Patent Publication Number: US-8125776-B2

Title: Socket and heat sink unit for use with removable LED light module

Description:
BACKGROUND 
     1. Field 
     The present invention is directed to a socket and heat sink unit for an LED light fixture, and more particularly to a replaceable socket and heat sink unit for use with a removable LED light module. 
     2. Description of the Related Art 
     Light fixture assemblies such as lamps, ceiling lights, and track lights are important fixtures in many homes and places of business. Such assemblies are used not only to illuminate an area, but often also to serve as a part of the decor of the area. However, it is often difficult to combine both form and function into a light fixture assembly without compromising one or the other. 
     Traditional light fixture assemblies typically use incandescent bulbs. Incandescent bulbs, while inexpensive, are not energy efficient, and have a poor luminous efficiency. To address the shortcomings of incandescent bulbs, a move is being made to use more energy-efficient and longer lasting sources of illumination, such as fluorescent bulbs, high-intensity discharge (HID) bulbs, and light emitting diodes (LEDs). Fluorescent bulbs and HID bulbs require a ballast to regulate the flow of power through the bulb, and thus can be difficult to incorporate into a standard light fixture assembly. Accordingly, LEDs, formerly reserved for special applications, are increasingly being considered as a light source for more conventional light fixtures assemblies. 
     LEDs offer a number of advantages over incandescent, fluorescent, and HID bulbs. For example, LEDs produce more light per watt than incandescent bulbs, LEDs do not change their color of illumination when dimmed, and LEDs can be constructed inside solid cases to provide increased protection and durability. LEDs also have an extremely long life span when conservatively run, sometimes over 100,000 hours, which is twice as long as the best fluorescent and HID bulbs and twenty times longer than the best incandescent bulbs. Moreover, LEDs generally fail by a gradual dimming over time, rather than abruptly burning out, as do incandescent, fluorescent, and HID bulbs. LEDs are also desirable over fluorescent bulbs due to their decreased size and lack of need of a ballast, and can be mass produced to be very small and easily mounted onto printed circuit boards. 
     While LEDs have various advantages over incandescent, fluorescent, and HID bulbs, the widespread adoption of LEDs has been hindered by the challenge of how to properly manage and disperse the heat that LEDs emit. The performance of an LED often depends on the ambient temperature of the operating environment, such that operating an LED in an environment having a moderately high ambient temperature can result in overheating the LED, and premature failure of the LED. Moreover, operation of an LED for extended period of time at an intensity sufficient to fully illuminate an area may also cause an LED to overheat and prematurely fail. 
     Accordingly, high-output LEDs require direct thermal coupling to a heat sink device in order to achieve the advertised life expectancies from LED manufacturers. This often results in the creation of a light fixture assembly that is not upgradeable or replaceable within a given light fixture. For example, LEDs are traditionally permanently coupled to a heat-dissipating fixture housing, requiring the end-user to discard the entire assembly after the end of the LED&#39;s lifespan. 
     Accordingly, there is a need for a replaceable socket and heat sink unit that can couple to a removable LED light module and can be easily incorporated in a variety of light fixtures. 
     SUMMARY 
     In accordance with one embodiment, a socket and heat sink unit for use with a removable LED light module is provided. The unit includes a socket portion configured to releasably couple to a removable LED light module. The unit also includes a heat sink portion attached to the socket portion and extending about a central axis. The heat sink portion comprises a plurality of fins, as well as one or more apertures configured to receive fasteners therein to fix the unit to a light fixture housing. The socket and heat sink portions are monolithic. 
     In accordance with another embodiment, a socket and heat sink unit coupleable to a removable LED light module is provided. The unit includes a socket portion configured to releasably couple to a removable LED light module, the socket having one or more openings formed in a base thereof and one or more ramps aligned with said openings, said ramps configured to releasably couple to an LED light module. The unit also includes a heat sink portion attached to the socket portion and extending about a central axis, the heat sink portion comprising a plurality of fins defining channels or recesses aligned with said openings in the socket. The socket and heat sink portions are monolithic, and the unit can be formed in a die casting process comprising a die and co-operating slides, said slides positionable relative to the die to form the channels, openings and one or more edges of said ramps, the slides removable from the die when the die casting process is complete. 
