Patent ID: 8618742

Claim:
A method for forming a light source comprising: disposing light emitting diodes (LEDs) on an insulated substrate having input pads for receiving an operating voltage for the LEDs; bonding a flexible printed circuit to the insulated substrate, the flexible printed circuit including input contacts to receive the operating voltage and output pads to provide the operating voltage to the insulated substrate; bonding the insulated substrate onto a planar region of a heat sink using a thermally conductive adhesive; forming a driving module having a plurality of electronic circuits on a printed circuit board, the driving module including input contacts configured to receive a driving voltage from an external voltage source and a plurality of output contacts configured to output the operating voltage; disposing the driving module within a casing having a base, the plurality of input contacts and the plurality of output contacts extending beyond an interior of the casing; inserting the casing within an interior channel of the heat sink; electrically bonding the plurality of output contacts of the driving module to the plurality of input contacts of the flexible printed circuit; inserting the base in a compatible base socket; applying the driving voltage from the external voltage source; determining a light output brightness for the light source, and when the light output brightness exceeds a desired light output brightness; and packaging the light source in a protective container.