Patent Publication Number: US-8534878-B2

Title: LED lamp assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation Application and claims priority to and the benefit of the filing date of U.S. application Ser. No. 12/545,160, filed Aug. 21, 2009, now U.S. Pat. No. 7,972,040 which relies on the disclosure and claims the benefit of the filing date of U.S. Provisional Application No. 61/091,072 filed Aug. 22, 2008, the disclosures of which are hereby incorporated by reference herein in their entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to lighting assemblies and more particularly to light bulbs comprising a support for one or more light emitting diode (LED) lenses, which can be used to position and support the lenses within a lamp housing and which facilitate assembly of the light bulbs during manufacturing. 
     2. Description of the Related Art 
     Spot light type bulbs are well known and are available in many formats, including bulbs with halogen or LED light sources. Typical formats include MR and PAR series in various sizes. Very generally, the number of the series (for example, MR 16) corresponds with the number of eighth-inch increments in the diameter of the lamp at its widest point. For example, the housing of an MR 16 lamp is typically about 16 eighths of an inch in diameter, or 2 inches. The present invention is applicable to any lamp type, including any MR or PAR series lamp of any size. 
     These lamps usually comprise a housing, a light source or multiple light sources operably connected to an electrically conductive pathway which is operably connected to a power source to provide electricity to the light source(s), one or more lenses and/or reflectors to guide and/or modify the light as desired, and a cover plate (housing cap) to secure within and protect the internal components of the housing, such as the light sources and electrical components. In the case of LED light sources, printed circuit boards (PCBs) are typically employed as an electrically non-conductive substrate to house part of the electrically conductive pathway for the lighting system. 
     Where one or more lenses or reflectors is used to control the direction and/or appearance of the light from the light source(s) and where the lenses or reflectors are not integral with or secured to or within the housing, it can be difficult to assemble such lamps during the manufacturing process. In particular, it has been found to be difficult, labor intensive, and time consuming to install the internal components within the lamp housing, especially in the situation where there are numerous individual components. For example, in a light bulb having ten LEDs and ten corresponding individual lenses, one for each LED, it becomes an impossible if not laborious and time-consuming task to position and secure each lens in the appropriate place within the bulb housing. The present invention makes it easier to manufacture such lamp assemblies by providing a lens support to cradle the individual lenses. Manufacturing of such lamps using these improved lamp assemblies can thus speed up the manufacturing process, simplify the process, and/or allow for concurrent installation of the lenses within the lamp housing. 
     More particularly, spot light type lamps that are assembled by hand are usually held in one hand by the housing while the components of the lamp are installed into the housing with the other hand. Specifically, while the housing is held in one hand a PCB board with LEDs installed on it can be operably connected to the electrical components within the lamp housing and positioned/secured in place. Next the lenses and/or reflectors can be appropriately positioned with respect to the LEDs. When multiple lenses are installed, each individual lens is typically inserted with one hand and then balanced in place with the installer&#39;s free fingers on the other hand being used to hold the housing. This process becomes increasing complex as the number of lenses increases and as the installer runs out of available fingers to support the lenses. Even if the lenses are capable of supporting themselves or combined with individual supports, such as cups, within the housing, the inventors have found that manufacturing time is increased by virtue of having more components than are needed. 
     Once the lenses are in the desired position with respect to the LEDs, a cover to the lamp housing is installed to secure the lenses in place and protect them and other internal components from environmental elements. Often the installers will encounter difficulty in keeping the lenses in the appropriate position while installing the cover plate. For example, if even one lens of a 10-lamp bulb slips out of position during this process the entire process must be halted so that the lens can be repositioned before the cover plate is installed. Often times, especially with numerous individual lenses being installed, the assembly process must be stopped and re-started multiple times. Additionally, lenses of existing lamp assemblies can shift within the lamp housing over time and cause a decrease in luminous efficiency due to the lenses tilting out of alignment with the light sources because of insufficient support within the lamp housing. Even further, there are no known devices with lens supports that encompass the side surface of the lenses in their entirety, which further guides the light as desired and increases the luminous efficiency of the device. Further, although in the past it has been preferable to have components that can be used with any spot light type bulb system, the inventors have found that this modular benefit is provided at the expense of increased manufacturing time and an overall more complex manufacturing system. Thus, a light assembly that simplifies the manufacturing process is greatly needed. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present invention provide lighting assemblies that address some of the deficiencies described above and improve the manufacturing process for spot-light type light bulbs. The present invention provides embodiments of light assemblies that improve existing manufacturing processes by providing lens support(s) and complementary shaped individual lenses. As is explained in more detail below, the lens support(s) can be of unitary or single-piece construction or a combination of individual, releasably connectable supports, so as to provide an integral, unitary lens support with multiple supports joined. 
     Advantages of embodiments of the invention can include the capability of installing multiple lenses simultaneously, by placing the lenses in the unitary support then installing the support in the housing, or the capability of maintaining the position of installed lenses while installing additional lenses within the housing, by installing the unitary support in the housing then installing the individual lenses in the support. Individual supports, one for each lens, can also be used. 
     One object of embodiments of the present invention is to provide light assemblies comprising: (a) a housing optionally comprising heat sink capabilities; (b) an electrically non-conductive substrate with an electrically conductive pathway; (c) one or more light emitting diodes (LEDs) operably connected to the pathway; (d) a lens for each LED; (e) a lens support having a through hole for each LED and a recess for each lens, wherein each recess is capable of supporting each lens; and (f) a cover plate for securing the lenses and lens support within the housing. 
     Another object of embodiments of the invention is to provide a light assembly as described above wherein each lens is an individual lens. 
     Still further, embodiments include light assemblies, wherein the lens support comprises multiple individual lens supports joined together to form an integral lens support having multiple recesses. The multiple individual lens supports, or cups, can be joined together with releasable connections, such as quick connect and disconnect features. Even further, the lens support can be of single-piece construction. 
     Embodiments include such light assemblies, wherein each recess of the lens support has an interior surface shape and each lens has an exterior surface shape and wherein the shapes are complementary. Further, the interior surface shape of each recess can match the exterior surface shape of each lens. 
     Light assemblies of embodiments according to the invention can also comprise recesses in the lens support that are capable of slideable and/or releasable engagement with a corresponding lens. For example, matching shapes can include embodiments where the interior surface of the recess and the exterior surface of the lens each have a conical shape. Such a conical shape would allow for the lens to be inserted and removed from the lens support readily easily. Any other equivalent shape, which allows for releasable engagement between the lens and lens support, is also within the scope of the invention. 
     Preferred is a light assembly comprising: (a) a housing optionally comprising heat sink capabilities; (b) an electrically non-conductive substrate with an electrically conductive pathway; (c) one or more light emitting diodes (LEDs) operably connected to the pathway; (d) a lens for each LED having a lower exterior surface; (e) a lens support having an upper exterior surface, a recess for each lens, and a through hole for each LED, wherein when assembled the lower exterior surface of each lens contacts the upper exterior surface and a recess of the lens support; and (f) a cover plate for securing the lenses and lens support within the housing. Further preferred is such a light assembly wherein the lower exterior surface of each lens is complementary in shape to the upper exterior surface and recess of the lens support. Even further preferred is such a light assembly, wherein an outline of the exterior surface shape of each lens matches an outline of the upper exterior surface and a recess of the lens support. Especially preferred are embodiments wherein when assembled the lens(es) are seated within the lens support (reflector) totally (meaning the side surface of the lens fits completely within the recess of the lens support) to provide for better positioning of the lenses with respect to the light sources. 
     Light assembly embodiments of the invention lamps having heat sink capabilities are also included. Common heat-sink type materials include ceramics, metals, such as aluminum, and metal alloys or composites, such as those comprising aluminum and copper, but plastic can also be used. In particular, embodiments of the invention include lamp housings comprising thermally conductive plastics as a plastic type heat sink. Even further, embodiments can incorporate heat pipe technology as part or all of the heat sink features, such as that provided by Celsia Technologies and described in U.S. Patent Application Publication No. 2007/0295494. 