     In accordance with yet another embodiment, a method of manufacturing a socket and heat sink unit is provided. The method includes the step of providing a die having one or more complementary halves, said die having a shape complementary to the socket and heat sink unit. The method also includes the step of positioning one or more slides in a desired position relative to the die. Further, the method includes injecting molten metal under pressure into the die to die cast the socket and heat sink unit, the socket portion having one or more openings formed in a base thereof and one or more ramps aligned with said openings, said ramps configured to releasably couple to an LED light module. The heat sink is attached to the socket portion and extending about a central axis, the heat sink portion comprising a plurality of fins defining channels aligned with said openings in the socket. The slides are positionable relative to the die to form the channels, openings and one or more edges of said ramps when the molten metal is injected into the die, the slides removable from the die when the die casting process is complete. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective top view of one embodiment of a socket and heat sink unit. 
         FIG. 2  is a perspective bottom view of the socket and heat sink unit in  FIG. 1 . 
         FIG. 3  is a top view of the socket and heat sink unit in  FIG. 1 . 
         FIG. 4  is a bottom view of the socket and heat sink unit in  FIG. 1 . 
         FIG. 5  is a side view of the socket and heat sink unit in  FIG. 1 . 
         FIG. 6  is another side view of the socket and heat sink unit in  FIG. 1 , rotated 90 degrees from the view in  FIG. 5 . 
         FIG. 7  is another side view of the socket and heat sink unit in  FIG. 1 , rotated 90 degrees from the view in  FIG. 6 . 
         FIG. 8  is another side view of the socket and heat sink unit in  FIG. 1 , rotated 90 degrees from the view in  FIG. 7 . 
         FIG. 9  is a perspective top view of another embodiment of a socket and heat sink unit. 
         FIG. 10  is a perspective bottom view of the socket and heat sink unit in  FIG. 9 . 
         FIG. 11  is a side view of the socket and heat sink unit in  FIG. 9 . 
         FIG. 12  is another side view of the socket and heat sink unit in  FIG. 9 , rotated 90 degrees from the view in  FIG. 11 . 
         FIG. 13  is another side view of the socket and heat sink unit in  FIG. 9 , rotated 90 degrees from the view in  FIG. 12 . 
         FIG. 14  is another side view of the socket and heat sink unit in  FIG. 9 , rotated 90 degrees from the view in  FIG. 13 . 
         FIG. 15  is a top view of the socket and heat sink unit in  FIG. 9 . 
         FIG. 16  is a bottom view of the socket and heat sink unit in  FIG. 9 . 
         FIG. 17  is a perspective schematic view of the socket and heat sink unit of  FIG. 1  and exploded view of one embodiment of a mold for forming the socket and heat sink unit. 
         FIG. 18A  is a perspective view of the socket and heat sink unit of  FIG. 1 . and a part of its corresponding mold during a step in the manufacturing process. 
         FIG. 18B  is a perspective view of the socket and heat sink unit of  FIG. 1 . and a part of its corresponding mold during another step in the manufacturing process. 
         FIG. 18C  is a perspective view of the socket and heat sink unit of  FIG. 1 . and a part of its corresponding mold during another step in the manufacturing process. 
         FIG. 18D  is a perspective view of the socket and heat sink unit of  FIG. 1 . and a part of its corresponding mold during another step in the manufacturing process. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIGS. 1-8  depict one embodiment of a socket and heat sink unit  100  for use with a removable LED light module. 
     The unit  100  includes a holder or socket  10  at a proximal end and a heat sink  50  at a distal end thereof, where the socket  10  and heat sink  50  extend along a longitudinal central axis X. In a preferred embodiment, the unit  100  is monolithic, so that the socket  10  and heat sink  50  are portions of a single piece. 
     The socket  10  preferably includes a wall  12  that can define a periphery of the socket  10 . In the illustrated embodiment, the wall  12  defines a continuous circumference of the socket  10 . In another embodiment, the wall  12  can define the circumference of the socket  10  but be discontinuous. 
