Light emitting assembly with independent heat sink LED support
A light emitting assembly ( 10 ) is fabricated by forming a continuous strip of aluminum heat sink having a pair of fins ( 32 ) aligned with the side edges ( 20 ) and cutting the continuous strip into a plurality of elongated sections ( 18 ). The elongated sections ( 18 ) are disposed in spaced and generally parallel relationship to one another and separated by an elongated slot ( 26 ) so that adjacent elongated sections ( 18 ) are independent of one another. A plurality of light emitting diodes ( 24 ) are disposed on the mounting surface ( 14 ) of each elongated section ( 18 ). Bridges ( 28 ) constructed of a material different from the material of the heat sink interconnect the elongated sections ( 18 ). An independent cover ( 52 ) is adhesively secured to the mounting surface ( 14 ) around the light emitting diodes ( 24 ) on each elongated section ( 18 ). A housing ( 56 ) spaced from the fins ( 32 ) is disposed over the assembly ( 10 ).
1. A light emitting assembly ( 10 ) comprising:
a heat sink presenting a mounting surface ( 14 ),
a plurality of light emitting diodes ( 24 ) disposed on said mounting surface ( 14 ),
said heat sink being defined by a plurality of elongated sections ( 18 ) extending between opposite ends ( 22 ) and being disposed in generally parallel relationship to one another to present side edges ( 20 ) extending continuously between said ends ( 22 ) to separate and render adjacent elongated sections ( 18 ) and said light emitting diodes ( 24 ) on said mounting surface ( 14 ) thereof independent of one another,
at least one bridge ( 28 , 128 ) interconnecting adjacent elongated sections ( 18 ) to maintain said elongated sections ( 18 ) connected together, and wherein said at least one bridge ( 28 , 128 ) comprises a material different from the material of said heat sink.
2. An assembly ( 10 ) as set forth in claim 1 wherein said at least one bridge ( 28 ) comprises a pair of said bridges ( 28 ) spaced and parallel to one another and extending transversely to said elongated sections ( 18 ) to interconnect adjacent elongated sections ( 18 ).
3. An assembly ( 10 ) as set forth in claim 1 wherein said at least one bridge ( 128 ) comprises a strip disposed between adjacent elongated sections ( 18 ) and extending continuously between opposite ends ( 22 ) of said elongated sections ( 18 ).
4. An assembly ( 10 ) as set forth in claim 1 including a plurality of independent covers ( 52 ) with each cover ( 52 ) being light transmissive and disposed over one of said elongated sections ( 18 ) so that one cover ( 52 ) independently covers said light emitting diodes ( 24 ) on each of said elongated sections ( 18 ).
5. An assembly ( 10 ) as set forth in claim 1 wherein said heat sink presents a heat transfer surface ( 16 ) facing in the opposite direction from said mounting surface ( 14 ) and including a plurality of fins ( 32 ) extending transversely from said heat transfer surface ( 16 ) of said heat sink for transferring heat away from said heat sink to surrounding air.
6. An assembly ( 10 ) as set forth in claim 5 including a housing ( 56 ) covering and spaced from said heat transfer surface ( 16 ) and said fins ( 32 ) for shielding said elongated sections ( 18 ).
7. An assembly ( 10 ) as set forth in claim 5 wherein said heat transfer surface ( 16 ) on each of said sections ( 18 ) is disposed at an angle other than ninety degrees relative to said fins ( 32 ) thereof.
8. An assembly ( 10 ) as set forth in claim 7 including at least one bridge ( 28 , 128 ) interconnecting adjacent elongated sections ( 18 ) to maintain said elongated sections ( 18 ) connected together.
9. An assembly ( 10 ) as set forth in claim 1 wherein said side edges ( 20 ) of adjacent elongated sections ( 18 ) define an elongated slot ( 26 ) therebetween extending continuously along said side edges ( 20 ) between said ends ( 22 ) of said adjacent elongated sections ( 18 ) so that each of said elongated slots ( 26 ) separates and renders adjacent elongated sections ( 18 ) spaced from one another.
10. An assembly ( 10 ) as set forth in claim 9 including at least one bridge ( 28 , 128 ) interconnecting adjacent elongated sections ( 18 ) to maintain said elongated sections ( 18 ) connected together and separating adjacent elongated sections ( 18 ) by said elongated slots ( 26 ).
11. An assembly ( 10 ) as set forth in claim 10 wherein said at least one bridge ( 28 ) comprises a pair of said bridges ( 28 ) spaced and parallel to one another and extending transversely to said elongated sections ( 18 ) and said elongated slots ( 26 ).
12. An assembly ( 10 ) as set forth in claim 10 wherein said at least one bridge ( 128 ) comprises a strip disposed between adjacent elongated sections ( 18 ) and extending continuously between opposite ends ( 22 ) of said elongated sections ( 18 ).