     Lamps according to embodiments of the invention can comprise any number of light sources. Of particular interest are lamps comprising up to 10 LEDs, more particularly for example from 3 to 10 LEDs. Such lamps can also comprise a lens support member having an equal number of recesses to support an equal number of corresponding lenses. Even further, for example, embodiments can include light assemblies comprising from 5 to 10 LEDs, a lens support with an equal number of recesses, and an equal number of lenses. 
     Methods of manufacturing a lighting assembly are also included as embodiments of the invention. Such methods can comprise: (a) installing one or more individual lenses in a light assembly housing by placing each lens in a recess of a lens support, wherein each recess has an interior surface shape complementary to an exterior surface shape of the lens; and (b) installing a cover plate to secure the lenses and lens support within the housing. 
     In embodiments of the manufacturing methods of the invention, lens supports and lenses can be used in which the interior surface shape of each lens support recess matches the exterior surface shape of each lens. 
     Still further, the lens support can comprise multiple individual lens supports joined together to form an integral lens support having multiple recesses, optionally where the individual lens supports are joined together with releasable connections, or the lens support can be of single-piece construction. 
     Additionally, the lamp assemblies according to the invention and the manufacturing processes for providing such lamps can comprise lens supports, wherein each recess and corresponding lens are capable of slideable and releasable engagement. 
     Heat sinks are also included as embodiments of the invention. For example, a heat sink for a lamp assembly comprising thermally conductive plastic(s) material and configured as in any of  FIGS. 13-18  is an embodiment of the invention. Preferred is a heat sink for a lamp assembly comprising polyamide or polyphenylene sulfide disposed in any combination of ridges, troughs, and vents to provide for a housing having a heat sink surface area that is twice or greater than and up to ten times that of a lamp assembly of the same size without ridges, troughs, or vents. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  shows an exemplary embodiment of a PAR-16 type light assembly according to the invention with the components assembled. 
         FIG. 1B  shows an exemplary embodiment of a PAR-16 type light assembly according to the invention with the components unassembled. 
         FIGS. 2A-2E  show various views of an exemplary lens support according to embodiments of the invention having three recesses for supporting three lenses. 
         FIGS. 3A-B  show bottom plan and side elevation views of an exemplary lens support according to embodiments of the invention having seven recesses for supporting seven lenses. 
         FIGS. 4A-B  show top plan and side elevation views of an exemplary lens support according to embodiments of the invention having ten recesses for supporting ten lenses. 
         FIGS. 5A-D  show respectively a top plan, a bottom plan, a side elevation, and a side elevation cross-section view of an exemplary lens embodiment according to the invention, which is compatible with lens supports shown in  FIGS. 2-4 . 
         FIGS. 6A-D  show unassembled and assembled an exemplary embodiment of a lens support, compatible lenses, and a housing cover for a PAR-16, MR-16, or PAR-20 type bulb having three LEDs. 
         FIGS. 7A-D  show schematic examples of PCBs for PAR-16, MR-16, PAR-20, PAR-30, and PAR-38 bulbs according to embodiments of the invention. 
         FIG. 8  provides a schematic representation of light measurements taken to compile the brightness measurement data of Table 3 for various types of bulbs according to the invention. 
         FIG. 9A  provides a graph of the viewing angles for an exemplary MR-16 type light bulb according to the invention with and without optical enhancement of the LED with a lens. 
         FIG. 9B  provides a graph of the viewing angles for PAR-16, 20, 30, and 38 type light bulbs according to the invention with and without optical enhancement of the LED with a lens. 
         FIG. 10  provides a graph of brightness characteristics of exemplary bulbs in accordance with embodiments of the invention. 
         FIGS. 11A-C  show various views of an exemplary spot light type bulb according to embodiments of the invention. 
         FIGS. 12A-C  show various views of an exemplary spot light type bulb according to embodiments of the invention. 
         FIG. 13  provides another example of a spot light type lighting device according to embodiments of the invention. 
         FIG. 14  is another embodiment of the invention. 
         FIGS. 15A-C  provide various views of another embodiment of a spotlight type device according to the invention. 
         FIGS. 16A-C  show several views of an embodiment of the invention. 
         FIGS. 17A-C  provide various views of an additional embodiment of an LED lighting device according to the invention. 
         FIGS. 18A-C  show various views of a spot light type bulb according to embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION 
     Reference will now be made in detail to various exemplary embodiments of the invention. The following detailed description is presented for the purpose of describing certain embodiments in detail and is, thus, not to be considered as limiting the invention to the embodiments described. Additionally, any features of any embodiment described herein are equally applicable to any other embodiment described herein or envisioned by one of ordinary skill in the art. Thus, the detailed descriptions provided herein should not be construed to exclude features otherwise described with respect to another embodiment. 
     Included in embodiments of the invention are lamp assemblies that provide for various forms of light. More particularly, and as will be described further below, features of lamp assemblies according to the invention can include, for the MR 16 lamps, 12V AC/DC input; with a color temperature range of approximately 2800K to 7500K; a standard GU5.3 two-pin MR 16 base or other appropriate base such as GU10, E26, and E27; brightness in the range of approximately 20-500 lm; a viewing angle in the range of approximately 6-120 degrees; lenses with a concave or convex configuration; as well as such assemblies appropriate for voltages of 12 VAC/VDC. 
     PAR 16 lamps according to embodiments of the invention can have for example 85-250 V AC input; with a color temperature range of approximately 2800K to 7500K; a standard E26/E27 base; brightness in the range of approximately 20-500 lm; a viewing angle in the range of approximately 6-120 degrees; lenses with a concave or convex configuration; and such assemblies appropriate for use with voltages of 12 VAC/VDC, 24 VAC/DC, 120 VAC, and 277 VAC. 
     PAR 20 lamp embodiments of the invention can have for example an AC input ranging from 85-130V or 210-277 V; with a color temperature range of approximately 2800K to 7500K; a standard E26 or E27 base; brightness in the range of approximately 20-1000 lm; a viewing angle in the range of about 6-120 degrees; lenses with a concave or convex configuration; and such assemblies appropriate for use with voltages of 12 VAC/VDC, 24 VAC/DC, 120 VAC, and 277 VAC. 
     Features of the PAR 30 lamp embodiments according to the invention can include 85-277 V AC input; with a color temperature range of approximately 2800K to 7500K; a standard E26 or E27 base; brightness in the range of about 20-2000 lm; a viewing angle in the range of approximately 6-120 degrees; lenses with a concave or convex configuration; and such bulbs appropriate for use with voltages of 12 VAC/VDC, 24 VAC/DC, 12 VAC, and 277 VAC. 
     Likewise, features of lamp assemblies according to the present invention can include, for the PAR 38 lamps, 85-277 V AC input; with a color temperature range of approximately 2800K to 7500K; a standard E26 or E27 base; brightness in the range of approximately 20-3000 lm; a viewing angle in the range of about 6-120 degrees; lenses with a concave or convex configuration; and such bulbs for use with voltages of 12 VAC/VDC, 24 VAC/DC, 120 VAC, and 277 VAC. 
     Numerous factors are considered in manufacturing LED lighting devices, including finding ways of increasing heat dissipation to keep the devices cooler, increasing life of the bulb, increasing brightness of the bulb(s), decreasing the amount of current required to operate the bulb(s), decreasing cost, and decreasing the overall weight of the device. Often some of these advantages can be gained but only at the expense of other of these advantages. For example, one way to increase the dissipation of heat from the lighting devices is to increase the surface area of the heat sink. An increase in the surface area of the heat sink, however, also increases the size of the heat sink, which usually results in an unfavorable increase in the weight of the overall device. Similarly, the amount of heat output can be decreased by decreasing the current, but this usually results in a decrease in the brightness of the bulb, which is usually disfavored by the consumer. It is thus a challenge to find the optimum combination and arrangement of materials which will result in a favorable product. 
     The absolute maximum ratings of the exemplary inventive MR 16, PAR 16, PAR 20, PAR 30, and PAR 38 lamps include those specified in Table 1, which are characteristics of the bulbs using VaOpto LEDs. The characteristics of bulbs with other LEDs may be slightly different. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Absolute Maximum ratings for MR-16, PAR-16, 20, 30, 38 
               
            
           
           
               
               
               
               
            
               
                 Parameter 
                 Rating 
                 Unit 
                 Condition 
               
               
                   
               
            
           
           
               
            
               
                 MR-16 
               
            
           
           
               
               
               
               
            
               
                 DC 
                 12 
                 V 
                 Ta: 25° C. (77° F.) 
               
