Heat sink for LED light source

• US 8,974,077 B2
• Filed: 03/15/2013
• Issued: 03/10/2015
• Est. Priority Date: 07/30/2012
• Status: Active Grant

• Current Assignee: Ultravision Technologies, LLC (Ultravision International Inc.)
• Original Assignee: Ultravision Technologies, LLC (Ultravision International Inc.)
• Inventors: Auyeung, David Siucheong
• Primary Examiner(s): Ward, John A
• Application Number:
  US13/836,517
• Publication Number:
  US 20140029259A1
• Time in Patent Office: 725 Days
• Field of Search: 362/218, 362/249.02
• US Class Current: 362/218
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• CPC Class Codes: F21S 6/006 for direct lighting only, e.g. task lighting
• CPC Class Codes: F21V 19/003 Fastening of light source holders, e.g. of circuit boards or substrates holding light sources
• CPC Class Codes: F21V 21/26 Pivoted arms
• CPC Class Codes: F21V 23/002 Arrangements of cables or conductors inside a lighting device, e.g. means for guiding along parts of the housing or in a pivoting arm
• CPC Class Codes: F21V 29/00 Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems lighting fixtures combined with outlets for air-treatment systems F24F13/078
• CPC Class Codes: F21V 29/15 Thermal insulation
• CPC Class Codes: F21V 29/503 of light sources cooling arrangements structurally associated with gas-discharge or vapour-discharge lamps H01J61/52; cooling arrangements structurally associated with electric incandescent lamps H01K1/58; cooling arrangements structurally associated with light-emitting diodes H01L33/64
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/745 the fins or blades being planar and inclined with respect to the joining surface from which the fins or blades extend
• 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 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 29/89 Metals
• CPC Class Codes: F21V 31/00 Gas-tight or water-tight arrangements
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 33/00 Structural combinations of lighting devices with other articles, not otherwise provided for
• CPC Class Codes: F21V 5/007 Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane combination of two or more refractors F21V5/008
• CPC Class Codes: F21W 2131/10 Outdoor lighting
• CPC Class Codes: F21W 2131/40 : Lighting for industrial, commercial, recreational or military use
• CPC Class Codes: F21Y 2105/10 : comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2105/12 : characterised by the geometrical disposition of the light-generating elements, e.g. arranging light-generating elements in differing patterns or densities
• CPC Class Codes: F21Y 2105/16 : square or rectangular, e.g. for light panels
• CPC Class Codes: F21Y 2115/10 : Light-emitting diodes [LED]
• CPC Class Codes: G02B 19/0014 : at least one surface having optical power
• CPC Class Codes: G02B 19/0028 : refractive and reflective surfaces, e.g. non-imaging catadioptric systems
• CPC Class Codes: G02B 19/0061 : the light source comprising a LED semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission H01L33/00
• CPC Class Codes: G02B 19/0066 : in the form of an LED array
• CPC Class Codes: G09F 13/02 : Signs, boards, or panels, illuminated by artificial light sources positioned in front of the insignia
• CPC Class Codes: G09F 13/22 : electroluminescent electroluminescent light sources per se H05B33/00
• CPC Class Codes: G09F 15/00 : Boards, hoardings, pillars, or like structures for notices, placards, posters, or the like
• CPC Class Codes: G09F 15/0037 : supported by a post
• CPC Class Codes: G09F 15/005 : for orientation or public information
• CPC Class Codes: G09F 2013/222 : with LEDs

Abstract

A back panel for use in a light emitting diode (LED) lighting assembly is disclosed. An extruded substrate formed of a thermally conductive material is provided, the substrate having a plurality of fins extending from a first side of the substrate, each of the fins having a substantially rectangular shape oriented so that a longitudinal axis of the fin is substantially parallel to a longitudinal axis of the substrate. At least some of the fins include a hole formed through the fin to enable heated air to rise through the fins. A plurality of LEDs are mounted on a second side of the substrate, and oriented in a longitudinal orientation with the fins oriented parallel to the bottom edge of a surface to be illuminated, such that heat rises perpendicular to the surface of the fin.

Claims

1. A back panel for use in a light emitting diode (LED) lighting assembly that is operable to be affixed to a structure supporting a display surface that is to be illuminated comprising:

an extruded substrate formed of a thermally conductive material, the substrate having a first and second substantially flat surface and first and second side edges perpendicular to a top edge extending therebetween and having a plurality of longitudinal fins extending from the first side edge of the substrate to the second side edge of the substrate, each of the fins having a substantially rectangular shape oriented so that a longitudinal axis of the fin is substantially parallel to a longitudinal axis of the substrate along the at least top edge, wherein at least some of the fins which are adjacent to each other include a plurality of holes formed through the plurality of fins to enable heated air to rise through the adjacent fins, the holes aligned such that they create a chimney effect between the associated adjacent fins, wherein a plurality of LEDs are mounted on the second surface of the substrate, and oriented in a longitudinal orientation and parallel to the top edge with the fins, when the back panel is affixed to the structure with the second surface substantially parallel to the display surface, oriented parallel to the bottom edge of the display surface to be illuminated, such that heat rises perpendicular to the surface of the fins, a first longitudinal protrusion extending from the second surface proximate the LEDs and parallel to the top edge between the LEDs and the top edge to cause water to be partially directed away therefrom when the back panel is affixed to the structure.

