Abstract:
A light emitting diode (LED) light engine is provided. According to one embodiment of the invention, the LED light engine includes a housing; an LED mounting board secured within the housing, the LED mounting board including one or more LED electrically connected to the LED mounting board, the LED mounting board configured to receive power from a power source to power the one or more LED; and a heat bridge conductively coupling the LED mounting board to the housing, wherein the heat bridge is configured to conduct heat from the LED mounting board to the housing, wherein the housing is configured to dissipate heat. The heat bridge may take one of several different configurations. A lighting assembly may be provided for securely mounting one or more LED light engines.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a light emitting diode (LED) lighting devices, and more particularly, to a LED light engine with multi-path heat dissipation. 
       BACKGROUND OF THE INVENTION 
       [0002]    Light emitting diode (LED) technology is currently one of the most innovative and fastest growing in the lighting industry. While LED have been in use for decades for indicator and signaling purposes, technology developments and improvements have allowed for a broader use. The use of LED in lighting applications has grown especially rapidly in recent years. 
         [0003]    The use of LED in lighting applications is attractive for a number of reasons, including the ability to provide higher levels of illumination, a longer life cycle, minimum maintenance requirements, energy efficient, and flexibility in terms of coloring and beam control. 
         [0004]    LED generate a generally high level of heat during operation. It is also known that changes in the temperature of the p-n junction of an LED (“the junction temperature”) can affect the performance of the LED. Efforts to control the temperature of LED have been made. However, previous efforts have failed to address certain applications or configurations. Using LED in outdoor lighting has proven to be particularly problematic since, for example, it is useful for the lighting assembly to be protected from water and dust. However, any kind of sealing of the lighting assembly may result in limited air ventilation, thereby limiting heat dissipation and increasing the operating temperature of the lighting assembly. Poor heat dissipation may therefore result in a short lifetime of the lighting assembly and poor luminary efficiency. 
         [0005]    Accordingly, there is a need for a lighting assembly and an LED light engine with multi-path heat dissipation that addresses these and other shortcomings of LED lighting. 
       SUMMARY OF THE INVENTION 
       [0006]    According to one embodiment of the present invention, a light emitting diode (LED) light engine is disclosed. The LED engine includes a housing; an LED mounting board secured within the housing, the LED mounting board including one or more LED electrically connected to the LED mounting board, the LED mounting board configured to receive power from a power source to power the one or more LED; and a heat bridge conductively coupling the LED mounting board to the housing, wherein the heat bridge is configured to conduct heat from the LED mounting board to the housing, wherein the housing is configured to dissipate heat. 
         [0007]    According to another embodiment of the present invention, an LED lighting assembly is disclosed. The LED lighting assembly includes a lighting assembly housing; a mounting frame secured within the lighting assembly housing; and multiple LED light engines movably secured to the mounting frame, each of the multiple LED light engines including a housing; an LED mounting board secured within the housing, the LED mounting board including one or more LED electrically connected to the LED mounting board, the LED mounting board configured to receive power from a power source to power the one or more LED; and a heat bridge conductively coupling the LED mounting board to the housing, wherein the heat bridge is configured to conduct heat from the LED mounting board to the housing, wherein the housing is configured to dissipate heat. 
         [0008]    Still other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein embodiments of the invention are described by way of illustration. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modifications in various respects, all without departing from the spirit and the scope of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a front perspective view of a lighting assembly  100 , in accordance with an embodiment of the present invention. 
           [0010]      FIG. 2  is an exploded view of the lighting assembly shown in  FIG. 1 , in accordance with an embodiment of the present invention. 
           [0011]      FIG. 3  is an exploded view of the mounting frame shown in  FIG. 2 , in accordance with an embodiment of the present invention. 
           [0012]      FIG. 4  is a top perspective view of a light engine, in accordance with a first embodiment of the present invention. 
           [0013]      FIG. 5  is an exploded view of a light engine, in accordance with an embodiment of the present invention. 
           [0014]      FIG. 6  is a top view of the light engine shown in  FIG. 4 , in accordance with an embodiment of the present invention. 
           [0015]      FIG. 7  is a side cross sectional view of the light engine shown in  FIG. 4 , in accordance with an embodiment of the present invention. 
