Solid state lighting device and method employing heat exchanger thermally coupled circuit board
First Claim
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1. A lighting device, comprising:
- a heat exchanger having a circuit board mounting surface curved along a lateral dimension and a longitudinal dimension, the lateral dimension perpendicular to the longitudinal dimension;
at least a first circuit board including a number of electrically insulative layers and a number of electrically conductive paths, the first circuit board having a longitudinal dimension and a lateral dimension perpendicular to the longitudinal dimension, a first major outer face, and a second major outer face, the first and the second major outer faces on opposite sides of the first circuit board from one another, at least one thickness of the first circuit board defined between the first and the second major outer faces; and
at least two solid state light emitters carried by the first circuit board and electrically coupled to the electrically conductive paths of the first circuit board, whereinat least the first circuit board is physically coupled to the circuit board mounting surface, such that the longitudinal dimension of the first circuit board is curved along the longitudinal dimension of the circuit board mounting surface and the lateral dimension of the first circuit board is curved along the lateral dimension of the circuit board mounting surface.
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Abstract
An illumination device comprises a circuit board that carries solid-state light sources and a heat transfer structure to which the circuit board is intimately physically coupled such that the circuit board is curved along at least one of a longitudinal dimension or a lateral dimension thereof. Such may allow less fasteners to be used than would otherwise be possible, while maintaining close contact over a large portion of the surface area. Some embodiments may employ a clamp, for example a peripheral clamp such as a cover or bezel clamp.
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Citations
20 Claims
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1. A lighting device, comprising:
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a heat exchanger having a circuit board mounting surface curved along a lateral dimension and a longitudinal dimension, the lateral dimension perpendicular to the longitudinal dimension; at least a first circuit board including a number of electrically insulative layers and a number of electrically conductive paths, the first circuit board having a longitudinal dimension and a lateral dimension perpendicular to the longitudinal dimension, a first major outer face, and a second major outer face, the first and the second major outer faces on opposite sides of the first circuit board from one another, at least one thickness of the first circuit board defined between the first and the second major outer faces; and at least two solid state light emitters carried by the first circuit board and electrically coupled to the electrically conductive paths of the first circuit board, wherein at least the first circuit board is physically coupled to the circuit board mounting surface, such that the longitudinal dimension of the first circuit board is curved along the longitudinal dimension of the circuit board mounting surface and the lateral dimension of the first circuit board is curved along the lateral dimension of the circuit board mounting surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A lighting device comprising:
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a heat exchanger having a circuit board mounting surface curved about at least one axis; at least a first circuit board including a number of electrically insulative layers and a number of electrically conductive paths, the first circuit board having a longitudinal dimension and a lateral dimension, a first major outer face, and a second major outer face, the first and the second major outer faces on opposite sides of the first circuit board from one another, at least one thickness of the first circuit board defined between the first and the second major outer faces; and at least two solid state light emitters carried by the first circuit board and electrically coupled to the electrically conductive paths of the first circuit board, wherein at least the first circuit board is physically coupled to the circuit board mounting surface, the first circuit board is curved such that at least one of the longitudinal dimension or the lateral dimension corresponds to the at least one axis about which the circuit board mounting surface is curved; and a number of cam fasteners configured to apply a force that places the first circuit board in tension when fastened proximate the circuit board mounting surface. - View Dependent Claims (12, 13, 14, 15, 16)
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17. A lighting device comprising:
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a heat exchanger having a circuit board mounting surface curved along both a lateral dimension and a longitudinal dimension, the lateral dimension perpendicular to the longitudinal dimension; at least a first circuit board including a number of electrically insulative layers and a number of electrically conductive paths, the first circuit board having a first major outer face, and a second major outer face, the first and the second major outer faces on opposite sides of the first circuit board from one another, at least one thickness of the first circuit board defined between the first and the second major outer faces; and at least two solid state light emitters carried by the first circuit board and electrically coupled to the electrically conductive paths of the first circuit board, wherein at least the first circuit board is physically coupled to the circuit board mounting surface, such that a longitudinal dimension of the first circuit board is curved along the longitudinal dimension of the circuit board mounting surface and a lateral dimension of the first circuit board, that is perpendicular to the longitudinal dimension of the first circuit board, is curved along the lateral dimension of the circuit board mounting surface; and a number of cam fasteners configured to apply a compressive force to the first circuit board when fastened.
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18. A method of constructing a lighting device, the method comprising:
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providing a heat exchanger having a circuit board mounting face curved along both a longitudinal dimension and a lateral dimension, the lateral dimension perpendicular to the longitudinal dimension, and a plurality of fins; providing at least one circuit board having a number of kerfs and a number of flats separate by the kerfs, the circuit board having a longitudinal dimension and a lateral dimension that is perpendicular to the longitudinal dimension, the circuit board carrying at least two solid state light emitters positioned at the flats between the kerfs; and removably physically coupling the circuit board to the heat exchanger under at least one of a tensile or a compressive force with at least one fastener including at least one cam fastener that applies at least one of an additional tensile force or an additional compressive force to the circuit board such that the longitudinal dimension of the first circuit board is curved along the longitudinal dimension of the circuit board mounting face and the lateral dimension of the first circuit board is curved along the lateral dimension of the circuit board mounting face when the circuit board is physically coupled to the heat exchanger circuit board mounting face by the at least one fastener. - View Dependent Claims (19, 20)
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Specification