Heat dispersion element

Heat-dispersion-elements for cooling light-module-inserts, as well as methods for cooling and systems for cooling are described. The heat-dispersion-element may have an outer arc and disposed opposite an inner arc. At least portions of the outer arc may be in direct physical contact with at least some portions of inside-surfaces of a housing. At least portions of the inner arc may be in direct physical contact with at least some portions of outside-surfaces of the light-module-insert. The heat-dispersion-element may be located between the light-module-insert and the housing. The heat-dispersion-element may have an overall torus or torus like shape, or a partial torus like shape. The heat-dispersion-element may have a base and fingers extending from that base. The base may be curved into the outer arc. The fingers may be curved to form the inner arc.

TECHNICAL FIELD OF THE INVENTION

The present invention relates in general to heat dispersion elements and more specifically to heat dispersion elements disposed between a light module and its housing; wherein the heat dispersion element is used to cool the light module.

COPYRIGHT AND TRADEMARK NOTICE

BACKGROUND OF THE INVENTION

Presently light-module-inserts are often housed within a housing, such as in recessed lighting applications. Such light-module-inserts, as electrical components, often generate heat. Over time, such generated heat may shorten the overall effective lifespan of such light-module-inserts. Over time, such generated heat may decrease operational efficiencies of such light-module-inserts. Over time, such generated heat may increase operational costs for running and using such light-module-inserts. Particularly in commercial and industrial buildings, where hundreds or thousands of such light-module-inserts may be utilized, increases in operational costs and shortening of effective life spans may be significant. Additionally, such generated heat may pose fire risks.

There is a need in the art to sufficiently cool such light-module-inserts, which significantly increasing costs.

It is to these ends that the present invention has been developed.

BRIEF SUMMARY OF THE INVENTION

To minimize the limitations in the prior art, and to minimize other limitations that will be apparent upon reading and understanding the present specification, embodiments of the present invention may describes heat-dispersion-elements for cooling light-module-inserts, as well as methods for cooling and systems for cooling. In some embodiments, the heat-dispersion-element may comprise an outer arc and disposed opposite an inner arc. In some embodiments, at least portions of the outer arc may be in direct physical contact with at least some portions of inside-surfaces of a housing. In some embodiments, at least portions of the inner arc may be in direct physical contact with at least some portions of outside-surfaces of the light-module-insert. In some embodiments, the heat-dispersion-element may be disposed between the light-module-insert and the housing. In some embodiments, the heat-dispersion-element may have an overall torus or torus like shape, or a partial torus like shape. In some embodiments, the heat-dispersion-element may comprise a base and fingers extending from that base. In some embodiments, the base may be curved into the outer arc. In some embodiments, the fingers may be curved to form the inner arc.

It is an objective of the present invention to provide heat-dispersion-elements that may be located between a housing a light-module-insert that would typically be housed within said housing.

It is another objective of the present invention to provide the heat-dispersion-element to cool the light-module-insert.

It is another objective of the present invention to extend the useful life of the light-module-insert by cooling the light-module-insert via use of one or more heat-dispersion-elements.

It is another objective of the present invention to increase operational efficiency of the light-module-insert by cooling the light-module-insert via use of one or more heat-dispersion-elements.

It is another objective of the present invention to decrease operational cost of the light-module-insert by cooling the light-module-insert via use of one or more heat-dispersion-elements.

It is another objective of the present invention to reduce fire risks by cooling the light-module-insert via use of one or more heat-dispersion-elements.

It is another objective of the present invention to provide heat-dispersion-elements that are easy and affordable to manufacture.

It is yet another objective of the present invention to provide heat-dispersion-elements that are easy and simple to use and install.

These and other advantages and features of the present invention are described herein with specificity so as to make the present invention understandable to one of ordinary skill in the art, both with respect to how to practice the present invention and how to make the present invention.

REFERENCE NUMERAL SCHEDULE

DETAILED DESCRIPTION OF THE INVENTION

In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying drawings that form a part thereof, where depictions are made, by way of illustration, of specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the invention.

FIG. 1may depict an exploded perspective view of a light-module-insert190, heat-dispersion-elements100, and a housing180. In some embodiments, a given light-module-insert190may be housed, inserted, and/or mounted within a given housing180. See e.g.,FIG. 5AandFIG. 1. Because such housings180and such light-module-inserts190may generally be cylindrical and/or conical, when a given light-module-insert190may be inserted into the given housing180, an annular ring region of void space may exist disposed between housing-inside-surface281and light-module-insert-outside-surface591(which might be fins191of the given light-module-insert190). See e.g.,FIG. 2C,FIG. 5A, andFIG. 5B. In some embodiments, one or more heat-dispersion-elements100may occupy portions of this annular ring region of void space. See e.g.,FIG. 1andFIG. 5A. In some embodiments, such positioned heat-dispersion-elements100may physically contact portions of the given housing180(e.g., housing-inside-surface281) and may also physically contact portions of the given light-module-insert190(e.g., fins191and/or light-module-insert-outside-surface591). See e.g.,FIG. 1,FIG. 2B,FIG. 2C,FIG. 5A,FIG. 5B, andFIG. 8.

