TECHNICAL FIELD
[0001] The present invention relates generally to heat sinks and, more specifically, to
a heat sink with an attached LED that hangs externally from a street lamp.
BACKGROUND INFORMATION
[0002] Light emitting diodes (LEDs) provide an energy-efficient light source and are increasingly
being used instead of fluorescent and halogen gas lamps for high capacity lighting
needs, such as street lamps. In order to increase the amount of light generated, LEDs
are often incorporated into street lamps, which can lead to significant problems of
overheating. The performance and lifetime of the LEDs is degraded if the operating
temperature exceeds a threshold level. The useful life of an LED street lamp is sometimes
specified as the number of hours of operation before which the luminous output of
the lamp drops to half of its initial output. Empirical data suggests that there is
an inverse exponential relationship between the useful life of an LED lamp and the
amount by which the average operating temperature exceeds a threshold level. For example,
some phosphors in LEDs have been found to degrade if the temperature of the phosphor
exceeds 165 degrees Celsius over an extended period. Thus, dissipating the heat generated
by the LEDs in the street lamp is a problem that must be solved.
[0003] The LEDs of a street lamp are enclosed by the shell of the street lamp. The shell
typically has a metal upper cover and a transparent lower cover. The shell typically
has openings at the top that allow the heat generated by the LEDs to escape. However,
the openings at the top allow dust, moisture and insects to enter the shell, which
can accumulate in the transparent lower cover and block much of the light that is
generated by the LEDs.
[0004] FIG. 1 (prior art) shows an existing LED street light 10 that does not permit dust,
moisture and insects to obstruct the transparent lower cover 11 through which the
generated light shines onto the street. Transparent lower cover 11 is kept free of
dust, moisture and insects by completely sealing off the lower compartment of the
shell of the street lamp. Consequently, most of the heat generated by the LEDs must
be dissipated through the upper compartment. The heat is transmitted from the LEDs
to a heat conducting plate 12. The heat then passes on to heat-dissipating fins 13
via a heat guiding piece 14. Heat is dissipated out of the upper compartment by fans
15 that blow heated air out of venting slots 16 in the upper cover 17. For additional
details on this prior art method of dissipating heat from a street lamp, see
U.S. Patent No. 7,278,761 to Kuan entitled "Heat Dissipating Pole Illumination Device."
[0005] This prior art method of dissipating heat from an LED street light has multiple disadvantages.
First, although dust, moisture and insects are prevented from entering the lower compartment
of the street lamp shell, they will nevertheless enter the upper compartment through
the venting slots 16 in the upper cover 17. The dust, moisture and insects that fall
through the venting slots 16 will collect in the upper compartment and clog the fans
15 and the spaces between the fins 13, thereby reducing the ability of street lamp
to dissipate heat. Second, the fans 15 have moving parts and will likely malfunction,
especially if they are subjected to the dust, moisture and insects that enter through
the venting slots 16. Moreover, the fans 15 also require a power supply, which might
not be able to be shared with the LEDs. Finally, the fans 15 add to the cost of the
street lamp.
[0006] A method is sought for dissipating heat from an LED street lamp that does not allow
dust, moisture and insects to enter through venting slots in the upper cover of the
street lamp and that does not require fans.
[0007] Attention is drawn to
US 2010/182795 A1 which relates to a kind of LED light, comprising: front housing, rear housing, light
pole fixation base, clear cap; also comprising the transformer fixed on the rear housing
and the LED panel connected with the front housing; there are couples of heat sinks
on external surface of the rear housing; the internal surface of the foresaid front
housing is equipped with minimum one slot with couples of heat sinks in; the heat
sinks are designed for conducting heat from the LED light panel to the air for timely
eliminating heat for the LED. By this way, it guarantees a sufficient heat elimination
for the LED street light achieving a longer lifespan of the LED street light and a
less light degradation that can be even neglected. Therefore, the brightness of the
LED street light is ensured.
SUMMARY
[0008] In accordance with the present invention an apparatus, and a method, as set forth
in the independent claims, respectively, are provided. Preferred embodiments of the
invention are described in the dependent claims.
[0009] A conventional street lamp is retrofitted by externally mounting an LED light source
with an attached heat sink. The heat sink has a very low height profile and hangs
inconspicuously with the LED light source just below the space otherwise occupied
by the lens of the street lamp. The heat sink light source includes a first fin structure
with larger fins, a second fin structure with smaller fins, a bulb, a mounting platform
and light emitting diodes attached to the mounting platform. The larger fins are oriented
parallel to the smaller fins. The larger fins are integrally formed with a first base,
and the smaller fins are integrally formed with a second base. The bottom surface
of the second base contacts the larger fins. The larger fins are more than twice as
tall as the smaller fins, and there are more than twice as many smaller fins as there
are larger fins across the same distance perpendicular to the fins. Ducts are formed
between the larger fins and the bottom surface of the second base. One end of each
duct is blocked by an end wall, and intake holes pass through the first base into
each duct near the end wall.
