LED package having protrusions for alignment of package within a housing
View Patent ↗A LED package ( 10 ) for use in a lamp as well as a method for manufacturing such kind of a LED package ( 10 ) are disclosed, wherein the LED package ( 10 ) comprises at least one LED ( 16 ), an optical element ( 18 ) for guiding light emitted by the LED ( 16 ), and a cover ( 26 ) for covering, at least partially, electrical components ( 20, 22, 24 ) connectable to the LED ( 16 ). The cover ( 26 ) includes three protrusions ( 38 ) that form the highest points on the package. The protrusions ( 38 ) abut a surface in a housing for accurately positioning the LED package relative to a lens ( 52 ) in the housing. The LED package ( 10 ) may be spring-loaded. Side protrusions ( 28 ) of the cover ( 26 ) additionally help to position the package within the housing.
1. A device comprising a light emitting diode (LED) package, the LED package comprising:
at least one LED mounted over a base having electrical connectors; and
a cover provided over the base,
wherein the cover comprises at least three alignment first protrusions on its top surface, the at least three alignment first protrusions having a same height above the base and forming the highest points of the LED package, for concurrently contacting a surface during positioning of the LED package in a housing for positioning the LED package at a correct height in the housing relative to a first optical element.
2. The device of claim 1 further comprising second protrusions from a side of the cover, the second protrusions contacting the housing for positioning the package at a correct position within the housing.
3. The device of claim 2 wherein the second protrusions are received by a recess in the housing.
4. The device of claim 1 wherein the base comprises a substrate onto which the at least one LED is mounted.
5. The device of claim 1 wherein the base comprises a heat sink configured to conduct heat away from the at least one LED.
6. The device of claim 1 further comprising a second optical element affixed to the base overlying the at least one LED.
7. The device of claim 6 wherein the first optical element comprises a lens, wherein the housing includes the lens, and the first protrusions cause the LED package to be positioned with respect to the lens.
8. The device of claim 7 wherein the housing is part of a motor vehicle lamp.
9. The device of claim 7 wherein the housing is part of a projection system.
10. The device of claim 6 wherein the second optical element is a collimator.
11. A method of positioning an LED package in a housing comprising:
providing at least three alignment first protrusions on a top surface of the package, forming the highest points of the LED package, the first protrusions having a same height above a base of the package; and
positioning the LED package in a housing such that the three alignment first protrusions concurrently contact a surface in the housing for positioning the LED package at a correct height in the housing relative to a first optical element.
12. The method of claim 11 wherein the package also comprises second protrusions from a side of the package, the second protrusions contacting the housing for positioning the package at a correct position within the housing.
13. The method of claim 12 wherein the second protrusions are received by a recess in the housing.
14. The method of claim 11 wherein the first optical element comprises a lens, and wherein the first protrusions position the LED package relative to the lens in the housing.
15. The method of claim 11 wherein the housing is part of a motor vehicle lamp.
16. The method of claim 11 wherein the housing is part of a projection system.