Heat sink structures, lighting elements and lamps incorporating same, and methods of making same

• US 10,030,863 B2
• Filed: 04/19/2011
• Issued: 07/24/2018
• Est. Priority Date: 04/19/2011
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Pickard, Paul Kenneth, Progl, Curt, Gray, Joshua N.
• Primary Examiner(s): Harris, William N
• Application Number:
  US13/089,807
• Publication Number:
  US 20120268936A1
• Time in Patent Office: 2,653 Days
• Field of Search: 36224901, 36224902, 362294, 362373, 362649, 362650
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21K 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 29/506 of globes, bowls or cover glasses
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/777 the planes containing the fins or blades having directions perpendicular to the light emitting axis
• CPC Class Codes: F21V 29/78 with helically or spirally arranged fins or blades
• CPC Class Codes: F21V 29/80 with pins or wires
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 29/85 characterised by the material liquid coolants F21V29/56
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21Y 2107/30 on the outer surface of cylindrical surfaces, e.g. rod-shaped supports having a circular or a polygonal cross section
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: Y10T 29/4935 Heat exchanger or boiler making

Abstract

In some embodiments, a lighting element comprising at least first and second solid state light emitters, a first heat sink structure with a fold region between first and second heat sink regions, and at least one light emitter on each of the heat sink regions, and methods of making. In some embodiments, a lighting element, comprising plural heat sink regions on respective regions of a flexible circuit board, and plural light emitters on respective regions of the flexible circuit board, and methods of making. In some embodiments, heat sink structures comprising plural heat sink regions and a circuit board with plural regions, and lighting elements comprising them. In some embodiments, a heat sink structure, comprising plural heat sink regions and an internal flow guide structure, and lighting elements comprising same. Also, other lighting elements, lamps and heat sink structures.

Claims

1. A lighting element, comprising:

at least a first heat sink structure; and

at least a first group of solid state light emitters and a second group of solid state light emitters,

the first heat sink structure a one-piece structure that comprises at least first and second heat sink regions integral with one another and at least a first fold region between the first and second heat sink regions, the fold region of rigidity that is lower than the rigidity of the first heat sink region and lower than the rigidity of the second heat sink region,

at least a first solid state light emitter on the first heat sink region, at least a second solid state light emitter on the second heat sink region,

the first heat sink structure defining a first internal space defined at least in part by the first and second heat sink regions,

an entirety of the first internal space between a first plane and a second plane, the first plane substantially parallel to the second plane,

the first internal space comprising at least one plenum extending from the first plane to the second plane,

each plenum extending from the first plane to the second plane having no path through which air can pass along a straight line from the first plane to the second plane,

each of the first group of solid state light emitters, when supplied with electricity, emitting light having a first color point,

each of the second group of solid state light emitter, when supplied with electricity, emitting light having a second color point,

the first color point different from the second color point,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a first string,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a second string,

a first ratio equal to (1) a number of solid state light emitters in said second group of solid state light emitters and in said first string, divided by (2) a number of solid state light emitters in said first group of solid state light emitters and in said first string,

a second ratio equal to (3) a number of solid state light emitters in said second group of solid state light emitters and in said second string, divided by (4) a number of solid state light emitters in said first group of solid state light emitters and in said second string,

the first ratio different from the second ratio.

2. A lighting element as recited in claim 1, wherein the first fold region is substantially linear and has a thickness that is less than a thickness of every portion of each of the first and second heat sink regions.

3. A lighting element as recited in claim 1, wherein the first heat sink structure further comprises at least a third heat sink region and a second fold region between the second and third heat sink regions.

4. A lighting element as recited in claim 3, wherein the first internal space is defined at least in part by the first, second and third heat sink regions.

5. A lighting element as recited in claim 3, wherein the first, second and third heat sink regions are substantially flat.

6. A lighting element as recited in claim 3, wherein:

a major surface of the first heat sink region has a plane of symmetry in a first plane,

a major surface of the second heat sink region has a plane of symmetry in a second plane,

a major surface of the third heat sink region has a plane of symmetry in a third plane,

the first plane defines an angle of at least 20 degrees relative to each of the second plane and the third plane,

the second plane defines an angle of at least 20 degrees relative to the third plane.

7. A lamp comprising a lighting element as recited in claim 1, wherein the lamp fits within an envelope of an A lamp.

8. A lighting element as recited in claim 1, wherein at least the first solid state light emitter comprises a light emitting diode.

