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WO2012064364A1 - Lampe à diodes électroluminescentes - Google Patents

Lampe à diodes électroluminescentes Download PDF

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Publication number
WO2012064364A1
WO2012064364A1 PCT/US2011/001880 US2011001880W WO2012064364A1 WO 2012064364 A1 WO2012064364 A1 WO 2012064364A1 US 2011001880 W US2011001880 W US 2011001880W WO 2012064364 A1 WO2012064364 A1 WO 2012064364A1
Authority
WO
WIPO (PCT)
Prior art keywords
fan
housing
heat sink
lamp
led
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2011/001880
Other languages
English (en)
Inventor
Sylwester D. Wilk
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US12/931,540 external-priority patent/US20120120658A1/en
Application filed by Individual filed Critical Individual
Publication of WO2012064364A1 publication Critical patent/WO2012064364A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/143—Light emitting diodes [LED] the main emission direction of the LED being parallel to the optical axis of the illuminating device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21L—LIGHTING DEVICES OR SYSTEMS THEREOF, BEING PORTABLE OR SPECIALLY ADAPTED FOR TRANSPORTATION
    • F21L14/00—Electric lighting devices without a self-contained power source, e.g. for mains connection
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/151—Light emitting diodes [LED] arranged in one or more lines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
    • F21S45/40—Cooling of lighting devices
    • F21S45/42—Forced cooling
    • F21S45/43—Forced cooling using gas
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S8/00—Lighting devices intended for fixed installation
    • F21S8/02—Lighting devices intended for fixed installation of recess-mounted type, e.g. downlighters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V21/00—Supporting, suspending, or attaching arrangements for lighting devices; Hand grips
    • F21V21/06—Bases for movable standing lamps; Fixing standards to the bases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V23/00—Arrangement of electric circuit elements in or on lighting devices
    • F21V23/003—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array
    • F21V23/004—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array arranged on a substrate, e.g. a printed circuit board
    • F21V23/006—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array arranged on a substrate, e.g. a printed circuit board the substrate being distinct from the light source holder
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V23/00—Arrangement of electric circuit elements in or on lighting devices
    • F21V23/003—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array
    • F21V23/007—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array enclosed in a casing
    • F21V23/009—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array enclosed in a casing the casing being inside the housing of the lighting device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V25/00—Safety devices structurally associated with lighting devices
    • F21V25/10—Safety devices structurally associated with lighting devices coming into action when lighting device is overloaded, e.g. thermal switch
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/60—Cooling arrangements characterised by the use of a forced flow of gas, e.g. air
    • F21V29/67—Cooling arrangements characterised by the use of a forced flow of gas, e.g. air characterised by the arrangement of fans
    • F21V29/677—Cooling arrangements characterised by the use of a forced flow of gas, e.g. air characterised by the arrangement of fans the fans being used for discharging
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/71—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks using a combination of separate elements interconnected by heat-conducting means, e.g. with heat pipes or thermally conductive bars between separate heat-sink elements
    • F21V29/717—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks using a combination of separate elements interconnected by heat-conducting means, e.g. with heat pipes or thermally conductive bars between separate heat-sink elements using split or remote units thermally interconnected, e.g. by thermally conductive bars or heat pipes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
    • F21V29/75—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with fins or blades having different shapes, thicknesses or spacing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
    • F21V29/77—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section
    • F21V29/773—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section the planes containing the fins or blades having the direction of the light emitting axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2131/00—Use or application of lighting devices or systems not provided for in codes F21W2102/00-F21W2121/00
    • F21W2131/10—Outdoor lighting
    • F21W2131/103—Outdoor lighting of streets or roads
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2105/00—Planar light sources
    • F21Y2105/10—Planar light sources comprising a two-dimensional array of point-like light-generating elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • This invention relates to LED lamps, and particularly to relatively high power lamps with cooling means for the LED light-producing elements.
  • LED lamps are becoming more popular because they are much more efficient than incandescent or fluorescent lighting, and therefore require much less energy, but also because the LED lamp normally lasts thousands of hours, under normal use, without requiring replacement.
