High power LED power pack for spot module illumination

• US 6,799,864 B2
• Filed: 05/24/2002
• Issued: 10/05/2004
• Est. Priority Date: 05/26/2001
• Status: Expired due to Term

• Current Assignee: Consumer Lighting, LLC (d/b/a GE Lighting) (Savant Systems, LLC)
• Original Assignee: Gelcore (General Electric Company)
• Inventors: Karlicek, Robert F. Jr., Weaver, Stanton E. Jr., Bohler, Christopher L., Becker, Charles A., Pollard, Anthony D., Petroski, James T., Sommers, Mathew L., Burkholder, Greg E.
• Primary Examiner(s): Sember, Thomas M.
• Assistant Examiner(s): SAWHNEY, HARGOBIND S
• Application Number:
  US10/063,924
• Publication Number:
  US 20020176250A1
• Time in Patent Office: 865 Days
• Field of Search: 362/310, 362/545, 362/555, 362/294, 362/373, 362/345, 362/800, 362/231, 362/236, 362/240, 372/36, 372/43, 361/697, 313/45, 165/104.33
• US Class Current: 362/236
• CPC Class Codes: F21K 9/233 specially adapted for generating a spot light distribution, e.g. for substitution of reflector lamps
• CPC Class Codes: F21V 19/0005 of sources having contact pins, wires or blades, e.g. pinch sealed lamp F21V19/001 takes precedence
• CPC Class Codes: F21V 29/74 with fins or blades
• 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 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/81 with pins or wires having different shapes, lengths or spacing
• CPC Class Codes: F21V 7/0083 Array of reflectors for a cluster of light sources, e.g. arrangement of multiple light sources in one plane combination of two or more reflectors F21V7/0025
• CPC Class Codes: F21V 7/041 with conical or pyramidal surface
• CPC Class Codes: F21V 7/06 with parabolic curvature
• CPC Class Codes: F21Y 2113/13 comprising an assembly of point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 33/642 characterized by the shape
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A light module includes a light emitting diode assembly defining a front side light emitting diode array and a rear side. The rear side is in thermal communication with a thermally conductive spreader, and a thermally conductive core is in thermal communication with the conductive spreader. The thermally conductive core includes an electrical conductor in operative communication with the front side light emitting diode array, and a plurality of appendages disposed about the thermally conductive core such that they are in thermal communication with the conductive spreader.

Claims

1. A light module, comprising:

a light emitting diode assembly including a generally planar front side light emitting diode array and a rear side, the rear side in thermal communication with a thermally conductive spreader;

a thermally conductive elongated core having a first end in thermal communication with the conductive spreader, the thermally conductive core being elongated in a direction transverse to the generally planar front side light emitting dode array to define a second end distal from the conductive spreader; and

a plurality of appendages, disposed around the thermally conductive core, the plurality of appendages in thermal communication with the conductive spreader, and extending away from the thermally conductive core.

2. The light module as set forth in claim 1, further comprising:

a housing surrounding the front side light emitting diode array; and

an optic removably affixed to the housing opposite the front side light emittting diode array.

3. The light module as set forth in claim 1, wherein the plurality of appendages comprises fins surroundingly attached to the thermally conductive core, said fins not contacting the thermally conductive spreader, said fins thermally conductively communicating with the thermally conductive spreader through the thermally conductive elongated core.

4. The light module as set forth in claim 1, wherein the light emitting diode assembly comprises a number of light emitting diodes, each light emitting diode disposed in a shaped recess, the recess and light emitting diode covered with a lens.

5. The light module as set forth in claim 1, wherein the light emitting diode assembly comprises individually packaged light emitting diode elements.

6. The light module as set forth in claim 5, wherein the individually packaged light emitting diode elements are secured in thermal communication to the thermally conductive spreader.

7. The light module as set forth in claim 1, wherein the light module has a thermal resistivity of less than 40 degrees Centigrade per watt.

8. The light module as set forth in claim 1, wherein the thermally conductive core has an electrical conduit passing from the first end to the second end to provide electrical access to the front side light emitting diode array from the second end of the thermally conductive elongated core, and a physical size and shape of an exterior of the thermally conductive elongated core and the electrical conductor are designed to be accommodated in a fixture selected from a group consisting of MR-style fixtures and PAR-style fixtures.

9. The light module as set forth in claim 1, wherein the front side light emitting diode array selectively produces saturated color light, the saturated color light being produced by the light emitting diodes emitting a narrow band light.

10. The light module as set forth in claim 1, wherein the front side light emitting diode array selectively produces white light.

11. The light module as set forth in claim 1, wherein the front side light emitting diode array selectively produces desaturated colors based on a mixture from a variety of saturated color LEDs.

12. The light module as set forth in claim 1, wherein the front side light emitting diode array selectively produces at least 50 lumens of light.

13. The light module as set forth in claim 1, further comprising individually powerable sets of diodes in the front side light emitting diode array.

14. A light emitting diode assembly including a light emitting face supported by a body through which electrical connection elements pass, the body comprising:

a thermally conductive elongated core in thermal communication with the light emitting face, the thermally conductive core providing a path for the electrical connection elements to be in electrical communication with light emitting diodes in the light emitting face; and

a plurality of thermally conductive elongated attachments surrounding the thermally conductive core, the plurality of attachments being in thermal communication with the light emitting diode assembly.

15. A lamp for use in connection with spot module platforms, said lamp comprising:

a plurality of LEDs arranged in an LED assembly having opposing forward and rearward facing sides, said forward facing side selectively providing illumination from the LEDs when power is supplied thereto;

a heat sink contacting the rearward facing side of the LED assembly to draw heat from the LEDs, the heat sink including;

(i) a thermally conductive base having a lateral area substantially coextensive with the rearward facing side of the LED assembly and in thermal contact with the rearward facing side of the LED assembly, and

(ii) an elongated thermally conductive core having a lateral area less than the lateral area of the rearward facing side and connecting with a central area of the thermally conductive base, the elongated thermally conductive core extending from the thermally conductive base in a direction away from the LED assembly; and

,

a heat dissipating structure including a plurality of heat-dissipating members each extending away from a connection of the heat-dissipating member with the heat sink, the heat dissipating structure connected with the elongated thermally conductive core.

16. The lamp according to claim 15, wherein the LEDs are disposed in reflector wells.

17. The lamp according to claim 15, wherein the saturated color light is produced by the LEDs emitting a narrow wavelength light.

18. The lamp according to claim 17, wherein the desaturated color is produced by mixing the LEDs producing a variety of saturated colors.

19. The lamp according to claim 15, wherein the heat dissipating structure is not connected with the thermally conductive base of the heat sink.