Lighting unit with improved cooling

• US 20040208009A1
• Filed: 06/07/2004
• Published: 10/21/2004
• Est. Priority Date: 06/12/2001
• Status: Abandoned Application

• Current Assignee: Pulsar Light of Cambridge Ltd.
• Original Assignee: Pulsar Light of Cambridge Ltd.
• Inventors: Gregory, Mark Leonard, Mardon, Paul Francis
• Application Number:
  US10/480,092
• Publication Number:
  US 20040208009A1
• Time in Patent Office: Days
• US Class Current: 362/373
• 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: F21V 29/677 the fans being used for discharging
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/30 Driver circuits

Abstract

Disclosed is a lighting unit comprising at least one light emitting diode (50), means for supplying power to the light emitting diode (50), and a motor driven pump means (18) for generating a stream of fluid for cooling the light emitting diode (50). The pump means is mounted in a resiliently compressible member (48) for absorbing vibrations produced by the pump means (18) which reduces the level of noise produced by the lighting unit. The lighting unit has control means operable to gradually increase or decease the speed of operation of the pump means in response to the power dissipation of the light emitting diode exceeding or falling below, respectively, a threshold level, which makes the noise produced by the pump means less noticeable.

Claims

1. A lighting unit comprising at least one light emitting diode (led), means for supplying power to the at least one led, and a motor driven pump means for generating a stream of fluid for cooling the at least one led:

2. A lighting unit according to claim 1, wherein the pump means comprises a fan which is operable to create a stream of air for cooling the at least one LED.

3. A lighting unit according to claim 1, which includes control means for activating the fan by supplying a progressively increasing voltage thereto, so as to produce a gentle acceleration of the fan blades up to a normal operating speed of the fan.

4. A lighting unit according to claim 3, wherein the control means is adapted to increase the speed of movement of the fan blades from standstill to the normal operating speed in not less than ten seconds.

5. A lighting unit according to claim 3, wherein the control means is adapted to deactivate the fan by gradually reducing the speed of movement of the fan blades so as to reduce residual heat from the at least one LED after the at least one LED has stopped generating sufficient heat to require cooling.

6. A lighting unit according to claim 3, wherein the control means is operable to activate the fan when the power supply to the at least one LED exceeds a first threshold, and to deactivate the fan when the power supply to the at least one LED drops below a second threshold.

7. A lighting unit according to claim 6, wherein the first threshold is equal to the second threshold.

8. A lighting unit according to claim 2, wherein the stream of air created by the fan impinges directly on the rear of the at least one LED or on an element thermally coupled to the rear of the at least one LED.

9. A lighting unit according to claim 8, which includes ducting means operable to channel the stream of air from the fan to the at least one LED or element thermally coupled to the rear of the at least one LED.

10. A lighting unit according to claim 2, wherein the at least one LED forms part of an array of LEDs mounted on a first face of a support board.

11. A lighting unit according to claim 10, which includes coupling means for thermally coupling each of the array of LEDs to an element on a second face of the support board, wherein, in use, the stream of air from the fan is directed over the second face of the support board.

12. A lighting unit according to claim 11, wherein the coupling means is provided by an electrical conductor for electrically connecting each of the array of LEDs to the power supply means.

13. A lighting unit according to claim 12, wherein the coupling means is provided by the cathode lead of each of the array of LEDs.

14. A lighting unit according to claim 11, wherein at least the second surface of the support board carries a thermally conductive layer.

15. A lighting unit according to claim 14, wherein the thermally conductive layer is formed from tinned copper.

16. A lighting unit according to claim 2, wherein the at least one LED and fan are mounted in a housing having an air inlet opening for the stream of air before it has cooled the at least one LED, and an air outlet opening which acts as an exhaust for the stream of air after it has cooled the at least one LED, wherein the inlet and outlet openings are situated generally behind the at least one LED.

17. A lighting unit according to claim 16, wherein the inlet and outlet openings are situated at the rear of the housing.

18. A lighting unit according to claim 17, wherein one of the openings is annular and encircles the other opening.

19. A lighting unit according to claim 18, wherein the annular opening is the air outlet opening.

20. A lighting unit according to claim any of claims 19, wherein the housing comprises an outer member into which a tubular core member extends, and the fan is mounted in the core member.

21. A lighting unit according to claim 20, wherein the core member defines the air inlet opening, is located relative to the support board such that the stream of air from the fan passes between the second surface of the support board and the core member, and is located relative to the outer member so as to define the annular air outlet opening.

22. A lighting unit according to claim 21, which includes sealing means adapted to prevent passage of air from the fan to the region in front of the first surface of the support board.

23. A lighting unit according to claim 20, wherein the fan is mounted in the core member through a resiliently compressible member operable to absorb vibrations produced by the fan.

24. A lighting unit according to claim 23, wherein the compressible member is annular and is compressed between the core member and the fan so as to retain the fan in the core member.

25. A lighting unit according to claim 10, which includes a reflector member comprising a piece of sheet material having a plurality of apertures, each aperture being located in a respective depression in the material, wherein each LED extends through a respective aperture and the associated depression reflects light emitted from the sides of the LED forwardly from the lighting unit.

26. (Cancelled)