               
                 AC 
                 12 
                 V 
               
               
                 Forward Current 
                 330 
                 mA 
               
               
                 Operating Temperature 
                  −40~+85 (−40~185) 
                 ° C. (° F.) 
               
               
                 Storage Temperature 
                 −40~+100 (−40~212) 
                 ° C. (° F.) 
               
               
                 Median Life Expectancy 
                 50,000 
                 Hours 
               
               
                 Median Life Expectancy 
                 10,000 
                 Hours 
                 Ta: 50° C. (122° F.) 
               
            
           
           
               
            
               
                 PAR-16 
               
            
           
           
               
               
               
               
            
               
                 AC 
                 85-250 
                 V 
                 Ta: 20° C. 
               
               
                 Forward Current 
                 330 
                 mA 
               
               
                 Operating Temperature 
                 −40~+85  
                 ° C. 
               
               
                 Storage Temperature 
                 −40~+100 
                 ° C. 
               
               
                 Median Life Expectancy 
                 50,000 
                 Hours 
               
               
                 Median Life Expectancy 
                 10,000 
                 Hours 
                 Ta: 50° C. 
               
            
           
           
               
            
               
                 PAR-20 
               
            
           
           
               
               
               
               
            
               
                 AC 
                 85-130 
                 V 
                 Ta: 20° C. 
               
               
                   
                 210-277  
                 V 
               
               
                 Forward Current 
                 430 
                 mA 
               
               
                 Operating Temperature 
                 −40~+85  
                 ° C. 
               
               
                 Storage Temperature 
                 −40~+100 
                 ° C. 
               
               
                 Median Life Expectancy 
                 50,000 
                 Hours 
               
               
                 Median Life Expectancy 
                 10,000 
                 Hours 
                 Ta: 50° C. 
               
            
           
           
               
            
               
                 PAR-30 and PAR-38 
               
            
           
           
               
               
               
               
            
               
                 AC 
                 85-277 
                 V 
                 Ta: 20° C. 
               
               
                 Forward Current 
                 300 
                 mA 
               
               
                 Operating Temperature 
                 −40~+85  
                 ° C. 
               
               
                 Storage Temperature 
                 −40~+100 
                 ° C. 
               
               
                 Median Life Expectancy 
                 50,000 
                 Hours 
               
               
                 Median Life Expectancy 
                 10,000 
                 Hours 
                 Ta: 50° C. 
               
               
                   
               
            
           
         
       
     
     Electro-optical characteristics of lamp assemblies according to embodiments of the invention can for example include those specified in Table 2. The characteristics described are reflective of bulbs using VaOpto LEDs and may be different when other LEDs from other manufacturers are used. 
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 MR-16, PAR-16, 20, 30, 38 Electro-Optical Characteristics 
               
            
           
           
               
               
               
               
               
               
            
               
                 Parameter 
                 Symbol 
                 Min. 
                 TYP. 
                 Max. 
                 Unit 
               
               
                   
               
            
           
           
               
            
               
                 MR-16 
               
            
           
           
               
               
               
               
               
               
            
               
                 Viewing Angle 
                 2T½ 
                 — 
                 60 
                 — 
                 Deg. 
               
               
                 Luminous Flux 
                 Flux 
                 130 
                 150 
                 180 
                 Lm 
               
               
                 Correlated Color 
                 CCT 
                 6000 
                 6500 
                 7000 
                 K 
               
               
                 Temperature CW 
               
               
                 Correlated Color 
                 CCT 
                 3800 
                 4100 
                 4500 
                 K 
               
               
                 Temperature NW 
               
               
                 Correlated Color 
                 CCT 
                 2700 
                 3500 
                 3800 
                 K 
               
               
                 Temperature WW 
               
               
                 Operating Current 
                 Lin 
                 300 
                 330 
                 360 
                 mA 
               
            
           
           
               
            
               
                 PAR-16 
               
            
           
           
               
               
               
               
               
               
            
               
                 Viewing Angle 
                 2T½ 
                 — 
                 30 
                 — 
                 Deg. 
               
               
                 Correlated Color 
                 CCT 
                 6000 
                 6500 
                 7000 
                 K 
               
               
                 Temperature CW 
               
               
                 Correlated Color 
                 CCT 
                 3800 
                 4100 
                 4500 
                 K 
               
               
                 Temperature NW 
               
               
                 Correlated Color 
                 CCT 
                 2700 
                 3500 
                 3800 
                 K 
               
               
                 Temperature WW 
               
               
                 Operating Current 
                 Lin 
                 300 
                 330 
                 360 
                 mA 
               
            
           
           
               
            
               
                 PAR-20 
               
            
           
           
               
               
               
               
               
               
            
               
                 Viewing Angle 
                 2T½ 
                 — 
                 30 
                 — 
                 Deg. 
               
               
                 Correlated Color 
                 CCT 
                 6000 
                 6500 
                 7000 
                 K 
               
               
                 Temperature CW 
               
               
                 Correlated Color 
                 CCT 
                 3800 
                 4100 
                 4500 
                 K 
               
               
                 Temperature NW 
               
               
                 Correlated Color 
                 CCT 
                 2700 
                 3500 
                 3800 
                 K 
               
               
                 Temperature WW 
               
               
                 Operating Current 
                 Lin 
                 420 
                 430 
                 450 
                 mA 
               
            
           
           
               
            
               
                 PAR-30 
               
            
           
           
               
               
               
               
               
               
            
               
                 Viewing Angle 
                 2T½ 
                 — 
                 30 
                 — 
                 Deg. 
               
               
                 Correlated Color 
                 CCT 
                 6000 
                 6500 
                 7000 
                 K 
               
               
                 Temperature CW 
               
               
                 Correlated Color 
                 CCT 
                 2700 
                 3000 
                 3500 
                 K 
               
               
                 Temperature WW 
               
               
                 Operating Current 
                 Lin 
                 300 
                 330 
                 360 
                 mA 
               
            
           
           
               
            
               
                 PAR-38 
               
            
           
           
               
               
               
               
               
               
            
               
                 Viewing Angle 
                 2T½ 
                 — 
                 30 
                 — 
                 Deg. 
               
               
                 Correlated Color 
                 CCT 
                 6000 
                 6500 
                 7000 
                 K 
               
               
                 Temperature CW 
               
               
                 Correlated Color 
                 CCT 
                 2700 
                 3000 
                 3500 
                 K 
               
               
                 Temperature WW 
               
               
                 Operating Current 
                 Lin 
                 380 
                 400 
                 420 
                 mA 
               
               
                   
               
            
           
         
       
     
