High brightness light emitting diode light source

• US 20060092639A1
• Filed: 10/29/2004
• Published: 05/04/2006
• Est. Priority Date: 10/29/2004
• Status: Active Grant

• Current Assignee: Goldeneye, Inc.
• Original Assignee: Goldeneye, Inc.
• Inventors: Livesay, William R., Beeson, Kari W., Livesay, Chad R., Ross, Richerd L., Ziromerman, Scott M.
• Granted Patent: US 7,331,691 B2
• Time in Patent Office: Days
• US Class Current: 362/294
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• CPC Class Codes: F21V 29/51 using condensation or evaporation of a fluid, e.g. heat pipes
• CPC Class Codes: F21V 29/767 the planes containing the fins or blades having directions perpendicular to the light emitting axis
• CPC Class Codes: F21V 29/777 the planes containing the fins or blades having directions perpendicular to the light emitting axis
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 33/648 the elements comprising fluids, e.g. heat-pipes

Abstract

High brightness LEDs are mounted directly on a heat pipe or are mounted on a substrate, which is mounted on the heat pipe. The heat pipe can be a common electrode for the LEDs mounted on the heat pipe. Multiple heat pipes can be arranged so that the LED arrays form a light recycling cavity to emit and reflect light. The resulting illumination system produces a higher brightness and higher total flux than any one of the individual LEDs making up the light source.

Claims

1. An illumination system, comprising:

a first array of light emitting diodes, wherein said first array of light emitting diodes emits light and wherein said first array of light emitting diodes reflects incident light; and

a heat transfer means, said first array of light emitting diodes being bonded to said heat transfer means, wherein said heat transfer means dissipates heat from said first array of light emitting diodes.

2. The illumination system of claim 1, wherein said heat transfer means is a heat pipe.

3. The illumination system of claim 1, wherein said first array of light emitting diodes is one or more light emitting diodes.

4. The illumination system of claim 1, further comprising:

a thermally conductive substrate between said first array of light emitting diodes and said heat transfer means, wherein said substrate is bonded to said first array of light emitting diodes and to said heat transfer means, wherein said thermally conductive substrate conducts heat generated by said first array of light emitting diodes to said heat transfer means, and wherein said thermally conductive substrate reflects light.

5. The illumination system of claim 2, further comprising a flat surface on said heat pipe, said first array of light emitting diodes being bonded to said flat surface on said heat pipe.

6. The illumination system of claim 5, wherein said flat surface is on the side of said heat pipe.

7. The illumination system of claim 5, wherein said flat surface is on one end of said heat pipe.

8. The illumination system of claim 2, further comprising:

a flat surface on said heat pipe, and

a thermally conductive substrate between said first array of light emitting diodes and said heat transfer means, wherein said substrate is bonded to said first array of light emitting diodes and to said flat surface of heat transfer means, wherein said thermally conductive substrate conducts heat generated by said first array of light emitting diodes to said heat transfer means, and wherein said thermally conductive substrate reflects light.

9. The illumination system of claim 6, wherein said flat surface is on the side of said heat pipe.

10. The illumination system of claim 6, wherein said flat surface is on one end of said heat pipe.

11. The illumination system of claim 1, wherein said heat transfer means is electrically conducting for supplying power to said first array of light emitting diodes.

12. The illuminations system of claim 2 wherein said heat pipe is electrically conducting for supplying power to said first array of light emitting diodes.

13. The illuminations system of claim 8, wherein said thermally conductive substrate is electrically conducting and said heat pipe is electrically conducting for supplying power to said first array of light emitting diodes.

14. An illumination system, comprising:

a first array of light emitting diodes, wherein said first array of light emitting diodes emits light and wherein said first array of light emitting diodes reflects incident light;

a heat transfer means, said first array of light emitting diodes being bonded to said heat transfer means, wherein said heat transfer means dissipates heat from said first array of light emitting diodes; and

a light recycling means, wherein said light recycling means reflects and recycles a portion of said light emitted by said first array of light emitting diodes back to said first array of light emitting diodes.

