contacting the pogo pins  1440  of the driver  1400 ; and the thermal conduction ring  1530  interfaces with the edge  1610  of the heat-sink housing  1600 . 
     Yet still referring to  FIGS. 5 and 6 , an optic  1700  may be provided into the heat sink housing. Preferably, the optic  1700  is positioned over the LED  1520  of the light source unit  1500  and held in place by a retainer ring  1800  that threadedly interfaces with the heat sink housing  1600 . The optic  1700  or retainer ring  1800  are optional features of the lighting device. 
       FIG. 16  is an exploded view of an alternate embodiment of an LED lamp  1000  with an alternate embodiment of a driver  1900  and a power transfer disk  2000 . As shown, the lamp  1000  is the same as the previously disclosed embodiment except the driver  1400  of the old embodiment is replaced by a new embodiment of a driver  1900  and a power transfer disk  2000 . More specifically, the pins  1410  of the earlier embodiment are replaced with pogo pins  1910  or other electromechanical or spring-loaded electrical contact and a power transfer disk  2000  with electrical contacts  2010  on one side for receiving wires from a power source and power transfer regions  2030 / 2040 . In a preferred embodiment, the pogo pins  1910  are configured for pressed contact with said power transfer regions  2030 / 2040 , which are in electric contact with said contacts  2010  for receiving wires from a power source. In this manner the lamp  1000  of  FIG. 16  may suitably be assembled. 
       FIGS. 17 and 18  respectively illustrate a top perspective view of the driver  1900  and a side view of the driver  1900 . Referring to  FIGS. 17 and 18 , the driver  1900  is preferably a disk-shaped board  1920  with electrical pogo pins  1910  disposed on the underside of the disk  1920 . In use, the pins  1910  are ultimately for electrically contacting a power source (not shown) for providing power to the driver  1900 . Suitably, the pins  1910  interact with a power transfer disk  2000  that is coupled to a power source. See  FIG. 16 . Suitably, the disk  1920  further features electronics  1930  or circuitry for voltage transformation of power from the power source, wherein said electronics are in electrical communication with said pogo pins  1910 . Finally, the disk features pogo pin electrical contact points  1940  that are in electrical contact with the electronics  1930 . The pogo pins  1940  or  1910  may be located on the outer circumference of the disk  1910  and may preferably be arranged side-by-side radially in a row. 
       FIGS. 19 through 22  respectively illustrate a top perspective view of the power transfer disk  2000 , a bottom perspective view of the power transfer disk, a top view of the power transfer disk  2000 , and a side view of the power transfer disk. As shown in those figures, the unit is a disk  2020  with on its topside (a) a first power transfer region  2030 ; and (b) a second power transfer region  2040 , in this case a circular region. Referring back to  FIG. 16 , the power transfer disk is installed within the module  1000  by being sandwiched between the base  1200  and the driver  1900  so that the first power transfer ring  2030  on the topside of the disk  2020  is compressively contacting one of the pogo pins  1910  of the driver  1900 ; and the second power transfer region  2040  on the topside of the disk  2020  is compressively contacting the other one of the pogo pins  1910  of the driver  1900 . As discussed further below, the shape of the circular power regions  2030 / 2040  and the compressibility of the pogo pings  1910  allow quick assembly of the module  1000  because driver  2000  may be drop-loaded into the base  1200  and under the driver  1900  in any orientation and with minimal regard for misalignment tolerances during assembly while nevertheless accomplishing an electrical contact between the driver  1900  and power transmission disk  2000 . 
     A preferred embodiment of the LED lighting module minimally comprises: an LED light source; power transmission ring(s); at least one thermal conduction ring; at least one electrical contact pogo pin; a base; and a housing. The pogo pins could be almost any type of electromechanical contact, including spring loaded electromechanical contacts. In said preferred embodiment, the parts of the module may be connected by interfacing male and female threads and sandwich fits, with all of the inner assemblies and parts self-registering. However, other embodiments include connection of parts via snap-fit, twist-lock-fit, or press-it wherein the power transmission regions, areas or zones and thermal conduction regions, areas, or zones may be incorporated instead of rings. In other words, all the parts of the module may self-register, fit together, and assemble very easily, wherein the preferred embodiment utilizes round, conical, or cylindrical assemblies and units that screw and sandwich together. 
     Although the method and apparatus is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead might be applied, alone or in various combinations, to one or more of the other embodiments of the disclosed method and apparatus, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus the breadth and scope of the claimed invention should not be limited by any of the above-described embodiments. 
     Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open-ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like, the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof, the terms “a” or “an” should be read as meaning “at least one,” “one or more,” or the like, and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that might be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future. 
     The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases might be absent. The use of the term “assembly” does not imply that the components or functionality described or claimed as part of the module are all configured in a common package. Indeed, any or all of the various components of a module, whether control logic or other components, might be combined in a single package or separately maintained and might further be distributed across multiple locations. 
     Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives might be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration. 
     All original claims submitted with this specification are incorporated by reference in their entirety as if fully set forth herein.