LED mounting system

Abstract

An electrically driven light emitting diode (LED) assembly and the method of assembling same. The assembly includes an electrically and thermally conductive heat dissipater (10) sandwiched under an electrically insulating layer (12) with circuit traces (14) disposed over the insulating layer (12) to prevent electrical conduction between the traces (14) and the heat dissipater (10). A plurality of light emitting diodes (20) have electrical leads (22) extending laterally from opposite extremities of each LED (20) to overlie the traces (14) for electrical contact with the traces (14) for powering the LEDs (20). An independent and generally U-shaped holding device (24, 26, 28, 30 and 32), as viewed in cross section, defines a base overlying the LED (20) and a pair of legs (36, 136) depending therefrom and transversely to the electrical leads (22) between the LED (20) and the heat dissipater (10). The base defines a hole (38) and the LED (20) protrudes (39) through the hole (38) to emit light. The insulating layer (12) includes a void (40) surrounding each LED (20) and the legs (36, 136) of each associated holding device (24, 26, 28, 30 and 32) and each holding device (24, 26, 28, 30 and 32) includes a tensioning portion (44 or 48) for applying a force urging the LED (20) through the void (40) and into thermal engagement with the heat dissipater (10) and the electrical leads (22) thereof into engagement with the traces (14). The tensioning portion may comprise barbs (44) on the legs (36, 136) and/or undulations (48) in the legs (36, 136).

Dependencies are inferred from the claim text.