Osram Sylvania Inc.

Osram Ag

Steven C Sidwell

Charles M Coushaine

Thomas Tessnow

Ralph J Johnson

Michael D Tucker

George J English

Kim Albright

Robert L Garrison

Paul R Lyman

Brad Ernest

Kim M Albright

A light emitting diode (LED) assembly and a method of making the assembly, in which a container having an open top is provided with a two sets of holes through a bottom of the container, an electrically conductive heat sink is attached to the container bottom beneath the first set of holes, and in which an electrically conductive sheet is attached to the container bottom beneath the second set of holes, where the heat sink and sheet are isolated from each other. LEDs are placed in the first set of holes so that each has a first LED terminal on and adhered to an exposed part of the heat sink through the respective one of the first holes and in which a second LED terminal is connected via a wire lead to the sheet through a respective one of the second holes.

LED assembly with LED position template and method of making an LED assembly using LED position template

A light gathering module () has a body () with a first end () comprising a single light transmitting surface () and a second end () having a plurality of arms (), each arm () having an independent light gathering terminus () that is rectangular. In a preferred embodiment of the invention, the first end () of the body also is rectangular. The light gathering module () can be fabricated from acrylic, plastic, glass or other suitable material and preferably has no cladding so that light output I maximized. When combined in a housing () with a projector lens () the light gathering module () provides a vehicle headlamp ().

Light emitting diode module for automotive headlamp

A lamp component has a support with a base surrounded by an interior wall defining a cavity with a central axis. A plurality of LEDs are supported on the interior wall and generally aimed to direct light towards the central axis. A center piece has a first reflective surface shaped and positioned to intercept light received from the LEDs and reflect such received light generally in a direction parallel to the axis.

Light emitting diode lamp with conically focused light guides

An LED lamp having a support with a metal substrate and a center portion with projecting wings. An electrically insulating, thermally conductive circuit is affixed to the substrate; and at least one LED is positioned on each wing with electrically conductive traces connected thereto. The center portion is planar. The wings are bent at multiple angles forming legs, a first angle being greater than 90 degrees, a second angle being normal to the planar center portion. The preferred center portion is pentagonal. The bulb cooperates with a socket that comprises a base; a hollow pedestal extending from the base, the pedestal having a polygonal interior; a thermally conductive, core having an exterior matching the interior; a gap between interior walls of the interior and exterior walls; and a plurality of electrical contacts positioned in the gap for contacting the traces when the bulb is inserted in the socket.

Automotive LED bulb

A high-density LED array () capable of presenting a density of X LEDs/unit area has a first printed circuit board () having X/2 LEDs/area and X/2 apertures arrayed therewith. A second printed circuit board () is spaced from the first printed circuit board () and has X/2 LEDs/unit area. The LEDs () on the second printed circuit board are aligned with the apertures () in the first printed circuit board. Each of the LEDs () on the second printed circuit board () has an optical fiber () associated therewith and each of the light guides () extends through one of the apterures (). Each of the mounted LEDs on the first printed circuit board can have an optical fiber associated therewith and the light guides can be bundled to direct light to a remote source.

High density LED array

A solid-state light sourcecompatible with existing sockets normally reserved for filamented lamps may be formed with a hollow baseformed to mechanically and electrically adapt to a socket. A sub-assemblyadapted to cooperate with and fit into the hollow basecomprises a metal corehaving a bulbous bodyand a narrow, depending foot. A circuit boardsubstantially surrounds the metal coreon two sides. The boardis preferably formed from a flexible printed circuit board material capable of sustaining a bend radius of at least 0.25 inches (6 mm). Solid-state light sources, for example, light emitting diodes (LEDs) are mechanically and electrically connected to one side of the circuit board by suitable electrically conductive traces. A glass domecovers the sub-assemblyafter it is inserted into the hollow baseand is sealed thereto.

Thermally efficient LED bulb

A solid-state lamp has a base formed to be received into a socket, and the base has a retainer receptacle formed therein. An axially extending support is fitted into the base. The support is formed of an electrically conductive, heat-sinking material and has a retainer engaging the retainer receptacle. An electrically insulating coating is formed on the support and electrically conductive traces are formed on the insulating coating. A plurality of solid-state light sources are formed on the support and are electrically connected to the traces, at least two of the traces providing electrical connection to the base whereby electrical connection can be made to the socket. The plurality of solid-state light sources are formed in a selected area of the support and in a preferred embodiment mimic the dual filaments of a prior art lamp.

Solid-state automotive lamp

A discharge lamp, such as a neon lamp or a subminiature fluorescent lamp, includes an elongated tubular lamp envelope containing a fill material for supporting a light-emitting discharge and electrodes mounted at opposite ends of the lamp envelope. A light-transmissive conductive coating on the lamp envelope substantially attenuates emission of RF energy. A conductor in electrical contact with the conductive coating couples the conductive coating to a reference potential, such as ground. The conductor may be a metal or conductive silicone strip in electrical contact with the conductive coating along the length of the lamp envelope. The discharge lamp may be connected to a ballast circuit by coaxial cables. The outer conductor of each coaxial cable is connected to the conductive coating to form a continuous RF shield. The conductive coating and/or the metal strip may be used for heating of the discharge lamp.

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Hopkinton, NH, United States of America

Steven C Sidwell