           [0016]      FIG. 8  is bottom view of the light engine shown in  FIG. 4 , in accordance with an embodiment of the present invention. 
           [0017]      FIG. 9  is a side view of the light engine shown in  FIG. 4 , in accordance with a third embodiment of the present invention. 
           [0018]      FIG. 10  is an end cross sectional view of the light engine shown in  FIG. 4 , in accordance with an embodiment of the present invention. 
           [0019]      FIG. 11  is a top view of a light engine, in accordance with a second embodiment of the present invention. 
           [0020]      FIG. 12  is bottom view of the light engine shown in  FIG. 11 , in accordance with an embodiment of the present invention. 
           [0021]      FIG. 13  is a side view of the light engine shown in  FIG. 11 , in accordance with an embodiment of the present invention. 
           [0022]      FIG. 14  is an end cross sectional view of the light engine shown in  FIG. 11 , in accordance with an embodiment of the present invention. 
           [0023]      FIG. 15  is a side cross sectional view of the light engine shown in  FIG. 11 , in accordance with an embodiment of the present invention. 
           [0024]      FIG. 16  is an end cross sectional view of a light engine, in accordance with a third embodiment of the present invention. 
           [0025]      FIG. 17  is a side cross sectional view of the light engine shown in  FIG. 16 , in accordance with an embodiment of the present invention. 
           [0026]      FIG. 18  is an end cross sectional view of a light engine, in accordance with a fourth embodiment of the present invention. 
           [0027]      FIG. 19  is a side cross sectional view of the light engine shown in  FIG. 18 , in accordance with an embodiment of the present invention. 
           [0028]      FIG. 20  is an end cross sectional view of a light engine, in accordance with a fifth embodiment of the present invention. 
           [0029]      FIG. 21  is a side cross sectional view of the light engine shown in  FIG. 20 , in accordance with an embodiment of the present invention. 
           [0030]      FIG. 22  is an end cross sectional view of a light engine, in accordance with a sixth embodiment of the present invention. 
           [0031]      FIG. 23  is a side cross sectional view of the light engine shown in  FIG. 22 , in accordance with an embodiment of the present invention. 
           [0032]      FIG. 24  is an end cross sectional view of a light engine, in accordance with a seventh embodiment of the present invention. 
           [0033]      FIG. 25  is a side cross sectional view of the light engine shown in  FIG. 24 , in accordance with an embodiment of the present invention. 
           [0034]      FIG. 26  is an end cross sectional view of a light engine, in accordance with an eighth embodiment of the present invention. 
           [0035]      FIG. 27  is a side cross sectional view of the light engine shown in  FIG. 26 , in accordance with an embodiment of the present invention. 
           [0036]      FIG. 28  is an end cross sectional view of a light engine, in accordance with a ninth embodiment of the present invention. 
           [0037]      FIG. 29  is a side cross sectional view of the light engine shown in  FIG. 28 , in accordance with an embodiment of the present invention. 
           [0038]      FIG. 30  is an end cross sectional view of a light engine, in accordance with a tenth embodiment of the present invention. 
           [0039]      FIG. 31  is a side cross sectional view of the light engine shown in  FIG. 30 , in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0040]    In the following description, reference is made to the accompanying drawings where, by way of illustration, specific embodiments of the invention are shown. It is to be understood that other embodiments may be used as structural and other changes may be made without departing from the scope of the present invention. Also, the various embodiments and aspects from each of the various embodiments may be used in any suitable combinations. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive. 
         [0041]    Generally, embodiments of the present invention are directed to an LED light engine with multi-path heat dissipation and a lighting assembly that provides for thermal management and heat dissipation. Embodiments of the present invention may be used for outdoor lighting, such as a streetlamp, floodlight, or other outdoor light. Embodiments of the present invention may also be used for indoor lighting or any desired lighting devices. The lighting assembly includes multiple LED light engines for generating light. 
         [0042]    Referring now to the figures,  FIG. 1  is a front perspective view of a lighting assembly  100 , in accordance with an embodiment of the present invention. The lighting assembly  100  includes a top cover  102  and a bottom cover  204  to protect the internal structure of the lighting assembly  100 . The holes on top cover  102  of various sizes may facilitate the air flow into and through the inside of the lighting assembly, which benefits heat dissipation. 