13. A light emitting assembly ( 10 ) comprising:
a heat sink of thermally conductive aluminum material presenting a mounting surface ( 14 ) and a heat transfer surface ( 16 ) facing in the opposite direction from said mounting surface ( 14 ),
said heat sink being defined by a plurality of elongated sections ( 18 ) extending between opposite ends ( 22 ),
each of said elongated sections ( 18 ) being disposed in spaced and parallel relationship to one another to present side edges ( 20 ) defining an elongated slot ( 26 ) therebetween extending continuously between said ends ( 22 ) and along adjacent edges ( 20 ) of said elongated sections ( 18 ) to separate and render adjacent elongated sections ( 18 ) and said light emitting diodes ( 24 ) on said mounting surface ( 14 ) thereof independent of one another,
said heat sink including a plurality of fins ( 32 ) extending transversely from said heat transfer surface ( 16 ) and disposed in spaced and parallel relationship to one another for transferring heat away from said heat sink to surrounding ambient air,
said fins ( 32 ) extending continuously between said ends ( 22 ) of each of said elongated sections ( 18 ) to present a first void space ( 34 ) between adjacent fins ( 32 ) and open at said ends ( 22 ) for exposing said first void space ( 34 ) between said adjacent fins ( 32 ) to air,
a plurality of bridges ( 28 , 128 ) interconnecting adjacent elongated sections ( 18 ) to maintain said elongated sections ( 18 ) connected together,
said bridges ( 28 , 128 ) being independent of and comprising a material different from the material of said heat sink,
a plurality of bridge connectors ( 30 ) securely connecting said bridges ( 28 , 128 ) to each of said elongated sections ( 18 ),
a coating ( 42 ) of electrically insulating material disposed over said mounting surface ( 14 ) of said heat sink,
said coating ( 42 ) being less than one thousand microns in thickness,
a plurality of circuit traces ( 44 ) spaced from one another on said coating ( 42 ) for preventing electrical conduction between said traces ( 44 ) so that said coating ( 42 ) prevents electrical conduction from each of said traces ( 44 ) to said heat sink,
a plurality of light emitting diodes ( 24 ) disposed in spaces ( 34 , 40 ) between adjacent ones of said traces ( 44 ),
each of said light emitting diodes ( 24 ) having a positive lead ( 46 ) and a negative lead ( 48 ),
said leads ( 46 , 48 ) of each of said L.E.D.s ( 24 ) being in electrical engagement with said adjacent ones of said traces ( 44 ) for electrically interconnecting said traces ( 44 ) and said light emitting diodes ( 24 ),
an adhesive ( 50 ) of electrically conductive material securing said leads ( 46 , 48 ) to said traces ( 44 ),
said light emitting diodes ( 24 ) on each of said elongated sections ( 18 ) being electrically interconnected in series with one another,
said light emitting diodes ( 24 ) on each of said elongated sections ( 18 ) being electrically interconnected in parallel with said light emitting diodes ( 24 ) on other elongated sections ( 18 ),
at least three of said traces ( 44 ) extending in end ( 22 ) to end ( 22 ) relationship along each of said elongated sections ( 18 ),
at least two of said light emitting diodes ( 24 ) disposed in each of the two spaces ( 34 , 40 ) between said three adjacent traces ( 44 ) on each one of said elongated sections ( 18 ),
a plurality of independent covers ( 52 ) with each cover ( 52 ) being light transmissive and disposed over one of said elongated sections ( 18 ) so that one cover ( 52 ) independently covers ( 52 ) said light emitting diodes ( 24 ) on each of said elongated sections ( 18 ),
each of said covers ( 52 ) defining a periphery ( 54 ) in sealed engagement with said mounting surface ( 14 ) around said light emitting diodes ( 24 ),
a housing ( 56 ) covering and spaced from said heat transfer surface ( 16 ) and said fins ( 32 ) for shielding said elongated sections ( 18 ),
said housing ( 56 ) including at least one vent ( 66 ) for allowing air to pass through said housing ( 56 ), and
a plurality of housing connectors ( 68 ) securely connecting said housing ( 56 ) to at least one of said elongated sections ( 18 ).
14. A light emitting assembly ( 10 ) as set forth in claim 13 wherein said housing ( 56 ) includes a back wall ( 58 ) extending between open housing ends ( 60 ) and spaced from said fins ( 32 ) and side walls ( 62 ) extending transversely from said back wall ( 58 ) to said elongated sections ( 18 ) to define a U-shape in cross section ( 18 ) extending between said open ends ( 60 ) for allowing air to flow along said fins ( 32 ) and through said housing ( 56 ).