15. An illumination system, comprising:

a first array of light emitting diodes, wherein said first array of light emitting diodes emits light and wherein said first array of light emitting diodes reflects incident light;

a first heat pipe, said first array of light emitting diodes being bonded to said first heat pipe, wherein said first heat pipe dissipates heat from said first array of light emitting diodes;

a second array of light emitting diodes, wherein said second array of light emitting diodes emits light and wherein said second array of light emitting diodes reflects incident light;

a second heat pipe, said second array of light emitting diodes being bonded to said second heat pipe, wherein said second heat pipe dissipates heat from said second array of light emitting diodes; and

a light recycling means, wherein said light recycling means reflects and recycles a portion of said light emitted by said first array of light emitting diodes and reflects and recycles a portion of said light emitted by said second array of light emitting diodes.

16. The illumination system of claim 15, wherein said light recycling means is a light recycling cavity formed by said first array of light emitting diodes on said first heat pipe and said second array of light emitting diodes on said second heat pipe.

17. The illumination system of claim 16, wherein said first array of light emitting diodes and said second array of light emitting diodes form a V-shaped light recycling cavity.

18. The illumination system of claim 17, further comprising a first diffuse reflector positioned at a first end of said first array of light emitting diodes and at a first end of said second array of light emitting diodes and a second diffuse reflector positioned at a second end of said first array of light emitting diodes and at a second end of said second array of light emitting diodes to form said V-shaped light recycling cavity.

19. The illumination system of claim 18, wherein said first heat pipe extends in the opposite direction from said second heat pipe.

20. The illumination system of claim 18, wherein said first heat pipe extends in the same direction as said second heat pipe.

21. The illumination system of claim 16, further comprising

a flat surface on said first heat pipe, said first array of light emitting diodes being bonded to said flat surface on said first heat pipe;

and

a flat surface on said second heat pipe, said second array of light emitting diodes being bonded to said flat surface on said second heat pipe.

22. The illumination system of claim 21, further comprising:

a first thermally conductive substrate between said first array of light emitting diodes and said first heat pipe, wherein said first thermally conductive substrate is bonded to said first array of light emitting diodes and to said flat surface of said first heat pipe, wherein said first thermally conductive substrate conducts heat generated by said first array of light emitting diodes to said first heat pipe, and wherein said first thermally conductive substrate reflects light within said light recycling cavity; and

a second thermally conductive substrate between said second array of light emitting diodes and said second heat pipe, wherein said second thermally conductive substrate is bonded to said second array of light emitting diodes and to said flat surface of said second heat pipe, wherein said second thermally conductive substrate conducts heat generated by said second array of light emitting diodes to said second heat pipe, and wherein said second thermally conductive substrate reflects light within said light recycling cavity.

23. The illumination system of claim 15, wherein said first heat pipe is electrically conductive for supplying power to said first array of light emitting diodes and said second heat pipe is electrically conductive for supplying power to said second array of light emitting diodes.

24. The illuminations system of claim 22, wherein said first thermally conductive substrate is electrically conductive and said first heat pipe is electrically conductive for supplying power to said first array of light emitting diodes and said second thermally conductive substrate is electrically conductive and said second heat pipe is electrically conductive for supplying power to said second array of light emitting diodes.

25. The illumination system of claim 15 wherein said first array of light emitting diodes emits light of a different color than said second array of light emitting diodes.

26. The illumination system of claim 15 wherein said first array of light emitting diodes emits light of more than one color and said second array of light emitting diodes emits light of more than one color.

27. An illumination system, comprising:

a first array of light emitting diodes, wherein said first array of light emitting diodes emits light and wherein said first array of light emitting diodes reflects incident light;

a first heat pipe, said first array of light emitting diodes being bonded to said first heat pipe, wherein said first heat pipe dissipates heat from said first array of light emitting diodes;

a second array of light emitting diodes, wherein said second array of light emitting diodes emits light and wherein said second array of light emitting diodes reflects incident light;

a second heat pipe, said second array of light emitting diodes being bonded to said second heat pipe, wherein said second heat pipe dissipates heat from said second array of light emitting diodes;

a third array of light emitting diodes, wherein said third array of light emitting diodes emits light and wherein said third array of light emitting diodes reflects incident light;

a third heat pipe, said third array of light emitting diodes being bonded to said third heat pipe, wherein third first heat pipe dissipates heat from said third array of light emitting diodes;

a fourth array of light emitting diodes, wherein said fourth array of light emitting diodes emits light and wherein said fourth array of light emitting diodes reflects incident light;

a fourth heat pipe, said fourth array of light emitting diodes being bonded to said fourth heat pipe, wherein said fourth heat pipe dissipates heat from said fourth array of light emitting diodes; and

a light recycling means, wherein said light recycling means reflects and recycles a portion of said light emitted by said first array of light emitting diodes;

reflects and recycles a portion of said light emitted by said second array of light emitting diodes;

reflects and recycles a portion of said light emitted by said third array of light emitting diodes; and

reflects and recycles a portion of said light emitted by said fourth array of light emitting diodes.

