Light-emitting diode lamp and method of making

1. A Light-Emitting Diode (LED) lamp, comprising:

an LED package;

a diffuser mounted over the LED package that forming an anti-dust enclosure with the LED package;

a heat sink directly attached to the LED package to form a conductive thermal path, wherein the heat sink comprises a body having a cavity, a plurality of fins radiating from the body, and a cover plate over the plurality of fins, wherein the plurality of fins and the cover plate form sides of a plurality of passive air flow ducts each having only a top opening and a bottom opening to an outside of the LED lamp, wherein the top opening and the bottom opening are aligned for each of the air flow ducts, and wherein the fins include holes configured to facilitate thermal communication between the air flow ducts;

a power supply enclosure within the cavity of the heat sink;

a power supply electrically coupled to the LED package and disposed inside the power supply enclosure; and

a screw base attached to the power supply enclosure and electrically connected to the power supply for fixing the LED lamp to a lighting fixture; and

wherein the body of the heat sink includes one or more openings so as to facilitate airflow from the power supply to one of the top and bottom openings.

2. The LED lamp of claim 1 , wherein the heat sink is a fan-less heat sink.

3. The LED lamp of claim 1 , wherein the body and the fins of the heat sink comprise a thermal plastic, ceramic, or a metal, and wherein the metal is at least one selected from the group consisting of copper, nickel, aluminum, and alloys thereof.

4. The LED lamp of claim 3 , wherein the metal is coated with a ceramic powder.

5. The LED lamp of claim 1 , wherein the cover plate of the heat sink comprises a material different from the body and the fins of the heat sink.

6. The LED lamp of claim 5 , wherein the cover plate is painted.

7. The LED lamp of claim 6 , wherein the cover plate is white.

8. The LED lamp of claim 1 , wherein the power supply enclosure is irrotationally engaged with the heat sink.

9. The LED lamp of claim 1 , wherein the LED package comprises an LED die on a package substrate with high thermal conductivity.

10. The LED lamp of claim 9 , wherein the package substrate with high thermal conductivity comprises a metal core printed circuit board (MCPCB), a silicon substrate, a ceramic substrate, or a metal substrate.

11. The LED lamp of claim 1 , wherein the cover plate reaches a maximum temperature of less than 45 degrees Celsius during operation of the LED lamp.

12. The LED lamp of claim 1 , wherein the plurality of fins includes at least 10 fins.

13. The LED lamp of claim 1 , wherein a thermal glue connects the power supply and the heat sink.

14. The LED lamp of claim 1 , wherein the anti-dust enclosure is hermetically sealed.

15. A Light-Emitting Diode (LED) lamp, comprising:

an LED package;

a diffuser mounted over the LED package and forming an anti-dust enclosure with the LED package;

a seamless heat sink directly attached to the LED package to form a conductive thermal path, wherein the heat sink comprises a body portion, a plurality of fins portions extending radially from the body portion, and a cover plate portion over the plurality of fin portions, and wherein the heat sink further defines therein a plurality of passive air flow ducts, wherein walls of each of the passive air flow ducts include a strip of the body portion, two adjacent fins, and a portion of the cover plate, and wherein the cover plate portion includes a plurality of first openings and a plurality of second openings, and wherein each of the passive air flow ducts is aligned with a respective first opening and a respective second opening, and wherein the fin portions each include a respective hole therein;

a power supply enclosure within the cavity of the heat sink;

a power supply electrically coupled to the LED package and disposed inside the power supply enclosure; and,

a screw base attached to the power supply enclosure and electrically connected to the power supply for fixing the LED lamp to a lighting fixture;

wherein the body portion of the heat sink includes one or more openings so as to facilitate airflow from the power supply to one of the first and second openings.

16. The LED lamp of claim 15 , wherein the heat sink is a die cast product of a single material.

17. The LED lamp of claim 16 , wherein the single material is copper, aluminum, ceramic, or thermal plastic.

18. A method of making a Light-Emitting Diode (LED) lamp, said method comprising:

providing LED dies;

packaging the LED dies on a heat conductive package substrate to form an LED package; attaching the LED package to a heat sink having a plurality of passive air flow ducts, wherein each of the passive air flow ducts is defined by a body of the heat sink, fins protruding from a body of the heat sink, the fins each including a respective hole therein, and a cover plate having a plurality of first openings and a plurality of second openings disposed over the fins, and wherein each of the passive air flow ducts is aligned with a respective one of the first openings and a respective one of the second openings;

electrically connecting the LED package to a power supply in a power supply enclosure, wherein the body of the heat sink includes one or more openings that facilitate airflow from the power supply to one of the first and second openings;

attaching the power supply enclosure to the heat sink;

installing a thermal conductive connection between the power supply and the heat sink;

electrically connecting the power supply to an Edison screw base;

attaching the Edison screw base to the power supply enclosure; and

sealing a diffuser to the LED package to form an anti-dust enclosure.

19. The method of claim 18 , wherein the plurality of passive air flow ducts includes 20 or more passive air flow ducts.