15. A light emitting assembly ( 10 ) comprising:
a heat sink presenting a mounting surface ( 14 ),
a plurality of light emitting diodes ( 24 ) disposed on said mounting surface ( 14 ),
said heat sink being defined by a plurality of elongated sections ( 18 ) extending between opposite ends ( 22 ) and being disposed in generally parallel relationship to one another to present side edges ( 20 ) extending continuously between said ends ( 22 ) to separate and render adjacent elongated sections ( 18 ) and said light emitting diodes ( 24 ) on said mounting surface ( 14 ) thereof independent of one another, wherein said heat sink presents a heat transfer surface ( 16 ) facing in the opposite direction from said mounting surface ( 14 ) and including a plurality of fins ( 32 ) extending transversely from said heat transfer surface ( 16 ) of said heat sink for transferring heat away from said heat sink to surrounding air,
a housing ( 56 ) covering and spaced from said heat transfer surface ( 16 ) and said fins ( 32 ) for shielding said elongated sections ( 18 ), and wherein said housing ( 56 ) includes a back wall ( 58 ) extending between open ends ( 60 ) and spaced from said fins ( 32 ) and side walls ( 62 ) extending transversely from said back wall ( 58 ) to said elongated sections ( 18 ) to define a U-shape in cross section extending between said open ends ( 60 ) for allowing air to flow along said fins ( 32 ) and through said housing ( 56 ).
16. A method of manufacturing a light emitting assembly ( 10 ) of the type including a plurality of L.E.D.s ( 24 ) disposed on the mounting surface ( 14 ) of a heat sink defined by independent elongated sections ( 18 ), and
comprising the steps of:
extruding a continuous strip of the heat sink having a cross section ( 18 ) presenting the mounting surface ( 14 ) and the heat transfer surface ( 16 ) and fins ( 32 ) extending from the heat transfer surface ( 16 ),
cutting the strip of heat sink into a plurality of elongated sections ( 18 ) extending between ends ( 22 ),
disposing the L.E.D.s ( 24 ) on the mounting surface ( 14 ) of each elongated section ( 18 ),
disposing the elongated sections ( 18 ) in generally parallel relationship to one another to present side edges ( 20 ) extending between the ends ( 22 ) and along adjacent edges ( 20 ) of the elongated sections ( 18 ), and
interconnecting the adjacent elongated sections ( 18 ) with at least one bridge ( 28 , 128 ) to maintain the elongated sections ( 18 ) connected together.
17. A method of manufacturing a light emitting assembly ( 10 ) of the type including a plurality of L.E.D.s ( 24 ) disposed on the mounting surface ( 14 ) of a thermally conductive heat sink defined by independent elongated sections ( 18 ), and
comprising the steps of:
forming a continuous strip of the heat sink having a cross section presenting the mounting surface ( 14 ),
dividing the strip of heat sink into a plurality of elongated sections ( 18 ) extending between ends ( 22 ),
disposing the L.E.D.s ( 24 ) on the mounting surface ( 14 ) of each elongated section ( 18 ), and
disposing the elongated sections ( 18 ) in generally parallel relationship to one another to present side edges ( 20 ) extending between the ends ( 22 ) and along adjacent edges ( 20 ) of the sections ( 18 ).
18. A method as set forth in claim 17 further comprising interconnecting the adjacent elongated sections ( 18 ) with at least one bridge ( 28 , 128 ) extending transversely between adjacent elongated sections ( 18 ).
19. A method as set forth in claim 17 further comprising spacing the elongated sections ( 18 ) apart from one another so that the side edges ( 20 ) of adjacent elongated sections ( 18 ) define an elongated slot ( 26 ) separating and rendering adjacent elongated sections ( 18 ) and the L.E.D.s ( 24 ) on the mounting surface ( 14 ) thereof independent of one another.
20. A method as set forth in claim 17 further comprising forming a plurality of fins ( 32 ) integral with the extruded heat sink and extending transversely from the heat transfer surface ( 16 ) facing in the opposite direction from the mounting surface ( 14 ) of the heat sink and disposed in spaced and parallel relationship to one another.
21. A method as set forth in claim 20 further comprising disposing a housing ( 56 ) over and spaced from the heat transfer surface ( 16 ) and the fins ( 32 ) for shielding the elongated sections ( 18 ).
22. A method as set forth in claim 20 wherein said forming a heat sink is further defined as forming a pair of side ribs ( 38 ) extending radially from the heat transfer surface ( 16 ) to the fins ( 32 ) to present a second void space ( 40 ) between the heat transfer surface ( 16 ) and each of the side ribs ( 38 ) and the fins ( 32 ) and extending longitudinally between the ends ( 22 ) of each of the sections ( 18 ) for transferring heat away from the heat sink to ambient air.
23. A method as set forth in claim 20 wherein said forming a heat sink is further defined as forming the mounting surface ( 14 ) on each of the elongated sections ( 18 ) at an angle other than ninety degrees relative to the parallel fins ( 32 ) thereof.