9. A lighting element as recited in claim 1, wherein the first heat sink structure comprises at least a first heat dissipation element attached to the first heat sink region.

10. A lighting element as recited in claim 9, wherein the first heat dissipation element comprises at least a first fin element.

11. A lighting element as recited in claim 1, wherein the lighting element further comprises at least a first circuit board that extends across the first fold region.

12. A method of making a lighting element, comprising:

mounting first and second groups of solid state light emitters on a first heat sink structure, said mounting comprising mounting at least a first solid state light emitter on a first heat sink region of the first heat sink structure; and

mounting at least a second solid state light emitter on a second heat sink region of the first heat sink structure,

the first heat sink structure a one-piece structure that comprises at least a first fold region between the first and second heat sink regions, the first and second heat sink regions integral with one another, the fold region of rigidity that is lower than the rigidity of the first heat sink region and lower than the rigidity of the second heat sink region,

the first heat sink structure defining a first internal space defined at least in part by the first and second heat sink regions,

an entirety of the first internal space between a first plane and a second plane, the first plane substantially parallel to the second plane,

the first internal space comprising at least one plenum extending from the first plane to the second plane,

each plenum extending from the first plane to the second plane having no path through which air can pass along a straight line from the first plane to the second plane,

each of the first group of solid state light emitters, when supplied with electricity, emitting light having a first color point,

each of the second group of solid state light emitter, when supplied with electricity, emitting light having a second color point,

the first color point different from the second color point,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a first string,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a second string,

a first ratio equal to (1) a number of solid state light emitters in said second group of solid state light emitters and in said first string, divided by (2) a number of solid state light emitters in said first group of solid state light emitters and in said first string,

a second ratio equal to (3) a number of solid state light emitters in said second group of solid state light emitters and in said second string, divided by (4) a number of solid state light emitters in said first group of solid state light emitters and in said second string,

the first ratio different from the second ratio.

13. A method as recited in claim 12, wherein the method further comprises bending the first heat sink structure substantially along the first fold region.

14. A method as recited in claim 13, wherein the method further comprises testing the first and second solid state light emitters before bending the first heat sink structure.

15. A method as recited in claim 12, wherein:

the first heat sink structure further comprises at least a second fold region, and

the method further comprises bending the first heat sink structure at least along the first fold region and bending the first heat sink structure along the second fold region so that first and second edges of the first heat sink structure are in contact with each other.

16. A method as recited in claim 15, wherein the method further comprises testing the first and second solid state light emitters before bending the first heat sink structure along the first fold region or along the second fold region.

17. A method as recited in claim 12, wherein the method further comprises:

supplying power to at least the first and second solid state light emitters, and then

bending the first heat sink structure substantially along the first fold region.

18. A method as recited in claim 12, wherein at least the first and second solid state light emitters comprise light emitting diodes.

19. A method as recited in claim 12, wherein the first heat sink structure comprises at least a first heat dissipation element attached to the first heat sink region.

20. A method as recited in claim 19, wherein the first heat dissipation element comprises at least a first fin element.

21. A method as recited in claim 12, wherein:

the method further comprises mounting at least a first circuit board on the first heat sink structure so that a first region of the first circuit board is on the first heat sink region and a second region of the first circuit board is on the second heat sink region, and

the first region of the first circuit board and the second region of the first circuit board are integral with each other, and the first circuit board is a one-piece structure.

22. A lighting element, comprising:

at least a first one-piece flexible circuit board;

at least first and second heat sink regions; and

at least first and second groups of solid state light emitters,

the first one-piece flexible circuit board having at least first and second circuit board regions,

the first heat sink region on the first circuit board region, the second heat sink region on the second circuit board region,

at least a first solid state light emitter on the first circuit board region, at least a second solid state light emitter on the second circuit board region,

the first and second heat sink regions both part of a first heat sink structure that defines a first internal space defined at least in part by the first and second heat sink regions,

an entirety of the first internal space between a first plane and a second plane, the first plane substantially parallel to the second plane,

the first internal space comprising at least one plenum extending from the first plane to the second plane,

each plenum extending from the first plane to the second plane having no path through which air can pass along a straight line from the first plane to the second plane,

each of the first group of solid state light emitters, when supplied with electricity, emitting light having a first color point,

each of the second group of solid state light emitter, when supplied with electricity, emitting light having a second color point,

the first color point different from the second color point,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a first string,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a second string,

a first ratio equal to (1) a number of solid state light emitters in said second group of solid state light emitters and in said first string, divided by (2) a number of solid state light emitters in said first group of solid state light emitters and in said first string,

a second ratio equal to (3) a number of solid state light emitters in said second group of solid state light emitters and in said second string, divided by (4) a number of solid state light emitters in said first group of solid state light emitters and in said second string,

the first ratio different from the second ratio.