     The wall  12  can define an outer surface  14  and an inner surface  16 . In one embodiment, the wall  16  can include one or more recessed portions  18  formed on one of the inner surface  16  and outer surface thereof. In the illustrated embodiment, the recessed portions  18  are formed on the inner surface  16  of the wall  12 . As best shown in  FIG. 3 , the socket  10  has four recessed portions  18  on the inner surface  16  of the wall  12 . However, the wall can have fewer or more recessed portions  18 . Preferably, the number of recessed portions  18  (or locking ramps) corresponds to a number of coupling members (e.g., protrusions or tabs) on the removable LED light module that fix the LED light module relative to the socket  10 . However, in another embodiment, the number of recesses  18  of the socket  10  can be different than the number of coupling members of the LED light module. Such coupling members may be formed on an outer surface of the LED light module housing (e.g., extend radially from an outer radial wall of said housing). 
     The recessed portion  18  can define an opening  18   a  proximate a rim  10   a  of the socket  10  that has a circumferential width W 1  smaller than a circumferential width W 2  of a generally horizontal portion  18   b  of the recessed portion  18 . In another embodiment, the width W 1  can be greater than the width W 2 . In use, each protrusion of the removable LED light module extends through the opening  18   a  of one of the recessed portions  18 . A user can then rotate the removable LED light module relative to the socket  10  so that the coupling members of the light module move within the horizontal portion  18   b  and along an underside edge  20 , which in one embodiment can be generally horizontal. The user can continue to rotate the LED light module until the coupling members contacts the stop portion  18   c  of the recessed portion  18  to thereby couple the LED light module to the socket  10 . However, the LED light module can be removably coupled to the socket  10  via other suitable mechanisms (e.g., brackets, press-fit connection, threads, etc.). 
     The socket  10  can also include a base  22 . In one embodiment, the base  22  and the wall  12  define a recessed cavity  24  into which at least a portion of the LED light module can extend. In another embodiment (not shown), the base of the socket is proximate the rim  10   a  of the socket  10 , so that the base  22  and wall  12  do not define such a recessed cavity. As used herein, “socket” refers to a holder to which the removable LED light module couples and is not limited to any particular shape. In a preferred embodiment, a heat transfer surface of the removable LED light module is brought into contact with the socket  10  (e.g., the base  22  of the socket  10 ), when the light module is coupled to the socket  10 , which facilitates the transfer of heat from the LED light module to the socket  10  and to the heat sink  50  attached to the socket  10 . 
     In the illustrated embodiment, the base  22  has one or more openings  26  aligned with the recessed portions  18 . Each opening can have a circumferential width W 3  and a radial width W 4 . In the illustrated embodiment, the circumferential width W 3  is substantially equal to the width W 2  of the horizontal portion  18   b , and the radial width W 4  is greater than the radial width W 5  of the recessed portion  18 , as best shown in  FIG. 3 . 
     With continued reference to  FIG. 3 , the base  22  of the socket  10  can have a raised portion  30  to which a terminal block with one or more electrical contacts can be fastened. For example, the terminal block can be attached to the raised portion  30  with one or more fasteners (e.g., screws, bolts, pins) inserted through holes  30   a  in the raised portion  30 . Advantageously, the terminal block can removably connect to an electrical contact on the removable LED light module when the light module is coupled to the socket  10 . The raised portion  30  can include an aperture  32  formed through the base  22 , as best shown in  FIG. 3 . The wall  12  can also include one or more apertures  34  formed therethrough. In one embodiment, an electrical cord for the terminal block can extend through the aperture  32  in the base  22 . In another embodiment, the electrical cord for the terminal block can extend through the aperture  34  in the wall  12 . 
