Light-Emitting diode reflector assembly having a heat pipe
First Claim
Patent Images
1. A light-emitting diode reflector assembly, comprising:
- a) a reflector body having a recessed portion with a light-reflecting surface, said reflector body comprising a first thermally-conductive polymer composition;
b) a circuit board-mounting member connected to the reflector body, said mounting member comprising;
i) an elongated heat sink component having an upper and lower outer surface, said component comprising a second thermally-conductive polymer composition; and
ii) a heat pipe embedded in the heat sink component; and
c) a circuit board mounted to the lower surface of the mounting member, said circuit board having an array of light-emitting diodes that direct light beams onto the light-reflecting surface of the reflector body.
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Abstract
A light-emitting diode reflector assembly having a heat pipe and a reflector body is provided. The assembly further includes a mounting member for mounting a circuit board having an array of light-emitting diodes. The mounting member and reflector body are made from a thermally-conductive polymer composition comprising: i) about 20% to about 80% by weight of a base polymer matrix such as polycarbonate; and ii) about 20% to about 80% by weight of a thermally-conductive material such as carbon graphite.
70 Citations
23 Claims
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1. A light-emitting diode reflector assembly, comprising:
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a) a reflector body having a recessed portion with a light-reflecting surface, said reflector body comprising a first thermally-conductive polymer composition;
b) a circuit board-mounting member connected to the reflector body, said mounting member comprising;
i) an elongated heat sink component having an upper and lower outer surface, said component comprising a second thermally-conductive polymer composition; and
ii) a heat pipe embedded in the heat sink component; and
c) a circuit board mounted to the lower surface of the mounting member, said circuit board having an array of light-emitting diodes that direct light beams onto the light-reflecting surface of the reflector body. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method for making a light-emitting diode reflector assembly, comprising the steps of:
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a) providing a first molten polymer composition comprising;
i) about 20% to about 80% by weight of a base polymer matrix; and
ii) about 20% to about 80% by weight of a thermally-conductive material;
b) injecting the first molten polymer composition into a mold to form a thermally-conductive reflector body having a recessed portion with a light-reflecting surface;
c) providing a second molten polymer composition comprising;
i) about 20% to about 80% by weight of a base polymer matrix; and
ii) about 20% to about 80% by weight of a thermally-conductive material;
d) injecting the second molten polymer composition into a mold having an inserted heat pipe to form a circuit board-mounting member comprising an elongated heat sink component having an upper and lower outer surface, and embedded heat pipe;
e) mounting a circuit board having an array of light-emitting diodes to the lower surface of the mounting member; and
f) connecting the mounting member to the reflector body to form a light-emitting diode reflector assembly. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23)
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Specification