English:
[0001] The present invention pertains to LED lights which generate substantial heat during operation, and more particularly the provision of a method to cool the LED during operation to facilitate longer life to the LED, assure a steady light output during operation, and operation at the least power usage rate.
[0002] Some prior art apparatus have used relatively high-powered LED's to generate a desired high light output to be sufficient for the lighting requirement. Such LED's typically generate so much heat that a heat sink is required. Heretofore, the prior art has not been able to satisfy the requirement of an adequate heat sink or cooling system for a high intensity LED light generation.
[0003] Several attempts to solve the problems described hereinabove have been made in the prior art. For example, published U.S. Patent No. 6,955,444 published June 2, 2005, and issues as a patent on October 18, 2005 for Surgical Headlight by Sushil Gupta, teaches a head mounted lamp assembly with at least two LED's mounted side by side and focused utilizing a rear reflector. Such rear reflector use greatly diminishes the efficiency of the projection of the light generated by the LED, and thus is unsatisfactory for providing a high intensity focused or unfocused light beam of the apparatus of the invention.
[0004] U.S. Patent No. 7, 108,400 entitled Light Source Unit and Projector by inventors Shuhei Yamada and Takeshi Seto teaches the use of a LED light source for lamination of high luminants which includes a cooling system for this system which generates substantial heat This design utilizes two liquid heat source absorbers and is very complex, and further is much more difficult to implement that the cooling system taught by the present invention.
[0005] U.S. Published Patent Application 22005/0243539 teaches a cooled light emitting apparatus comprising a light source including a close packed array of LED's and a cooling system for the LED's. The cooling system is a thermoelectric cooling system in the form of a peltier device connected by a heat spreader to the light source, and a second heat exchange system for removing heat from the peltier device. The heat exchange system utilizes a liquid coolant to cool the peltier device, and the combination of a heat pipe configuration as well. This is far less satisfactory than the single liquid cooling system taught by the invention.
[0008] It is a further object of the invention is to provide a printed circuit board to which the LED is mounted which is between about 1 to 1.5 mm in thickness, and the heat sink layer is preferably made of aluminum, and is between about 2.0 to 2.5 mm in thickness, and that the coolant liquid is preferably water, and the flow rate of water adjacent the heat sink layer is approximately 400 ml per minute.
[0009] A further object of the invention is to utilize the cooling system for the LED whether or not the LED is focused or not, and where the cone of light emitted from the LED is approximately an 80 degree conically shaped beam of light.
[0011] Fig. 1 is a cross-sectional elevation showing the LED in combination with the mounting printed circuit board, and showing the LED in adjacent contact with the heat sink material, which is adjacent the cooling fluid flow to provide the cooling effect of the invention to the LED.
[0012] Fig. 2 is a cross-sectional elevation showing of a focusing lens showing the relationship between the cone of light emission from the LED, and the resulting condensing of that emission into a focused cone of light achieved by the focusing lens; and
[0013] Fig. 3 is a side view in schematic form showing the remotely located cooling and battery powered system assembly.
[0014] For purposes of brevity and clarity, components and elements of the apparatus of this invention will bear the same designation or numbering through the Figures.
[0015] The present invention provides a high intensity LED light which can operate at its best high intensity efficiency because of the combination of a very simplified cooling system to remove heat generated by the operation of the LED, and thus promote longevity of the LED, along with optimum performance thereof.
[0016] Referring first to Fig. 1 of the drawings, 10 indicates generally a LED, which is a high intensity light source that usually operates with an electric draw of at least about 1 amp, and puts out a light intensity of between 700 and 1200 lumens. It is this type of LED that generates heat which can affect the operating characteristics, life, etc. The LED 10 is typically with a polymer outer cover 12, the actual structure of the LED at 14, and a metallic mount 16, which is secured to a printed circuit board 18. The board 18 is directly in contact with a heat sink layer 20, meaning that the bottom surface of the mount 16 is in direct and intimate contact with the heat sink layer 20.
[0017] The cooling of the heat picked up by the layer 20 is achieved by incorporating a fluid flow path 22 having an input side 24 and an exit side 26. Preferably, the fluid utilized is water, and the flow rate on the water is preferably between 300 to 500 ml per minutes. The circuit board 18 is between 1.0 to 1.5 mm, and the heat sink layer is between 2.0 to 2.5 mm in thickness. The openings for the fluid flow paths 24 and 26 are between 1.0 to 1.75 mm in diameter.
