Patent Document

FIELD OF THE INVENTION 
       [0001]    The present invention relates, in general, to a high power Light Emitting apparatus and, more particular, this invention relates to a Light Emitting Diode(LED), attaching to a heat conductive objective. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to electrical device that generates heat, and more particularly to a high power light emitting diode, or LED chip incorporated with heat dissipation device (heat sink) for dissipating waste heat and keeping operation temperature low. The LED element used in present invention has body structure that is design to sit directly on heat conductive object. 
         [0004]    2. Description of the Related Art 
         [0005]    A number of different principles of LED devices have been developed over the years. Since LED operates the best at lower temperature and it has a luminary at top, many high power LEDs employ underbelly thermal pad to dissipate heat out of device into PCB and then eventually to a heat sink. 
         [0006]    A conventional high power LED chip has a luminary at top side of device, an underbelly thermal pad to dissipate heat and few electrodes for conduct electricity or signal. Both thermal pad and electrode contacts are facing downward for easy connection to printed circuit board (PCB). 
         [0007]    Typically path for waste heat of LED comes out of thermal pad goes in and through PCB then eventually goes into heat sink attaching at back of PCB. This conventional thinking of combining pre-made LED circuit board and pre-made heat sink method does not help reducing thermal path length; but increase both weight and cost. 
       DESCRIPTION OF THE RELATED ART 
       [0008]    A number of different principles of LED devices have been developed over the years. Since LED operates the best at lower temperature and it has a luminary at top, many high power LEDs employ underbelly thermal pad to dissipate heat out of device into PCB and then eventually to a heat sink. 
         [0009]    A conventional high power LED chip has a luminary at top side of device, an underbelly thermal pad to dissipate heat and few electric contacts for conduct electricity. 
         [0010]    Typically path for waste heat of LED comes out of thermal pad then goes in and through PCB then eventually goes into heat sink attaching at back of PCB. This conventional thinking of combining pre-made LED circuit board and pre-made heat sink method does not help reducing thermal path length; but increase both weight and cost. 
         [0011]    U.S. Pat. No. 5,785,418 to Peter A. Hochstein describes a LED array attach to PCB and then to heat sink block to fast dissipate heat. 
         [0012]    U.S. Pat. No. 7,227,750 to Bishou Chen, Sheng Li describes a LED module has pins to conduct heat to back of PCB. 
         [0013]    U.S. Pat. No. 7,806,574 to Peter Van Laanen and Jeff Bisberg describes a LED base lighting system which dissipates heat through PCB and structure member. 
         [0014]    U.S. Pat. No. 7,044,620 to Paul D. Van Duyn describes a LED lighting system which dissipate heat through high conductivity material and use a separated PCB with reversed mounting pad and traces. 
         [0015]    application Ser. No. 12/928,644 from Taiming Chen (same Inventor) describes a LED LAMP comprising of modules with LEDs mounted on edge of plates. 
       BRIEF SUMMARY OF THE INVENTION 
       [0016]    The present invention comprises an improved light emitting device, such as a high power LED chip, the device is designed to easily mount directly on a high conductivity object such as metal plate with its underbelly thermal pad making direct contact to metal plate. Heat comes out of LED thermal pad goes direct into metal plate and eventually dissipate into surrounding air through surface area of metal plate. 
         [0017]    Compare to conventional mounting method for heat generating device, the present invention does not mount on top of PCB via electrodes and thermal pad; the under side of present invention has only thermal unit to make contact and bounding with heat conductive object; all electronic contacts, such as electrodes, are away from the mounting area. The major functions of a Printed Circuit Board are to provide attachment and circuit contacts to components. Since bounding to heat conductive object already provide function of attachment, a rigid PCB is no longer needed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a perspective view of a traditional LED device. 
           [0019]      FIG. 2  is a sectional view of a traditional LED device mounted on PCB and corporate with heat sink. 
           [0020]      FIGS. 3 and 4  are perspective views of a LED and a corporative PCB. 
           [0021]      FIG. 5  is cancelled. 
           [0022]      FIG. 6  is a perspective view, showing two LED, a corporative PCB and heat conductive object. 
           [0023]      FIG. 7  is a perspective view of a present invention, showing two LED mounting on heat conductive object, with flexible wiring. 
           [0024]      FIG. 8  is a perspective view of present inventions, LED with bulge heat stub. 
           [0025]      FIG. 9  is a perspective view of present invention and heat conductive object. 
           [0026]      FIG. 10  is a perspective view, showing two LED attach to a heat conductive object. 
           [0027]      FIG. 11-14  are perspective views of present invention, LED with clamping walls to attach on edge of plate. 
           [0028]      FIG. 15  is a perspective view of a present invention adaptor with traditional LED. 
