Light emitting diode source with protective barrier

Abstract

An apparatus having a substrate, an LED light source attached to the substrate, an electrical connector attached to the substrate and electrically connected to the LED light source, a potting material on the substrate and covering at least a portion of the electrical connector; and a barrier separating the potting material from the LED light source, the barrier having a height that exceeds the thickness of the potting material on the substrate.

1 . An apparatus, comprising:
 a substrate;   a LED light source attached to the substrate;   at least one electrical connector attached to the substrate and electrically connected to the LED light source;   a barrier separating the potting material from the LED light source; and   a potting material on the substrate covering at least a portion of the electrical connector, wherein the barrier has a height that exceeds a thickness of the potting material at the barrier.   
     
     
         2 . The apparatus of  claim 1  wherein the LED light source comprises an LED array. 
     
     
         3 . The apparatus of  claim 1  wherein the LED light source comprises at least one LED encapsulated within an encapsulation material disposed within the barrier. 
     
     
         4 . The apparatus of  claim 3  wherein the height of the bather exceeds a thickness of the encapsulation material at the barrier. 
     
     
         5 . The apparatus of  claim 3 , wherein each of said at least one LED comprises a blue LED and the encapsulation material includes phosphor. 
     
     
         6 .- 7 . (canceled) 
     
     
         8 . The apparatus of  claim 1 , wherein the barrier comprises a tapered rim that extends over at least a portion of the potting material. 
     
     
         9 . The apparatus of  claim 1  wherein the barrier includes a reflective surface arranged to reflect light emitted from the LED light source. 
     
     
         10 . (canceled) 
     
     
         11 . An apparatus, comprising:
 a substrate;   an LED light source attached to the substrate;   a barrier surrounding at least a portion of the LED light source;   at least one electrical connector attached to the substrate and electrically connected to the LED light source, the electrical connector being on the opposite side of the barrier from the LED light source; and   a potting material on the substrate and covering at least a portion of the electrical connector, wherein the barrier has a height that exceeds a thickness of the potting material on the substrate at the barrier.   
     
     
         12 . (canceled) 
     
     
         13 . The apparatus of  claim 11  wherein the LED light source comprises at least one LED encapsulated with an encapsulation material, wherein the barrier separates the potting material and the encapsulation material. 
     
     
         14 . The apparatus of  claim 13  wherein the height of the barrier exceeds the thickness of the encapsulation material at the barrier. 
     
     
         15 . The apparatus of  claim 13  wherein each of said at least one LED comprises a blue LED and the encapsulation material includes phosphor. 
     
     
         16 .- 17 . (canceled) 
     
     
         18 . The apparatus of  claim 11  wherein the barrier comprises a rim that extends over at least a portion of the potting material. 
     
     
         19 . The apparatus of  claim 11  wherein the barrier includes a reflective surface arranged to reflect light emitted from the LED light source. 
     
     
         20 . (canceled) 
     
     
         21 . An apparatus, comprising:
 a substrate;   an LED light source attached to the substrate;   at least one electrical connector attached to the substrate and electrically connected to the LED light source;   a potting material on the substrate and covering at least a portion of the electrical connector; and   a barrier between the LED light source and the electrical connector, the barrier having a height that exceeds the thickness of the potting material at the barrier on the substrate.   
     
     
         22 . (canceled) 
     
     
         23 . The apparatus of  claim 21 , wherein the LED light source comprises at least one LED encapsulated within the encapsulation material. 
     
     
         24 . The apparatus of  claim 23  wherein the height of the barrier exceeds the thickness of the encapsulation material at the barrier. 
     
     
         25 . The apparatus of  claim 23 , wherein each of said at least one LED comprises a blue LED and the encapsulation material comprises a phosphor. 
     
     
         26 .- 27 . (canceled) 
     
     
         28 . The apparatus of  claim 21 , wherein the barrier comprises a rim that extends towards the potting material and extends over at least a portion of the potting material. 
     
     
         29 . The apparatus of  claim 21  wherein the barrier includes a reflective surface arranged to reflect light emitted from the LED light source. 
     
     
         30 .- 31 . (canceled) 
     
     
         32 . An apparatus, comprising:
 a substrate;   a barrier attached to the substrate;   an LED light source attached to the substrate;   at least one electrical connector attached to the substrate and electrically connected to the LED light source, wherein the electrical connector is on a side of the barrier opposite to the LED light source; and   a potting material on the substrate covering at least a portion of the electrical connector, wherein the barrier has a rim that extends over at least a portion of the potting material, and wherein the barrier includes a reflective surface arranged to reflect light emitted from the LED light source.