     Even more particularly, exemplary lamp assemblies according to the invention are described in further detail below with reference to  FIGS. 1-10 . 
       FIG. 1A  shows an exemplary embodiment of a PAR-16 type light assembly  100  according to the invention with the components assembled. As shown, bulb  100  comprises a housing  110  comprising heat sink material  111 . This embodiment of the PAR-16 bulb comprises three light sources (not visible) with three corresponding individual lenses  120 . The lenses  120  are held in place within the housing by a cover plate  130 . This bulb  100  has an incandescent-compatible plug end  112 . 
     Light bulbs with high heat output, for example MR and PAR series bulbs, typically comprise a housing  110  with heat sink  111  capabilities to remove heat from the bulb that is generated by the light source. It is a general rule that the greater the number of light sources or the total wattage of the light sources, then the greater the heat that is generated by the bulb. This heat, if left within the bulb system, can lead to overheating of the lighting unit, which in turn can lead to failure of the bulb or the lighting unit, as well as to various heat-related hazards, including fire. 
     A further aspect of the present invention includes various lamp housings having innovative heat sink capabilities. Various types of heat sink features are known and include using materials and/or configurations that provide for heat dissipation from the bulb. For example, part of the light assembly housing  110  can comprise ceramic, metal, alloy, or metal composite material, the composition of which promotes dissipation of heat from light assembly  100  during operation. Metals with high thermal conductivity are preferred, including iron, copper, aluminum, silver, gold, and alloys or composites comprising them. A preferred material for heat sinks is aluminum or an aluminum and copper combination, such as an alloy. This invention also comprises heat sinks  111  constructed of thermally conductive polymers, which are lightweight and moldable and which exhibit high heat transfer characteristics. Exemplary materials include polyamide and polyphenylene sulfide materials, such as CoolPoly E3603 and E5101 manufactured by Cool Polymers, Inc. Such materials are favorable due to their thermal conductivity (20 W/mK) and thermal diffusivity (0.12 cm 2 /sec) characteristics. Heat sinks  111  of embodiments of the invention can also include heat transfer devices, such as the NanoSpreader provided by Celsia Technologies, which is an ultra-thin heat pipe comprising a copper encased two-phase vapor chamber. 
     The heat sink  111  can be constructed so as to provide for and facilitate heat dissipation by way of maximizing the surface area of the heat sink  111 . There exist numerous structures capable of dissipating heat in this way, including incorporating multiple metal structures or a structure shaped to provide rows of material with air space between the rows, which extend lengthwise along or circumferentially around housing  110 . The rows of material are preferably constructed of high conductivity materials for pulling heat out of the light assembly  110  system and radiating it into the environment over the material&#39;s large surface area. In particular, for example, a heat dissipation module as described in U.S. Pat. No. 7,549,774 could be used as heat sink  111  in embodiments of the light assemblies  100  according to this invention. Such shapes are likewise equally applicable to plastic-based heat sinks. 
     The lamp assemblies  100  of the present invention are applicable to any spot light type bulb, for example, MR 16, PAR 16, PAR 20, PAR 30, PAR 38, and PAR 56, to name a few, and can be used in place of any existing equivalent bulb. Accordingly, the base  112  of the light assemblies  100  of the present invention can also be constructed or modified to cooperate with any existing bulb type lighting fixture. For example, the bulbs  100  of the present invention can comprise a base  112  having a 2-pin configuration, and turn-and-lock configuration, a screw-type base (as shown), or a bayonet-type base to name a few. One of skill in the art could use an existing plug-type end  112  on the light assemblies  100  for compatibility with any corresponding socket. 
       FIG. 1B  shows an exemplary embodiment of a PAR-16 type light assembly according to the invention with the components unassembled. As shown, within housing  110  is a PCB  140  operably connected to the electrical components (not shown) of the bulb  100 . Operably connected to the PCB  140  are three LEDs  150 . Lens support  160  is configured with three recesses  161  for supporting lenses  120 . At the base of the support  160  within the recesses  161  are three through holes  162 . The through holes  162  allow for placement of support  160  over LEDs  150 . In this embodiment, when support  160  is placed within housing  110  on PCB  140 , LEDs  150  protrude into the space defined by the recesses  161  and support  160  thereby surrounds LEDs  150 . Lenses  120  can then be easily and conveniently inserted into housing  110  by placing lenses  120  in support  160 . Cover plate  130  can then be positioned over lenses  120  and support  160  and secured to housing  110 . 
       FIGS. 2A-2E  show various views of an exemplary lens support according to embodiments of the invention having three recesses for supporting three lenses.  FIG. 2A  is a top plan view of an exemplary unitary 3-recess support  260 . Each of the recesses  261  is capable of supporting an individual lens, in this embodiment up to and including three lenses could be used. At the base of support  260  and within each recess  261  is a through hole  262  for accommodating a light source. 
       FIG. 2B  is a cross-sectional view of support  260  taken along cross-sectional line B-B in  FIG. 2A . As shown, support  260  comprises recesses  261  with a conical interior surface shape. This embodiment of unitary support  260  also shows structural support members  263  between the outside surfaces of recesses  261 . 
       FIG. 2C  provides a cross-sectional view of support  260  taken along cross-sectional line C-C in  FIG. 2A . As shown, the structural support members  263  can comprise material between recesses  261  which extends from the top of the outside surface of the recess to a point along the outside surface of the recess. In embodiments, it may be desired to have the support  263  end at a point above the through holes  262  so that when assembled there is sufficient clearance above the PCB for supports  263  to not interfere with components mounted on the PCB, such as electrical contacts for providing electrical power to the electrical circuit of the PCB during use of the bulb. Support  260  can also be constructed of more rigid material to obviate the need for additional structural supports  263  or supports  263  can comprise a build up of material strategically placed between the outside surfaces of recesses  261 . 
       FIG. 2D  shows a bottom plan view of support  260 . As shown, embodiments of support  260  can comprise structural support members  263  that are strips of material between the outside surfaces of recesses  261 . Support members  263  can be of any shape, size, or material, with low-profile configurations being preferred to reduce or eliminate interference with other components within the light assembly housing, such as components mounted to the PCB. 
       FIG. 2E  shows a side elevation view of an embodiment of support  260  with three recesses  261  supported by additional structural support members  263 . 
     The lens support  260  can comprise any material suitable for installation within a lamp housing. In particular, the material is preferably able to withstand high heat output from a light source or several light sources. Materials that can be used include metals, such as copper and aluminum, and plastics, including ABS plastic. The materials identified here are only examples of the many types of materials that can be used and it will be apparent to one of skill in the art which materials are best suited for a particular purpose. The lens support  260  may be used with or without lenses and, depending on its composition and/or surface characteristics, may be used as a reflector of light from the light source, as an absorber of light from the light source, or may be used to enhance the reflectivity or absorption of the light in combination with lenses. Accordingly, the lens support  260  can also be referred to as a reflector, as it can be used alone or in combination with lenses to direct the light from the light source. Further, the support can be shaped so as to guide the light from the light source in the desired direction. Generally, the support comprises a number of recesses or cups that corresponds with the number of light sources used in the lighting apparatus. For example, for MR 16 type lamps with three light sources, the support will typically comprise three recesses when the lamp is assembled. At the bottom of each lens support recess  261  is a void or through hole  262  large enough to accommodate the light source to enable the light source to protrude into the recess of the support and be encompassed by the surface(s)  261  of the recess. The shape of through hole  262  is not critical, so long as it is large enough to allow the light source to be surrounded by the recess. The recesses  261  in the lens support  260  need not be the same shape or of any particular shape, however, a generally conical shape is preferred, for example, with the bottom of the recess (where the void for accommodating the light source is located) being smaller than the top of the recess. In this manner, light from the light source can be directed out of the lamp assembly housing in a particular direction. Changing the slope of surface  261  can alter the path or coverage of the light being emitted from the lamp during use. Of course, one of skill in the art will recognize the many variations available for adjusting the size and shape of the recess(es) to control the direction and intensity of the light as desired. 
     It is preferred that the lens support  260  be shaped to accommodate a lens or lenses such that the lenses rest within the recesses  261  loosely enough to allow for the lenses to be inserted and removed from the recesses  261  freely. A preferred embodiment includes using lenses having an outer surface shape that corresponds with the inner surface shape of the recess. For example, a recess could be configured to be of conical shape in order to accommodate a conical-shaped lens. The more complementary the surfaces of the lens and recess are, the less the lens will move within the recess, thus, facilitating installation of the lens in the lamp housing because the lens will be stabilized temporarily for alignment with the corresponding voids of the housing cover plate, which is installed over the lenses. 
     Additionally, the lens support, whether used alone or in combination with lenses, can be constructed of a reflective material, coated with a material to reflect light, and/or comprise a surface that absorbs light so as to provide control over the amount and direction of the light from each of the light sources. 
     Embodiments of lens support  260  include multiple individual cups each comprising a recess  261  and means for connecting the cups together to form an integrated lens support  260 . In this manner, lens supports  260  are modular and can be used in any type bulb assembly with any number of light sources. It is preferred that the means for connecting the cups  260  together be a quick connect-disconnect to add to the ease of modularity of the components. The cups  260  may also be irremovably or connectable (e.g., using adhesive) or otherwise difficult to disconnect so that once several cups are combined and integrated into a single lens support member  260  for a particular application, they are fixed in that configuration. 
       FIG. 3A  shows a bottom plan view of an exemplary lens support  360  according to embodiments of the invention which has seven recesses  361  for supporting seven lenses and  FIG. 3B  shows a side elevation view of that support  360 . Any configuration of recesses  361  is possible, although as shown in this embodiment there is a single central recess  361  surrounded by six peripheral recesses  361 . Additional structural support members  363  are provided between each peripheral recess  361  and the central recess  361 . According to design preference or if desired for certain applications, it is equally possible to have structural support members  363  between some or all of the peripheral recesses  361  in addition to or instead of the support members  363  shown. 