28. The illumination system of claim 27, wherein said light recycling means is a light recycling cavity formed by said first array of light emitting diodes on said first heat pipe;

said second array of light emitting diodes on said second heat pipe;

said third array of light emitting diodes on said third heat pipe; and

said fourth array of light emitting diodes on said fourth heat pipe.

29. The illumination system of claim 28, further comprising a diffuse reflector positioned at a first end of said first array of light emitting diodes;

at a first end of said second array of light emitting diodes;

at a first end of said third array of light emitting diodes; and

at a first end of said fourth array of light emitting diodes to form said light recycling cavity.

30. The illumination system of claim 28, wherein said first heat pipe, said second heat pipe, said third heat pipe and said fourth heat pipe extend at right angles to the adjacent heat pipe.

31. The illumination system of claim 28, wherein said first heat pipe, said second heat pipe, said third heat pipe and said fourth heat pipe extend in the same direction.

32. The illumination system of claim 28, further comprising

a beveled surface on one end of said first heat pipe, said first array of light emitting diodes being bonded to said beveled surface on said first heat pipe;

a beveled surface on one end of said second heat pipe, said second array of light emitting diodes being bonded to said beveled surface on said second heat pipe;

a beveled surface on one end of said third heat pipe, said third array of light emitting diodes being bonded to said beveled surface on said third heat pipe; and

a beveled surface on one end of said fourth heat pipe, said fourth array of light emitting diodes being bonded to said beveled surface on said fourth heat pipe.

33. The illumination system of claim 32, further comprising:

a first thermally conductive substrate between said first array of light emitting diodes and said first heat pipe, wherein said first thermally conductive substrate is bonded to said first array of light emitting diodes and to said beveled surface of said first heat pipe, wherein said first thermally conductive substrate conducts heat generated by said first array of light emitting diodes to said first heat pipe, and wherein said first thermally conductive substrate reflects light within said light recycling cavity;

a second thermally conductive substrate between said second array of light emitting diodes and said second heat pipe, wherein said second thermally conductive substrate is bonded to said second array of light emitting diodes and to said beveled surface of said second heat pipe, wherein said second thermally conductive substrate conducts heat generated by said second array of light emitting diodes to said second heat pipe, and wherein said second thermally conductive substrate reflects light within said light recycling cavity;

a third thermally conductive substrate between said third array of light emitting diodes and said third heat pipe, wherein said third thermally conductive substrate is bonded to said third array of light emitting diodes and to said beveled surface of said third heat pipe, wherein said third thermally conductive substrate conducts heat generated by said third array of light emitting diodes to said third heat pipe, and wherein said third thermally conductive substrate reflects light within said light recycling cavity; and

a fourth thermally conductive substrate between said fourth array of light emitting diodes and said fourth heat pipe, wherein said fourth thermally conductive substrate is bonded to said fourth array of light emitting diodes and to said beveled surface of said fourth heat pipe, wherein said fourth thermally conductive substrate conducts heat generated by said fourth array of light emitting diodes to said fourth heat pipe, and wherein said fourth thermally conductive substrate reflects light within said light recycling cavity.

34. The illumination system of claim 27, wherein said first heat pipe is electrically conductive for supplying power to said first array of light emitting diodes, said second heat pipe is electrically conductive for supplying power to said second array of light emitting diodes, said third heat pipe is electrically conductive for supplying power to said third array of light emitting diodes, and said fourth heat pipe is electrically conductive for supplying power to said fourth array of light emitting diodes.