     With reference to FIGS.  2  and  5 - 8 , the heat sink  50  can include a plurality of plate-like members  52  spaced axially apart from each other along the axis X so that the plate-like members  52  are stacked relative to each other. In one embodiment, the plate-like members  52  are all spaced apart from each other by the same amount. In another embodiment, at least two adjacent plate-like members  52  are closer to each other than to other adjacent plate-like members  52 . The plate-like members  52  are attached to each other at a central portion  54  that extends along the axis X. In one embodiment, the central portion  54  is symmetric about the axis X. The plate like members  52  can also include a fin portion  56  that extends radially outward from the central portion  54 . In a preferred embodiment, as illustrated in  FIGS. 3-4 , the plate-like members  52  are symmetric about the axis X and the fin portion  56  extends radially outward relative to the axis X to a boundary  56   a  so that the fin portion  56  has a maximum outer radius that is generally equal to a radius of the outer surface  14  of the socket  10 . In another embodiment, the fin portion  56  has a maximum outer radius that is larger than the radius of the outer surface  14  of the socket  10 . 
     With reference to  FIGS. 1 ,  2  and  5 - 8 , the fin portion  56  of each plate-like member  52  can have one or more recesses  58  formed along the circumference of the plate-like member  52 . Each recess  58  can extend radially inward from the boundary  56   a  of the fin portion  56 . In another embodiment, the fin portion  56  has a maximum outer radius equal to the outer radius of the recess  58 . In the illustrated embodiment, as best shown in  FIGS. 2 and 4 , the recesses  58  of the fin portions  56  on each plate-like member  52  generally axially align with each other. In one embodiment, each recess  58  has the same size as the corresponding opening  26  in the base  22  and the recesses  58  have generally the same shape. For example, in one embodiment, the circumferential and radial widths W 6 , W 7  of the recesses  58  are generally equal to the radial and circumferential widths W 3 , W 4  of the openings  26  in the base  22 , respectively. 
     In another embodiment, as best shown in  FIGS. 2 and 4 , at least one of the recesses  58  in a fin portion  56  has a different shape than the other recesses  58  of the fin portion  56 . As shown in  FIG. 2 , one or more of the recesses  58  of each plate-like member  52  can have a hook portion  58   a , such that the hook portions  58   a  are axially aligned. In the illustrated embodiment, the hook portions  58   a  have a generally circular shape. However, in other embodiments the hook portion  58   a  can have other suitable shapes. Preferably, the hook portions  58   a  are sized to allow the passage of an electrical cord therethrough, which can pass through the aperture  32  in the base  22  and connect to the terminal block. 
     With continued reference to FIGS.  2  and  5 - 8 , the fin portion  56  of each plate-like member  52  can have one or more bores  60  that extend radially inward from the boundary  56   a  toward the central portion  54 . In the illustrated embodiment, each fin portion  56  has four bores  60 , and the bores  60  on each plate-like member  52  generally align with the bores  60  on the other plate-like members  52 . However, the fin portion  56  of the plate-like members  52  can have fewer or more bores than shown in  FIG. 2 . For example, in some embodiments, the fin portion  56  of each plate-like member  52  can have only one bore. In another embodiment, not all plate-like members  52  have bores formed on their fin portions  56 . Additionally, the plate-like member  52  at a distal end  50   a  of the heat sink  50  can also have one or more bores  62  that extend generally axially or parallel to the X axis. Advantageously, the bores  60 ,  62  allow the socket and heat sink unit  100  to be fastened to, for example, a housing of a light assembly in a variety of orientations, therefore increasing the versatility of the socket and heat sink unit  100 . Additionally, the plurality of bores  60 ,  62  allow the unit  100  to be easily replaced and/or repositioned as needed. For example, where the housing is a recessed can of a recessed lighting fixture, the socket and heat sink unit  100  can be fastened to the circumferential and/or rear walls of the recessed can via fasteners (e.g., screws) inserted through the bores  60 ,  62 , respectively. 
