High power solid-state lamp
First Claim
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1. An optical device, comprising:
- a solid state light source;
a reflector positioned to reflect light from said light source into directional light emission, heat from said light source at least partially transmitting into said reflector; and
a first heat sink mounted to said reflector positioned in thermal contact with said light source such that heat from said light source transmits into said first heat sink, said first heat sink comprising a thermally conductive conformable porous material layer adjacent said light source, said porous material layer comprising a 3-dimensional pore structure comprising interconnected pores, with the surfaces of said pore structure providing increased surface area for heat to dissipate into the ambient compared to bulk heat sinks, said porous material layer further comprising a graded porous material region wherein part of said porous material region comprises a higher density pore structure than the remainder of said region, said first heat sink shaped to fit around said reflector, wherein said reflector is configured to spread heat from said light source throughout said first heat sink;
wherein said reflector comprises a reflective metal and wherein said reflector is affixed to said first heat sink.
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Abstract
A high power semiconductor component structure having a semiconductor device arranged to operate in response to an electrical signal, with the device heating up during operation in response to the electrical signal. A heat sink is positioned in thermal contact with the semiconductor device such that heat from the device transmits into the first heat sink. The heat sink has at least partially a porous material region of a thermally conductive material in a 3-dimensional pore structure with the surfaces of the pore structure providing surface area for heat to dissipate into the ambient air.
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Citations
60 Claims
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1. An optical device, comprising:
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a solid state light source; a reflector positioned to reflect light from said light source into directional light emission, heat from said light source at least partially transmitting into said reflector; and a first heat sink mounted to said reflector positioned in thermal contact with said light source such that heat from said light source transmits into said first heat sink, said first heat sink comprising a thermally conductive conformable porous material layer adjacent said light source, said porous material layer comprising a 3-dimensional pore structure comprising interconnected pores, with the surfaces of said pore structure providing increased surface area for heat to dissipate into the ambient compared to bulk heat sinks, said porous material layer further comprising a graded porous material region wherein part of said porous material region comprises a higher density pore structure than the remainder of said region, said first heat sink shaped to fit around said reflector, wherein said reflector is configured to spread heat from said light source throughout said first heat sink; wherein said reflector comprises a reflective metal and wherein said reflector is affixed to said first heat sink. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. An optical device, comprising:
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a solid state light source; and a first heat sink positioned in thermal contact with said light source such that heat from said light source transmits into said first heat sink, said first heat sink comprising a porous material layer adjacent said light source, said porous material comprising a thermally conductive material with a 3-dimensional pore structure comprising interconnected pores, with the surfaces of said pore structure providing increased surface area for heat to dissipate into the ambient compared to bulk heat sinks, said heat sink comprising a graded porous material region wherein part of said porous material region comprises a higher density pore structure than the remainder of said region. - View Dependent Claims (14)
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15. A lamp, comprising:
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a solid state light source mounted to a circuit board; a reflector mounted to said circuit board to reflect at least some of the light from said light source into directional light emission; contacts for providing electrical power to said solid state light source; and first and second heat sinks, each of which comprises a layer of thermally conductive conformable porous material in a 3-dimensional pore structure comprising interconnected pores, said porous material layer comprising a graded porous material region wherein part of said porous material region comprises a higher density pore structure than the remainder of said region, said first heat sink shaped to fit around said reflector and said second heat sink affixed to and covering said circuit board, wherein said reflector is configured to spread heat from said light source throughout said first heat sink, wherein said first and second heat sinks are on opposite sides of said circuit board; wherein said reflector comprises a reflective metal and wherein said reflector is affixed to said first heat sink. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23)
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24. A lamp, comprising:
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a solid state light source mounted to a circuit board; a reflector mounted to said circuit board to reflect at least some of the light from said light source into directional light emission; contacts for providing electrical power to said solid state light source; and first and second heat sinks, each comprising a conformable porous material region made of a thermally conductive material in a 3-dimensional pore structure, wherein part of said porous material region comprises a graded region, part of said graded region comprising a higher density pore structure than the remainder of said graded region, said first heat sink shaped to fit around said reflector and said second heat sink affixed to said circuit board, said reflector comprising reflectively coated plastic and a heat conductive path comprising a heat conductive layer between said reflector and said first heat sink for heat to transmit from said light source and spread into and throughout said first heat sink through said heat conductive path, wherein said first and second heat sinks are on opposite sides of said circuit board. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37)
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38. A lamp, comprising:
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a solid state light source mounted to a circuit board; a reflector mounted to said circuit board to reflect at least some of the light from said light source into directional light emission; contacts for providing electrical power to said solid state light source; and first and second heat sinks, each comprising a porous material region made of a thermally conductive material in a 3-dimensional pore structure, said first heat sink affixed to said reflector and said second heat sink affixed to said circuit board, wherein said reflector is made of reflectively coated plastic, and further comprising a heat conductive path between said reflector and said first heat sink for heat to transmit from said light source into first heat sink through said heat conductive path, said porous material region of said first or second heat sinks being graded such that part of said porous material region comprises a higher density pore structure than the remaining of said region.
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39. A high power semiconductor component structure, comprising:
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a semiconductor device configured to operate in response to an electrical signal, said device heating up during operation in response to said electrical signal; a thermally conductive metal layer; a first heat sink mounted to said thermally conductive metal layer positioned in thermal contact with said semiconductor device such that heat from said device transmits into said first heat sink, said first heat sink comprising a conformable porous material region, said porous material region comprising a thermally conductive material in a 3-dimensional pore structure comprising interconnected pores with the surfaces of said pore structure providing surface area for heat to dissipate into the ambient, wherein part of said porous material region comprises a graded region, part of said graded region comprising a higher density pore structure than the remainder of said graded region, wherein said porous material region is thermally conductive, said first heat sink shaped to fit around said thermally conductive metal layer, wherein said thermally conductive metal layer is configured to spread heat from said device throughout said first heat sink; wherein said thermally conductive metal layer is affixed to said first heat sink; and a second heat sink, said second heat sink comprising a conformable porous material region, said porous material region comprising a thermally conductive material in a 3-dimensional pore structure comprising interconnected pores with the surfaces of said pore structure providing surface area for heat to dissipate into the ambient, wherein said porous material region is thermally conductive. - View Dependent Claims (40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52)
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53. A high power semiconductor component structure, comprising:
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a semiconductor device configured to operate in response to an electrical signal, said device heating up during operation in response to said electrical signal; and a first heat sink covering a surface of said semiconductor device and positioned in thermal contact with said semiconductor device such that heat from said device transmits into said first heat sink, said first heat sink comprising a porous material region, said porous material region comprising a thermally conductive material in a 3-dimensional pore structure comprising interconnected pores with the surfaces of said pore structure providing surface area for heat to dissipate into the ambient, said heat sink comprising a graded porous material region wherein part of said porous material region comprises a higher density pore structure than the remaining of said region.
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54. An optical device, comprising:
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a solid state light source; a reflector positioned to reflect light from said light source into directional light emission, heat from said light source at least partially transmitting into said reflector; and a first heat sink mounted to said reflector positioned in thermal contact with said light source such that heat from said light source transmits into said first heat sink, said first heat sink comprising a thermally conductive conformable porous material layer adjacent said light source, said porous material layer further comprising a graded porous material region wherein part of said porous material region comprises a higher density pore structure than the remainder of said region, said first heat sink shaped to fit around said reflector, wherein said reflector is configured to spread heat from said light source throughout said first heat sink; wherein said reflector comprises a reflective metal and wherein said reflector is affixed to said first heat sink. - View Dependent Claims (55, 56, 57, 58, 59, 60)
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Specification