         [0043]      FIG. 2  is an exploded view of the lighting assembly shown in  FIG. 1 , in accordance with an embodiment of the present invention. The lighting assembly  100  includes the top cover  102 , the bottom cover  204  and a mounting frame  206 . The mounting frame  206  includes multiple LED light engines  208 . While the illustrated embodiment includes five light engines  208 , embodiments of the present invention may include any number of light engines  208 . The shape of top cover  102  and bottom cover  204  is not limited to the one shown in the illustrated embodiment. For example, the shape can be curved down or up and occupy any suitable shape to accommodate the LED light engines. The top cover  102  and the bottom cover  204  are joined around the mounting frame  206 , forming the lighting assembly  100  with the light engines  208  enclosed within the top cover  102  and the bottom cover  204 . 
         [0044]      FIG. 3  is an exploded view of the mounting frame shown in  FIG. 2 , in accordance with an embodiment of the present invention. The light engines  208  are shown removed from the mounting frame  206 . Each of the light engines  208  includes a set of mounting pins  302 , one at each end of the light engines  208 . Mounting slots  304  are defined in the mounting frame  206 . The position and size of the mounting slots  304  are configured to receive the mounting pins  302  of each of the light engines  208 . Each of the light engines  208  may be pivotable within the mounting frame  206  and individually adjustable in order to direct light in desired directions. 
         [0045]    Referring now to  FIGS. 4 to 10 , a light engine is illustrated and described, in accordance with a first embodiment of the present invention.  FIG. 4  is a top perspective view of the light engine  208 . Each of the light engines  208  include a housing  402 , side panels  404 , a top panel  406 , and a lower panel  408 . In the illustrated embodiment, the lower panel  408  is a glass panel to permit the light from the LEDs to be admitted from the light engine  208 . The side panels  404  and the top panel  406  include multiple heat dissipation fins  410 . 
         [0046]    Referring now to  FIG. 5 , an exploded view of a light engine is shown and described. A mounting board  412  is provided within the housing  402  with multiple LED at fixed to the mounting board  412 . An optical reflector  414  may also be provided proximate to or abutting the mounting board  412  to modify the light output distribution of the LEDs. A heat bridge  416  maybe provided within the housing  402  to act as bridge between the mounting board  412  to the top panel  406 . The heat bridge  416  maybe configured to transfer heat from the mounting board  412  to the back panel  406  for increase heat dissipation. Panel frames  418  maybe provided help secure the front panel  408  to housing  402 . The internal structure shown in  FIG. 5  is one example embodiment according to the present invention. Specifically, the heat bridge  416  and internal components may occupy other configurations different from that shown in  FIG. 5 . 
         [0047]      FIG. 6  is a top view of the light engine shown in  FIG. 4 , in accordance with an embodiment of the present invention. In  FIG. 6 , the heat dissipation fins  410  of the back panel  406  and the heat dissipation fins  410  of the side panels  404  may be seen. The mounting pins  302  are also shown in  FIG. 6 . 
         [0048]      FIG. 7  is a side cross sectional view of the light engine shown in  FIG. 4 , in accordance with a second embodiment of the present invention. Different from the embodiment illustrated and described with reference to  FIG. 5 , the heat bridge includes heat conduction pipes  702  in  FIG. 7 . A first end of the heat conduction pipes  702  is connected to the mounting board  412 , and a second end of the heat conduction pipes  702  is connected to one of the panels, either the side panels  404  or the top Panel  406 . Each of the heat conduction pipes  702  serves to transfer heat from the mounting board  412  to the one of the panels. 
         [0049]      FIG. 8  is bottom view of the light engine shown in  FIG. 4  and  FIG. 9  is a side view of the light engine shown in  FIG. 4 , in accordance with an embodiment of the present invention. The lower panel  408 , the heat dissipation fins  41   0 , and the mounting pins  402  may be seen in  FIG. 8 . 
         [0050]      FIG. 10  is an end cross sectional view of the light engine shown in  FIG. 7 , in accordance with an embodiment of the present invention. The side heat conduction pipes  702  may be clearly seen joining the mounting board  412  to each of the side panels  404 . A top heat conduction pipe  1002  joins the mounting board  412  to the top panel  406 . LED  1004  are coupled to the mounting board  412 , each of the LED positioned within the optical reflector  414 . 