     As noted above, the socket  10  and heat sink  50  of the unit  100  are preferably monolithic. For example, the unit  100  can be molded from a single piece. In a preferred embodiment, the unit  100  can be die cast using a single die-casting tool set  300  (see  FIGS. 17-18D ). In one embodiment, the tool set  300  can include two or more complementary sections  300 A- 300 F that together form the die for the unit  100 . The tool set  300  can also preferably include one or more slides  350  positionable relative to at least one of the sections  300 A- 300 E of the die to define the recesses  58 . Said slides  350  advantageously extend through strategically aligned slots  310  and past openings  312  in sections  300 B- 300 E of the die, which correspond to the openings  26  in the socket  10 . Additionally, a proximal portion  352  of the slide  350  can have a contour C that defines one or both of the horizontal edge  20  and the stop portion  18   c  of the recessed portion  18 . Once the die casting process is complete, the slides  350  can be removed from the die, leaving the openings  26  and recesses  58  formed in the socket  10  and heat sink  50 , respectively. Preferably, the slides  350  have an inner surface contour  354  that corresponds to the contour of the surface of the fin  56  and openings  26 . For example, the slides  350  can have a curved contour that corresponds to the curved edge of the recesses  58  and curved edge of the openings  26 . Other slides can be used to form the bores  60 ,  62  in the fin portions  56  and the bore  34  in the socket  10 . 
     In the embodiment shown in  FIGS. 17-18D , the tool set  300  includes a top section  300 A, a plurality of side sections  300 B- 300 E and a bottom section  300 F. In use, the side sections  300 B- 300 E can be placed adjacent each other so as to form a block. Advantageously, one or more of the side sections  300 B- 300 E have one or more strategically aligned slots  310  that extend from the bottom  302  of the section  300 B- 300 E to a location proximal the top  304  of the section  300 B- 300 E. Preferably, the slot  310  defines an opening  312  in a base  306  of a top portion  308  of the section  300 B- 300 E. 
     With continued reference to  FIG. 17 , in one embodiment each of the sections  300 B- 300 E forms one quadrant of the socket and heat sink unit  100 . However, in other embodiments the tool set  300  can have more or fewer sections. In the illustrated embodiment, the slots  310  define a surface  318  between the base  306  and the top  304  of the section  300 B- 300 E. Additionally, at least one of the sections  300 A- 300 E can have a generally circumferential surface  316  that extends between the surfaces  318  defined by the slots  310 . At least a portion of the surfaces  316 ,  318  define a surface of the socket  10 . The tool set  300  also includes a blade section  320  that defines a plurality of blades spaced apart by slots  322 . Advantageously, the blade section  320  defines the heat sink section  50  of the socket and heat sink unit  100 . 
     With reference to  FIGS. 18A-18D , after the sections  300 A- 300 F are assembled into the tool set  300  to form a die, molten metal is introduced into the die. Once the die casting process has been completed, the top section  300 A and side sections  300 B- 300 E can be removed, as shown in  FIG. 18A . The bottom section  300 F with the slides  350  can then be withdrawn, as shown in  FIGS. 18A-18D . As can be seen as the bottom section  300 F is withdrawn, the slides  350  have formed the recesses  58  in the heat sink section  50  of the unit  100 . Additionally, the contour C of the proximal portion  352  of the slide  350  has advantageously formed one or more surface of the recessed portions  18  of the socket  10 . In the illustrated embodiment, the contour C of the proximal portion  352  of the slide  350  has formed the underside edge  20  and a stop portion  18   c , as well as a front edge  18   d  of the recessed portion  18 . Accordingly, the tool set  300  can advantageously be used to manufacture a one piece socket and heat sink unit  100 , including all features (e.g., recessed portions  18  or locking ramps) needed to couple a removable LED light module to the socket  10  without additional machining. 
     Advantageously, said die-casting process allows the socket and heat sink unit  100  to be manufactured in an efficient and cost effective manner without requiring any additional machining, thus resulting in less cost and time for manufacturing the unit  100 . Additionally, die-casting the unit  100  allows the socket  10  to also function as a heat dissipating member, with the wall  12  and base  22  of the socket  10  able to dissipate heat from the LED light module when said module is coupled to the socket  10 . 
     In another embodiment, the unit  100  can be machined from a single piece using machining methods known in the art, with the recesses  58  and the openings  26  in the base  22  are formed generally at the same time. In still another embodiment, the unit  100  can be injection molded (e.g., where the unit  100  is made from a thermoplastic material). 
