Micro-channel-cooled high heat load light emitting device
First Claim
1. A lamp head module comprising:
- an optical macro-reflector including a window having an outer surface;
an array of light emitting diodes (LEDs) positioned within the optical reflector, the array having a high fill factor and a high aspect ratio operable to provide a high irradiance output beam pattern having a peak irradiance of greater than 25 W/cm2 at a work piece surface at least 1 mm away from the outer surface of the window of the optical reflector;
a micro-channel cooler assembly operable to maintain a substantially isothermal state among p-n junctions of LEDs in the array at a temperature of less than or equal to 80°
Celsius, the micro-channel cooler assembly also providing a common anode substrate for the array, wherein a thermally efficient electrical connection is formed between the array and the common anode substrate by mounting the array to the micro-channel cooler assembly;
a flex-circuit, including a patterned cathode layer, to independently address a plurality of groups of one or more LEDs of the array;
a thermally conductive lamp body having opposing thin outer walls and having formed therein deep and long coolant flow channels in fluid communication with the micro-channel cooler; and
integrated LED drivers mounted to the outer walls of the lamp body,wherein the deep and long coolant flow channels serve to balance flow of coolant through the micro-channel cooler and create a sufficient surface area to reduce heat transfer coefficient to maintain operational temperature requirements of the integrated LED drivers andwherein the thin outer walls of the lamp body allow for the lamp head module to be narrow which (i) reduces length requirement of the patterned cathode layer and (ii) reduces thermal resistance between coolant in the coolant flow channels and the integrated LED drivers.
8 Assignments
0 Petitions
Accused Products
Abstract
Micro-channel-cooled UV curing systems and components thereof are provided. According to one embodiment, a lamp head module includes an optical macro-reflector, an array of LEDs and a micro-channel cooler assembly. The array is positioned within the reflector and has a high fill factor and a high aspect ratio. The array provides a high irradiance output beam pattern having a peak irradiance of greater than 25 W/cm2 at a work piece surface at least 1 mm away from an outer surface of a window of the reflector. The micro-channel cooler assembly maintains a substantially isothermal state among p-n junctions of the LEDs at less than or equal to 80° Celsius. The micro-channel cooler assembly also provides a common anode substrate for the array. A thermally efficient electrical connection is formed between the array and the common anode substrate by mounting the array to the micro-channel cooler assembly.
83 Citations
43 Claims
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1. A lamp head module comprising:
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an optical macro-reflector including a window having an outer surface; an array of light emitting diodes (LEDs) positioned within the optical reflector, the array having a high fill factor and a high aspect ratio operable to provide a high irradiance output beam pattern having a peak irradiance of greater than 25 W/cm2 at a work piece surface at least 1 mm away from the outer surface of the window of the optical reflector; a micro-channel cooler assembly operable to maintain a substantially isothermal state among p-n junctions of LEDs in the array at a temperature of less than or equal to 80°
Celsius, the micro-channel cooler assembly also providing a common anode substrate for the array, wherein a thermally efficient electrical connection is formed between the array and the common anode substrate by mounting the array to the micro-channel cooler assembly;a flex-circuit, including a patterned cathode layer, to independently address a plurality of groups of one or more LEDs of the array; a thermally conductive lamp body having opposing thin outer walls and having formed therein deep and long coolant flow channels in fluid communication with the micro-channel cooler; and integrated LED drivers mounted to the outer walls of the lamp body, wherein the deep and long coolant flow channels serve to balance flow of coolant through the micro-channel cooler and create a sufficient surface area to reduce heat transfer coefficient to maintain operational temperature requirements of the integrated LED drivers and wherein the thin outer walls of the lamp body allow for the lamp head module to be narrow which (i) reduces length requirement of the patterned cathode layer and (ii) reduces thermal resistance between coolant in the coolant flow channels and the integrated LED drivers. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A lamp head module comprising:
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a high aspect ratio monolithically bonded foil micro-channel cooler substrate layer having a greater length than width; a high aspect ratio light emitting device array layer having a greater length than width mounted to the micro-channel cooler substrate layer, wherein the micro-channel cooler substrate layer serves a common anode function for the light emitting device array layer, the light emitting device array layer having a high fill-factor and comprising a p-n junction layer; a flex-circuit layer, including a patterned cathode circuit material layer and a thin dielectric layer, mounted to the micro-channel cooler substrate layer, the cathode circuit material layer separated from the micro-channel cooler substrate layer by the thin dielectric layer, wherein the cathode circuit material layer and the thin dielectric layer combine in thickness to be less than 3×
a thickness of the light emitting device array layer; andan optical reflector layer to direct photons emitted by said light emitting device array layer, the optical reflector layer being at least 25×
a thickness of the light emitting device array layer, wherein the thicknesses are measured in a direction substantially perpendicular to the p-n junction layer,wherein the optical reflector layer comprises a macro-reflector having an entrance aperture and an exit aperture, the entrance aperture being at least as wide as a sum of a width of the light emitting device array layer plus 2×