[0010] The mounting platform with the LEDs is attached to the bottom of the first base.
The bulb is attached to the bottom surface of the first base such that the mounting
platform and the LEDs are enclosed by the bulb and the bottom surface. The ambient
air is expelled from the enclosure, and the enclosure is filled with an inert gas
in order to protect the LEDs from degradation. The enclosure is then hermetically
sealed. Heat that is generated by the LEDs is conducted through the mounting platform,
the first base and the larger fins into the air in the ducts. The expanding heated
air exits the ducts through the open ends opposite the end wall and draws cooler air
into the ducts through the intake holes. By transferring heat away from the LEDs without
using fans and without requiring venting slots in the upper cover of the street lamp,
the externally mounted heat sink prevents the LEDs from operating at excessively high
temperatures and protects the LEDs and associated phosphor from degradation.
[0011] A replaceable LED light bulb that can be used to retrofit a conventional street lamp
is removably attached to a heat sink that is permanently attached to the street lamp.
The LED light bulb includes a base, a bulb, a gasket, a mounting platform and LEDs
attached to the mounting platform. The mounting platform is attached to the base.
The thermal pad completely covers the mounting platform and a portion of the outside
surface of the base. The surface of the mounting platform opposite the LEDs is substantially
coplanar with the portion of the outside surface of the base covered by the thermal
pad.
[0012] A chamber that contains the LEDs is formed between the base and the bulb. The chamber
is filled with an inert gas and then hermetically sealed. The gasket is disposed in
a groove in the outside surface of the base. The gasket forms an air-tight boundary
between the outside surface of the base and the heat sink such that no gas that exits
the chamber over time through the base and around the mounting platform may escape
beyond the boundary of the gasket.
[0013] A method of manufacturing a replaceable LED light bulb includes attaching a mounting
platform to a base of the LED light bulb, covering the mounting platform with a thermal
pad, attaching a bulb to the base to form a chamber, and filling the chamber with
an inert gas. The mounting platform with attached LEDs is attached to the base of
the LED light bulb. Thermal grease is then used to attach the thermal pad to the surface
of the mounting platform opposite the LEDs. The entire mounting platform and a portion
of the outside surface of the base are covered by the thermal pad. The bulb is attached
to the base opposite the outside surface such that a chamber is formed between the
base and the bulb. The chamber is filled with an inert gas, such as argon, and is
then hermetically sealed. The gasket is inserted into a groove in the outside surface
of the base. The base is then removably attached to a heat sink such that the gasket
forms a boundary between the outside surface of the base and the heat sink through
which none of the inert gas that may exit the chamber over time through the base and
around the mounting platform may escape beyond the boundary.
[0014] Further details and embodiments and techniques are described in the detailed description
below. This summary does not purport to define the invention. The invention is defined
by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, where like numerals indicate like components, illustrate
embodiments of the invention.
FIG. 1 (prior art) is a perspective view of an existing LED street lamp that dissipates
heat by blowing hot air out the top through venting slots.
FIG. 2 is a perspective side view of a retrofitted street lamp with an externally
mounted LED light source and attached heat sink.
FIG. 3 is a more detailed perspective view the heat sink light source FIG. 2.
FIGS. 4A-B are cross sectional views of the heat sink light source of FIG. 2.
FIG. 5 is a perspective view from below the heat sink light source of FIG. 2 without
the bulb.
FIG. 6 is a cross sectional perspective view of a replaceable LED bulb that can be
removably attached to a heat sink.
FIG. 7 is a more detailed cross sectional view of the LED bulb of FIG. 6.
FIG. 8 is a perspective view of the outside surface of the base of the LED bulb of
FIG. 6 opposite the bulb.
FIG. 9 is a perspective view of the opposite side of the base of the LED bulb shown
in FIG. 8.
FIG. 10 is a flowchart of steps for manufacturing the replaceable LED light bulb of
FIG. 6.
DETAILED DESCRIPTION
[0016] Reference will now be made in detail to some embodiments of the invention, examples
of which are illustrated in the accompanying drawings.
[0017] FIG. 2 is a perspective side view of a retrofitted street lamp 20 to which an LED
light source with attached heat sink 21 has been externally mounted. FIG. 2 shows
the shell of a GE M400 cobrahead-style luminaire, but retrofitted street lamp 20 can
be the shell of any conventional mercury vapor, sodium or metal halide street lamp
that is retrofitted with an LED light source. The shell of street lamp 20 includes
an upper cover 22 and a lower cover 23. The conventional light source and the lens
have been removed from street lamp 20. Heat sink light source 21 hangs from a grate
24 that is attached on the inside of the lip around the opening in lower cover 23
into which the removed lens originally fit. Grate 24 bolts into lower cover 23 from
the inside. Heat sink light source 21 is attached to grate 24 by four spacers 25.