35. The illuminations system of claim 33, wherein said first thermally conductive substrate is electrically conductive and said first heat pipe is electrically conductive for supplying power to said first array of light emitting diodes;

said second thermally conductive substrate is electrically conductive and said second heat pipe is electrically conductive for supplying power to said second array of light emitting diodes;

said third thermally conductive substrate is electrically conductive and said third heat pipe is electrically conductive for supplying power to said third array of light emitting diodes; and

said fourth thermally conductive substrate is electrically conductive and said fourth heat pipe is electrically conductive for supplying power to said fourth array of light emitting diodes.

36. The illumination system of claim 27 wherein said first array of light emitting diodes, said second array of light emitting diodes, said third array of light emitting diodes and said fourth array of light emitting diodes emit light of at least two different colors.

37. The illumination system of claim 27 wherein at least one of wherein said first array of light emitting diodes, said second array of light emitting diodes, said third array of light emitting diodes and said fourth array of light emitting diodes emits light of at least two different colors.

38. An illumination system, comprising:

a plurality of arrays of light emitting diodes, wherein each of said light emitting diodes emits light and wherein each of said plurality of light emitting diodes reflects incident light;

a plurality of heat pipes, each of said plurality of arrays of light emitting diodes being bonded to one of a corresponding plurality of heat pipes, wherein said corresponding heat pipe dissipates heat from said array of light emitting diodes; and

a light recycling means, wherein said light recycling means reflects and recycles a portion of said light emitted by said plurality of arrays of light emitting diodes.

39. The illumination system of claim 38, wherein said light recycling means is a light recycling cavity formed by said plurality of arrays of light emitting diodes.

40. The illumination system of claim 39, further comprising:

a plurality of thermally conductive substrates, each of said plurality of thermally conductive substrates being bonded to one of a corresponding plurality of arrays of light emitting diodes and to one of a corresponding plurality of heat pipes, wherein each of said thermally conductive substrates conducts heat generated by said array of light emitting diodes to said heat pipe.

41. The illumination system of claim 38, wherein said light recycling means is a plurality of light recycling cavities formed by said plurality of arrays of light emitting diodes.

42. An illumination system, comprising:

a first array of light emitting diodes, wherein said first array of light emitting diodes emits light and wherein said first array of light emitting diodes reflects incident light;

a first heat pipe, said first array of light emitting diodes being bonded to said first heat pipe, wherein said first heat pipe dissipates heat from said first array of light emitting diodes;

a second array of light emitting diodes, wherein said second array of light emitting diodes emits light and wherein said second array of light emitting diodes reflects incident light;

a second heat pipe, said second array of light emitting diodes being bonded to said second heat pipe, wherein said second heat pipe dissipates heat from said second array of light emitting diodes;

a third array of light emitting diodes, wherein said third array of light emitting diodes emits light and wherein said third array of light emitting diodes reflects incident light;

a third heat pipe, said third array of light emitting diodes being bonded to said third heat pipe, wherein third first heat pipe dissipates heat from said third array of light emitting diodes;

a fourth array of light emitting diodes, wherein said fourth array of light emitting diodes emits light and wherein said fourth array of light emitting diodes reflects incident light;

a fourth heat pipe, said fourth array of light emitting diodes being bonded to said fourth heat pipe, wherein said fourth heat pipe dissipates heat from said fourth array of light emitting diodes;

a fifth array of light emitting diodes, wherein said fifth array of light emitting diodes emits light and wherein said fifth array of light emitting diodes reflects incident light;

a fifth heat pipe, said fifth array of light emitting diodes being bonded to said fifth heat pipe, wherein said fifth heat pipe dissipates heat from said fifth array of light emitting diodes; and

a light recycling means having a light recycling cavity formed by said first array of light emitting diodes on said first heat pipe;

said second array of light emitting diodes on said second heat pipe;

said third array of light emitting diodes on said third heat pipe;

said fourth array of light emitting diodes on said fourth heat pipe; and

said fifth array of light emitting diodes on said fifth heat pipe;

wherein said light recycling means reflects and recycles a portion of said light emitted by said first array of light emitting diodes;

reflects and recycles a portion of said light emitted by said second array of light emitting diodes;

reflects and recycles a portion of said light emitted by said third array of light emitting diodes;

reflects and recycles a portion of said light emitted by said fourth array of light emitting diodes; and

reflects and recycles a portion of said light emitted by said fifth array of light emitting diodes.