     Forming the socket  10  and heat sink  50  from a single piece advantageously reduces the cost of manufacture and the waste of material. For example, since all of the recesses  58  and openings  26  can be formed at the same time, the amount of time necessary for manufacturing the unit  100  is reduced. Additionally, the unit  100  has improved resiliency since the assembly of multiple pieces is avoided. 
     The unit  100  can be made from any suitable material configured to conduct heat in an amount suitable for the removal of heat from the removable LED light module. In one embodiment, the unit  100  can be made of metal. In another embodiment, the unit  100  can be made of a heat conductive plastic. 
       FIGS. 9-16  show another embodiment of a socket and heat sink unit  200 . The unit  200  has some similar features as the unit  100 , except as noted below. Thus, the reference numerals used to designate the various components of the unit  200  are identical to those used for identifying the corresponding components of the unit  100 , except that a “2” has been added to the reference numerals. 
     In the illustrated embodiment, the unit  200  includes a holder or socket portion  210  and a heat sink portion  250  that extend (e.g., symmetrically) about a central axis X. The socket portion  210  has generally the same structure as the socket portion  10  described above and includes a wall  212  with an outer surface  214  and an inner surface  216 , where one or more recess portions  218  can be formed on one of the inner and outer surfaces  214 ,  216 . The recess portions  218  can be spaced circumferentially along the wall  212  (e.g., evenly spaced from each other), and can include an opening  218   a  proximate the rim  210   a  of the socket portion  210  and a horizontal portion  218   b  defined by a horizontal edge  220  and stop edge  218   c.    
     With continued reference to  FIG. 9 , the socket portion  210  can have a base  222 , which in one embodiment can define a recessed cavity with the wall  212 . The base  222  can include one or more openings  224  along a boundary between the base  222  and the wall  212 . The openings  224  can correspond to the recess portions  218 , where each opening  224  has a circumferential width that generally corresponds to the circumferential width of the horizontal portion  218   b  of the recess  218 . In one embodiment, the radial width of the opening  224  can be equal to or greater than the radial width of the recess portion  218 . 
     As shown in  FIGS. 9 and 15 , the base  222  of the socket  210  can include a raised portion  230  to which a terminal block, as described above, can be fastened. For example, the terminal block can be attached to the raised portion  230  with one or more fasteners (e.g., screws, bolts, pins) inserted through holes  230   a  in the raised portion  230 . Additionally, one or more apertures  230   b  can be formed through the base  222  between the raised portion  230  and the wall  212  through which an electrical cord for the terminal block can extend. The wall  212  can also include one or more apertures  234  formed therethrough and in another embodiment the electrical cord for the terminal block can extend through the aperture  234 . 
     With reference to  FIGS. 9-14  and  16 , the heat sink  250  can include a plurality of plate like fins  252  extending radially outward from a central potion  254 . The plate like fins  252  can include one or more primary fins  252   a  that extend radially outward from the central portion  254  to an outer edge  252   b . In one embodiment, the outer edge  252   b  can be a distance from the X axis generally equal to the radius of the outer surface  214  of the wall  212 . In the illustrated embodiment, the heat sink  250  has four primary fins  252   a . However, the heat sink  250  can have more or fewer primary fins  252   a . In one embodiment, the primary fin  252   a  can have one or more bores  260  formed on the outer edge  252   b  and extending generally horizontal toward the central portion  254 . 
     The plate-like fins  252  can also include one or more secondary fins  252   c . In the illustrated embodiment, as best shown in  FIG. 16 , the heat sink  250  has eight secondary fins  252   c , with a secondary fin  252   c  disposed on either side of the primary fin  252   a . Preferably, the secondary fin  252   c  has an outer edge  252   d  generally axially aligned with the outer surface  214  of the wall  212  of the socket portion  210 . However, the heat sink  250  can have more or fewer secondary fins  252   c.    
