LIGHTING ASSEMBLY AND METHOD FOR MANUFACTURING A LIGHTING ASSEMBLY

Abstract

Lighting systems are described. A lighting system includes a first lead frame portion and a second lead frame portion. The first lead frame portion has at least a top surface, a bottom surface, and an opening. The second lead frame portion is within the opening of the first lead frame portion and has at least a top surface and a bottom surface. Light-emitting diode (LED) devices are each mechanically and electrically coupled to the top surface of the first lead frame portion and the top surface of the second lead frame portion. An electrically insulating and optically reflective material is disposed over exposed regions of the top surfaces of the first and second lead frame portions.

Claims

1. A lighting system comprising: a first lead frame portion comprising at least a top surface, a bottom surface, and an opening; and a second lead frame portion within the opening of the first lead frame portion and comprising at least a top surface and a bottom surface; a plurality of light-emitting diode (LED) devices each mechanically and electrically coupled to the top surface of the first lead frame portion and the top surface of the second lead frame portion; and an electrically insulating and optically reflective material over exposed regions of the top surfaces of the first and second lead frame portions.

2. The lighting system of claim 1, wherein the electrically insulating and optically reflective material is further under at least a portion of at least one of the bottom surface of the first lead frame portion and the bottom surface of the second lead frame portion.

3. The lighting system of claim 2, wherein the first lead frame portion and the second lead frame portion are separated by a space, and the electrically insulating and optically reflective material fills the space.

4. The lighting system of claim 1, wherein the second lead frame portion comprises a thick portion and a thin portion spaced apart from the thin portion.

5. The lighting system of claim 4, wherein each of the plurality of LEDs is mechanically coupled to the thin portion of the second lead frame portion.

6. The lighting system of claim 4, wherein the electrically insulating and optically reflective material further fills gaps between the thick portion and the thin portion of the second lead frame portion and between the second lead frame portion and the first lead frame portion.

7. The lighting system of claim 1, wherein at least a portion of the first lead frame portion has a shape that curves toward the plurality of LEDs.

8. The lighting system of claim 7, wherein the shape is a concave shape with the top surfaces of the first and second lead frame portions inside the concave shape.

9. The lighting system of claim 7, wherein a plurality of notches extend into outer edges of the first lead frame portion to form a plurality of spaced apart flanges.

10. The lighting system of claim 1, wherein at least a portion of the first lead frame portion has a shape that includes a flat portion and a portion that bends away from the plurality of LEDs.

11. The lighting system of claim 10, wherein the portion that bends away from the plurality of LEDs is covered by the electrically insulating and optically reflective material on both the top and bottom surfaces.

12. The lighting system of claim 10, wherein the the portion that bends away from the plurality of LEDs is bent at a 90 angle with respect to flat portion of the first lead frame portion.

13. The lighting system of claim 10, wherein notches are formed in outer edges of the portion that bends away from the plurality of LEDs to form a plurality of spaced apart flanges.

14. The lighting system of claim 1, wherein each of the plurality of LEDs comprises at least a first electrode electrically and mechanically coupled to the first lead frame portion and a second electronic electrically and mechanically coupled to the second lead frame portion.

15. The lighting system of claim 1, wherein the first lead frame portion and the second lead frame portion comprise tin-coated copper.

16. A lighting system comprising: a first lead frame portion comprising: a flat region with an opening therethrough, and a plurality of spaced apart flanges mechanically coupled to outer edges of the flat region and having a concave shape relative to the flat portion; a second lead frame portion within the opening through the flat region of the first lead frame portion; a plurality of light-emitting diodes (LEDs) mechanically and electrically coupled within the concave shape to the second lead frame portion and the flat region of the first lead frame portion; and an electrically insulating and optically reflective material covering at least exposed regions of a surface of the first lead frame portion and the second lead frame portion inside the concave shape.

17. The lighting system of claim 16, wherein the electrically insulating and optically reflective material further covers at least regions of a surface of the first lead frame portion and the second lead frame portion opposite the plurality of LEDs.

18. A lighting system comprising: a first lead frame portion comprising: a flat region with an opening therethrough, the flat region comprising at least a top surface and a bottom surface, and a bent region bent away from the top surface of the flat region at an angle; a second lead frame portion within the opening through the flat region of the first lead frame portion, the second lead frame portion comprising at least a top surface and a bottom surface; a plurality of light-emitting diodes (LEDs) mechanically and electrically coupled to the top surface of the flat region of the first lead frame portion and the top surface of the second lead frame portion; and an electrically insulating and optically reflective material over at least exposed regions of the top surfaces of the first and second lead frame portions.

19. The lighting system according to claim 18, wherein the electrically insulating and optically reflective material covers at least regions of the bottom surfaces of the first and second lead frame portions.