43. The illumination system of claim 42, wherein said first heat pipe, said second heat pipe, said third heat pipe and said fourth heat pipe extend at right angles to the adjacent heat pipe, further wherein said fifth heat pipe is at right angles to first heat pipe, said second heat pipe, said third heat pipe and said fourth heat pipe, said heat pipes forming a cubical light recycling cavity.

44. The illumination system of claim 42, further comprising:

a first thermally conductive substrate between said first array of light emitting diodes and said first heat pipe, wherein said first thermally conductive substrate is bonded to said first array of light emitting diodes and to a flat surface of said first heat pipe, wherein said first thermally conductive substrate conducts heat generated by said first array of light emitting diodes to said first heat pipe, and wherein said first thermally conductive substrate reflects light within said light recycling cavity;

a second thermally conductive substrate between said second array of light emitting diodes and said second heat pipe, wherein said second thermally conductive substrate is bonded to said second array of light emitting diodes and to a flat surface of said second heat pipe, wherein said second thermally conductive substrate conducts heat generated by said second array of light emitting diodes to said second heat pipe, and wherein said second thermally conductive substrate reflects light within said light recycling cavity;

a third thermally conductive substrate between said third array of light emitting diodes and said third heat pipe, wherein said third thermally conductive substrate is bonded to said third array of light emitting diodes and to a flat surface of said third heat pipe, wherein said third thermally conductive substrate conducts heat generated by said third array of light emitting diodes to said third heat pipe, and wherein said third thermally conductive substrate reflects light within said light recycling cavity;

a fourth thermally conductive substrate between said fourth array of light emitting diodes and said fourth heat pipe, wherein said fourth thermally conductive substrate is bonded to said fourth array of light emitting diodes and to a flat surface of said fourth heat pipe, wherein said fourth thermally conductive substrate conducts heat generated by said fourth array of light emitting diodes to said fourth heat pipe, and wherein said fourth thermally conductive substrate reflects light within said light recycling cavity; and

a fifth thermally conductive substrate between said fifth array of light emitting diodes and said fifth heat pipe, wherein said fifth thermally conductive substrate is bonded to said fifth array of light emitting diodes and to a flat surface of said fifth heat pipe, wherein said fifth thermally conductive substrate conducts heat generated by said fifth array of light emitting diodes to said fifth heat pipe, and wherein said fifth thermally conductive substrate reflects light within said light recycling cavity.

45. The illumination system of claim 42, wherein said first heat pipe is electrically conductive for supplying power to said first array of light emitting diodes, said second heat pipe is electrically conductive for supplying power to said second array of light emitting diodes, said third heat pipe is electrically conductive for supplying power to said third array of light emitting diodes, said fourth heat pipe is electrically conductive for supplying power to said fourth array of light emitting diodes, and said fifth heat pipe is electrically conductive for supplying power to said fifth array of light emitting diodes.

46. The illuminations system of claim 44, wherein said first thermally conductive substrate is electrically conductive and said first heat pipe is electrically conductive for supplying power to said first array of light emitting diodes;

said second thermally conductive substrate is electrically conductive and said second heat pipe is electrically conductive for supplying power to said second array of light emitting diodes;

said third thermally conductive substrate is electrically conductive and said third heat pipe is electrically conductive for supplying power to said third array of light emitting diodes; and

said fourth thermally conductive substrate is electrically conductive;

said fourth heat pipe is electrically conductive for supplying power to said fourth array of light emitting diodes; and

said fifth heat pipe is electrically conductive for supplying power to said fifth array of light emitting diodes.

47. The illumination system of claim 42 wherein said first array of light emitting diodes, said second array of light emitting diodes, said third array of light emitting diodes, said fourth array of light emitting diodes and said fifth array of light emitting diodes emit light of at least two different colors.

48. The illumination system of claim 42 wherein at least one of wherein said first array of light emitting diodes, said second array of light emitting diodes, said third array of light emitting diodes, said fourth array of light emitting diodes and said fifth array of light emitting diodes emits light of at least two different colors.

49. The illumination system of claim 42, wherein said first heat pipe is bent at a 90 degree angle, said second heat pipe is bent at a 90 degree angle, said third heat pipe is bent at a 90 degree angle, said fourth heat pipe is bent at a 90 degree angle, and said fifth heat pipe is bent at a 90 degree angle.