[0018] Heat sink light source 21 includes multiple light emitting diodes (LEDs) attached
to a bottom surface 26 of heat sink 27. Heat sink 27 has a very low height profile
for the amount of heat dissipated, which permits heat sink light source 21 to fit
externally yet inconspicuously under the shell of retrofitted street lamp 20. The
LEDs are packaged as an array and are encapsulated by a bulb 28. Bulb 28 is attached
to bottom surface 26 through a gasket 29. In one embodiment, bulb 28 is made of transparent
polycarbonate. Bulb 28 can also be made of glass or plexiglass (poly[methyl methacrylate]).
Gasket 29 has adhesive on both sides, such that one side sticks to bottom surface
26 and the other side sticks to bulb 28. The electrical drivers for the LEDs are housed
in the shell of street lamp 20. In one embodiment, the wires that power the LEDs pass
through gaps in gasket 29. In another embodiment, the wires that provide electricity
to the LEDs pass from the shell through hollow spacers 25, through heat sink 27 and
into the enclosure formed by bulb 28. In yet another embodiment, the wires that provide
electricity to the LEDs simply drop loosely through the center hole in grate 24, through
holes in heat sink 27, and then into the enclosure formed by bulb 28. Likewise, the
openings through which bulb 28 is filled with an inert gas and through which ambient
air is expelled from bulb 28 can also pass through gasket 29 or through bottom surface
26 of heat sink 27. FIG. 2 shows the holes 30 in bottom surface 26 of heat sink 27
through which ambient air is drawn into heat sink 27 as heated air exists from the
other side (towards the back in FIG. 2) of heat sink 27.
[0019] FIG. 3 is a more detailed perspective view of heat sink light source 21. Heat sink
light source 21 includes a first fin structure 31 and a second fin structure 32. First
fin structure 31 has a plurality of parallel-oriented larger fins 33 that are integrally
formed with a first base 34. First base 34 has a first bottom surface 26 opposite
the larger fins 33. First bottom surface 26 of first base 34 is also the bottom surface
26 of heat sink 27. Second fin structure 32 has a plurality of parallel-oriented smaller
fins 35 that are integrally formed with a second base 36. Second base 36 has a second
bottom surface 37 opposite the smaller fins 35. Second bottom surface 37 contacts
the tops of the larger fins 33. Second fin structure 32 is bolted tightly to first
fin structure 31 so as to ensure good thermal conductivity between larger fins 33
and bottom surface 37. The larger fins 33 are more than twice as tall as the smaller
fins 35. For example, the larger fins 33 are more than six centimeters tall, whereas
the smaller fins 35 are less than three centimeters tall. Ducts 38 are formed between
the larger fins, the second bottom surface 37 and the first base 34. One end of each
duct 38 is blocked by an end wall 39. End wall 39 is part of first base 34. The outside
of end wall 39 is visible in FIG. 2. Intake holes 30 pass through first base 34 into
each of the ducts 38 at the end of each duct that is blocked by end wall 39. In the
embodiment of FIG. 3, three intake holes 30 open into each duct 38.
[0020] Heat generated by the LEDs attached to first bottom surface 26 is drawn into first
fin structure 31 and heats the air between larger fins 33, thereby removing some of
the thermal energy from surfaces of heat sink 27. The heated air then exits the open
ends of the ducts 38, drawing cool air into the blocked ends of the ducts through
the intake holes 30. The larger fins 33 are taller and wider apart than the smaller
fins 35 in order to permit air to flow more easily through the ducts 38 in a horizontal
direction. Some heat is transferred from first fin structure 31 to second fin structure
32 and heats the smaller fins 35. Heated air can rise vertically unobstructed over
the shorter height of the smaller fins 35. Consequently, the smaller fins 35 can dissipate
more heat despite having narrower channels between the fins, which permits more surface
area over the entire second fin structure 32.
[0021] FIG. 3 also shows grate 24 from which heat sink light source 21 hangs. After installation,
heat sink light source 21 is attached to the shell of street lamp 20 via grate 24
and is disposed below the shell. During installation, upper cover 22 of the shell
of street lamp 20 is removed from lower cover 23, and the LED light source with the
attached heat sink 21 is inserted from the inside of the shell through the opening
(for the original lens) in lower cover 23 such that grate 24 rests on the inside lip
of the opening. Grate 24 has an opening in the middle and curved slats that permit
air to flow through the grate.
