LED LAMP WITH A FLEXIBLE HEAT SINK

• US 20180023795A1
• Filed: 09/29/2017
• Published: 01/25/2018
• Est. Priority Date: 07/22/2015
• Status: Active Grant

• Current Assignee: Putco Incorporated
• Original Assignee: Putco Incorporated
• Inventors: ELWELL, JAMES P., QUICK, TRENT, XU, BAOZHOU
• Granted Patent: US 9,909,752 B2
• Time in Patent Office: Days
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• CPC Class Codes: F21S 41/141 Light emitting diodes [LED]
• CPC Class Codes: F21S 41/19 Attachment of light sources or lamp holders achieving variable light distribution by movable light sources F21S41/657
• CPC Class Codes: F21S 41/192 Details of lamp holders, terminals or connectors
• CPC Class Codes: F21S 45/47 Passive cooling, e.g. using fins, thermal conductive elements or openings
• CPC Class Codes: F21S 45/49 Attachment of the cooling means
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/89 Metals
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

An LED lamp uses a flexible metal belt as a heat sink. At least one light emitting diode is attached to a circuit board that is mounted on a heat conducting member. The flexible heat sink is attached to the heat conducting member, such that heat generated by the light emitting diode and circuit board is conducted to the flexible heat sink. The flexible heat sink can be deformed to fit in a variety of spaces. The flexible heat sink dissipates the heat generated by the LED lamp without the need for a fan. The flexible heat sink may be made from braided copper fabric or even a plurality of flexible metal sheets.

Claims

1. An LED lamp with a heat sink, the lamp comprising:

a wire harness adapted for connection to an electrical system;

a first circuit board electrically connected to the wire harness;

a heat conducting member, wherein the first circuit board is mounted the heat conducting member;

a first light emitting diode on the first circuit board; and

a flexible heat sink comprising a plurality of flexible metal sheets mechanically connected to the heat conducting member.

2. The LED clamp of claim 1, further comprising:

a second circuit board electrically connected to the wire harness;

a second light emitting diode on the second circuit board;

wherein the second circuit board is mounted on an opposite side on the heat conducting member.

3. The LED lamp of claim 2, further comprising a mounting housing, wherein the circuit boards and the heat conducting member are enclosed within the mounting housing, the mounting housing has openings to accommodate the light emitting diodes, and the flexible metal sheets extend outwardly out of the mounting housing.

4. The LED lamp of claim 3, wherein the flexible metal sheets have a plurality of holes.

5. The LED lamp of claim 4, wherein the holes have a raised edge to prevent the flexible metal sheets from sticking together.

6. The LED lamp of claim 5, further comprising a row of the holes.

7. The LED lamp of claim 5, further comprising a plurality of rows of the holes, the rows of the holes being positioned parallel to one another.

8. The LED lamp of claim 7, wherein the flexible metal sheets have a fold positioned between the rows of the holes and the fold is raised in a direction opposite the direction the raised edges extrude from the flexible metal sheets.

9. The LED lamp of claim 2, wherein the flexible metal sheets are made of aluminum.

10. An LED lamp with a heat sink, the lamp comprising:

a wire harness adapted for connection to an electrical system;

a first circuit board electrically connected to the wire harness;

a second circuit board electrically connected to the wire harness;

a heat conducting member, wherein the circuit boards are mounted on opposite sides of the heat conducting member;

a first light emitting diode on the first circuit board;

a second light emitting diode on the second circuit board; and

a flexible heat sink comprising a flexible metal belt mechanically connected to the heat conducting member.

11. The LED lamp of claim 10, wherein the heat conducting member comprises a copper bar and further wherein the circuit boards are mounted on the heat conducting member by a heat conducting adhesive.

12. The LED lamp of claim 10, wherein the circuit boards are mounted to the heat conducting member with the light emitting diodes proximate to a first end of the heat conducting member and further wherein the flexible heat sink is connected at a second end of the heat conducting member opposite from the first end of the heat conducting member.

13. The LED lamp of claim 10, wherein the light emitting diodes produce at least 1100 lumens.

14. The LED lamp of claim 13, wherein the LED lamp is free from fans.

15. The LED lamp of claim 10, further comprising a mounting housing, wherein the circuit boards and the heat conducting member are enclosed within the mounting housing, the mounting housing has openings to accommodate the light emitting diodes, and the flexible metal belt extends outwardly out of the mounting housing.

16. The LED lamp of claim 15, wherein the wire harness is adapted for connection to an automobile electrical system and the mounting housing is adapted to mount within an automobile headlight fixture.

17. An LED lamp with a heat sink, the lamp comprising:

a wire harness adapted for connection to an electrical system;

a circuit board electrically connected to the wire harness;

a heat conducting member, wherein the circuit board is mounted on the heat conducting member;

a first light emitting diode on the first circuit board; and

a flexible heat sink comprising a flexible metal belt comprising a plurality of flexible metal sheets mechanically connected to the heat conducting member.

18. The LED lamp of claim 17, wherein the plurality of flexible metal sheets are embossed or debossed.

19. The LED lamp of claim 17, further comprising a mounting housing comprised of stackable metal discs and wherein the flexible metal sheets are secured between the stackable metal discs.

20. The LED lamp of claim 19, further comprising a flexible and braided metal sleeve running through the mounting housing to protect the wire harness.