  • a further problem with such lamps is that when LED lamps of relatively high wattage, such as 20 Watts to 100 Watts are used, the LED lamp arrays (the light-producing elements) usually need cooling. Therefore, in some prior LED lamps, relatively expensive, high- throughput fans and ductwork often have been proposed for use in cooling the LED lamp arrays. This equipment not only is relatively expensive, but it also is bulky so that it is relatively difficult to fit the lamps into cramped spaces.
  • Certain lamps are known as "work lights” or “work lamps.” These are lamps used, typically, by painters, plumbers, construction workers, home owners, etc., to light indoor and outdoor building and other work sites. Typically, such lamps use incandescent, fluorescent, halogen or LED light sources.
  • Halogen work lamps emit high intensity light, but they can get very hot during use and therefore usually use heavy wire shields over the outlet light window to prevent bums. Also, the bulbs bum out relatively quickly so that spares usually are kept on hand, and the cost of replacing bulbs can be significant.
  • LED work lamps are available, but usually are relatively expensive and are limited in output light intensity.
  • LED lamp structure which is relatively inexpensive, compact, and easy to install.
  • a LED lamp fixture with a heat sink structure to which the LED array is attached directly, with a fan mounted nearby.
  • the heat sink has a central area without fins, and the fan is mounted in the central area of the heat sink structure so as to give the lamp a relatively low profile and make the lamp structure compact and relatively easy to fit into recessed spaces.
  • the fan blades are shaped so as to push the air sideways through the spaces between the fins.
  • the fan/heat sink structure can be comparatively inexpensive and compact, in part because the preferred devices are those that have been produced in great quantities for use in computers. Not only are they relatively compact and inexpensive, but the applicant has found that such units are very efficient in cooling LED lamps, when they are correctly positioned.
  • the fans can be mounted in recessed housings in buildings in the air spaces between the ceiling and the floor above it, and discharge the air flow directly into that air space, without use of expensive ducting. This is believed to be because the air flow rate is relatively low and the air escapes sufficiently rapidly through natural crevices and cracks in the building structure.
  • Cooling fan air is exhausted directly into the housing of the lamp where it easily escapes through natural crevices in the lamp structure.
  • the same advantageous LED lamp structure is used to advantage in a work light or work lamp which is a portable lamp, with its own support structure, which is used to give bright illumination for professional painters, carpenters and other workers, as well as for nonprofessional workers.
  • the lamp output usually can be tilted to shine upwardly from the floor or ground at a variable angle.
  • the lamp structure is used to further advantage in vehicle headlights such as automobile or truck headlights, to provide a reliable, low power-consumption, relatively low cost headlight package.
  • a back-up battery emergency power supply is provided as well. Because the LED lamp usually draws fewer watts of electrical energy for a given light output than many other lamps, the lamp of the invention can continue providing light for a substantial time after the normal power source has failed.
  • Figure 1 is a perspective view of a lamp fixture embodiment of the present invention
  • Figure 2 is a cross-sectional view of the lamp fixture installed in a typical location, with a cross-sectional view of the lamp being taken along Line 2-2 of Figure 1.
  • Figure 3 is a cross-sectional view, like that of Figure 2, of a different LED lamp fixture of the present invention
  • Figure 4 is a cross-sectional view taken along Line 4-4 of Figure 3 ;
  • FIG. 5 is a perspective view of a heat sink and fan structure used in the lamp fixtures of Figures 1-4;
  • Figure 6 is a cross-sectional view of another lamp fixture embodiment of the present invention.
  • Figure 7 is a broken-away view take along Line 7-7 of Figure 6;
  • Figure 8 is a top plan view of a component of the structure shown in Figure 6.
  • Figure 9 is a perspective view of a work light utilizing the invention.