[0022] FIGS. 4A-B are cross sectional views of heat sink light source 21 attached to grate
24 by spacers 25. FIG. 4A is a cross sectional view looking parallel to the larger
fins 33 and smaller fins 35 and down the ducts 38. FIG. 4A shows that there are more
than twice as many smaller fins 35 disposed across second base 36 as there are larger
fins 33 disposed across first base 34 per unit distance perpendicular to smaller fins
35. In FIG. 4A, there are thirty-five smaller fins 35 for each sixteen larger fins
33 in the dimension perpendicular to the fins. In an embodiment in which the larger
fins 33 are about six centimeters tall, this is equivalent to about 1.17 smaller fins
for each 0.53 larger fins per centimeter perpendicular to smaller fins 35.
[0023] FIG. 4A also shows that bolts 40 pass through the hollow center of spacers 25 and
screw into the second base 36. Other bolts 41 pass through second base 36 and screw
into first base 34. Yet other smaller bolts 42 attach a mounting platform 43 to first
bottom surface 26 of first base 34. Mounting platform 43 is also attached to first
bottom surface 26 using thermal grease that coats the surfaces between first fin structure
31 and mounting platform 43. The thermal grease also enhances the transfer of heat
from mounting platform 43 to first fin structure 31. Mounting platform 43 is thermally
conductive, yet electrically nonconductive. For example, platform 43 can be made of
aluminum oxide (Al
2O
3) or aluminum nitride (AlN).
[0024] Light emitting diode (LED) dice are attached to the bottom surface of mounting platform
43 via a dielectric layer. The LED dice are covered by a layer of phosphor 44 that
converts a portion of the blue light generated by the LEDs to light in the yellow
region of the optical spectrum. The combination of the blue and yellow light is perceived
as "white" light by a human observer. When heat sink light source 21 is installed,
the light generates by the LED dice and the phosphor 44 shines downwards from mounting
platform 43 through bulb 28 and onto the street below retrofitted street lamp 20.
[0025] Bulb 28 is attached to first bottom surface 26 by means of gasket 29 such that mounting
platform 43 and the LEDs are enclosed by bulb 28 and first bottom surface 26. Gasket
29 can have several components, such as a wider ring with adhesive on both sides and
a narrower, taller ring into which bulb 28 fits. The taller ring has openings through
which wires and gas tubes can pass between the wider ring and bulb 28.
[0026] FIG. 4B is a cross sectional view of heat sink light source 21 looking perpendicular
to the larger fins 33 and smaller fins 35. Heat that is generated by the LEDs and
phosphor 44 is conducted through mounting platform 43 to first base 34 and larger
fins 33 into the air in ducts 38. The expanding heated air exits the ducts 38 through
the open ends opposite end wall 39 and draws cooler air into the ducts through the
intake holes 30, as illustrated by the dashed lines in FIG. 4B. Air heated by smaller
fins 35 rises straight up towards grate 24.
[0027] FIG. 5 is a perspective view from below heat sink light source 21. Bulb 28 has been
removed from the drawing of FIG. 5 in order to expose mounting platform 43 attached
to first bottom surface 26 of first fin structure 31. In the embodiment of FIG. 5,
bulb 28 is permanently attached to first bottom surface 26. LEDs 45 arranged in a
4x4 matrix are mounted to mounting platform 43 and are covered by a layer of phosphor
44. In another embodiment, the LEDs 45 are arranged in a 10x10 array. The four screw
holes 46 in first bottom surface 26 are not used in the embodiment of FIG. 5. In another
embodiment, however, bulb 28 and the LEDs 45 are not permanently attached to first
bottom surface 26. Instead, mounting platform 43 and LEDs 45 are included in a replaceable
LED bulb that bolts into the four screw holes 46.
[0028] FIG. 6 is a cross sectional perspective view of a replaceable LED bulb 47 that can
be removably attached to bottom surface 26 of heat sink 27. LED bulb 47 includes a
base 48, a thermal pad 49, mounting platform 43, LEDs 45, a gasket 50 and a bulb 51.
LEDs 45 are attached to mounting platform 43 in the same manner as in the embodiment
of FIG. 5. Base 48 is made of metal, such as aluminum, or of ABS plastic. Mounting
platform 43 snaps into four columns 52 that extend upward (in the orientation of FIG.
6) from protrusions from base 48 into indentations in mounting platform 43. Thermal
pad 49 completely covers mounting platform 43 and a portion of the outside surface
53 of base 48. Mounting platform 43 has a first surface 54 opposite the LEDs 45 that
is substantially coplanar with the portion of outside surface 53 of base 48 that is
covered by thermal pad 49. In one embodiment, there is a shallow indentation in outside
surface 53 that is approximately the same size and depth as the size and thickness
of thermal pad 49. The indentation permits the outside surface of thermal pad 49 to
be substantially coplanar with the remainder of the outside surface 53 of base 48.
Adhesive around the edges of thermal pad 49 glues the pad to outside surface 53. Thermal
grease is also used to attach thermal pad 49 over mounting platform 43 and over a
portion of the outside surface 53.
