LED Flashlight with Improved Heat Sink and Battery Protection

摘要

One electrical lead from an LED package is soldered to an inner electrically conductive member positioned and electrically isolated from an outer electrically conductive member by electrically insulating material while a second electrical lead and a neutral lead from the LED are soldered to the outer electrically conductive member so that heat is transferred from an LED die within the LED package to the outer electrically conductive member and then to a thermally conductive outer casing with a thermal path that minimizes thermal resistance and a tail cap is used to create a snug mechanical fit between a bottom surface of a metal can of a terminal battery held within the outer casing and the a surface of the tail cap.

主权项

1: A flashlight, comprising:
a flashlight barrel that is thermally conductive; a light emitting diode (“LED”) package contained within the flashlight barrel, said LED package comprising:
a substrate;an LED die atop a substrate top surface; anda first electrically conductive contact, a second electrically conductive contact and an electrically neutral contact located under the substrate relative to the LED die, each of which is electrically isolated from each other;wherein the LED die emits light out of a first end of the flashlight barrel when power is applied to the first and the second electrically conductive contacts and heat is transferred from the LED die through the substrate to the electrically neutral contact; and a heatsink assembly held within the outer casing, said heatsink assembly comprising:
an outer electrically conductive member that is thermally conductive and which is mechanically connected to the flashlight barrel;an electrically insulating material which is held within the outer electrically conductive member; andan inner electrically conductive member which is positioned and electrically isolated from the outer electrically conductive member by the electrically insulating material; wherein the first electrically conductive member of the LED package is electrically bonded to a top surface of the outer electrically conductive member and the second electrically conductive member of the LED package is electrically bonded to the inner electrically conductive member; wherein the electrically neutral contact is thermally bonded directly to the top surface of the outer electrically conductive member without the use of a printed circuit board (“PCB”); and wherein the LED package is turned on when power from an electrical circuit is applied to the outer electrically conductive member and the inner electrically conductive member.