[0018] The LED typically produces a conical light pattern of about 40 degrees as shown by the dotted lines 28 showing the 40 degree span. This LED producing the approximately 40 degree pattern can be used for a multiplicity of purposes where brightness and a semi-coherent light is emitted by the LED. It is applicable to general lighting requirements where the light is not focused, as this is shown and will be described in connection with Fig. 2. The semi-coherent light emitted by the LED is in a lanαberton distribution.
[0019] Figure 2 is similar to Figure 1 except that a focus lens has been added at 30. The focus lens 30 can achieve whatever focus is desired with the beam 28 from a specific focal point to an oval or circular shape at the point of focus. The example illustrated in Figure 2 shows the beam 28 has been focused to a 6 degree output from the lens 30, and this is completely flexible to the nature of the end result desired in the emitted light. The 6 degree focused beam happens to be applicable to a surgical headlamp and provides a focal point in conjunction with other LED's in a circle positioned approximately 20 inches from the emission of the light from the lens 30.
[0020] Figure 3 shows a portable power pack and fluid pump indicated generally by 40 which can be used with the LED's of either Figures 1 and/or 2. It should be understood that this is just to depict a means for showing the components for operating the cooling system of Figures 1 and 2, but such system could be a permanent power source and pump with any suitable storage system for the cooling fluid.
[0021] In Figure 3 the pack and pump 30 comprises a LED power supply indicated by dotted lines 42. The power supply is a conventional rechargeable battery typically used for any portable system and is conveniently located for replacement or recharging. The box or assembly 40 also incorporates a coolant reservoir 44 again shown in dotted lines, and the reservoir also contains a coolant pump 46 also indicated by dotted line within the assembly 40. The pump 4 transmits coolant fluid through the coolant tube 48, also indicated by dotted line. There is a quick connect or disconnect unit 50 located between the flexible tubing 52 that is the coolant fluid entering at 24 in Figures 1 and 2.
[0022] Since other modifications and changes vary to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not limited thereto or thereby. Further, the invention is not considered limited to the examples for purposes or disclosure and covers all changes and modifications which do not constitute departures from the true spirit and scope of the invention. What is desired to be protected by letters patent is presented in the appended claims.