     Additionally, support  360  could have an overall circular configuration rather than the scalloped edge as shown. For example, a scalloped edge may be preferable where a housing cover is attached to the housing by way of screws through the face plate into the housing of housing components, such as the PCB. If the edge of support  360  is configured to avoid the screws, there is no need to line up holes in support  360  with holes in the face plate when securing with screws. A scalloped edge on support  360  thus in this way can also contribute to ease of manufacturing.  FIG. 3B  shows a side elevation view of support  360  with seven recesses  361  and structural supports  363  between the peripheral recesses and central recess  361 . The lens support  360  could typically be used in MR-16, PAR-16, and PAR-20 type bulbs. 
       FIGS. 4A-B  show top plan and side elevation views of an exemplary lens support  460  according to embodiments of the invention having ten recesses  461  for supporting ten lenses. Again, any configuration of the ten recesses  461  is possible and structural supports  463  can be added or omitted between any of the recesses  461 . In this embodiment, no structural support members are shown. The top surface  464  of support  460 , as shown in this embodiment, can be shaped (e.g., scalloped or otherwise) to comprise cut outs  465  for accommodating by not interfering with screws for securing the cover plate to the housing of the bulb. Alternatively, or in addition, screw holes can be provided in the top surface  464  of support  460 , if desired. 
     The lens support  460  shown in  FIGS. 4A-B  could be used to support lenses in a PAR 38 type bulb. To manufacture a PAR 38 type bulb, a manufacturer typically holds all ten lenses or reflectors in place over or in the appropriate vicinity of their corresponding light source at the same time or balances the lenses in position with a very steady hand while installing the cover plate to permanently secure the lenses and other interior lighting components within the housing. The present invention alleviates this manufacturing difficulty by providing a support  460  that enables the simultaneous placement of the lenses within the housing. 
       FIGS. 5A-D  show a top plan view, a bottom plan view, a side elevation view, and a cross-sectional view of the side elevation view of an exemplary lens embodiment according to the invention. As shown in  FIG. 5A , a lens  520  is provided that is compatible for use with any lens support described in this application, including in particular the lens supports shown in and discussed with respect to the embodiments of  FIGS. 2-4 . As shown in  FIG. 5A , a top plan view of lens  520 , there is provided an optional rim  521 . Rim  521  provides means for supporting lens  520  in a lens support, provides means for handling the lens  520  during manufacturing to minimize damage to or dirtying of the upper lens surface  522 , as well as provides a surface for facilitating insertion and withdrawal of lens  520  into and out of the lens support while minimizing disruption of other installed lenses and/or avoiding inversion of the housing or support during manufacturing in the situation where a lens needs to be removed. Also shown is an outline  523  of the uppermost portion of a lens recess  524  of lens  520  into which a light source projects its light for transmission through the lens  520  during use. As used throughout this application, orientation of components are described with respect to the lamp housing standing in a perpendicular orientation with the cover plate on top. 
       FIG. 5B  shows a bottom plan view of lens  520 . As shown, rim  521  circumscribes the conical shaped lens  520  at or near the lens surface (not shown). An outline  523  shows the uppermost boundary of lens recess  524  within the lens  520 . The lowermost portion of lens recess  524  is defined by outline  525 . Surface  526  is a side surface of lens  520 , which in this embodiment is conical and extends from the uppermost portion  523  of lens recess  524  to the bottommost portion of rim  521 . In this embodiment, surface  526  is conical and complementary to and thus would be compatible with any lens support shown in  FIGS. 2-4 . Exterior surface  526  of lens  520  is slideably and removeably engageable with the interior surface of the conical and complementary recess of the lens supports shown in  FIGS. 2-4 . Likewise, rim  521 , when assembled with a lens support, can contact the upper surface of the lens support to provide further stability for the lens. In this embodiment, the exterior surface  526  and the bottom surface of rim  521  of lens  520  are said to match respectively the interior surface of the lens support recess and the upper surface of the lens support. In preferred embodiments, exterior surface  526  of lens  520  is shaped to render the lens capable of contacting or resting on a corresponding surface of a lens support. The entire surface  526  need not contact the corresponding surface of the support completely and/or exactly, so long as sufficient support is provided to enable proper positioning of the lenses within the housing. 
       FIG. 5C  shows a side elevation view of lens  520 . In particular, as shown in this embodiment, lens  520  can be generally conical in shape as defined by outer surface  526 . One configuration for rim  521  is also shown, wherein rim  521  circumscribes lens  520  near the top face or upper lens surface  522 . The rim  521  comprises an upper rim surface  527  and a lower rim surface  528 . Accordingly, the rim surfaces  527  and  528  can be desirable for containing the lens within the lamp housing. In embodiments, a cover plate can be installed on the lamp housing to contain the lenses  520  within the housing by contacting or otherwise being operably connected with upper rim surface  527  to prevent the lens  520  from escaping the housing once installed with the cover plate in place. Additionally lower rim surface  528  can be used the further support lens  520  within the lens support by contacting lower rim surface  528  with a surface of the lens support, usually the upper lens support surface. In the context of this application, surfaces  526  and  528  are said to form the lower exterior surface of lens  520 . There may be an additional portion of the lower exterior surface of the lens, however, whether this additional surface, typically at the base of the lens, interacts with the lens support is inconsequential. 
       FIG. 5D  shows a cross-section of the side elevation view of lens  520  provided in  FIG. 5C . Recess  524  can be of any size and shape desired, so long as the recess  524  is capable of accommodating the light source for the lamp assembly. Within recess  524  is surface  529  shaped for directing, projecting, or otherwise controlling or manipulating light emitted from a light source of the lamp assembly during use. In this embodiment, light controlling surface  529  is of a generally convex shape toward the light source. Surface  529  can also be concave or planar or of any appropriate shape for controlling the light emitted from the light source. 
       FIGS. 6A-D  show unassembled and assembled an exemplary embodiment of a light assembly  600  comprising a lens support, compatible lenses, and a housing cover plate for a PAR-16, MR-16, or PAR-20 type bulb having three LEDs.  FIG. 6A  provides an unassembled view of a lens support  660  comprising three recesses  661 , three complementary lenses  620 , and a cover plate  630  for securing the components within the lamp housing when assembled.  FIG. 6B  provides a partial assembly view of the components, including a view of lens support  660  assembled with lenses  620  and the cover plate  630  unassembled. A cross-sectional view of  FIG. 6B  is provided in  FIG. 6C . Of particular interest in this view (taken along line C-C of  FIG. 6B ) are the complementary shapes of outer surface  626  of lens  620  and inner surface  661  of lens support  660  as well as the complementary surface of the lower surface of the lens  620  rim which contacts the upper surface of lens support  660 . As shown, these surfaces can be of corresponding shape, here both the exterior  626  surface of the lens and the interior  661  surface of the lens recess of support  660  are conical, to provide for maintaining a position of lens  620  within the lamp assembly housing once installed. Similarly, the bottom surface of lens  620  rim can be shaped to contact the upper surface of lens support  660  also as shown. For purposes of this application, maintaining refers to keeping the lenses  620  in a desired position, which may mean for temporarily or permanently fixing the lens within the support or also allowing for some variation of position when installed in the housing without adversely affecting operation of the device. Once installed, the lens  620  need not be in a concrete, fixed position within the housing and some movement of the components is possible, and may even be desirable in certain embodiments. It may even be desirable to fix the lenses  620 , once properly positioned, to prevent rearrangement of the components during use. Many possibilities exist for complementary surfaces  626 ,  661  and this embodiment shows complementary conical shapes, which is just one example. Similarly, many embodiments exist for shapes of the lower surface of the lens rim and the upper surface of the lens support. Especially preferred are embodiments wherein when assembled the lens(es) are seated within the lens support (reflector) totally (meaning the side surface of the lens  626  fits completely within the recess of the lens support) to provide for better positioning of the lenses with respect to the light sources. Even further preferred are such embodiments wherein the side surface  626  of the lens is complementary to and matches the inner surface  661  of the lens support recess, to provide for more exact positioning of the lens within the housing.  FIG. 6D  shows lens support  660  assembled with lenses  620  and cover plate  630  installed. In this embodiment, the top surface  622  of lens  620  is shown protruding through through-hole  631  of cover plate  630 . In this manner, cover plate  630  secures lenses  620  in place within the lamp housing by opposing the rim (not shown in this view) of the lenses  620 . When installed in the lamp housing, the top surface  622  of lens  620  can be positioned at or about the same plane as cover plate  630 . Other ways of securing the lenses within the housing exist, such as by constructing the upper surface of the lens with or without a rim to be larger in diameter than a hole in the cover plate through which the light will pass during use. 
       FIGS. 7A-D  show various examples of PCBs for PAR-16, MR-16, PAR-20, PAR-30, and PAR-38 bulbs according to embodiments of the invention.  FIG. 7A  shows an example of a PCB  740  that can be used for an MR-16 or PAR-16 type bulb having three light sources.  FIG. 7B  shows an exemplary PCB  740  for a PAR-20 type lamp with three light sources.  FIG. 7C  shows an example of a PCB  740  for a PAR-30 type lamp with seven light sources.  FIG. 7D  shows an example of a PCB that can be used for a PAR-38 type lamp with ten light sources. Applicable to  FIGS. 7A-D , the pathway of electrical circuit  741  is completed when the light sources are mounted where indicated at  742 . The light sources can be secured at  742  and operably connected to the electrical circuit  741  by way of soldering electrical contacts of the light sources to the electrical circuit  741  at for example where indicated at  745 . Wire leads, or other structure operably connecting electrical pathways  741  and the light sources to a power source to complete the circuit, can be operably connected where indicated at  743 . Various strategically placed cut-outs or notches  744  can be provided for providing a means to engage with corresponding structure (e.g., posts) in the lamp housing to deter or prevent the PCB  740  from moving within the housing once positioned in a desired manner within the lamp assembly housing. Further, for example, such cut-outs  744  can allow for wire leads or other components within the lamp housing to pass through from below the PCB  740  to be operably connected to the upper surface of PCB  740 . 
     The brightness characteristics of lamp assemblies according to embodiments of the invention include those specified in Table 3. Brightness measurements were taken at various distances of which a schematic representation of the illumination and distances measured is provided in  FIG. 8 . The characteristics described are reflective of bulbs using VaOpto LEDs and may be different when other LEDs from other manufacturers are used. 
     
