Themrally conductive thermoplastic for light emitting diode fixture assembly

Abstract

The present invention relates to a light emitting diode fixture assembly, having at least one component made out of thermally conductive thermoplastic which is comprised of a thermally conductive thermoplastic composition which is comprised of at least one thermoplastic polymer and at least one thermally conductive filler. The light emitting diode fixture assembly is comprised of (1) at least one light emitting diode, (2) a lens covering a portion of the light emitting diode, (3) a back plate to which the light emitting diode is affixed, (4) the housing for the light emitting diode and the base plate, and (5) electrical connectors which are in electrical communication with the light emitting diode and an electrical supply source with a enclosing cup/sleeve.

What is claimed is: 
     
         1 . A flame retardant thermally conductive polymeric which is comprised of (1) at least one thermoplastic polymer, (2) at least one thermally conductive filler, (3) at least one flame retardant system which is present in the thermally conductive thermoplastic composition at a level which is in the range of 1 to 30 weight percent, wherein said flame retardant system includes a primary flame retardant selected from the group consisting of brominated epoxy oligomers, brominated polystyrene, decabromodiphenyl, and decabromodiphenylethane, and a synergist selected from the group consisting of antimony trioxide, antimony dioxide, and zinc borate, and wherein the ratio of the primary flame retardant to the synergist is within the range of 5:1 to 3:1, (3) at least one flame retardant system, (4) at least one impact modifier, and (5) a surface active agent. 
     
     
         2 . The thermally conductive polymeric composition as specified in  claim 1  wherein the thermally conductive filler is electrically insulating. 
     
     
         3 . The thermally conductive polymeric composition as specified in  claim 1  wherein the thermally conductive filler is electrically conductive. 
     
     
         4 . The thermally conductive polymeric composition as specified in  claim 1  wherein the thermally conductive filler is a mixture of thermally conductive fillers having at least two different compositions, at least two different sizes or two different shapes. 
     
     
         5 . The thermally conductive polymeric composition as specified in  claim 1  wherein said composition is void of boron nitrides. 
     
     
         6 . The thermally conductive polymeric composition as specified in  claim 1  wherein the thermoplastic polymer is selected from the group consisting of polyamides, polycarbonates, polyphenylene sulfides, liquid crystal polymers, and polyesters and wherein the thermally conductive filler is selected from the group consisting of ceramics, metal oxides, minerals and carbon based materials. 
     
     
         7 . The thermally conductive polymeric composition as specified in  claim 1  wherein the thermally conductive filler is present in the thermoplastic polymer at a level which is within the range of 20 weight percent to 80 weight percent, based upon the total weight of the thermoplastic composition, and wherein the thermally conductive filler is a mixture of thermally conductive fillers having at least two different compositions, at least two different sizes or two different shapes. 
     
     
         8 . The thermally conductive polymeric composition as specified in  claim 1  wherein the thermoplastic polymer is a polyamide. 
     
     
         9 . The thermally conductive polymeric composition as specified in  claim 1  wherein the thermoplastic polymer is a polyamide 66. 
     
     
         10 . The thermally conductive polymeric composition as specified in  claim 1  wherein the primary flame retardant is brominated polystyrene. 
     
     
         11 . The thermally conductive polymeric composition as specified in  claim 1  wherein the synergist is antimony trioxide. 
     
     
         12 . The thermally conductive polymeric composition as specified in  claim 1  wherein the flame retardant system is present in the thermally conductive thermoplastic composition at a level which is in the range of 10 weight percent to 20 weight percent. 
     
     
         13 . The thermally conductive polymeric composition as specified in  claim 1  wherein the flame retardant system is present in the thermally conductive thermoplastic composition at a level which is in the range of 12 weight percent to 16 weight percent. 
     
     
         14 . The thermally conductive polymeric composition as specified in  claim 1  wherein the impact modifier is present at a level which is within the range of 2 weight percent to 50 weight percent. 
     
     
         15 . The thermally conductive polymeric composition as specified in  claim 1  wherein the impact modifier is present at a level which is within the range of 10 weight percent to 45 weight percent. 
     
     
         16 . The thermally conductive polymeric composition as specified in  claim 1  wherein the impact modifier is present at a level which is within the range of 15 weight percent to 40 weight percent. 
     
     
         17 . The thermally conductive polymeric composition as specified in  claim 1  wherein the thermoplastic polymer has a melting point of less than 200° C. 
     
     
         18 . The thermally conductive polymeric composition as specified in  claim 1  wherein the thermally conductive filler is a combination of carbon black, carbon fibers and graphite. 
     
     
         19 . The thermally conductive polymeric composition as specified in  claim 1  which is further comprised of an electrically conductive additive. 
     
     
         20 . The thermally conductive polymeric composition as specified in  claim 19  wherein the electrically conductive additive is multiwall carbon nanotubes.