20. The lighting system according to claim 18, wherein the angle is 90.

Description

BRIEF DESCRIPTION OF THE DRAWING(S)

[0030] The above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, with reference to the appended drawings, in which:

[0031] FIGS. 1a-1c illustrate a general outline of a method for manufacturing a lighting assembly according to an embodiment of the present invention;

[0032] FIGS. 2a-2c illustrate an outline of a method according to another embodiment of the present invention;

[0033] FIG. 3 schematically depicts a cross sectional side view of a lighting assembly manufactured according to an embodiment of the present invention;

[0034] FIGS. 4a and 4b schematically depict a top view of a lighting assembly according to an embodiment of the present invention, comprising a reflector formed out of a portion of the leadframe encapsulated with an electrically insulating and optically reflective material;

[0035] FIG. 5 schematically depicts a cross sectional side view of the lighting assembly of FIG. 4;

[0036] FIG. 6 schematically depicts a top view of a lighting assembly according to an embodiment of the present invention, wherein the lighting assembly comprises a heat sink formed out of a portion of the leadframe; and

[0037] FIG. 7 schematically illustrates a cross sectional side view of a lighting assembly according to an embodiment of the present invention, wherein a portion of the leadframe forms a heatsink encapsulated with an electrically insulating and optically reflective material.

[0038] All the figures are schematic, not necessarily to scale, and generally only show parts which are necessary in order to elucidate the embodiments of the present invention, wherein other parts may be omitted or merely suggested.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0039] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplifying embodiments of the present invention are shown. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of example so that this disclosure will convey the scope of the invention to those skilled in the art. Furthermore, like numbers refer to the same or similar elements or components throughout.

[0040] With reference to FIGS. 1a-1c, there is shown a general outline of a method for manufacturing a lighting assembly in accordance with an embodiment of the present invention.

[0041] The method comprises providing a leadframe 110, for example out of a flat metal sheet material such as a tin-coated copper sheet (FIG. 1a). The leadframe may be provided with a structure obtained for example by stamping such that leads, flanges, and not directly electrically connected first and second portions are obtained.

[0042] In the next step, a LED element 120 is arranged on the leadframe 110. The LED element 120 may for example be arranged by surface mounting, wherein solder paste is screen printed on contact pads of the first portion 112 and the second portion 114 of the leadframe 110, the LED element 120 is positioned with a pick-and-place machine, and the solder paste reflowed such that a mechanical and electrically conductive fixation is provided by solder joints 117. The resulting structure is shown in FIG. 1b.

[0043] After the mounting of the LED element 120, wherein the LED element 120 is brought in electrical contact with the leadframe, the leadframe 110 may be provided with a compound comprising an optically reflective and electrically insulating material 130. In FIG. 1c, the compound 130 is provided to the first surface 116 and a portion of the second surface 118 by foil assisted molding, in which the leadframe 110 with the LED element 120 is placed in between a bottom mold and a top mold. The top mold is provided with a soft, protective material, such as for example a foil or polyimide, which abuts the surface of the LED element 120 as the top mold is applied to the leadframe 110, and may thereby protect the LED element 120 from being provided with the compound 130 during molding. As the top mold and the foil are applied, the molding compound 130 is heated and flows into the cavity which is defined by the top and bottom molds. The compound may for example be pressed into the cavity, or sucked by means of an applied vacuum.

[0044] In FIGS. 2a-2c, a method for manufacturing a lighting assembly is illustrated wherein the provided leadframe 110 (FIG. 2a) is encapsulated with the compound comprising an optically reflective and electrically insulating material 130 prior to the arranging of the LED element 120 on the leadframe 110. The compound 130 may be provided to the first surface 116 of the leadframe 110, the second surface 118 of the leadframe 110, or both. The level of electrical insulation of the second surface 118 may be controlled by the surface area covered by the compound 130 and/or the thickness of the compound 130. For example, by providing the compound 130 to the electrical paths of the second side 118 of the leadframe 110, electrical insulation is provided as the remaining areas may be directly connected to a separate heatsink (not shown in the FIGS. 2a-2c), having a mating surface adapted to fit with the corresponding structure of the second surface 118 of the leadframe 110. FIG. 2b shows an example wherein the compound 130 is provided to the second surface 118 of the leadframe 110 by molding, and wherein the gap between a first and second portion 112, 114 is filled with the compound 130. After the encapsulation, the LED element 120 is mounted to the first surface 116 of the leadframe 110 as shown in FIG. 2c.

[0045] With reference to FIG. 3, the leadframe 110 may comprise a thinner portion 119 which is thinner than the first portion 112 and/or the second portion 114 of the leadframe 110. The thinner portion 119 may have a first surface 111 that share a common plane with the first surface 116 of the adjacent first and second leadframe portions 112, 114, and a second surface 113 parallel with the second surface 118 of the adjacent first and second leadframe portions 112, 114. The method for manufacturing a lighting assembly may comprise a step of providing the first surface 116 of the leadframe 110 with the electrically insulating and optically reflective material 130 such that the compound 130 fills up the space between the first portion 112, the thinner portion 119, and the second portion 114 of the leadframe 110. Thereby the second surface 111 of the thinner portion 119 may be electrically insulated from the surroundings, whereas the second surface 118 of the surrounding first and second portions 112, 114 still is exposed to the surroundings. The resulting lighting assembly is shown in FIG. 3.