       
         
           
               
             
               
                 TABLE 3 
               
             
            
               
                   
               
               
                 MR-16, PAR-16, 20, 30, 38 Brightness Characteristics 
               
            
           
           
               
               
            
               
                   
                 ILLUMINANCE 
               
               
                   
                 (CENTER) IN LUX 
               
            
           
           
               
               
               
               
               
            
               
                   
                 at 
                 at 
                 at 
                 at 
               
               
                 TYPE 
                 0.5M 
                 1M 
                 2M 
                 3M 
               
               
                   
               
            
           
           
               
            
               
                 MR-16 
               
            
           
           
               
               
               
               
               
            
               
                 VO-MR16-1WW3-130-53V30 
                 1000 
                 300 
                 80 
                 30 
               
               
                 VO-MR16-1NW3-150-53V30 
                 1200 
                 400 
                 100 
                 40 
               
               
                 VO-MR16-1CW3-180-53V30 
                 1400 
                 500 
                 120 
                 50 
               
            
           
           
               
            
               
                 PAR-16 
               
            
           
           
               
               
               
               
               
            
               
                 VO-PAR16-1WW3-180-30-120 
                 2500 
                 750 
                 200 
                 80 
               
               
                 VO-PAR16-1NW3-240-30-120 
                 3500 
                 1000 
                 250 
                 100 
               
               
                 VO-PAR16-1CW3-300-30-120 
                 6000 
                 2000 
                 500 
                 200 
               
            
           
           
               
            
               
                 PAR-20 
               
            
           
           
               
               
               
               
               
            
               
                 VO-PAR20-2WW3-240-30-120 (277) 
                 3600 
                 1100 
                 270 
                 110 
               
               
                 VO-PAR20-2NW3-320-30-120 (277) 
                 4500 
                 1300 
                 330 
                 150 
               
               
                 VO-PAR20-2CW3-400-30-120 (277) 
                 8000 
                 2600 
                 650 
                 250 
               
            
           
           
               
            
               
                 PAR-30 
               
            
           
           
               
               
               
               
               
            
               
                 VO-PAR30-1WW7-450-30-120 (277) 
                 7000 
                 1950 
                 500 
                 220 
               
               
                 VO-PAR30-1NW7-550-30-120 (277) 
                 9000 
                 2600 
                 700 
                 350 
               
               
                 VO-PAR30-1CW7-700-30-120 (277) 
                 1100 
                 3300 
                 900 
                 450 
               
            
           
           
               
            
               
                 PAR-38 
               
            
           
           
               
               
               
               
               
            
               
                 VO-PAR38-2WW10-900-30-120 (277) 
                 13600 
                 3600 
                 960 
                 440 
               
               
                 VO-PAR38-2NW10-1100-30-120 (277) 
                 17200 
                 4400 
                 1280 
                 560 
               
               
                 VO-PAR38-2CW10-1300-30-120 (277) 
                 19600 
                 4960 
                 1440 
                 720 
               
               
                   
               
            
           
         
       
     
     The viewing angles of lamp assemblies according to embodiments of the invention include those specified in  FIGS. 9A and 9B .  FIG. 9A  provides a graph of the viewing angles for an MR-16 type bulb according to the invention with and without optical enhancement of the LED with a lens. Similarly,  FIG. 9B  provides a graph of the viewing angles for PAR-16, 20, 30, and 38 type bulbs according to the invention with and without optical enhancement of the LED with a lens. 
     Additional brightness characteristics are provided below in Table 4 for exemplary MR-16, PAR-16, PAR-20, PAR-30, and PAR-38 type spot light bulbs in accordance with the invention. The wavelength characteristics are also provided in graphical form in  FIG. 10 . The characteristics described in Table 4 are reflective of bulbs using VaOpto LEDs and may be different when other LEDs from other manufacturers are used. 
     
       
         
           
               
             
               
                 TABLE 4 
               
             
            
               
                   
               
               
                 MR-16, PAR-16, 20, 30, 38 Brightness Characteristics 
               
            
           
           
               
               
               
            
               
                   
                 Dominant 
                   
               
               
                   
                 wavelength 
               
               
                   
                 (nm) or CCT (K) 
                 Typical 
               
            
           
           
               
               
               
               
               
            
               
                 TYPE 
                 Color 
                 Min. 
                 Max. 
                 Luminous 
               
               
                   
               
            
           
           
               
            
               
                 MR-16 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 VO-MR16-1R3V-30G53A-12N 
                 Red 
                 620 
                 nm 
                 630 
                 nm 
                 150 lm 
               
               
                 VO-MR16-1Y3V-30G53A-12N 
                 Amber 
                 585 
                 nm 
                 595 
                 nm 
                 150 lm 
               
               
                 VO-MR16-1G3V-30G53A-12N 
                 Green 
                 520 
                 nm 
                 535 
                 nm 
                 180 lm 
               
               
                 VO-MR16-1B3V-30G53A-12N 
                 Blue 
                 465 
                 nm 
                 475 
                 nm 
                  60 lm 
               
               
                 VO-MR16-1CW3V-30G53A-12N 
                 Cool White 
                 5000 
                 K 
                 10000 
                 K 
                 210 lm 
               