2. The back panel of claim 1, the LEDs are mounted on an upper surface of a first LED structure having a longitudinal structure which is in turn has a lower surface that is mounted on the second surface of the substrate with an edge thereof proximate the first longitudinal protrusion.

3. The back panel of claim 2, wherein the LED structure with the LEDs mounted thereon is less in thickness that the height of the protrusion above the second surface.

4. The back panel of claim 2, wherein the LED structure is comprised of a support layer for mounting of the LEDs on the upper surface and an optical layer disposed over the LEDs and wherein the edge of the LED structure abuts the first protrusion.

5. The back panel of claim 4, wherein the optical layer overlaps the edge of support layer.

6. The back panel of claim 4, where the interface between the lower surface of the support layer and the optical layer form a joint and the edge of the joint abuts the first protrusion.

7. The back panel of claim 2, wherein the first protrusion has an angled surface.

8. The back panel of claim 2, wherein the first protrusion has a curved surface.

9. The back panel of claim 1, and further comprising a second LED structure similar to the first LED structure mounted on the second surface diametrically opposite the top edge from the first LED structure and a second longitudinal protrusion extending from the second surface proximate the edge of the second LED structure that is nearest the top edge, the second longitudinal protrusion proximate the edge of the first LED structure farthest from the top edge.

10. The back panel of claim 1, and further comprising a mount to allow the surface of the substrate to have the angle thereof varied.

11. The back panel of claim 1, wherein a plurality of the fins are disposed perpendicular to the first surface and a plurality of the fins are disposed at an angle thereto.

12. A lighting display, comprising:

a display surface for being illuminated;

a support structure for supporting the display surface in an upright position such that the display surface is viewable from a horizontal viewing plane;

a mounting structure disposed on the lower edge of the support structure anterior to the display surface; and

a back panel for use in a light emitting diode (LED) lighting assembly that is operable to be affixed to the display surface, including;

an extruded substrate formed of a thermally conductive material, the substrate having a first and second substantially flat surface and first and second side edges perpendicular to a top edge extending there between and having a plurality of longitudinal fins extending from the first side edge of the substrate to the second side edge of the substrate, each of the fins having a substantially rectangular shape oriented so that a longitudinal axis of the fin is substantially parallel to a longitudinal axis of the substrate along the at least top edge, wherein at least some of the fins which are adjacent to each other include a plurality of holes formed through the plurality of fins to enable heated air to rise through the adjacent fins, the holes aligned such that they create a chimney effect between the associated adjacent fins, wherein a plurality of LEDs are mounted on the second surface of the substrate, and oriented in a longitudinal orientation and parallel to the top edge with the fins, when the back panel is affixed to the structure with the second surface substantially parallel to the display surface, oriented parallel to the bottom edge of the display surface to be illuminated, such that heat rises perpendicular to the surface of the fins, a first longitudinal protrusion extending from the second surface proximate the LEDs and parallel to the top edge between the LEDs and the top edge to cause water to be partially directed away therefrom when the back panel is affixed to the mounting structure.

13. A support structure for a light emitting diode (LED) lighting assembly comprising:

a heat sink comprising a thermally conductive substrate, the thermally conductive substrate comprising a first major surface and an opposite second major surface, wherein the first major surface has a first edge along a first direction and a second edge along a second direction perpendicular to the first direction, wherein the heat sink is configured to support a LED panel and an optics panel over the first major surface along a third direction perpendicular to the first and the second directions; and

a plurality of fins extending away from the second major surface and disposed on the thermally conductive substrate, wherein a fin of the plurality of fins comprise a length along the first direction longer than a width along the second direction, wherein the thermally conductive substrate comprises protrusions extending away from the first major surface into the third direction, wherein the protrusions comprise a length along the first direction longer than a width along the second direction.

14. The support structure of claim 13, wherein the plurality of fins comprise air holes.

15. The support structure of claim 13, wherein one of the protrusions overlaps with a fin of the plurality of fins.

16. The support structure of claim 13, wherein the plurality of fins comprise a first fin, a second fin, and a third fin, wherein the first fin is parallel to the second fin, wherein the second fin is oriented at an acute angle to the third fin.