[0029] A chamber 55 or enclosure is formed between base 48, mounting platform 43 and bulb
51. The LEDs 45 are disposed inside chamber 55. Chamber 55 is filled with nitrogen
or an inert gas, such as argon, in order to protect the LEDs 45 and phosphor 44 from
degradation. The nitrogen or inert gas is added through a first valved hole 56, and
the air inside chamber 55 is expelled through a second valved hole 57. The valved
holes 56-57 are closed after chamber 55 is filled with gas, and chamber 55 is hermetically
sealed. The wires 58 that provide power to the LEDs 45 pass through holes in the sides
of base 48. The wire holes include an expanded portion containing a grommet 59 through
which the wires 58 pass. An epoxy adhesive 60 seals the small spaces between grommet
59 and the hole as well as between grommet 59 and the wires 58.
[0030] Before installation of LED bulb 47 on heat sink 27, the thermal grease and thermal
pad 49 create a seal that prevents the inert gas from escaping chamber 55 around mounting
platform 43. The thermal pad 49 and the epoxy adhesive 60 around grommets 59 are used
to create the hermetic seal of chamber 55. The hermetic seal, however, may deteriorate
over time. Over the long operational lifetime of LED bulb 47, the inert gas may escape
chamber 55 by passing around mounting platform 43 and out from under thermal pad 49.
Thus, gasket 50 is used to create a lasting seal between outside surface 53 of base
48 and bottom surface 26 of heat sink 27. Although over time the inert gas may escape
past mounting platform 43, the inert gas does not escape between outside surface 53
and bottom surface 26 beyond the seal created by gasket 50. Gasket 50 is disposed
in a groove 61 in outside surface 53 of base 48. Gasket 50 is pressed into the corners
of groove 61 to create tight seal as LED bulb 47 is bolted onto heat sink 27 and outside
surface 53 and bottom surface 26 are screwed together.
[0031] As LED bulb 47 is installed on heat sink 27, base 48 is bolted straight to the heat
sink without rotating outside surface 53 of base 48 over bottom surface 26 of heat
sink 27. Rotating LED bulb 47 while pressing outside surface 53 onto bottom surface
26 would twist thermal pad 49 and dislodge the seal formed around mounting platform
43 and thermal pad 49 that prevents the inert gas from escaping chamber 55. Thus,
the non-twisting method of attaching LED bulb 47 to heat sink 27 allows a large thermal
pad that can transfer over 100 Watts of heat energy to remain in place as LED bulb
47 is installed. Twist-on methods of attaching LED bulbs currently do not accommodate
thermal pads between the LEDs and the external heat sink that can transfer a large
amount of energy, for example, over 30 Watts.
[0032] FIG. 6 also shows that LED bulb 47 includes a reflector 62 that disburses the light
generated by the LEDs 45 and phosphor 44 over a wider area on the ground below street
lamp 20.
[0033] FIG. 7 is a more detailed cross sectional view of LED bulb 47 of FIG. 6. FIG. 7 shows
how thermal pad 49 completely covers mounting platform 43 and a portion of the outside
surface 53 of base 48. FIG. 7 also shows how epoxy adhesive 60 seals the wire holes
around grommet 59.
[0034] FIG. 8 is a perspective view of outside surface 53 of base 48. Thermal pad 49 has
been removed from the drawing of FIG. 8 to reveal mounting platform 43 that has been
snapped down over the four columns 52 that extend upwards from protrusions in base
48 into holes in mounting platform 43. FIG. 8 shows the shallow indentation 63 in
outside surface 53 that is approximately the same area and depth as the area and thickness
of thermal pad 49.
[0035] FIG. 9 is a perspective view of the opposite side of base 48 as that shown in FIG.
8. FIG. 9 shows mounting platform 43 that has been snapped into the four columns 52
that extend from protrusions in base 48. The layer of phosphor 44 within the round
containing ring on mounting platform 43 covers the LED dice 45. With bulb 51 removed
from the drawing of FIG. 9, a ringed wall 64 of base 48 is visible to which bulb 51
attaches.
[0036] FIG. 10 is a flowchart illustrating steps 65-70 of a method of making a replaceable
LED light bulb for a street lamp. The LED light bulb can be replaced independently
of the associated heat sink that remains attached to the street lamp.
[0037] In a first step 65, mounting platform 43 is attached to base 48 of LED bulb 47. At
least one LED die is attached to mounting platform 43 before the platform is attached
to the base of LED bulb 47. Mounting platform 43 is attached to base 48 by snapping
the platform into support columns 52 that extend from base 48. Mounting platform 43
is attached to base 48 from outside surface 53 and covers a rectangular opening in
base 48.
[0038] In step 66, mounting platform 43 is completely covered from outside surface 53 (opposite
the LED) by thermal pad 49. Thermal pad 49 also covers a portion of the outside surface
that frames mounting platform 43. An adhesive glues the edges of thermal pad 49 to
outside surface 53. In addition, thermal grease is used to attach thermal pad 49 to
mounting platform 43 and to outside surface 53.