In some embodiments, during normal operation, as an electrical component, light-module-insert190may generate heat. Over time, such generated heat may reduce a lifespan of the given light-module-insert190. Over time, such generated heat may reduce operational efficiencies of the given light-module-insert190. Such generated heat may also pose a fire hazard.

However, by locating one or more heat-dispersion-elements, such as heat-dispersion-elements100, between and in physical contact with housing-inside-surface281and light-module-insert-outside-surface591, at least some such generated heat from light-module-insert190may be dispersed away from light-module-insert190. Thus, proper use of such placed one or more heat-dispersion-elements, such as heat-dispersion-elements100, may increase the operational lifespan of light-module-insert190; may increase operational efficiencies of light-module-insert190; and/or may help to reduce fire hazard risks from heat generated by light-module-insert190.

FIG. 2Amay depict a top perspective view of housing180.FIG. 2Bmay depict a top perspective view of housing180, but wherein heat-dispersion-elements100may be shown located within housing180, wherein the heat-dispersion-element100may be shown as transparent, using broken lines.

Note, housing180as shown inFIG. 2Aand as shown inFIG. 1may be different types of housings. However, a given heat-dispersion-element100may be successfully used in a variety of housings180and with a variety of light-module-inserts190.

FIG. 2Cmay depict a bottom view ofFIG. 2B, showing heat-dispersion-elements100located inside of housing180. In some embodiments, outer arc101portions of a given heat-dispersion-element100may be in physical contact with portions of housing-inside-surface281.

In some embodiments, a given heat-dispersion-element100may be mounted to (attached to) a given housing180. In some embodiments, heat-dispersion-element100may comprise attachment-region309. See e.g.,FIG. 3B. In some embodiments, attachment-region309may be used to attach heat-dispersion-element100to housing-inside-surface281. In some embodiments, attachment-region309may be a through hole through base301of heat-dispersion-element100. In some embodiments, various mechanical fasteners may be used to attach attachment-region309to housing180. In some embodiments, such mechanical fasteners may comprise one or more of: screws, bolts, snaps, buttons, rivets, press fits, friction fits, and/or the like.

FIG. 3Amay depict a bottom perspective view of an embodiment of heat-dispersion-element100.FIG. 3Bmay be depict heat-dispersion-element100, shown from an outside side view.FIG. 3Cmay be depict heat-dispersion-element100, shown from bottom view. In some embodiments, heat-dispersion-element100may be shaped substantially as a torus or substantially as a portion of a torus. In some embodiments, heat-dispersion-element100may be shaped substantially like a letter “p”, in cross-section, where an end of the bowl of the “p” does not touch the stem of the “p” and that “p” like structure (see e.g.,FIG. 6) is then revolved around in a circle. In some embodiments, heat-dispersion-element100may resemble an arc of a coil. In some embodiments, heat-dispersion-element100may resemble an arc of a spring. In some embodiments, heat-dispersion-element100may have characteristics of a spring. In some embodiments, heat-dispersion-element100may have characteristics of a coil spring. In some embodiments, heat-dispersion-element100may be formed from an elongate element configured as a helical coil spring around void-space-region627(seeFIG. 6for void-space-region627) and then shaped into a torus or partial torus like shape.

In some embodiments, heat-dispersion-element100may comprises outer arc101and disposed opposite an inner arc103. See e.g.,FIG. 1,FIG. 3A, andFIG. 3C. In some embodiments, at least portions of outer arc101may be in direct physical contact with at least some portions of housing-inside-surfaces281of housing180. See e.g.,FIG. 2C,FIG. 5A, andFIG. 5B. In some embodiments, at least portions of inner arc103may be in direct physical contact with at least some portions of light-module-insert-outside-surfaces591of light-module-insert190. See e.g.,FIG. 5A, andFIG. 5B. In some embodiments, disposed between outer arc101and inner arc103may be void-space-region627; which may be a region of void space. See e.g.,FIG. 1andFIG. 6. In some embodiments, void-space-region627may facilitate desirable heat transfer (such as, via convection and/or via radiation).