  • Figure 10 is a cross-sectional view, taken along line 10-10 of Figure 9;
  • Figure 11 is a rear elevation view, partially broken-away, showing a component of the Figure 9 structure
  • Figure 12 is a perspective view of the invention used to advantage in an automobile headlight module
  • Figure 13 is a broken-away rear elevation view of the Figure 12 structure
  • Figures 14 and 15 are broken-away side elevation schematic and cross-sectional views of the structures in Figure 12;
  • Figures 16 and 17 are schematic circuit diagrams of battery back-up power supplies for the LED lamps of the invention.
  • FIG. 1 shows a fixture 10 which is termed herein a “floodlight” fixture, in that it is of the type which normally receives an incandescent or other screw-in type bulb in a socket, and the bulb spreads light outwardly over a relatively wide area.
  • a fixture 10 which is termed herein a "floodlight” fixture, in that it is of the type which normally receives an incandescent or other screw-in type bulb in a socket, and the bulb spreads light outwardly over a relatively wide area.
  • the fixture includes a bell-shaped housing 12 having an inlet opening at 14 and an outlet opening at 16 (Figure 2) where light leaves the fixture.
  • the housing has a flange 22 with corrugated section 20 near its outlet end 16, and a relatively straight neck portion 24 leading to the inlet 14,
  • an LED array 26 is positioned at the inlet opening just inside the housing.
  • the LED array 26 emits its light through a convex lens 27 which tends to spread the light outwardly.
  • a convex lens 27 which tends to spread the light outwardly.
  • other lenses could be provided to shape the output light beam as desired.
  • the LED array 26 has a central array 70 of LED light elements, in a package having flanges 64 and a body portion (behind the array 70 in Figure 4).
  • the body portion extends through the opening 14 and makes contact with the flat bottom of a heat sink 28.
  • the LED array is attached to the flat bottom of the heat sink preferably by heat-conducting silicone thermal glue.
  • the body of the LED array makes intimate, heat-conducting contact with the bottom of the metal heat sink.
  • a power supply 30 is provided. It is mounted above and spaced from the upper surface of the heat sink 28 by screws and spacers 32 (not shown in Figure 1).
  • the power supply 30 may or may not have a cover such as that shown in Figures 2 and 3, and in dashed outline in Figure 1.
  • Input leads 34 and 36 to the power supply are connected directly to the wiring of the building to supply the usual 120 Volts 60 Hz AC power.
  • the power supply has a well-known construction. It typically uses a step-down transformer and a rectifier to convert AC voltage to 12 Volts DC for the fan motor, and 14 Volts DC for the LED array. Although separate power supplies can be provided for the two devices, a single power supply combining these functions is compact and relatively simple to mount and can be provided relatively inexpensively.
  • the preferred heat sink 28 and fan combination is shown in Figure 5.
  • the heat sink preferably is made out of aluminum or similar light-weight, inexpensive good heat-conducting material.
  • the heat-sink has a hollowed-out body with a central cavity 40, and a plurality of fins 38.
  • a fan 34 with blades 36 forces air out sideways between the fins to provide cooling.
  • the fan and heat sink combination shown in Figure 5 is used for cooling VGA cards in computers. It is relatively inexpensive because it is manufactured in great quantities for use in computers around the world.
  • the fan 34 and heat-sink 28 combination is highly advantageous for use in the present invention in that its vertical height is quite small. This keeps the height of the structure above the inlet end of the lamp 12 housing relatively low.
  • the fixture can be used in the space between the ceiling and floor in a building, as shown in Figure 2, or in other cramped spaces without undue difficulty.
  • the power supply 30 preferably has a round, flat circuit board 31 (Figure 1) on which the components are mounted.
  • This board serves as a baffle for air flowing to or from the fan, so as to insure that the air will travel sideways as indicated in Figure 2 by the arrows 42. This additionally gives some cooling, if needed, to the power supply.
  • the power supply has a thermistor which will open the power circuit to the LED lamp if and when it overheats due to failure of the fan, or a circuit like a light dimmer circuit which reduces the power delivered to the LED lamp when it overheats, usually by pulse- width modulation, until the lamp cools sufficiently.
  • the heat sink 28 has mounting holes 33 and 35, but other mounting holes can be provided as needed.