           [0029]      FIG. 16  is a perspective view of a present invention adaptor with traditional LED. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0030]    Prior to proceeding to the more detailed description of the present invention, it should be noted that, for the sake of clarity and understanding, identical components which have identical functions have been identified with identical reference numerals throughout the several views illustrated in the drawing figures. 
         [0031]      FIG. 1  shows a perspective view of a traditional LED chip that has luminary  1  on top of base  2 , a thermal pad  3  and electrodes  4  and  5  are underneath the base. 
         [0032]      FIG. 2  shows a sectional view of traditional LED  2  mounted on top side of a PCB  10  and corporate with a heat sink  20  at the other side of PCB. Both electrodes and thermal pad of LED are connected toward PCB  10  at below. 
         [0033]      FIG. 3  shows another perspective view of a LED  2  has only thermal pad  3  at underneath of LED base  2 . A corporative PCB  10  with cut out  15  for exposing luminary  1 . PCB  10  has contact points  11  and  12  facing downward to LED base  2 . 
         [0034]      FIG. 4  shows another perspective view of a LED  2 , same as  FIG. 3 . Wherein shows electrodes  4  and  5  at top side LED base  2 . Electrodes  4  and  5  are facing upward toward PCB  10  from above. 
         [0035]      FIG. 5  is a cancelled. 
         [0036]      FIG. 6  shows another perspective view of a example, showing at least two LED luminaries  1 , sharing one PCB  10  and one heat conductive object  20 . PCB  10  is fasten by two screws  21  on to heat conductive object  20  and can be used to hold down LED  1 . 
         [0037]      FIG. 7  shows a perspective view of two LED  2  mounted on top of a heat connective object  20  with screws  21 . Circuitry is provided by electrical wires  50  solder on electric contacts  4 , 5 . Electric contacts  4 ,  5  are away from heat conductive object  20 . 
         [0038]      FIG. 8  shows a perspective view of two instances of presenting invention, each LED comprising of a LED luminary  1 , a main body structure  42 , an penetrative thermal stub  43  underneath the body structure  42  for entering and anchoring to heat conductive object  20 , two electric contacts  4 ,  5  are at up side of main body structure  42 . 
         [0039]      FIG. 9  shows a perspective view of presenting invention and a heat conductive object with two pre-drilled pilot holes  25  to accept penetrative thermal stub  43 . Thermal stub  43  may have screw thread to bite into edge of hole  25  or just fasten with friction force to hole  25  wall tightly. 
         [0040]      FIG. 10  shows a perspective view of two presenting LED  42  bound on top of a heat conductive object. Circuitry are connected by flexible wires  50 . 
         [0041]      FIG. 11  shows a perspective view of a present invention comprising of a LED luminary  1 , a main body structure  32 , a thermal pad  3  is underneath the body  32 , two electric contact  4 ,  5  and two clamping walls  30 . Clamping walls  30  are to clamp on both side surfaces of a matching plate  20 . Matching plate  20  has two large side surfaces and narrower edge surface  22  around said side surfaces. Electric contacts  4 , 5  are away from matching plate  20 . 
         [0042]      FIG. 12  shows another perspective view of present invention same as in  FIG. 8 . When this improved LED device  32  goes down to clamp at edge of matching plate  20 , underneath thermal pad  3  would made direct contact with edge surface  22  of a plate. The clamping would work best when plate has matching thickness close to distance between two clamping walls  30  of said LED device  32 . 
         [0043]      FIG. 13  shows a perspective view of a present invention, similar to  FIGS. 8 and 9 ; in additional the device  32  has snap bumps  35  alongside of clamping wall  30 ; the plate  20  has matching notch hole  23  for accepting snap bumps  11 . When bump snap  35  is actuated with notch hole  23 , the device  32  is held at desired position. 
         [0044]      FIG. 14  is another view of a present invention same as in  FIG. 10 . Wherein the device&#39;s snap bumps  35  actuated into notch holes  23  to hold the device  32  in position. 
         [0045]      FIG. 15  is a perspective view of a present invention; where an adaptor device has body structure  33  is designed to work with a traditional LED device  2  same as in  FIG. 1 . Adaptor  33  has groove channels  31  to accept base  2  of LED. Once adaptor  33  is integrated with LED device  2 , adaptor device  33  has two clamping walls  30  to clamp on both side surfaces of a matching plate  20  and position LED  2  to sit on the edge surface  22  of plate. 
         [0046]      FIG. 16  is a perspective view of a present invention; where an adaptor device  53  is designed work with a traditional LED  2  same as  FIG. 1 . Said adaptor device has a hex nut shape base  53  and bulge thermal stub  43  extend from under said base  53  to top side of base to make contact with thermal pad  3  of a traditional LED  2 . Said base  53  also has electrodes  54 , 55  to make contact with electrodes  4 ,  5  of traditional LED  2 .

Technology Category: 2