17. The support structure of claim 16, further comprising a fourth fin and a fifth fin, wherein the fourth fin is oriented at an acute angle to the third fin, and the fifth fin is parallel to the first major surface.

18. The support structure of claim 17, wherein the fourth fin and the fifth fin are adjacent the first edge.

19. The support structure of claim 16, further comprising a fourth fin parallel to the first major surface.

20. The support structure of claim 13, further comprising:

a groove on the second major surface of the thermally conductive substrate; and

a mounting plate disposed over the second major surface of the heat sink, wherein the groove is configured to receive a tongue of the mounting plate.

21. The support structure of claim 20, further comprising an adjustable mounting bracket configured to couple the lighting assembly to a billboard and/or a support member, wherein the adjustable mounting bracket is attached to the mounting plate.

22. The support structure of claim 20, wherein the groove is spaced away from the plurality of fins along the second direction, and wherein the thermally conductive substrate is thinner at the groove than at a location directly below the plurality of fins.

23. The support structure of claim 20, further comprising a power supply enclosure mounted over the mounting plate, wherein the power supply enclosure is separated from the heat sink by the mounting plate.

24. The support structure of claim 20, wherein the thermally conductive substrate comprises secondary protrusions extending away from the first major surface into the third direction, wherein the secondary protrusions extend along the entire length of the thermally conductive substrate along the first direction, wherein a protrusion of the secondary protrusions overlaps with the groove.

25. The support structure of claim 13, wherein the protrusions extend along the entire length of the thermally conductive substrate along the first direction.

26. The support structure of claim 13, wherein the protrusions comprise a first protrusion spaced from a second protrusion, wherein the spacing between the first protrusion and the second protrusion is configured to enable mounting of the LED panel and the optics panel between the first protrusion and the second protrusion.

27. The support structure of claim 13, wherein the width of the protrusions is about the same as the width of a fin of the plurality of fins.

28. A support structure for a light emitting diode (LED) lighting assembly comprising:

a heat sink comprising a thermally conductive substrate, the thermally conductive substrate comprising a first major surface and an opposite second major surface, wherein the first major surface has a first edge along a first direction and a second edge along a second direction perpendicular to the first direction, wherein the heat sink is configured to support a LED panel and an optics panel over the first major surface along a third direction perpendicular to the first and the second directions; and

a plurality of fins extending away from the second major surface and disposed on the thermally conductive substrate, wherein the plurality of fins comprise a first fin, a second fin, and a third fin, wherein the first fin and the second fin comprise a length along the first direction longer than a width along the second direction, wherein the first fin is parallel to the second fin, wherein the second fin is oriented at an acute angle to the third fin, wherein the thermally conductive substrate comprises protrusions extending away from the first major surface into the third direction, wherein the protrusions comprise a length along the first direction longer than a width along the second direction;

a mounting plate disposed over the second major surface of the heat sink;

a power supply enclosure mounted over the mounting plate; and

an adjustable mounting bracket configured to couple the lighting assembly to a billboard and/or a support member, wherein the adjustable mounting bracket is attached to the mounting plate.

29. The support structure of claim 28, wherein a protrusion of the protrusions overlaps with a fin of the plurality of fins.

30. The support structure of claim 28, further comprising a fourth fin and a fifth fin, wherein the fourth fin is oriented at an acute angle to the third fin, and the fifth fin is parallel to the first major surface.

31. The support structure of claim 28, further comprising a fourth fin parallel to the first major surface.

32. The support structure of claim 28, further comprising:

a groove on the second major surface of the thermally conductive substrate, wherein the groove is spaced away from the plurality of fins along the second direction, and wherein the thermally conductive substrate is thinner at the groove than at a location directly below the plurality of fins.

33. A support structure for a light emitting diode (LED) lighting assembly comprising:

a heat sink comprising a thermally conductive substrate, the thermally conductive substrate comprising a first major surface and an opposite second major surface, wherein the first major surface has a first edge along a first direction and a second edge along a second direction perpendicular to the first direction, wherein the heat sink is configured to support a LED panel and an optics panel over the first major surface along a third direction perpendicular to the first and the second directions; and

a plurality of fins extending away from the second major surface and disposed on the thermally conductive substrate, wherein the plurality of fins comprise a first fin, a second fin, a third fin, a fourth fin and a fifth fin, wherein the first fin and the second fin comprise a length along the first direction longer than a width along the second direction, wherein the first fin is parallel to the second fin, wherein the second fin is oriented at a first acute angle to the third fin, wherein the fourth fin is oriented at a second acute angle to the third fin, and the fifth fin is parallel to the first major surface, wherein the first acute angle is different from the second acute angle, wherein the thermally conductive substrate comprises protrusions extending away from the first major surface into the third direction, wherein the protrusions comprise a length along the first direction longer than a width along the second direction.