[0039] In step 67, gasket 50 is inserted into groove 61 in outside surface 53 of base 48.
Upon installation, gasket 50 is used to create a tight seal between outside surface
53 of LED bulb 47 and bottom surface 26 of heat sink 27, which is attached to street
lamp 20.
[0040] In step 68, bulb 51 is attached to ringed wall 64 of base 48 opposite outside surface
53. Attaching bulb 51 forms chamber 55 between base 48, mounting platform 43 and bulb
51.
[0041] In step 69, chamber 55 is filled with an inert gas, such as argon. The inert gas
is added to chamber 55 through first valved hole 56, and the air inside chamber 55
is expelled through second valved hole 57. After about five minutes of pumping the
inert gas into chamber 55, nearly all of the ambient air in the chamber has been expelled,
and the chamber contains more than 99% inert gas. Chamber 55 is then hermetically
sealed.
[0042] In step 70, base 48 of LED bulb 47 is removably attached to double-plated heat sink
27 such that gasket 50 forms a boundary between outside surface 53 of base 48 and
bottom surface 26 of heat sink 27 through which none of the inert gas from chamber
55 that passes from chamber 55 around mounting platform 43 may escape beyond the boundary.
[0043] Although certain specific embodiments are described above for instructional purposes,
the teachings of this patent document have general applicability and are not limited
to the specific embodiments described above. Accordingly, various modifications, adaptations,
and combinations of various features of the described embodiments can be practiced
without departing from the scope of the invention as set forth in the claims.
1. An apparatus, comprising:
a first fin structure (31) with a first number of parallel oriented larger fins (33)
integrally formed with a first base (34), wherein the first base has a first bottom
surface (26) opposite the larger fins;
a second fin structure (32) with a second number of parallel oriented smaller fins
(35) integrally formed with a second base (36), wherein the second base has a second
bottom surface (37) opposite the smaller fins, wherein the second bottom surface contacts
the larger fins, wherein the larger fins are oriented parallel to the smaller fins,
and wherein ducts (38) are formed between the larger fins, the second bottom surface
and the first base; a mounting platform (43) attached to the first bottom surface;
and a light emitting diode (LED) (45) attached to the mounting platform;
characterized in that
the larger fins are more than twice as tall as the smaller fins, there are more than
twice as many smaller fins disposed across the second base as there are larger fins
disposed across the first base per unit distance perpendicular to the smaller fins,
a first end of each duct is blocked by an end wall (39), and that an intake hole (30)
passes through the first base into each duct at the first end of each duct.
2. The apparatus of claim 1, further comprising:
a bulb (28, 51) attached to the first bottom surface, wherein the mounting platform
and the LED are enclosed by the bulb and the first bottom surface.
3. The apparatus of claim 1, wherein an enclosure between the bulb and the first bottom
surface is hermetically sealed.
4. The apparatus of claim 1, wherein the mounting platform is attached to the first bottom
surface using thermal grease.
5. The apparatus of claim 1, wherein the second fin structure is made of extruded aluminum.
6. The apparatus of claim 1, wherein the first base is thicker than the second base.
7. The apparatus of claim 1, further comprising:
a heat sink light source (21) including:
the first fin structure, the second fin structure, the mounting platform, and the
light emitting diode (LED); and
a shell of a street lamp (20), wherein the heat sink light source (21) is attached
to the shell and is disposed below the shell.
8. The apparatus of claim 7, wherein the heat sink light source is externally mounted
to the shell by spacers (25) attached to the second fin structure.
9. A method of manufacturing, comprising:
forming a first fin structure (31) with a first number of parallel oriented larger
fins (33) integrally formed with a first base (34), wherein the first base has a first
bottom surface (26) opposite the larger fins;
forming a second fin structure (32) with a second number of parallel oriented smaller
fins (35) integrally formed with a second base (36), wherein the second base has a
second bottom surface (37) opposite the smaller fins, wherein
the second bottom surface contacts the larger fins, wherein the larger fins are oriented
parallel to the smaller fins, wherein the larger fins are more than twice as tall
as the smaller fins, wherein there are more than twice as many smaller fins disposed
across the second base as there are larger fins disposed across the first base per
unit distance perpendicular to the smaller fins, wherein ducts (38) are formed between
the larger fins, the second bottom surface and the first base, wherein a first end
of each duct is blocked by an end wall (39), and wherein an intake hole (30) passes
through the first base into each duct at the first end of each duct;
attaching a mounting platform to the first bottom surface; and
attaching a light emitting diode (LED) to the mounting platform.