  • the power supply cord 44 to the fan 34 is connected into the power supply 30 through a connection which is not shown in the drawings.
  • two pairs of spring arms, 46, 48, and 50 are provided on opposite sides of the housing 12. As it is well known, the spring arms are inserted into mounting receptacles, part of which are shown at 52, to retractabiy mount the fixture in the opening in the ceiling.
  • Figure 2 shows the ceiling 56 and schematically shows the floorboards 58 of the floor above the ceiling 56. This provides an air space between the floorboards and the ceiling. That air space is indicated at 60 in Figure 2.
  • the air discharged from the fan is discharged sideways directly into the air space 60 without the use of ducting or other expensive construction features. This is due to the realization that the air need not be vented into the room below or elsewhere because it is easily able to escape through the normal crevices and openings in building construction air spaces.
  • the fans that are selected are very low volume in their output because the heat-sink and fan arrangement is so efficient in cariying heat away from LED lamp arrays. Therefore, the output air volume is relatively low and can be essentially negligible.
  • FIG 3 shows a shower lamp fixture which is like that shown in Figure 2, with certain exceptions.
  • a frustro-conical housing 62 is provided with a glass outlet cover 82 with a rough pebbled outer surface 84 and a bezle 80.
  • a rubber seal (not shown) is provided between the bezle and the ceiling 56 to make the fixture reasonably watertight so it can be used readily in showers or other wet areas.
  • Three convenient hook fasteners 76 are provided for the easy mounting of the fixture in a ceiling mounting structure, as is well known.
  • the bezle 80 is secured to the lower flange 82 of the housing 62.
  • FIG 6 is a cross-sectional view of a typical street lamp housing 86, which is mounted on a pole indicated schematically at 88, for street lighting purposes.
  • the LED array used in the fixtures shown in Figures 1 , 2 and 3 are relatively low power (e.g. 20 Watts to 50 Watts) which give illumination in the range of 60 Watt incandescent bulbs to 150 Watt incandescent bulbs
  • the street fighting fixture shown in Figure 6 usually requires higher wattage for LED arrays, say 100 Watts or more. As a result, more cooling is required.
  • the LED array 26 is mounted in a reflector 90 within the housing 86 to reflect light from the LED lamp array outwardly through a window 92.
  • the fixture 84 shown in Figure 6 has a single fan 98 in a circular housing mounted on top of a heat sink 96, and a power supply is mounted at 100 above the fan 98.
  • the fan 98 draws air upwardly though the heat sink 96 and spreads it sideways in the directions of the arrows 99.
  • Figure 8 is a top plan view of the fan 98. It has a circular housing 105 with a fan motor 101 with blades 103 mounted within the housing 99. The housing and fan are mounted on the heat sink 96 by screws and spacers 107.
  • this fan like the fan 34 used in the fixtures shown in Figures 1-3 is used in cooling computers. Specifically, it is used to cool the CPU units in desk-top and other computers.
  • a fan and heat-sink combination like that in Figures 1-5 but with a higher output volume can be used, in order to keep the profile low.
  • WORK LIGHTS Figure 9 is a perspective view of a work light or work lamp 110 provided in accordance with the invention.
  • work lights are used by painters, brick and tile layers, homeowners and others who need to have a well-lit work area, either indoors or outdoors, in which to perform their work.
  • Work lights are used indoors to light up dark rooms, or to light dark areas in basements or elsewhere to give adequate light to work by. Work lights also are used outdoors to illuminate work objects and areas, especially at night or on dark days.
  • the work light 110 includes a metal housing 1 12, a front glass window 114, a carrying handle 1 16 on top of the housing 112, and a support structure including mounting legs 1 17 and 121 extending downwardly from the housing 112, and support legs 1 19 and 123 coupled to the legs 1 17 and 121 by pivotable connections 1 18 and 120.
  • the pivotable connections allow the work light housing 1 12 to be pivoted forward and backward, in the directions indicated by arrow 147 ( Figure 10), to tilt the light up or down, as needed. As it is well known, the tilt mechanism will hold the housing at the angle to which it is set.