               
                 VO-MR16-1NW3V-30G53A-12N 
                 Neutral White 
                 3700 
                 K 
                 5000 
                 K 
                 195 lm 
               
               
                 VO-MR16-1WW3V-30G53A-12N 
                 Warm White 
                 2600 
                 K 
                 3700 
                 K 
                 180 lm 
               
            
           
           
               
            
               
                 PAR-16 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 VO-PAR16-1R3V-30E26B-120N 
                 Red 
                 620 
                 nm 
                 630 
                 nm 
                 150 lm 
               
               
                 VO-PAR16-1Y3V-30E26B-120N 
                 Amber 
                 585 
                 nm 
                 595 
                 nm 
                 150 lm 
               
               
                 VO-PAR16-1G3V-30E26B-120N 
                 Green 
                 520 
                 nm 
                 535 
                 nm 
                 180 lm 
               
               
                 VO-PAR16-1B3V-30E26B-120N 
                 Blue 
                 465 
                 nm 
                 475 
                 nm 
                  60 lm 
               
               
                 VO-PAR16-1CW3V-30E26B-120N 
                 Cool White 
                 5000 
                 K 
                 10000 
                 K 
                 210 lm 
               
               
                 VO-PAR16-1NW3V-30E26B-120N 
                 Neutral White 
                 3700 
                 K 
                 5000 
                 K 
                 195 lm 
               
               
                 VO-PAR16-1WW3V-30E26B-120N 
                 Warm White 
                 2600 
                 K 
                 3700 
                 K 
                 180 lm 
               
            
           
           
               
            
               
                 PAR-20 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 VO-PAR20-2R3V-30E26B-120N 
                 Red 
                 620 
                 nm 
                 630 
                 nm 
                 200 lm 
               
               
                 VO-PAR20-2Y3V-30E26B-120N 
                 Amber 
                 585 
                 nm 
                 595 
                 nm 
                 200 lm 
               
               
                 VO-PAR20-2G3V-30E26B-120N 
                 Green 
                 520 
                 nm 
                 535 
                 nm 
                 230 lm 
               
               
                 VO-PAR20-2B3V-30E26B-120N 
                 Blue 
                 465 
                 nm 
                 475 
                 nm 
                  80 lm 
               
               
                 VO-PAR20-2CWV-30E26B-120N 
                 Cool White 
                 5000 
                 K 
                 10000 
                 K 
                 270 lm 
               
               
                 VO-PAR20-2NW3V-30E26B-120N 
                 Neutral White 
                 3700 
                 K 
                 5000 
                 K 
                 250 lm 
               
               
                 VO-PAR20-2WW3V-30E26B-120N 
                 Warm White 
                 2600 
                 K 
                 3700 
                 K 
                 230 lm 
               
            
           
           
               
            
               
                 PAR-30 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 VO-PAR30-1R7V-30E26B-120N 
                 Red 
                 620 
                 nm 
                 630 
                 nm 
                 310 lm 
               
               
                 VO-PAR30-1Y7V-30E26B-120N 
                 Amber 
                 585 
                 nm 
                 595 
                 nm 
                 310 lm 
               
               
                 VO-PAR30-1G7V-30E26B-120N 
                 Green 
                 520 
                 nm 
                 535 
                 nm 
                 390 lm 
               
               
                 VO-PAR30-1B7V-30E26B-120N 
                 Blue 
                 465 
                 nm 
                 475 
                 nm 
                 110 lm 
               
               
                 VO-PAR30-1CW7V-30E26B-120N 
                 Cool White 
                 5000 
                 K 
                 10000 
                 K 
                 490 lm 
               
               
                 VO-PAR30-1NW7V-30E26B-120N 
                 Neutral White 
                 3700 
                 K 
                 5000 
                 K 
                 455 lm 
               
               
                 VO-PAR30-1WW7V-30E26B-120N 
                 Warm White 
                 2600 
                 K 
                 3700 
                 K 
                 420 lm 
               
            
           
           
               
            
               
                 PAR-38 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 VO-PAR38-2R10V-30E26B-120N 
                 Red 
                 620 
                 nm 
                 630 
                 nm 
                 310 lm 
               
               
                 VO-PAR38-2Y10V-30E26B-120N 
                 Amber 
                 585 
                 nm 
                 595 
                 nm 
                 310 lm 
               
               
                 VO-PAR38-2G10V-30E26B-120N 
                 Green 
                 520 
                 nm 
                 535 
                 nm 
                 390 lm 
               
               
                 VO-PAR38-2B10V-30E26B-120N 
                 Blue 
                 465 
                 nm 
                 475 
                 nm 
                 110 lm 
               
               
                 VO-PAR38-2CW10V-30E26B-120N 
                 Cool White 
                 5000 
                 K 
                 10000 
                 K 
                 490 lm 
               
               
                 VO-PAR38-2NW10V-30E26B-120N 
                 Neutral White 
                 3700 
                 K 
                 5000 
                 K 
                 455 lm 
               
               
                 VO-PAR38-2WW10V-30E26B-120N 
                 Warm White 
                 2600 
                 K 
                 3700 
                 K 
                 420 lm 
               
               
                   
               
            
           
         
       
     