1. Eine Vorrichtung, die Folgendes aufweist:
eine erste Finnenstruktur (31) mit einer ersten Anzahl parallel ausgerichteter größerer
Finnen (33), die integral mit einer ersten Basis (34) ausgebildet sind, wobei die
erste Basis eine erste Bodenfläche (26) gegenüber den größeren Finnen hat;
eine zweite Finnenstruktur (32) mit einer zweiten Anzahl parallel ausgerichteter kleinerer
Finnen (35), die integral mit einer zweiten Basis (36) ausgebildet sind, wobei die
zweite Basis eine zweite Bodenfläche (37) gegenüber den kleineren Finnen hat, wobei
die zweite Bodenfläche die größeren Finnen kontaktiert, wobei die größeren Finnen
parallel zu den kleineren Finnen ausgerichtet sind, und wobei Durchgänge bzw. Schächte
(38) zwischen den größeren Finnen, der zweiten Bodenfläche und der ersten Basis gebildet
sind;
eine Befestigungsplattform (43), die an der ersten Bodenfläche angebracht ist; und
eine Licht emittierende Diode (LED) (45), die an der Befestigungsplattform angebracht
ist;
dadurch gekennzeichnet, dass die größeren Finnen mehr als doppelt so hoch sind wie die kleineren Finnen, dass
es mehr als doppelt so viele kleinere Finnen gibt, die über die zweite Basis hinweg
angeordnet sind, als es größere Finnen gibt, die über die ersten Basis angeordnet
sind, und zwar pro Streckeneinheit quer zu den kleineren Finnen,
wobei ein erstes Ende jedes Schachtes durch eine Endwand (39) blockiert ist, und dass
ein Aufnahmeloch (30) durch die erste Basis in jeden Schacht am ersten Ende jedes
Schachtes hindurch geht.
2. Vorrichtung nach Anspruch 1, die weiter Folgendes aufweist:
einen Glaskolben bzw. Kolben (28, 51), der an der ersten Bodenfläche angebracht ist,
wobei die Befestigungsplattform und die LED von dem Kolben und der ersten Bodenfläche
umschlossen sind.
3. Vorrichtung nach Anspruch 1, wobei ein umschlossener Raum bzw. ein Einschluss zwischen
dem Kolben und der ersten Bodenfläche hermetisch abgedichtet ist.
4. Vorrichtung nach Anspruch 1, wobei die Befestigungsplattform an der ersten Bodenfläche
unter Verwendung von Wärmeleitpaste angebracht ist.
5. Vorrichtung nach Anspruch 1, wobei die zweite Finnenstruktur aus extrudiertem Aluminium
hergestellt ist.
6. Vorrichtung nach Anspruch 1, wobei die erste Basis dicker ist als die zweite Basis.
7. Vorrichtung nach Anspruch 1, die weiter Folgendes aufweist:
eine Wärmesenke- bzw. Kühlkörperlichtquelle (21), die Folgendes beinhaltet:
die erste Finnenstruktur, die zweite Finnenstruktur, die Befestigungsplattform und
die Licht emittierende Diode (LED); und
ein Gehäuse bzw. eine Umhüllung einer Straßenlampe (20), wobei die Kühlkörperlichtquelle
(21) an der Umhüllung angebracht ist und unter der Umhüllung angeordnet ist.
8. Vorrichtung nach Anspruch 7, wobei die Kühlkörperlichtquelle extern an der Umhüllung
durch Beabstandungselemente (25) befestigt ist, die an der zweiten Finnenstruktur
angebracht sind.
9. Ein Herstellungsverfahren, das Folgendes aufweist:
Bilden einer ersten Finnenstruktur (31) mit einer ersten Anzahl von parallel ausgerichteten
größeren Finnen (33), die integral mit einer ersten Basis (34) ausgebildet sind, wobei
die erste Basis eine erste Bodenfläche (26) hat, die gegenüber den größeren Finnen
liegt;
Bilden einer zweiten Finnenstruktur (32) mit einer zweiten Anzahl von parallel ausgerichteten
kleineren Finnen (35), die integral mit einer zweiten Basis (36) ausgebildet sind,
wobei die zweite Basis eine zweite Bodenfläche (37) gegenüber den kleineren Finnen
hat, wobei die zweite Bodenfläche die größeren Finnen kontaktiert, wobei die größeren
Finnen parallel zu den kleineren Finnen ausgerichtet sind, wobei die größeren Finnen
mehr als doppelt so hoch wie die kleineren Finnen sind, wobei es mehr als doppelt
so viele kleinere Finnen gibt, die über die zweite Basis angeordnet sind als es größere
Finnen gibt, die über die erste Basis angeordnet sind, und zwar pro Streckeneinheit
quer zu den kleineren Finnen, wobei die Schächte (38) zwischen den größeren Finnen,
der zweiten Bodenfläche und der ersten Basis gebildet werden, und wobei ein erstes
Ende jedes Schachtes durch eine Endwand (39) blockiert ist und wobei ein Aufnahmeloch
(30) durch die erste Basis in jeden Schacht am ersten Ende jedes Schachts hindurch
geht;
Anbringen einer Befestigungsplattform an der ersten Bodenfläche; und
Anbringen einer Licht emittierenden Diode (LED) an der Befestigungsplattform.