the diameter of the at least one wire but no more than 5×
the sum andwherein the macro-reflector comprises a right-hand half and a left-hand half each of which represent a portion of an ellipse, each ellipse having two focuses, wherein the two focuses of the right-hand half have corresponding focal points that are offset to the left of a centerline of an intended output beam and the two focuses of the left-hand half have corresponding focal points that are offset to the right of the centerline. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24)
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25. A lamp head module comprising:
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a package including; a high aspect ratio array of electrically paralleled light emitting diodes (LEDs), the high aspect ratio array having a greater length than width; a flex circuit having a segmented cathode layer to which wire bond pads of the high aspect ratio array are electrically coupled; and a high aspect ratio monolithically bonded foil micro-channel cooler having a greater length than width providing a common anode substrate surface to which the high aspect ratio array is directly mounted; a lamp body having formed therein an input coolant fluid channel and an output coolant fluid channel, wherein coolant fluid flows from the input coolant fluid channel through the micro-channel cooler and to the output coolant fluid channel to remove waste heat from the high aspect ratio array; at least two anode bodies affixed to opposing sides of the lamp body, running substantially parallel to one another and orthogonal to the common anode substrate surface; and a plurality of cathode bodies each having a first surface substantially parallel to the common anode substrate surface and a second surface substantially parallel to the at least two anode bodies, wherein the package is clamped to the lamp body and the at least two anode bodies by the plurality of cathode bodies.
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26. An ultraviolet (UV) light emitting diode (LED) curing system comprising:
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a plurality of end-to-end serially connected UV LED lamp head modules each including; an optical macro-reflector including a window having an outer surface, wherein the optical macro-reflector comprises a right-hand half and a left-hand half each of which represent a portion of an ellipse, each ellipse having two focuses, wherein the two focuses of the right-hand half have corresponding focal points that are offset to the left of a centerline of an intended output beam and the two focuses of the left-hand half have corresponding focal points that are offset to the right of the centerline; an LED array positioned within the optical reflector, the array having a high fill factor and a high aspect ratio operable to provide a substantially uniform high irradiance output beam pattern having an irradiance of greater than 25 W/cm2 at a work piece surface at least 1 mm away from the outer surface of the window of the optical reflector; and a micro-channel cooler assembly operable to maintain a substantially isothermal state among p-n junctions of LEDs in the LED array at a temperature of less than or equal to 80°
Celsius, the micro-channel cooler assembly also providing a common anode substrate for the LED array, wherein a thermally efficient electrical connection is formed between the LED array and the common anode substrate by directly mounting the LED array to the micro-channel cooler assembly.
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27. A lamp head module comprising:
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a package including; a high aspect ratio array of light emitting devices having a greater length than width; a flex circuit having a segmented cathode layer to which wire bond pads of the high aspect ratio array are electrically coupled; and a high aspect ratio monolithically bonded foil micro-channel cooler having a greater length than width providing a common anode substrate surface to which the high aspect ratio array is mounted; a lamp body having formed therein an input coolant fluid channel and an output coolant fluid channel, wherein coolant fluid flows from the input coolant fluid channel through the micro-channel cooler and to the output coolant fluid channel to remove waste heat from the high aspect ratio array; an anode body affixed to the lamp body, the anode body being substantially parallel to the input coolant fluid channel and the output coolant fluid channel and orthogonal to the common anode substrate surface; a cathode body having a surface substantially parallel to the common anode substrate surface; and wherein the package is clamped to the lamp body and the anode body. - View Dependent Claims (28)
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29. A lamp head module comprising:
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an optical macro-reflector including a window having an outer surface, wherein the optical macro-reflector comprises a right-hand half and a left-hand half each of which represent a portion of an ellipse, each ellipse having two focuses, wherein the two focuses of the right-hand half have corresponding focal points that are offset to the left of a centerline of an intended output beam and the two focuses of the left-hand half have corresponding focal points that are offset to the right of the centerline; an array of light emitting diodes (LEDs) positioned within the optical reflector, the array having a high fill factor and a high aspect ratio operable to provide a high irradiance output beam pattern having a peak irradiance of greater than 25 W/cm2 at a work piece surface at least 1 mm away from the outer surface of the window of the optical reflector; and a micro-channel cooler assembly operable to maintain a substantially isothermal state among p-n junctions of LEDs in the array at a temperature of less than or equal to 80°
Celsius, the micro-channel cooler assembly also providing a common anode substrate for the array, wherein a thermally efficient electrical connection is formed between the array and the common anode substrate by mounting the array to the micro-channel cooler assembly. - View Dependent Claims (30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43)
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Specification