     The plate-like fins  252  can also include one or more short fins  252   e . In the illustrated embodiment, as best shown in  FIG. 16 , the heat sink  150  has twelve short fins  252   e , with three short fins  252   e  disposed between each pair of primary fins  252   a . However, the heat sink  250  can have more or fewer short fins  252   e . Preferably, the short fins  252   e  have an outer edge  252   f  aligned with an inner edge of the openings  224  so that the short fins  252   e  do not obstruct the openings. Therefore, in the illustrated embodiment, the fins  252  of the heat sink  250  define four generally identical quadrants about the X axis, as best shown in  FIG. 16 . 
     In one embodiment, the short fins  252   e  are spaced apart from each other by an equal amount. In another embodiment, at least two adjacent short fins  252   e  are closer to each other than to other adjacent short fins  252   e . In one embodiment, the spacing between the short fins  252   e  and the secondary fins  252   c  is generally the same as the spacing between adjacent short fins  252   e . In another embodiment, the spacing between the short fins  252   e  and the secondary fins  252   c  is different (e.g., larger or smaller) than the spacing between adjacent short fins  252   e . In still another embodiment, the spacing between the primary fin  252   a  and the secondary fin  252   c  is generally the same as the spacing between the secondary fin  252   c  and an adjacent short fin  252   e . In other embodiments, the spacing between the primary fin  252   a  and the secondary fin  252   c  can be different (e.g., larger or smaller) than the spacing between the secondary fin  252   c  and an adjacent short fin  252   e . In still another embodiment, the primary fins  252   a , secondary fins  252   b  and short fins  252   e  can be equally spaced apart about the circumference of the heat sink  250 . In another embodiment, the fins  252  can have a curved or arcuate shape, such that when viewed from the end, as in  FIG. 16 , the fins  252  define a spiral shape, with some fins  252   a  being longer and some fins  252   e  being shorter. As discussed further below, the outer edge of the short fins  252   e  can correspond to the edge of the openings  224  and can, in one embodiment, be formed by slides used in conjunction with a die in a die-casting process. In one embodiment, the central portion  254  can have a circular cross-sectional shape, rather than the generally square shape shown in  FIG. 16 . However, the central portion  254  can have other suitable shapes. 
     In one embodiment, one or more bores  262  can be formed on the distal end  250   b  of the heat sink  250 , that extend generally axially or parallel to the X axis. Advantageously, the bores  260 ,  262  allow the socket and heat sink unit  200  to be fastened to, for example, a housing of a light assembly in a variety of orientations, therefore increasing the versatility of the socket and heat sink unit  200 . 
     As with the unit  100 , the unit  200  can be made from any suitable material configured to conduct heat in an amount suitable for the removal of heat from the removable LED light module. In one embodiment, the unit  200  can be made of metal (e.g., aluminum or zinc) or metal alloy. In another embodiment, the unit  200  can be made of a heat conductive plastic. Additionally, the unit  200  can be injection molded or machined using processes known in the art. Preferably, as discussed above in connection with the embodiment of  FIGS. 1-8 , a die-casting process can be used to manufacture the unit  200  from a single tool set. In particular, a die with two complementary halves can be used in conjunction with one or more slides positionable relative to the die so as to form the openings  224  in the socket  210 , as well as the outer edges  252   f  of the short fins  252   e . Accordingly, the slides facilitate the formation of the quadrants of the heat sink  250  described above. As noted above, the die-casting process provides an efficient method of manufacturing the socket and heat sink unit  200  without additional machining, thus resulting in reduced time and cost for manufacturing the unit  200 . Additionally, as discussed above, die casting advantageously allows the socket  210  to function as a heat dissipating member, with the wall  212  and base  222  of the socket  210  dissipating heat from the LED light module when the module is coupled to the socket  210 . 
     Of course, the foregoing description is that of certain features, aspects and advantages of the present invention, to which various changes and modifications can be made without departing from the spirit and scope of the present invention. Moreover, the socket and heat sink unit need not feature all of the objects, advantages, features and aspects discussed above. Thus, for example, those of skill in the art will recognize that the invention can be embodied or carried out in a manner that achieves or optimizes one advantage or a group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. In addition, while a number of variations of the invention have been shown and described in detail, other modifications and methods of use, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is contemplated that various combinations or subcombinations of these specific features and aspects of embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the discussed socket and heat sink unit.