         [0051]    In the figures, unless otherwise identified, like elements of the light engines shown with reference to  FIGS. 11 to 31  are considered to be similar to those illustrated and described with reference to the first embodiment of the light engine. Therefore, for the purpose of clarity, not all elements of the additional embodiments of the light engine are referenced in  FIGS. 11 to 31 . 
         [0052]    Referring to  FIGS. 11 to 15 , a second embodiment of a light engine is illustrated and described.  FIG. 11  is a top view of the second embodiment of the light engine  1108 , in accordance with an embodiment of the present invention. In the second embodiment of the light engine, the top panel  1106  is a heat sink, without heat dissipation fins.  FIG. 12  is bottom view of the light engine shown in  FIG. 11 ,  FIG. 13  is a side view of the light engine shown in  FIG. 11 ,  FIG. 14  is an end cross sectional view of the light engine shown in  FIG. 11 , and  FIG. 15  is a side cross sectional view of the light engine shown in  FIG. 11 , in accordance with a second embodiment of the present invention. The remaining components of the second embodiment of the light engine  1108  are similar to those illustrated and described with reference to  FIGS. 4 to 10 . 
         [0053]    Referring to  FIGS. 16 and 17 , a third embodiment of the light engine is illustrated and described.  FIG. 16  is an end cross sectional view of the third embodiment of the light engine  1608  and  FIG. 17  is a side cross sectional view of the light engine shown in  FIG. 16 , in accordance with an embodiment of the present invention. In the third embodiment of a light engine  1608  shown in  FIG. 16 , the heat bridge  416  is comprised of multiple internal fins  1616 . The multiple internal fins  1616  join the mounting board  412  to the top panel  406 . The remaining components of the light engines  1608  are similar to those illustrated and described with reference to  FIGS. 4 to 10 . 
         [0054]    Referring to  FIGS. 18 and 19 , a fourth embodiment of a light engine is illustrated and described.  FIG. 18  is an end cross sectional view of the fourth embodiment of the light engine and  FIG. 19  is a side cross sectional view of the light engine shown in  FIG. 18 , in accordance with an embodiment of the present invention. In the fourth embodiment of the light engine, multiple internal fins  1816  join the mounting board  412  to the top panel  406  as seen in  FIG. 19 , the multiple internal fins  1816  are arranged in groups, each group of internal fins  1816  positioned proximate to one of the multiple LEDs  1004 . In the illustrated embodiment, each of the groups of internal fins  1816  includes three heat dissipation fins. However, any number of fins may be used. The remaining components of the light engines  1808  are similar to those illustrated and described with reference to  FIGS. 4 to 10 . 
         [0055]    Referring to  FIGS. 20 and 21 , a fifth embodiment of a light engine is illustrated and described.  FIG. 20  is an end cross sectional view of a fifth embodiment of the light engine and  FIG. 21  is a side cross sectional view of the light engine shown in  FIG. 20 , in accordance with an embodiment of the present invention. In the fifth embodiment of the light engine  2008 , internal cylinders  2016  join the mounting board  412  to the top panel  406 . The internal cylinders  2016  serve as a heat bridge to transfer heat from the mounting board  412  to the top panel  406 . As seen in  FIG. 21 , each of the internal cylinders  2016  is position such that it is generally aligned with one of the multiple LED  1004 . The remaining components of the light engines  2008  are similar to those illustrated and described with reference to  FIGS. 4 to 10 . 
         [0056]    Referring to  FIGS. 22 and 23 , a sixth embodiment of a light engine is illustrated and described.  FIG. 22  is an end cross sectional view of a sixth embodiment of the light engine  2208  and  FIG. 23  is a side cross sectional view of the light engine  2208  shown in  FIG. 22 , in accordance with an embodiment of the present invention. In the sixth embodiment of light engine illustrated in  FIG. 22 , heat conduction pipes  702  join the mounting board  412  to the side panels  404 . In the illustrated embodiment shown in  FIGS. 22 and 23 , no heat bridge is connected to the top panel  406 , thereby resulting in a transfer of greater amount of heat through the heat conduction pipe  702  to the side panels  404 . The remaining components of the light engines  2208  are similar to those illustrated and described with reference to  FIGS. 4 to 10 . 
