Method for manufacturing an led light engine with applied foil construction

Abstract

An L.E.D. lamp assembly ( 20 ) includes an electrically insulative coating ( 24 ) disposed on a thermally conductive substrate ( 22 ). A plurality of light emitting diodes ( 26 ) are secured to the coating ( 24 ) and a circuit ( 40 ) is adhesively secured to the coating ( 24 ) in predetermined spaced lengths ( 42 ) along the coating ( 24 ) to establish discrete and electrically conductive spaced lengths ( 42 ) with the light emitting diodes ( 26 ) disposed between the spaced lengths ( 42 ). LED electrical leads ( 32 ) are secured to the spaced lengths ( 42 ) of the circuit ( 40 ) to electrically interconnect the light emitting diodes ( 26 ). The circuit ( 40 ) includes a foil tape ( 46 ) having an electrically conductive tape portion ( 48 ) and a coupling portion ( 50 ) disposed on the tape portion ( 48 ) for securing the foil tape ( 46 ) to the insulated substrate ( 22 ). Heat generated by the light emitting diodes ( 26 ) is transferred through the insulative coating ( 24 ) to the electrically and thermally conductive substrate ( 22 ) for dissipating the heat.

1 . A method of manufacturing an electrically driven L.E.D. lamp assembly ( 20 ) comprising the steps of;
 disposing an electrically insulative coating ( 24 ) having a low thermal resistance on an electrically conductive and thermally conductive substrate ( 22 ),   securing a plurality of light emitting diodes ( 26 ) to the coating ( 24 ) with each light emitting diode ( 26 ) having a pair of LED electrical leads ( 32 ),   disposing a coupling agent on a tape portion ( 48 ) of a foil tape ( 46 ) to establish a coupling portion ( 50 ) of the foil tape ( 46 ) for securing the foil tape ( 46 ) to the coating ( 24 ),   securing the foil tape ( 46 ) to the coating ( 24 ) with the coupling agent in predetermined spaced lengths ( 42 ) along the coating ( 24 ) to establish discrete and electrically conductive spaced lengths ( 42 ) of the foil tape ( 46 ) for preventing electrical conduction between the spaced lengths ( 42 ) and from the spaced lengths ( 42 ) to the light emitting diodes ( 26 ), and   securing the LED electrical leads ( 32 ) to the spaced lengths ( 42 ) of the foil tape ( 46 ) to electrically interconnect the light emitting diodes ( 26 ).   
     
     
         2 . A method as set forth in  claim 1  wherein said securing the LED electrical leads ( 32 ) step is further defined as soldering the LED electrical leads ( 32 ) to the spaced lengths ( 42 ) of the foil tape ( 46 ) to electrically interconnect the light emitting diodes ( 26 ). 
     
     
         3 . A method as set forth in  claim 1  including the steps of;
 cutting a sheet of metal foil to define a circuit ( 40 ) of the foil tape ( 46 ), and 
 transferring the circuit ( 40 ) of the foil ape ( 46 ) to the coating ( 24 ) by placing the circuit ( 40 ) on a transfer sheet for disposing the circuit ( 40 ) on the coating ( 24 ).