  • the supports 1 19 and 123 are secured, as by bolts or welding, to a metal crossbar 122 which is secured to transverse support pipes 124 and 126 with rubber feet 128 to provide a stable support platform for the work light,
  • the work light 110 shown in Figure 9 is relatively large work light of the size which normally uses a 500 watt halogen bulb to produce a great deal of output light power.
  • a shiny metal reflector 140 which reflects the light from the lamp and through the window 114.
  • an LED array 142 At the center of the reflector 140 is an LED array 142.
  • the LED array is one which requires 100 watts of power and produces white light with an intensity of approximately 8000 lumens. This is a very powerful light.
  • a heat-sink/fan cooling device 146 consists of a conductive plate 152 from which extend a plurality of metallic fins 150 (also see Figure 1 1) on opposite sides of a fan motor 148 with fan blades 149. Extending from the plate 150 is an extension structure 154, also thermally conductive, which is fastened to the support substrate of the LED array by electrically conductive glue,
  • the heat-sink and fan combination 146 preferably is one like those used for cooling computer video cards, such as the "Super Silent Professional Video Card Heat Pipe Cooler,” sold by Dealer Extreme (dealerextreme.com). It uses a 2500 rpm fan.
  • the blades 149 of the fan 148 are shaped with squared-off tips and are otherwise shaped to throw air outwardly laterally to flow in the spaces between the fins 150.
  • the structure 146 has side-walls 153 and 155 which tend to guide air from the blades 149 towards the fins 150.
  • the structure 146 also has a heat-pipe structure 157 to increase its cooling capabilities.
  • the heat pipe consists of a sealed copper tube with two central sections 159 and 161, which are somewhat flattened in the flat plane of the projection 154 to which the LED array 142 is secured to make good thermal contact with the surface to be cooled, and two end portions 163 and 165.
  • the end portions 163 and 165 extend through holes in the fins 150 so as to transfer heat conducted from the LED array into the heat pipe into the fins 150 where the heat is removed by the fan 148.
  • a metal housing 134 secured to the bottom of the housing 112, which contains the power supply for the LED array and fan, and is connected to the LED and fan by conductors indicated at 138.
  • An a!ternative location for the power supply is inside the housing, at a location indicated by the reference numeral 135, Spacers attach the power supply to the heat sink, as in the Figures 1 -5 embodiments. This location is preferred if there is sufficient room in the housing 112.
  • Electrical power is supplied to the circuitry in the housing 134 by means of a cord 136.
  • this power will be either 120 volts or 230 volts AC.
  • the AC voltage is converted to the necessary DC voltages required by the fan and LED array, as described herein above.
  • the housing 1 12 optionally has a plurality of holes 132 at opposite sides of the housing walls to serve as ventilation ports. These need not be provided if there are sufficient crevices or openings in the housing due to its natural construction to provide adequate egress for the cooling air developed by the fan 148.
  • the power supply can include a thermistor to shut off the power, or a light dimmer control circuit to cool off the LED array, should it overheat, due to failure of the fan, temporary occlusion of the air vent holes, or other abnormal causes.
  • the structure shown for the work light provides more light than usually is available in work lights, and yet at a cost which is not prohibitively high. It is believed that the light output from the work lamp can be greater than that presently available for most work lamps, but without the excessive heating of the glass window, and without the short life of halogen bulbs when halogen lighting is used.
  • the life of the LED array can be as high as 50,000 hours or more.
  • Figure 12 is a perspective view of a headlight module 160 which fits into one of the right-receptacle if the front-end of a modern automobile, The particular unit shown forms the right side headlight moduie when viewing the automobile from the driver's seat, and there will be another module, a mirror-image of the module 160, at the left front corner of the vehicle.
  • Module 160 comprises a body 166, usually molded of plastic materials, having a floor
  • the lamp 168 is the "high beam” or high intensity lamp, and the lamp 170 is the “low beam” headlamp.
