Patent ID: 8317358

Claim:
A method of manufacturing a light emitting diode (LED) lamp, comprising: providing first and second light engines each including: a substrate comprising a transparent or translucent thermally conductive material, a plurality of LED semiconductor devices mounted to the substrate, a plurality of conductive traces formed over the substrate to electrically interconnect each of the plurality of LED semiconductor devices, and conductive leads connected to the substrate for supplying electrical energy to the plurality of LED semiconductor devices; providing a thermally conductive rod including a circular first end and a flattened second end with a distance between opposing parallel sides of the flattened second end less than a diameter of the circular first end and a face of the flattened second end perpendicular to a length of the thermally conductive rod; mounting the first and second light engines respectively over the opposing parallel sides of the flattened second end of the thermally conductive rod; forming a heatsink by an extrusion, molding, stamping, or die casting process to provide a fin structure for dissipating heat energy; inserting the diameter of the circular first end of the thermally conductive rod into an opening in the heatsink; and mounting an optical housing to the heatsink and disposed over the face of the flattened second end such that the first and second light engines are suspended within the optical housing.