Automotive LED headlight cooling system

• US 9,366,394 B2
• Filed: 09/30/2014
• Issued: 06/14/2016
• Est. Priority Date: 06/27/2012
• Status: Active Grant

• Current Assignee: Flextronics America LLC (Flextronics International Limited)
• Original Assignee: Flextronics America LLC (Flextronics International Limited)
• Inventors: Musser, Jordon, Stratas, Chris
• Primary Examiner(s): Mai, Anh
• Assistant Examiner(s): Fallahkhair, Arman B
• Application Number:
  US14/502,805
• Publication Number:
  US 20150016123A1
• Time in Patent Office: 623 Days
• Field of Search: 362/373, 362/294, 362/547, 362/345, 362/218, 362/264, 362/249.01, 362/249.02, 362/382
• US Class Current: 1/1
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• CPC Class Codes: F21S 41/153 arranged in a matrix
• CPC Class Codes: F21S 45/47 Passive cooling, e.g. using fins, thermal conductive elements or openings
• CPC Class Codes: F21S 8/04 intended only for mounting on a ceiling or the like overhead structures F21S8/02 takes precedence; details of ceiling bases F21V21/03
• CPC Class Codes: F21V 29/51 using condensation or evaporation of a fluid, e.g. heat pipes
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A lighting assembly includes a cooling system configured to enable the dissipation of a large amount of energy in the form of heat generated by a light source. The cooling system is configured as a gravity feed cooling loop that does not require a powered fluid pump. The light source can be a plurality of LEDs mounted on a printed circuit board (PCB). The PCB is aligned and mounted vertically onto an evaporator. The evaporator is configured to enable the vertical alignment of the PCB and to cool the PCB while in this vertical alignment. The vertical alignment of the PCB enables horizontal projection of light emitted by the LEDs, such as in an automotive headlight application.

Claims

1. A lighting assembly for cooling a light source, the lighting assembly comprising:

a. a light source having a vertically aligned thermal exchange surface;

b. an evaporator having a side thermal exchange surface thermally coupled to the vertically aligned thermal exchange surface of the light source, wherein the evaporator comprises a reservoir and a fluid within the reservoir, the evaporator is configured such that at least a portion of the fluid is vaporized by heat transferred from the light source; and

c. a cooling loop coupled to the evaporator, wherein the cooling loop comprises a transfer pipe coupled to the evaporator, a radiator coupled to the transfer pipe, and a return pipe coupled to the radiator and to the evaporator, wherein the return pipe includes a first end coupled to the radiator and a second end coupled to the evaporator, the return pipe is configured and aligned having the first end of the return pipe positioned higher than the second end of the return pipe and an entirety of the return pipe is positioned higher than a bottom surface of the evaporator thereby enabling gravity feeding of fluid from the radiator to the evaporator, further wherein the radiator is configured to receive vapor from the evaporator via the transfer pipe and to condense the vapor to fluid, and the radiator is configured to gravity feed the fluid to the return pipe.

2. The lighting assembly of claim 1 wherein the fluid comprises a fluid mixture having at least a first fluid and a second fluid having a higher boiling temperature than the first fluid, wherein the first fluid comprises the portion of the fluid vaporized by heat transferred from the light source.

3. The lighting assembly of claim 2 wherein the evaporator and the fluid mixture are configured such that when the portion of the fluid is vaporized by heat transferred from the light source a boiling fluid is formed, further wherein the evaporator and the transfer pipe are configured such that the boiling fluid is siphoned from the evaporator to the radiator.

4. The lighting assembly of claim 1 wherein the light source comprises a plurality of light emitting diodes.

5. The lighting assembly of claim 4 wherein the light source further comprises a printed circuit board coupled to the plurality of light emitting diodes.

6. The lighting assembly of claim 1 wherein the radiator includes a first end coupled to the transfer pipe and a second end, and the radiator is aligned along a non-horizontal plane with the first end positioned higher than the second end.

7. The lighting assembly of claim 1 wherein the transfer pipe is configured to be vertically ascending.

8. The lighting assembly of claim 1 wherein the radiator comprises a finned radiator.

9. The lighting assembly of claim 1 wherein the light source is aligned to emit a horizontal projection of light.

10. The lighting assembly of claim 1 wherein a fluid level of the fluid in the reservoir is at least as high as a highest vertical point of the light source.

11. A lighting assembly for cooling a light source, the lighting assembly comprising:

a. a light source having a vertically aligned thermal exchange surface;

b. an evaporator having a side thermal exchange surface thermally coupled to the vertically aligned thermal exchange surface of the light source, wherein the evaporator comprises a reservoir and a fluid within the reservoir, the evaporator is configured such that at least a portion of the fluid is vaporized by heat transferred from the light source;

c. a transfer pipe coupled to the evaporator such that vapor formed in the evaporator rises through the transfer pipe;

d. a radiator coupled to the transfer pipe, wherein the radiator includes a first end coupled to the transfer pipe and a second end, and the radiator is aligned along a non-horizontal plane with the first end positioned higher than the second end, further wherein the radiator is configured such that vapor received from the transfer pipe is condensed to fluid and the fluid is gravity fed to the second end; and

e. a return pipe coupled to the radiator, wherein the return pipe includes a first end coupled to the second end of the radiator and a second end coupled to the evaporator, the return pipe is configured and aligned having the first end of the return pipe positioned higher than the second end of the return pipe and an entirety of the return pipe is positioned higher than a bottom surface of the evaporator such that fluid output from the second end of the radiator is gravity fed to the evaporator.

12. The lighting assembly of claim 11 wherein the fluid comprises a fluid mixture having at least a first fluid and a second fluid having a higher boiling temperature than the first fluid, wherein the first fluid comprises the portion of the fluid vaporized by heat transferred from the light source.

13. The lighting assembly of claim 12 wherein the evaporator and the fluid mixture are configured such that when the portion of the fluid is vaporized by heat transferred from the light source a boiling fluid is formed, further wherein the evaporator and the transfer pipe are configured such that the boiling fluid is siphoned from the evaporator to the radiator.

14. The lighting assembly of claim 11 wherein the light source comprises a plurality of light emitting diodes.

15. The lighting assembly of claim 14 wherein the light source further comprises a printed circuit board coupled to the plurality of light emitting diodes.

16. The lighting assembly of claim 11 wherein the transfer pipe is configured to be vertically ascending.

17. The lighting assembly of claim 11 wherein the radiator comprises a finned radiator.

18. The lighting assembly of claim 11 wherein the light source is aligned to emit a horizontal projection of light.