  • a turn signal lamp 173 also is present in the module.
  • the high beam lamp 168 includes a reflector 172 with a centrally-located circular LED array 174, and a central beam shaper 176 mounted on an arm 170 which is attached to the structure of the reflector 172.
  • the beam shaper 176 has a conical-shaped forward end 178. The purpose of this is to shape the high beam properly.
  • the low-beam lamp 170 includes a reflector 180, a central circular LED array 182, and a convex lens 184 covering the LED array and shaping the light that it emits.
  • Figure 13 is a partially broken-away and partially schematic rear view of the housing 166 with exit doors 188 and 190 open to show the heat sinks and the fans of the two LED lamps.
  • a heat sink 186 with a fan 187 As shown in Figures 1-5.
  • the LED array 182 is attached to the heat sink in the same manner as the LED array is attached to the heat sink as shown in Figure 1.
  • the light from the LED array 182 is not as bright as that from the other LEDs.
  • the LED array for the lamp 168 has a larger heat sink 192 and fan 193, circular as shown above. As before, the heat sink is connected directly to the LED array in intimate heat conducting contact with it, to maximize heat transfer to the fins of the heat sink.
  • the heat-sink is located immediately behind the LED light source and behind the inner opening of the reflector at the center of the reflector.
  • the power supply or supplies for the lamps 168 and 170 are not shown because they are the same as those shown and described above for the other embodiments of the invention. There is ample room in the module 166 in which to mount the power supplies. Although separate power supplies can be provided for each of the two headlamps, a single power supply could be used for both, if desired.
  • LED lamps shown in Figures 12-14 are used instead of halogen or incandescent lights, the electrical power used and, hence, the gasoline used to energize the headlamps is reduced, thus increasing gasoline mileage for the vehicle, and providing very bright light. Furthermore, the bulbs last for a very long time, probably longer than the car.
  • a battery back-up system to be described below, can be provided for each of the headlights.
  • An optional feature of the invention is to provide battery back-up for operation of the automobile headlight and any of the other lamps described herein.
  • Figure 16 is a schematic circuit diagram for a battery back-up circuit 194, Figure 16 does not show the entire electrical circuit of an automobile, but only the part relevant to the feature here described.
  • the circuit includes the main battery 200 of the automobile, the alternator of the automobile, the light switching device 202 to switch the lights on and off, and to switch from dim to bright and bright to dim, etc. Both the high beam lamp 168 and the low beam 170 are connected to the switch 202. Connected between the headlamp and the switch 202 is a series combination of an electrical level sensing circuit 198 and a back-up rechargeable battery 196.
  • the back-up battery advantageously can consist of one or more low-vo!tage rechargeable batteries, such as those producing 4000 mAh protected lithium-ion rechargeable batteries. Any other batteries suitable to the task also can be used. Such batteries are relatively low-cost and can store adequate energy to continue the operations of the LED headlights 168 and 170 for up to an hour and a half or longer after the automobile battery 200 ceases to supply energy.
  • the device 198 senses the voltage supplied by the main battery 200. When that voltage drops below a predetermined level, such as when the battery dies and the alternator 202 is not running, and the light switch 202 is turned on, the device 198 forms an electrical connection of the back-up battery 196 to the lamps 168 and 170. The condition of the switch 202 is delivered to the devices 198 over lines 199.
  • the back-up battery system will be inactive and will not light the headlights.
  • the switch 202 is on, and the voltage sensed by the device 198 is too low, the back-up battery is enabled to supply the relatively low power and voltage needed for the LED power supplies to continue enabling them to provide light. This can be very valuable in times of emergencies.
  • a similar circuit 204 is shown in Figure 17 for providing battery back-up service for the other lamps described in this patent application which are supplied with AC voltage from a connection to the power grid 206 or other AC source.
  • a circuit 2 ⁇ 6 and a back-up battery unit 214 are connected in series.
  • the back-up battery 214 is connected to supply energy to the power supply 210 for the LED lamp. 212.
  • the back-up battery 214 is recharged by the power supply 206.