         [0057]    Referring to  FIGS. 24 and 25 , a seventh embodiment of a light engine is illustrated and described.  FIG. 24  is an end cross sectional view of a seventh embodiment of the light engine  2408  and  FIG. 25  is a side cross sectional view of the light engine shown in  FIG. 24 , in accordance with an embodiment of the present invention. In the seventh embodiments of the light engine  2408 , an internal metal block  2416  is used as a heat bridge to join the mounting board  412  to the top panel  406 . The internal metal block  2416  maybe made from any suitable metal or metal alloy material that is suitable for transferring heat from the mounting board  412  to the top panel  406 . The remaining components of the light engines  2408  are similar to those illustrated and described with reference to  FIGS. 4 to 10 . 
         [0058]    Referring to  FIGS. 26 and 27 , an eighth embodiment of a light engine is illustrated and described.  FIG. 26  is an end cross sectional view of an eighth embodiment of the light engine  2608  and  FIG. 27  is a side cross sectional view of the light engine shown in  FIG. 26 , in accordance with an embodiment of the present invention. In the eighth embodiment of the light engine  2608 , a heat conduction board  2616  is used as a heat bridge to join the mounting board  412  to the top panel  406 . The heat conduction board  2616  is curved or bent such that a part of heat conduction board  2616  joins the mounting board  412  and a part of the heat conduction board  2616  join the top panel  406 . The heat conduction board  2616  may be made from any metal or metal alloy material that sufficiently transfers heat. The remaining components of the light engines  2608  are similar to those illustrated and described with reference to  FIGS. 4 to 10 . 
         [0059]    Referring to  FIGS. 28 and 29 , a ninth embodiment of a light engine is illustrated and described.  FIG. 28  is an end cross sectional view of a ninth embodiment of the light engine  2808  and  FIG. 29  is a side cross sectional view of the light engine shown in  FIG. 28 , in accordance with an embodiment of the present invention. In the ninth embodiment of the light engine, a combination of internal cylinders  2816  and a heat conduction board  2818  are both used as a heat bridge to join mounting board  412  and the top panel  406 . Heat conduction pipes  702  are also included, joining the mounting board  412  to the side panels  404 . The remaining components of the light engines  2808  are similar to those illustrated and described with reference to  FIGS. 4 to 10 . 
         [0060]    Referring to  FIGS. 30 and 31 , a tenth embodiment of a light engine is illustrated and described.  FIG. 30  is an end cross sectional view of a tenth embodiment of the light engine  3008  and  FIG. 31  is a side cross sectional view of the light engine shown in  FIG. 30 , in accordance with an embodiment of the present invention. In the tenth embodiment of the light engine shown in  FIGS. 30 and 31 , a combination of internal fins  3016  and a heat conduction board  3018  are used as a heat bridge to join the mounting board  412  to the top panel  406 . Heat conduction pipes  702  are also included, joining the mounting board  412  to the side panels  404 . The remaining components of the light engines  3008  are similar to those illustrated and described with reference to  FIGS. 4 to 10 . 
         [0061]    In the respective embodiments, the various dissipation pins, the heat conduction pipes, the internal cylinders, the metal block, and the heat conduction board may each be made from any suitable material that dissipates heat. For example, the components may be made from metal or metal alloy material including, for example, aluminum or copper. 
         [0062]    While the invention has been particularly shown and described with reference to the illustrated embodiments, those skilled in the art will understand that changes in form and detail may be made without departing from the spirit and scope of the invention. For example, while certain types of materials have been described, other suitable material may also be used. Also, while the specific shape of housings and dissipation plates is illustrated and described, other shapes and configurations may be used without departing from the scope of the present invention. Also, while a specific number of components, such as LEDs internal cylinder, and heat dissipation fins, are shown in the illustrated embodiment, these components may be provided in different shapes and numbers according to the particular implementation. 
         [0063]    Accordingly, the above description is intended to provide example embodiments of the present invention, and the scope of the present invention is not to be limited by the specific examples provided.