LED bulb for high intensity discharge bulb replacement

• US 8,378,559 B2
• Filed: 08/20/2010
• Issued: 02/19/2013
• Est. Priority Date: 08/20/2009
• Status: Expired due to Fees

• Current Assignee: Progressive Cooling Solutions Incorporated
• Original Assignee: Progressive Cooling Solutions Incorporated
• Inventors: Shuja, Ahmed, Griffin, Tom, Medis, Praveen, Craine, Phil
• Primary Examiner(s): Santiago, Mariceli
• Assistant Examiner(s): RALEIGH, DONALD L
• Application Number:
  US12/860,707
• Publication Number:
  US 20110043092A1
• Time in Patent Office: 914 Days
• Field of Search: 257/40, 257/72, 257 98-100, 257642-643, 257/759, 313498-512, 313/46, 315/169.1, 315/169.3, 427/58, 427/64, 427/66, 427532-535, 427/539, 428690-691, 428/917, 438 26- 29, 438/34, 438/82, 438/455, 445 24- 25, 362543-549, 362/555, 362/800, 36224901-24903
• US Class Current: 313/34
• 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: F21V 29/51 using condensation or evaporation of a fluid, e.g. heat pipes
• CPC Class Codes: F21V 29/717 using split or remote units thermally interconnected, e.g. by thermally conductive bars or heat pipes
• CPC Class Codes: F21V 29/76 with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section
• 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 29/78 with helically or spirally arranged fins or blades
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

The disclosed system includes a two-phase cooling apparatus configured for cooling an array of LED dies.

Claims

1. A lamp, comprising:

an LED array;

a light reflector;

a circular remote vapor condenser positioned below the light reflector, wherein the circular remote vapor condenser having at least one vapor line and at least one liquid line; and

a thermo-mechanical system coupled to the LED array, wherein the thermo-mechanical system includes;

a top cap thermally coupled to the LED array, the top cap comprising one or more spaces to accommodate a vapor generated from a phase change of a liquid due to a heat emitted from the LED array;

a liquid-permeable porous structure coupled to the top cap, wherein the liquid-permeable porous structure causes a capillary force to move the vapor to the vapor line; and

a liquid chamber coupled to the liquid-permeable porous structure and hydraulically coupled to the liquid line, wherein the chamber is configured to accommodate the liquid;

wherein the circular remote vapor condenser comprises a plurality of spiraling fins to increase a vapor path length to facilitate condensation of the vapor.

2. The lamp of claim 1, wherein the vapor is generated at a liquid meniscus of the liquid-permeable porous structure at a phase change temperature.

3. The lamp of claim 1, wherein the liquid chamber is configured to accommodate the liquid below a phase change temperature.

4. The lamp of claim 1, wherein the vapor condenses to a liquid form in the circular remote vapor condenser and returns to the liquid chamber via the liquid line.

5. The lamp of claim 1, wherein the vapor condenses to a liquid form in the circular remote vapor condenser and returns to the liquid chamber via the liquid line due to a thermodynamic pressure difference across the liquid-permeable porous structure.

6. The lamp of claim 1, wherein the vapor condenses to a liquid form in the circular remote vapor condenser and returns to the liquid chamber via the liquid line due to a gravity force.

7. The lamp of claim 1, wherein the circular remote vapor condenser comprises a heat sink.

8. The lamp of claim 7, wherein the heat sink comprises a plurality of metal fins.

9. The lamp of claim 1, wherein the liquid-permeable porous structure comprises a porous silicon wick.

10. The lamp of claim 1, further comprising:

a mogul base.

11. The lamp of claim 1, further comprising:

an E39 socket.

12. The lamp of claim 1, further comprising:

a power supply.

13. The lamp of claim 1, wherein the vapor condenses to a liquid form in the circular remote vapor condenser and spreads heat along a surface of a heat sink in an isothermal process.

14. A lamp, comprising:

an LED array emitting a light having at least 10,000 lumens from each square inch of an emitting surface of the LED array;

a light reflector;

a circular remote vapor condenser positioned below the light reflector;

a thermo-mechanical system hydraulically coupled to the circular remote vapor condenser and thermally coupled to the LED array, the thermo-mechanical system comprising a liquid-permeable porous structure; and

a mogul base configured for connecting to a high intensity discharge fixture;

wherein a total weight of the lamp is less than five pounds.

15. The lamp of claim 14, wherein the circular remote vapor condenser having at least one vapor line and at least one liquid line;

and wherein the thermo-mechanical system includes;

a top cap thermally coupled to the LED array, the top cap comprising one or more spaces to accommodate a vapor generated from a phase change of a liquid due to a heat emitted from the LED array;

the liquid-permeable porous structure coupled to the top cap, wherein the liquid-permeable porous structure causes a capillary force to move the vapor to the vapor line; and

a liquid chamber coupled to the liquid-permeable porous structure and hydraulically coupled to the liquid line, wherein the chamber is configured to accommodate the liquid.

16. The lamp of claim 14, wherein the thermo-mechanical system comprising two-phase cooling device having a thermal resistance of less than 0.5 C/W.

17. The lamp of claim 14, wherein an efficacy of the lamp is at least 80 lumens per watt.

18. A method, comprising:

packaging surface mount LEDs of an LED array with a less than one inch spacing between the surface mount LEDs;

transferring a heat emitted from the LED array to a working fluid and causing a phase change of the working fluid to a vapor in an evaporator;

moving the vapor from the evaporator to a condenser via a vapor line, by a capillary force from a liquid-permeable porous structure in the evaporator, wherein the condenser comprises a plurality of spiraling fins to increase a vapor path length to facilitate condensation of the vapor;

condensing the vapor to the working fluid by exchanging heat from the vapor to an ambient air via a heat sink of the condenser; and

returning the working fluid from the condenser to the evaporator via a liquid line.

19. The method of claim 18, wherein the working fluid is returned via the liquid line, by a thermodynamic pressure difference across the liquid-permeable porous structure, or by a gravity force.

20. The method of claim 18, further comprising:

emitting a light having at least 10,000 lumens from each square inch of an emitting surface of the LED array.