1. Appareil comprenant :
une première structure à ailettes (31) munie d'un premier nombre d'ailettes dites
plus grandes orientées en parallèle (33) et formées d'une seule pièce avec une première
base (34), la première base ayant une première surface inférieure (26) opposée aux
ailettes plus grandes ;
une deuxième structure à ailettes (32) munie d'un deuxième nombre d'ailettes dites
plus petites orientées en parallèle (35) et formées d'une seule pièce avec une deuxième
base (36), la deuxième base ayant une deuxième surface inférieure (37) opposée aux
ailettes plus petites, dans lequel la deuxième surface inférieure contacte les ailettes
plus grandes, dans lequel les ailettes plus grandes sont orientées en parallèle avec
les ailettes plus petites, et dans lequel des conduits (38) sont formés entre les
ailettes plus grandes, la deuxième surface inférieure et la première base ;
une plate-forme de montage (43) fixée à la première surface inférieure ; et une diode
électroluminescente (45) (LED) fixée à la plate-forme de montage ;
caractérisé en ce que les ailettes plus grandes sont plus que deux fois plus grandes que les ailettes plus
petites, en ce qu'il y a plus que deux fois plus d'ailettes plus petites disposées en travers de la
deuxième base qu'il y a d'ailettes plus grandes disposées en travers de la première
base par unité de distance perpendiculairement aux ailettes plus petites,
la première extrémité de chaque conduit est bloquée par une paroi d'extrémité (39),
et en ce qu'un trou d'admission (30) passe à travers la première base dans chaque conduit au niveau
de la première extrémité de chaque conduit.
2. Appareil selon la revendication 1, comprenant en outre :
une ampoule (28, 51) fixée à la première surface inférieure, la plate-forme de montage
et la LED étant enfermées par l'ampoule et la première surface inférieure.
3. Appareil selon la revendication 1, dans lequel une enceinte entre l'ampoule et la
première surface inférieure est fermée de façon hermétique.
4. Appareil selon la revendication 1, dans lequel la plate-forme de montage est fixée
à la première surface inférieure en utilisant de la graisse thermique.
5. Appareil selon la revendication 1, dans lequel la deuxième structure à ailettes est
en aluminium extrudé.
6. Appareil selon la revendication 1, dans lequel la première base est plus épaisse que
la deuxième base.
7. Appareil selon la revendication 1, comprenant en outre :
une source lumineuse à dissipateur thermique (21) comprenant :
la première structure à ailettes, la deuxième structure à ailettes, la plate-forme
de montage, et la diode électroluminescente (LED) ; et
une coque de lampadaire urbain (20), dans laquelle la source lumineuse à dissipateur
thermique (21) est fixée à la coque et est disposée en dessous de la coque.
8. Appareil selon la revendication 7, dans lequel la source lumineuse à dissipateur thermique
est montée à l'extérieur de la coque par des entretoises (25) fixées à la deuxième
structure à ailettes.
9. Procédé de fabrication comprenant :
former une première structure à ailettes (31) munie d'un premier nombre d'ailettes
dites plus grandes orientées en parallèle (33) et formées d'une seule pièce avec une
première base (34), la première base ayant une première surface inférieure (26) opposée
aux ailettes plus grandes ;
former une deuxième structure à ailettes (32) munie d'un deuxième nombre d'ailettes
dites plus petites orientées en parallèle (35) et formées d'une seule pièce avec une
deuxième base (36), la deuxième base ayant une deuxième surface inférieure (37) opposée
aux ailettes plus petites, dans lequel la deuxième surface inférieure contacte les
ailettes plus grandes, dans lequel les ailettes plus grandes sont orientées en parallèle
avec les ailettes plus petites, dans lequel les ailettes plus grandes sont plus que
deux fois plus grandes que les ailettes plus petites, dans lequel il y a plus que
deux fois plus d'ailettes plus petites disposées en travers de la deuxième base qu'il
y a d'ailettes plus grandes disposées en travers de la première base par unité de
distance perpendiculairement aux ailettes plus petites, dans lequel des conduits (38)
sont formés entre les ailettes plus grandes, la deuxième surface inférieure et la
première base, dans lequel une première extrémité de chaque conduit est bloquée par
une paroi d'extrémité (39), et dans lequel un trou d'admission (30) passe à travers
la première base dans chaque conduit au niveau de la première extrémité de chaque
conduit ;
fixer une plate-forme de montage à la première surface inférieure ; et
fixer une diode électroluminescente (LED) à la plate-forme de montage.