中文:
[0001]本发明涉及在运行过程中生成大量热的LED灯,更具体地提供了一种在运行过程中冷却LED的方法,该方法促使LED的寿命更长,确保在运行过程中的稳定光输出,并且以最小功率利用率运行。
[0002]一些现有技术设备使用相对高功率的LED以产生足以满足照明需求的所需高光输出。这种LED典型地生成很多热以至于需要散热装置。迄今为止,现有技术还不能满足对用于高强度LED光生成的合适的散热器或冷却系统的需求。
[0003]现有技术中为解决上述问题已经进行了若干尝试。例如,2005年6月2日公开,2005年10月18日授予专利权的Sushil Gupta的“Surgical Headlight”的公开美国专利No.6,955,444教导了头戴式灯组件,该灯组件具有并排安装并且利用后反射器聚焦的至少两个LED。这种后反射器的使用很大地降低了由LED生成的光的投射效率,并且因此对于提供本发明设备的高强度聚焦或未聚焦光束是不令人满意的。
[0004]发明人Shuhei Yamada和Takeshi Seto的题为“Light SourceUnit and Projector”的美国专利No.7,108,400教导了用于高发光体叠层的LED光源的使用,该LED光源包括用于生成大量热的此系统的冷却系统。此设计利用两个液体热源吸收器并且是非常复杂的,并且此外此设计更加难以应用本发明教导的冷却系统。
[0005]美国公开专利申请22005/0243539教导了包括光源的冷却了的发光设备,该光源包括密集堆积的LED阵列和LED的冷却系统。该冷却系统是以由传热器连接到光源和第二热交换系统的珀尔帖装置的形式的热电冷却系统,所述第二热交换系统用于从珀尔帖装置去除热。该热交换系统利用液体冷却剂来冷却珀尔帖装置以及热管构造的结合。这与本发明教导的单一液体冷却系统相比远不能令人满意。
[0008]本发明的进一步目的是提供一种印刷电路板,LED安装到所述印刷电路板上并且所述印刷电路板的厚度在1mm至1.5mm之间,散热层优选地由铝制成并且厚度在大约2.0mm至2.5mm之间,并且冷却剂液体优选地为水,并且与散热层相邻的水的流速近似为400ml/分钟。
[0009]本发明的进一步目的是利用LED的冷却系统而不管LED是否聚焦,并且LED发出的光圆锥为近似80度的圆锥形状的光束。
[0011]图1是剖面图,该剖面图示出与安装印刷电路板相结合的LED,并示出与散热材料邻近接触的LED,该散热材料与冷却流体流相邻以向LED提供本发明的冷却效果。
[0012]图2是示出聚焦透镜的剖面图,该剖面图示出了从LED的发光圆锥与由聚焦透镜实现的将发射聚集成聚焦光圆锥的结果聚集之间的关系;以及
[0013]图3是以示意性形式示出设置在远处的冷却和电池供电系统组件的侧视图。
[0014]为了简洁和清楚的目的,本发明设备的部件和元件在所有附图中将具有相同的附图标记或标号。
[0015]本发明提供高强度LED灯,因为结合了非常简化的冷却系统以去除由LED的运行所产生的热,所以该高强度LED灯可以以其最佳高强度效率运行,并且由此增进LED的寿命及其最优性能。
[0016]首先参照附图的图1,10总体指代LED,该LED为高强度光源,该光源通常以至少大约1amp的电汲取量(electric draw)运行,并输出700流明至1200流明之间的光强。这种类型的LED产生可影响运行特性和寿命等的热。LED 10典型地具有聚合物外罩12、LED的实际结构14、以及固定到印刷电路板18的金属底座16。板18直接与散热层20接触,这意味着底座16的底表面直接且紧密地与散热层20接触。
[0017]由层20进行的热的冷却通过结合具有进入侧24和退出侧26的流体流径22而实现。优选地,所利用的流体是水,并且水的流速优选地在300至500ml/分钟之间。电路板18的厚度在1.0mm至1.5mm之间,并且散热层的厚度在2.0mm至2.5mm之间。流体流径的开口24和26的直径在1.0mm至1.75mm之间。
[0018]LED典型地产生如示出40度跨度的虚线28所示的大约40度的圆锥光图案。产生近似40度图案的该LED可被用于亮度和部分相干(semi-coherent)光由该LED发出的多重目的。如所示出并将结合图2所述的那样,该LED可适用于光不被聚焦的一般照明需求。LED发出的部分相干光呈朗伯(lamberton)分布。
[0019]图2类似于图1,除了加上聚焦透镜30。凡是需要对在聚焦点处呈现为从特定的焦点到椭圆形或圆形的光束28进行聚焦,聚焦透镜30都可实现。图2所示的例子示出了光束28被聚焦成6度从透镜30输出,并且这对于发出光所需的最终结果的本质是完全灵活的。该聚焦为6度的光束正好适用于手术头灯并与位于距离透镜30的光发射近似20英寸的位置的圆周上的其他LED相结合来提供焦点。
[0020]图3示出了总体由40指代的便携电源组和流体泵,该便携电源组和流体泵可与图1和/或图2的LED一起使用。应理解的是这仅绘出了用于示出运行图1和图2的冷却系统的部件的装置,但这种系统可为具有用于冷却流体的任意适合的储存系统的永久性电源和泵。
[0021]在图3中,电源组和泵30包括由虚线42指代的LED电源。电源为传统的可再充电电池,其典型地用于任意便携系统并位于便于更换或再充电的位置。箱或组件40还并入了也是以虚线示出的冷却剂容器44,并且该容器还包含组件40内的也由虚线表示的冷却剂泵46。泵4经过也由虚线表示的冷却剂管48传送冷却剂流体。柔性管52和冷却剂管48之间具有快速连接或断开单元50,冷却剂流体在图1和图2中的24处进入该柔性管52。
[0022]因为改变以适合具体运行需求和环境的其他修改和变化对于本领域技术人员将是明显的,所以本发明不限于此或由此限制。此外,本发明不应被认为限于针对目的或公开的例子,并且覆盖不偏离本发明的真实精神和范围的所有变化和修改。期望获得专利保护的呈现在所附权利要求中。