  • the back-up batteries 196 shown in Figure 16 are recharged when the main battery 200 of the automobile is working normally.
  • LED arrays are typical examples of arrays which can be used:

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Geometry (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)

Abstract

L'invention concerne des structures de lampes à diodes électroluminescentes (LED) et des luminaires, notamment des luminaires "bas" ou en creux, des éclairages publics, des "feux de travaux", et des phares d'automobiles. Chaque lampe est munie d'un ventilateur et d'un puits thermique et la matrice de diodes électroluminescentes est directement fixée au puits thermique. Les ventilateurs utilisés sont de préférence des ventilateurs de refroidissement pour ordinateurs qui sont particulièrement petits, efficaces et peu coûteux. Il est préférable que les ventilateurs contraignent l'air à passer vers le côté sur les ailettes. Les ventilateurs de certains modes de réalisation sont encastrés parmi les ailettes du puits thermique afin d'effectuer des économies de volume et d'assurer un écoulement direct de l'air à travers les ailettes. Le faible volume évacué en provenance des ventilateurs est directement libéré dans le volume d'air ou le boîtier dans lequel sont montées les lampes sans qu'il soit nécessaire de prévoir des conduits particuliers, pour ainsi tirer profit des fissures naturelles et des ouvertures permettant l'évacuation de la totalité ou d'une partie de l'air.
PCT/US2011/001880 2010-11-13 2011-11-10 Lampe à diodes électroluminescentes Ceased WO2012064364A1 (fr)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US41342010P 2010-11-13 2010-11-13
US61/413,420 2010-11-13
US12/931,540 US20120120658A1 (en) 2010-11-13 2011-02-02 LED lamp
US12/931,540 2011-02-02
US13/136,707 2011-08-08
US13/136,707 US20120188780A1 (en) 2010-11-13 2011-08-08 Led lamp

Publications (1)

Publication Number Publication Date
WO2012064364A1 true WO2012064364A1 (fr) 2012-05-18

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WO2014011930A3 (fr) * 2012-07-11 2014-02-27 Leader International Corporation Ensemble d'éclairage plat à led
US8845132B2 (en) 2011-02-09 2014-09-30 Differential Energy Products, Llc Flat LED lamp assembly
US8882297B2 (en) 2011-02-09 2014-11-11 Differential Energy Products, Llc Flat LED lamp assembly

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US20100142194A1 (en) * 2008-12-05 2010-06-10 Koito Manufacturing Co., Ltd. Automotive lamp lighting system
US20100220486A1 (en) * 2007-10-04 2010-09-02 Probasco Design Portable lightbox assembly

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US20060187658A1 (en) * 2005-01-21 2006-08-24 Cyberlux Corporation Portable light device
US20080165535A1 (en) * 2007-01-09 2008-07-10 Mazzochette Joseph B Thermally-Managed Led-Based Recessed Down Lights
US20100220486A1 (en) * 2007-10-04 2010-09-02 Probasco Design Portable lightbox assembly
US20090168351A1 (en) * 2007-12-26 2009-07-02 Delta Electronics, Inc. Heat dissipation module and fan thereof
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US7575346B1 (en) * 2008-07-22 2009-08-18 Sunonwealth Electric Machine Industry Co., Ltd. Lamp
US20100124071A1 (en) * 2008-11-19 2010-05-20 Samsung Electro-Mechanics Co., Ltd. Cooling device for light emitting device package of vibration generating machine and head lamp for vibration generating machine
US20100142194A1 (en) * 2008-12-05 2010-06-10 Koito Manufacturing Co., Ltd. Automotive lamp lighting system

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8845132B2 (en) 2011-02-09 2014-09-30 Differential Energy Products, Llc Flat LED lamp assembly
US8882297B2 (en) 2011-02-09 2014-11-11 Differential Energy Products, Llc Flat LED lamp assembly
WO2014011930A3 (fr) * 2012-07-11 2014-02-27 Leader International Corporation Ensemble d'éclairage plat à led

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