23. A lighting element as recited in claim 22, wherein the first and second heat sink regions are separate from one another.

24. A lighting element as recited in claim 23, wherein the lighting element further comprises at least a third heat sink region.

25. A lighting element as recited in claim 24, wherein the first, second and third heat sink regions, alone or with more heat sink regions, together define the first internal space.

26. A lighting element as recited in claim 24, wherein the first, second and third heat sink regions are each substantially flat.

27. A lighting element as recited in claim 24, wherein:

a major surface of the first heat sink region has a plane of symmetry in a first plane,

a major surface of the second heat sink region has a plane of symmetry in a second plane,

a major surface of the third heat sink region has a plane of symmetry in a third plane,

the first plane defines an angle of at least 20 degrees relative to each of the second plane and the third plane,

the second plane defines an angle of at least 20 degrees relative to the third plane.

28. A lighting element as recited in claim 22, wherein the heat sink structure is an integral one-piece structure.

29. A lighting element as recited in claim 28, wherein the heat sink structure comprises at least a first fold region between the first and second heat sink regions.

30. A lamp comprising a lighting element as recited in claim 22, wherein the lamp fits within an envelope of an A lamp.

31. A lighting element as recited in claim 22, wherein at least a first heat dissipation element is attached to the first heat sink region.

52. A lighting element as recited in claim 22, wherein:

the first solid state light emitter is directly on the first circuit board region, and

the second solid state light emitter is directly on the second circuit board region.

32. A method of making a lighting element, comprising:

mounting first and second groups of solid state light emitters on a first heat sink structure, said mounting comprising mounting at least a first solid state light emitter on a first heat sink region of a first heat sink structure; and

mounting at least a second solid state light emitter on a second heat sink region of the first heat sink structure,

the first heat sink region on a first circuit board region of a first one-piece flexible circuit board, the second heat sink region on a second circuit board region of the first one-piece flexible circuit board,

the first heat sink structure defining a first internal space defined at least in part by the first and second heat sink regions,

an entirety of the first internal space between a first plane and a second plane, the first plane substantially parallel to the second plane,

the first internal space comprising at least one plenum extending from the first plane to the second plane,

each plenum extending from the first plane to the second plane having no path through which air can pass along a straight line from the first plane to the second plane,

each of the first group of solid state light emitters, when supplied with electricity, emitting light having a first color point,

each of the second group of solid state light emitter, when supplied with electricity, emitting light having a second color point,

the first color point different from the second color point,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a first string,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a second string,

a first ratio equal to (1) a number of solid state light emitters in said second group of solid state light emitters and in said first string, divided by (2) a number of solid state light emitters in said first group of solid state light emitters and in said first string,

a second ratio equal to (3) a number of solid state light emitters in said second group of solid state light emitters and in said second string, divided by (4) a number of solid state light emitters in said first group of solid state light emitters and in said second string,

the first ratio different from the second ratio.

33. A method as recited in claim 32, wherein the method further comprises folding the first flexible circuit board along a first line segment extending between the first circuit board region and the second circuit board region.

34. A method as recited in claim 33, wherein the method further comprises testing the first and second solid state light emitters before folding the first flexible circuit board.

35. A method as recited in claim 32, wherein:

the method further comprises mounting a third solid state light emitter on a third heat sink region of the first heat sink structure,

the third heat sink region is on a third circuit board region of the first flexible circuit board, and

the method further comprises folding the first flexible circuit board along a second line segment extending between the second circuit board region and the third circuit board region.

36. A method as recited in claim 32, wherein the method further comprises:

supplying power to at least the first and second solid state light emitters, and then

folding the first flexible circuit board along a first line segment extending between the first circuit board region and the second circuit board region.