[0046] With reference to FIG. 4a, the first portion 112 and the second portion 114 of the leadframe may be joined by a connecting portion 115 which is comprised of the sheet material and formed at the same time as the rest of the leadframe 110 is formed, or patterned. The connecting portion 115 may hold the first portion 112 and the second portion 114 of the leadframe together such that the mechanical stability of the leadframe 110 is improved, which may facilitate the handling of the leadframe 110 e.g. during manufacturing.

[0047] Any one of the methods as described with reference to FIGS. 1a-1c, 2a-2c, and 3 may comprise a step of removing the connecting portions 115 of the leadframe 110 after encapsulation and/or mounting of the LED elements 120, for example by cutting, in order to electrically disconnect the first portion 112 and the second portion 114 of the leadframe 110 from each other. Thereby the LED elements 120 can be supplied with electrical power by means of the first and second portions 112, 114 of the leadframe 110 such that light is emitted by the LED elements 120. The resulting lighting assembly is shown in FIG. 4b. The electrical power can be supplied by an electrical power source (not shown in the figures) which may be included in the lighting assembly or connected to the lighting assembly.

[0048] The leadframe as described with reference to FIGS. 4a and 4b may constitute a unit which may be joined with a plurality of other, similar units such that a panel is formed (not shown in the figures). The units may be joined by connecting portions of the sheet material to form a panel. The units may be separated, or singulated, prior to or after encapsulation. Singulating the panel prior to encapsulation may enable easier access to each unit and provide a smooth, fully encapsulated end product. Singulating the units after the encapsulation may improve the robustness of the process flow, thereby increasing the yield.

[0049] Any one of the methods as described with reference to FIGS. 1a-1c, 2a-2c, 3, 4a and 4b may comprise a step of bending the leadframe 110 such that at least a portion of the leadframe 110 provides a heat sink dissipating the generated heat. The molding tool may be configured to form, or bend, the edge portions of the leadframe 110 during the encapsulation with the optically reflective and electrically insulating material 130, for example by pressing or applying vacuum. A separate mold may also be used, wherein the leadframe 110 is formed in a separate step prior to the encapsulation. Any portions of the leadframe 110 which are not provided with the compound 130 may also be bent into a desired shape after the molding step.

[0050] By forming the first surface 116 of the leadframe 110 such that it conforms to a concave or substantially concave shape and provide the first surface 116 with an optically reflecting layer 130, an optical reflector that redirects light emitted by the LED element 120 is provided. The resulting lighting assembly is shown in FIG. 5, wherein the optically reflecting layer 130 of the first surface 116 for example may form a wall in a mixing chamber (not shown in FIG. 5).

[0051] FIG. 6 is a top view of a lighting assembly manufactured according to the method described with reference to FIG. 5. The leadframe 110 comprises a first, inner portion 112 and a second, outer portion 114 which is provided with several flanges 140. The flanges 140 may help dissipating the heat generated by the LED elements 120. The flanges 140 are bent such that they provide an optical reflector 140 for redirecting the emitted light. The first portion 112 of the leadframe 110 is mechanically and electrically connected to the second portion 114 by means of several LED elements 120, for example according to the example depicted in FIG. 6 by four LED elements 120 that are arranged on the leadframe 110, e.g. fixated to the leadframe 110 by means of soldered joints (not shown in FIG. 6). The encapsulating compound 130 (not shown in FIG. 6), comprising an electrically insulating and optically reflective material 130, provides for mechanical support of the first and second portions 112, 114 of the leadframe 110, as well as electrical insulation from the surroundings and optical performance.

[0052] It will be appreciated that the leadframe 110, the electrically insulating and optically reflective material 130, and the LED elements 120 may be arranged in various configurations. The leadframe 110 may for example comprise three or more portions that are electrically and/or mechanically separated, which may enable individual control of the LED elements 120. The shape of the leadframe 110 may further conform to any suitable shape in order to achieve a desired optical and/or heat dissipation function.

[0053] FIG. 7 depicts an example of a lighting assembly manufactured in accordance with a method according to an embodiment of the present invention. The lighting assembly comprises a leadframe 110 having a first portion 112 and a second portion 114 provided with flanges 150, forming (part of) a heat sink 150. The flanges 150 are provided by bending the second portion of the leadframe downwards, i.e. in a direction away from the first surface of the leadframe onto which the LED elements 120 are arranged by means of soldered joints 117. The encapsulation compound 130 is provided on the first surface 116 and second surface 118 of the leadframe 110, which may enable incident light to be reflected.

[0054] In conclusion, a method for manufacturing a lighting assembly is disclosed, wherein a LED element is arranged on a leadframe. The LED element is configured to emit light when supplied with electrical power by means of the leadframe. At least a portion of the leadframe is provided with an optically reflective and electrically insulating material arranged to reflect light emitted from the LED element and to electrically insulate at least a portion of the leadframe. A lighting assembly comprising the LED element and the leadframe is also disclosed.

[0055] While the present invention has been illustrated and described in detail in the appended drawings and the foregoing description, such illustration and description are to be considered illustrative or exemplifying and not restrictive; the present invention is not limited to the disclosed embodiments. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.