       FIGS. 11A-C  provide various views of an exemplary spot light bulb according to embodiments of the invention. As shown, this MR-16 type bulb  1100  can be provided in 12V AC/DC input, having red, amber, green, blue, or white color LEDs. This bulb  1100  shows lenses  1120  secured by cover plate  1130  in the lamp housing  1110 , through which the lenses  1120  protrude by way of holes  1132  through the top surface or face  1131  of cover plate  1130 . The lamp housing  1110  comprises heat sink  1111 , cover plate  1130 , and base  1112 , in addition to other components or features not shown or highlighted herein. Of particular interest in this embodiment is the configuration of heat sink  1111 , which provides for dissipation of heat by way of the circumferentially arranged protrusions and depressions in the housing surface. The heat sink  1111  can comprise ceramic, plastic, metal, combinations and composites thereof, as well as heat pipe technology. The preferred heat sinks  1111  comprise the materials discussed earlier in this application and are preferred for and applicable to all embodiments of the invention. The base  1112  shown is a standard 2-pin GU5.3 base, which can be used for any embodiment of the invention. 
       FIGS. 12A-C  provide various views of an exemplary spot light bulb according to embodiments of the invention. As shown, this MR-16 type bulb  1200  can be provided with 85-260V AC input, having red, amber, green, blue, or white color LEDs. This bulb  1200  shows lenses  1220  secured by cover plate  1230  in the lamp housing  1210 , through which the lenses  1220  protrude by way of holes  1232  through the top surface or face  1231  of cover plate  1230 . The cover plate  1230  is secured to the housing by way of screws  1234  and can comprise vents  1233  as shown. The lamp housing  1210  comprises heat sink  1211 , cover plate  1230 , and base  1212 , in addition to other components or features not shown or highlighted herein. Of particular interest in this embodiment is the configuration of heat sink  1211 , which provides for dissipation of heat by way of longitudinally arranged protrusions and depressions in the housing surface. The heat sink  1211  can comprise ceramic, plastic, metal, combinations and composites thereof, as well as heat pipe technology. The preferred heat sinks  1211  comprise the materials discussed earlier in this application and are preferred for and applicable to all embodiments of the invention. The base  1212  shown is a standard 2-pin GU10 base, which can be used for any embodiment of the invention. 
       FIG. 13  provides another example of an MR-16 type bulb according to the invention. In particular, as shown, this MR-16 type bulb  1300  can be provided with 12V AC/DC input, having red, yellow, green, blue, or white color (including cool, neutral, or warm white) LEDs. This bulb  1300  shows a single lens  1320  protruding through the cover plate of the housing and significantly above the cover plate surface  1331 . The cover plate can be secured to the housing by way of screws, pressure fit, adhesive, or other male/female type connectors. The heat sink  1311  provides for another configuration of the heat sink with a solid and continuous surface, which can comprise ceramic, plastic, metal, combinations and composites thereof, as well as heat pipe technology. The preferred heat sinks  1311  comprise the materials discussed earlier in this application and are preferred for and applicable to all embodiments of the invention. The base  1312  shown is a standard 2-pin GU5.3 base, which can be used for any embodiment of the invention. 
       FIG. 14  provides another example of an MR-16 type bulb according to the invention. In particular, as shown, this MR-16 type bulb  1400  can be provided with 12V AC/DC input, having red, yellow, green, blue, or white color (including cool, neutral, or warm white) LEDs. This bulb  1400  shows a single lens  1420  protruding through the cover plate of the housing and significantly above the cover plate surface  1431 . The cover plate can be secured to the housing by way of screws, pressure fit, adhesive, or other male/female type connectors. The heat sink  1411  provides for a heat dissipating surface arranged laterally or circumferentially around the housing, which can comprise ceramic, plastic, metal, combinations and composites thereof, as well as heat pipe technology. The preferred heat sinks  1411  comprise the materials discussed earlier in this application and are preferred for and applicable to all embodiments of the invention. In particular, the heat sinks of the invention preferably comprise polyamide or polyphenylene sulfide disposed in any combination of ridges and troughs (which together create projections commonly referred to as fins), and vents to provide for a housing having a heat sink surface area that is twice or greater than that of a lamp assembly of the same size without ridges, troughs, or vents. For example, the surface area of heat sink  1411  of  FIG. 14  when compared with the heat sink  1311  of the same size lamp assembly in  FIG. 13 , the ridges and troughs shown in  FIG. 14  provide for an increased surface area, which increases the capability of the lamp assembly to dissipate heat. Base  1412  shown is a standard 2-pin GU5.3 base. 
       FIGS. 15A-C  provide various views of another exemplary spot light bulb according to embodiments of the invention. As shown, this PAR-16 type bulb  1500  can be provided in 85-260V AC/DC input, having red, amber, green, blue, or white color LEDs. This bulb  1500  shows three lenses  1520  secured by cover plate  1530  in the lamp housing  1510 , through which the lenses  1520  protrude by way of holes  1532  through the top surface or face  1531  of cover plate  1530 . The lamp housing  1510  comprises heat sink  1511 , cover plate  1530 , and base  1512 , in addition to other components or features not shown or highlighted herein. Of particular interest in this embodiment is the configuration of heat sink  1511 , which provides for dissipation of heat by way of the longitudinally arranged ridges and valleys in the housing surface. The heat sink  1511  can comprise ceramic, plastic, metal, combinations and composites thereof, as well as heat pipe technology. The preferred heat sinks  1511  comprise the materials discussed earlier in this application and are preferred for and applicable to all embodiments of the invention. The base  1512  shown is a standard E26/E27 base, which can be used for any embodiment of the invention. Vents  1533  can also be provided in the housing, as here the vents are provided in the top surface  1531  of the cover plate. Further, any means can be used for securing the cover plate to the housing, including screws  1534  as shown, which are accommodated by the face plate through holes  1535 . 
       FIGS. 16A-C  provide various views of another exemplary spot light bulb according to embodiments of the invention. As shown, this PAR-20 type bulb  1600  can be provided in 85-260V AC input, having red, amber, green, blue, or white color LEDs. This bulb  1600  shows three lenses  1620  secured by the housing cover plate, through which the lenses protrude by way of holes  1632  through the top surface or face  1631 . The lamp housing comprises heat sink  1611 , cover plate, and base  1612 , in addition to other components or features not shown or highlighted herein. Of particular interest in this embodiment is the configuration of heat sink  1611 , which provides for dissipation of heat by way of the longitudinally arranged ridges and valleys in the housing surface and cut-outs or vents  1636  around the circumference of the lamp. The heat sink  1611  can comprise ceramic, plastic, metal, combinations and composites thereof, as well as heat pipe technology. The preferred heat sinks  1611  comprise the materials discussed earlier in this application and are preferred for and applicable to all embodiments of the invention. The base  1612  shown is a standard E26/E27 base, which can be used for any embodiment of the invention. Any means can be used for securing the cover plate to the housing, including screws  1634  as shown. 
       FIGS. 17A-C  provide various views of another exemplary spot light bulb according to embodiments of the invention. As shown, this PAR-30 type bulb  1700  can be provided in 85-260V AC/DC input, having red, amber, green, blue, or white color LEDs. This bulb  1700  shows seven lenses  1720  secured by the housing cover plate, through which the lenses protrude by way of holes  1732  through the top surface  1731  of the cover plate. The lamp housing comprises heat sink  1711 , cover plate, and base  1712 , in addition to other components or features not shown or highlighted herein. Of particular interest in this embodiment is the configuration of heat sink  1711 , which provides for dissipation of heat by way of the longitudinally arranged ridges and valleys in the housing surface and cut-outs or vents  1736  around the circumference of the lamp. The heat sink  1711  can comprise ceramic, plastic, metal, combinations and composites thereof, as well as heat pipe technology. The preferred heat sinks  1711  comprise the materials discussed earlier in this application and are preferred for and applicable to all embodiments of the invention. The base  1712  shown is a standard E26/E27 base. Any means can be used for securing the cover plate to the housing, including screws  1734  which are accommodated through holes  1735  in the cover plate. 
       FIGS. 18A-C  provide various views of another exemplary spot light bulb according to embodiments of the invention. As shown, this PAR-38 type bulb  1800  can be provided in 85-260V AC input, having red, amber, green, blue, or white color LEDs. This bulb  1800  shows ten lenses  1820  secured by the housing cover plate, through which the lenses protrude by way of holes  1832  through the top surface  1831  of the cover plate. The lamp housing comprises heat sink  1811 , cover plate, and base  1812 , in addition to other components or features not shown or highlighted herein. Of particular interest in this embodiment is the configuration of heat sink  1811 , which provides for dissipation of heat by way of the longitudinally arranged ridges and valleys in the housing surface and cut-outs or vents  1836  around the circumference of the lamp. The heat sink  1811  can comprise ceramic, plastic, metal, combinations and composites thereof, as well as heat pipe technology. The preferred heat sinks  1811  comprise the materials discussed earlier in this application and are preferred for and applicable to all embodiments of the invention. The base  1812  shown is a standard E26/E27 base. Any means can be used for securing the cover plate to the housing, including screws  1834  which are accommodated through holes  1835  in the face  1831  of the cover plate as shown. As discussed above, various configurations for the housings can be used, which will include modifying the diameter of the housing larger or smaller and/or modifying the length of the housing shorter or longer. One advantage to making these modifications can be to increase or decrease the surface area of the heat sink as desired for a particular type bulb, application, or the number of LEDs used. 
     As can be seen in comparing the heat sinks  1611 ,  1711 , and  1811  respectively of  FIGS. 16 ,  17 , and  18 , modifications can be made to the lamp assemblies and in particular the disposition of the heat sink can be tailored for particular applications. For example, the number, size, and shape of vents  1636 ,  1736 , or  1836  can be increased or decreased as needed, as well as that of the fins (ridges). 
     A further object of the present invention is to provide a method of manufacturing a light assembly comprising: (a) positioning one or more lenses above one or more light emitting diodes (LEDs) by using a lens support comprising a recess for each lens, wherein each recess has an interior surface shape complementary to an exterior surface shape of a lens, and wherein each recess has a void capable of encompassing an LED; and (b) installing a cover plate to secure the lenses within a light assembly housing. 
     The lamp assemblies/bulbs of the present invention can be used for general illumination purposes, safety and security, signaling, backlighting, and for signage and decorative lighting. The lamp assemblies of the present invention can provide lighting in a range of colors, including for example red, yellow, green, blue, warm white, neutral white, and cool white. Further, the bulbs can be dimmable or non-dimmable, and/or programmable or non-programmable. 
     The present invention has been described with reference to particular embodiments having various features. It will be apparent to those skilled in the art that various modifications and variations can be made in the practice of the present invention without departing from the scope or spirit of the invention. One skilled in the art will recognize that these features may be used singularly or in any combination based on the requirements and specifications of a given application or design. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention. It is intended that the specification and examples be considered as exemplary in nature and that variations that do not depart from the essence of the invention are intended to be within the scope of the invention.