37. A method as recited in claim 32, wherein the first and second heat sink regions are separate from one another.

38. A lighting element as recited in claim 32, wherein the first heat sink structure is an integral one-piece structure.

39. A lighting element comprising:

a first heat sink structure comprising at least first and second heat sink regions;

at least a first circuit board; and

at least first and second groups of solid state light emitters,

the first circuit board a one-piece structure comprising at least a first circuit board region and a second circuit board region,

the first circuit board region on the first heat sink region,

the second circuit board region on the second heat sink region,

at least a first solid state light emitter on the first circuit board region,

at least a second solid state light emitter on the second circuit board region,

the first circuit board region integral with the second circuit board region,

the first circuit board region having a first circuit board region surface that extends in a first plane of symmetry,

the second circuit board region having a second circuit board region surface that extends in a second plane of symmetry,

the first plane of symmetry defining an angle of at least 20 degrees relative to the second plane of symmetry,

the first heat sink structure defining a first internal space defined at least in part by the first and second heat sink regions,

an entirety of the first internal space between a first plane and a second plane, the first plane substantially parallel to the second plane,

the first internal space comprising at least one plenum extending from the first plane to the second plane,

each plenum extending from the first plane to the second plane having no path through which air can pass along a straight line from the first plane to the second plane,

each of the first group of solid state light emitters, when supplied with electricity, emitting light having a first color point,

each of the second group of solid state light emitter, when supplied with electricity, emitting light having a second color point,

the first color point different from the second color point,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a first string,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a second string,

a first ratio equal to (1) a number of solid state light emitters in said second group of solid state light emitters and in said first string, divided by (2) a number of solid state light emitters in said first group of solid state light emitters and in said first string,

a second ratio equal to (3) a number of solid state light emitters in said second group of solid state light emitters and in said second string, divided by (4) a number of solid state light emitters in said first group of solid state light emitters and in said second string,

the first ratio different from the second ratio.

40. A lighting element as recited in claim 39, wherein each of the heat sink regions has two opposite edges that each abut another heat sink region of the lighting element.

41. A lighting element as recited in claim 39, wherein:

the first heat sink structure further comprises at least a third heat sink region,

the first circuit board further comprises at least a third circuit board region, and

the third circuit board region is on the third heat sink region.

42. A lighting element as recited in claim 41, wherein the first internal space is defined at least in part by the first, second and third heat sink regions.

43. A lighting element as recited in claim 41, wherein the first, second and third heat sink regions are substantially flat.

44. A lighting element as recited in claim 41, wherein:

a major surface of the first heat sink region has a plane of symmetry in a first heat sink plane,

a major surface of the second heat sink region has a plane of symmetry in a second heat sink plane,

a major surface of the third heat sink region has a plane of symmetry in a third heat sink plane,

the first heat sink plane defines an angle of at least 20 degrees relative to each of the second heat sink plane and the third heat sink plane,

the second heat sink plane defines an angle of at least 20 degrees relative to the third heat sink plane.

45. A lamp comprising a lighting element as recited in claim 39, wherein the lamp fits within an envelope of an A lamp.

46. A lighting element as recited in claim 39, wherein the lighting element comprises at least a first heat dissipation element attached to the first heat sink region.

47. A lighting element as recited in claim 46, wherein the first heat dissipation element comprises at least a first fin element.

48. A lamp comprising:

at least a first heat sink structure, the first heat sink structure comprising at least first and second heat sink regions;

at least a first power supply element; and

at least first and second groups of solid state light emitters,

the first heat sink structure defining at least a first internal space defined at least in part by the first and second heat sink regions,

the first heat sink structure comprising a first surface and a second surface, the first surface opposite the second surface,

a first solid state light emitter on the first surface of the first heat sink structure,

the second surface of the first heat sink structure facing the first internal space,

at least the first power supply element on the first heat sink structure,

an entirety of the first internal space between a first plane and a second plane, the first plane substantially parallel to the second plane,

the first internal space comprising at least one plenum extending from the first plane to the second plane,

each plenum extending from the first plane to the second plane having no path through which air can pass along a straight line from the first plane to the second plane,

each of the first group of solid state light emitters, when supplied with electricity, emitting light having a first color point,

each of the second group of solid state light emitter, when supplied with electricity, emitting light having a second color point,

the first color point different from the second color point,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a first string,

at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a second string,

a first ratio equal to (1) a number of solid state light emitters in said second group of solid state light emitters and in said first string, divided by (2) a number of solid state light emitters in said first group of solid state light emitters and in said first string,

a second ratio equal to (3) a number of solid state light emitters in said second group of solid state light emitters and in said second string, divided by (4) a number of solid state light emitters in said first group of solid state light emitters and in said second string,

the first ratio different from the second ratio.

49. A lamp as recited in claim 48, wherein the first power supply element receives DC power and outputs DC power.

50. A lamp as recited in claim 48, wherein the lamp fits within an envelope of an A lamp.

51. A lamp as recited in claim 48, wherein at least the first solid state light emitter comprises a light emitting diode.