LED lamp heat sink

• US 20050111234A1
• Filed: 11/26/2003
• Published: 05/26/2005
• Est. Priority Date: 11/26/2003
• Status: Active Grant

• Current Assignee: Signify North America Corporation (Signify N.V.)
• Original Assignee: Lumileds Lighting US LLC (Apollo Global Management, Inc.)
• Inventors: Martin, Paul S., Wall, Franklin J. Jr.
• Granted Patent: US 7,144,135 B2
• Time in Patent Office: Days
• US Class Current: 362/555
• CPC Class Codes: F21K 9/233 specially adapted for generating a spot light distribution, e.g. for substitution of reflector lamps
• CPC Class Codes: F21S 6/003 for task lighting, e.g. for reading or desk work, e.g. angle poise lamps
• CPC Class Codes: F21S 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• CPC Class Codes: F21V 17/101 permanently, e.g. welding, gluing or riveting
• CPC Class Codes: F21V 17/164 the parts being subjected to bending, e.g. snap joints
• CPC Class Codes: F21V 29/505 of reflectors
• CPC Class Codes: F21V 29/67 characterised by the arrangement of fans
• CPC Class Codes: F21V 29/673 the fans being used for intake
• 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 29/77 with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 7/0091 using total internal reflection
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

An LED lamp includes an exterior shell that has the same form factor as a conventional incandescent light bulb, such as a PAR type bulb. The LED lamp includes an optical reflector that is disposed within the shell and that directs the light emitted from one or more LEDs. The optical reflector and shell define a space that is used to channel air to cool the device. The LED is mounted on a heat sink that is disposed within the shell. A fan moves air over the heat sink and through the spaced defined by the optical reflector and the shell. The shell includes one or more apertures that serve as air inlet or exhaust apertures. One or more apertures defined by the optical reflector and shell at the opening of the shell can also be used as air exhaust or inlet apertures.

Claims

1. An apparatus comprising:

a shell;

an optical reflector disposed at least partially within the shell, wherein a space is formed between the optical reflector and the shell;

at least one light emitting diode disposed within the optical reflector;

a heat sink disposed at least partially within the shell, the light emitting diode being mounted to the heat sink; and

a motor and a fan in flow communication with the space, the fan being configured to move air over the heat sink and through the space.

2. The apparatus of claim 1, wherein the fan is configured to move air over the heat sink before moving air through the space.

3. The apparatus of claim 1, wherein the shell has at least one air inlet aperture, the fan drawing air through the air inlet aperture.

4. The apparatus of claim 3, wherein the shell and optical reflector define at least one air exhaust aperture, wherein air is expelled through the at least one air exhaust aperture after moving over the heat sink.

5. The apparatus of claim 3, wherein the shell further has at least one air exhaust aperture, wherein air is expelled through the at least one air exhaust aperture after moving over the heat sink.

6. The apparatus of claim 1, wherein the shell and optical reflector define at least one air inlet aperture and the shell further has at least one air exhaust aperture, wherein the fan draws air through the air inlet aperture and moves air through the space, over the heat sink and through the air exhaust aperture.

7. The apparatus of claim 3, wherein the apparatus further comprises a base coupled to the shell, wherein the shell has a plurality of air inlet apertures located near the base.

8. The apparatus of claim 1, wherein the heat sink includes at least one of a plurality of fins and a plurality of heat pipes that extend into the space.

9. The apparatus of claim 1, wherein the motor and fan are within the shell.

10. The apparatus of claim 1, further comprising a hollow neck coupled to the shell and a base coupled to the hollow neck, wherein the motor and fan are within the base.

11. A method of cooling a light emitting diode in a lamp, the lamp including an optical reflector that directs the light emitted from the light emitting diode, the method comprising:

drawing air through at least one air inlet aperture;

moving the air over a heat sink that is coupled to the light emitting diode;

moving the air along at least a portion of the optical reflector; and

expelling the air through at least one air exhaust aperture.

12. The method of claim 11, wherein the air is moved along at least a portion of the optical reflector before the air is moved over the heat sink.

13. The method of claim 11, wherein moving the air along at least a portion of the optical reflector comprises moving the air through a space defined by the optical reflector and an external shell that surrounds at least a portion of the optical reflector.

14. The method of claim 11, wherein drawing air, moving the air over a heat sink, moving the air along at least a portion of the optical reflector, and expelling the air is performed by a fan.

15. The method of claim 11, wherein air is expelled through at least one air exhaust aperture defined by the optical reflector and an external shell that surrounds at least a portion of the optical reflector.

16. The method of claim 11, further comprising moving the air through a hollow element that supports the optical reflector and a base that is coupled to the hollow element.

17. An apparatus comprising:

a light emitting diode;

an optical reflector that controls the direction of light emitted from the light emitting diode;

a heat sink, the light emitting diode being mounted on the heat sink;

a fan for moving air over the heat sink; and

an air flow channel through which the fan moves air, the air flow channel follows the general outline of the optical reflector.

18. The apparatus of claim 17, wherein the air flow channel is at least partially defined by the optical reflector.

19. The apparatus of claim 18, further comprising an exterior shell in which the optical reflector is at least partially disposed, wherein the air flow channel is further defined by the exterior shell.

20. The apparatus of claim 19, wherein the exterior shell has a plurality of apertures through which air is drawn prior to being moved over the heat sink.

21. The apparatus of claim 17, wherein the heat sink comprises at least one of a plurality of fins and a plurality of heat pipes that extend in the general direction of the optical reflector.

22. The apparatus of claim 17, further comprising a hollow support element that is coupled to the optical reflector and heat sink, wherein the hollow support element defines a portion of the air flow channel.