Continuing discussingFIG. 3A,FIG. 3B, andFIG. 3C, in some embodiments, base301may be a substantially elongate member. In some embodiments, base301may be a structural member. In some embodiments, base301may be a substantially planar member. In some embodiments, base301may be substantially shaped as a rectangular prism. In some embodiments, base301may be substantially semi-rigid. In some embodiments, base301may comprise attachment-region309(see e.g.,FIG. 3B), as discussed above. In some embodiments, base301may be shaped into an arc. In some embodiments, base301may be curved into the arc. In some embodiments, base301may be bent into the arc. In some embodiments, an exterior of this arc may be outer arc101. In some embodiments, this arc of base301may comprise an angle-of-arc311of substantially 135 degrees, plus or minus five degrees. See e.g.,FIG. 3C.

In some embodiments, a given embodiment of angle-of-arc311may be a degree selected from the range of 360 degrees to 90 degrees. In some embodiments, when angle-of-arc311may be selected from the range of more than 180 degrees to 360 degrees, there may be only one heat-dispersion-element100disposed between housing180and light-module-insert190. In some embodiments, when angle-of-arc311may be selected from the range of more than 90 degrees to 180 degrees, there may be two heat-dispersion-elements100disposed between housing180and light-module-insert190; see e.g.,FIG. 1.

Continuing discussingFIG. 3A,FIG. 3B, andFIG. 3C, in some embodiments, each finger303of the plurality of fingers303may extend substantially perpendicularly away from a longitude of base301. In some embodiments where each such finger303extends away from base301, adjacent fingers303may have a predetermined spacing; i.e., adjacent fingers303may be spaced. Note, such void space spacing between any given pair of adjacent fingers303may facilitate desirable heat transfer. In some embodiments, each finger303may be a substantially elongate member. In some embodiments, each finger303may be a substantially planar member. In some embodiments, each finger303may be substantially shaped as a rectangular prism. In some embodiments, each finger303may be substantially semi-rigid. In some embodiments, the plurality of fingers303may all be curved and/or bent in a same direction, such that heat-dispersion-element101may resemble a hollow cylinder shape, but with a bent arc due to the arcing of base301.

Continuing discussingFIG. 3A,FIG. 3B, andFIG. 3C, in some embodiments, due to the arc of base301and the direction of fingers303extending away base301, portions of fingers303may comprise engagement-region307. In some embodiments, where base301may occupy outer arc101of heat-dispersion-element100, then engagement-region307may occupy inner arc103of heat-dispersion-element100. In some embodiments of heat-dispersion-element100, engagement-region307may be disposed opposite of where base301transitions into fingers303. In some embodiments, engagement-region307may physically contact at least some portions of light-module-insert-outside-surface591(see e.g.,FIG. 5AandFIG. 5B). Physical contact between the at least some portions of light-module-insert-outside-surface591and at least some of engagement-regions307may permit heat transfer via conduction from the at least some portions of light-module-insert-outside-surface591to the at least some of engagement-regions307where there may be such physical contact. In some embodiments, light-module-insert-outside-surface591may comprise one or more fins191of light-module-insert190.

Continuing discussingFIG. 3AandFIG. 3C, in some embodiments, the plurality of fingers303may comprise fin-engagement-region305. In some embodiments, a given fin-engagement-region305may be a region between two adjacent fingers303that may accommodate receiving at least a portion of a given fin191of a given light-module-insert190. In some embodiments, a given fin-engagement-region305may be spaced and/or sized to frictionally engage and/or hold the at least the portion of the given fin191. In some embodiments, due to semi-rigidity of base301and/or of fingers303, heat-dispersion-element100may be generally stiff, but may be bend and/or flex to such that portions of fins191may be held by fin-engagement-region305. See e.g.,FIG. 8. In some embodiments, heat-dispersion-element100may be characterized as a heat dispersion spring or as a heat dispersion coil.

FIG. 4Amay depict a perspective view of a heat-dispersion-element400prior to being shaped to arrive at heat-dispersion-element100.FIG. 4Bmay depict heat-dispersion-element400, shown from a top view (or a bottom view which may be equivalent to the top view). In some embodiments, heat-dispersion-element400may be an intermediary before arriving at heat-dispersion-element100. In some embodiments, heat-dispersion-element400may be molded, 3D printed, and/or die cut (stamped). In some embodiments, heat-dispersion-element400may then be bent, shaped, and/or pressed into a final shape of heat-dispersion-element100.

Continuing discussingFIG. 4AandFIG. 4B, in some embodiments, heat-dispersion-element400may comprise a base401and a plurality of fingers403extending from base401. In some embodiments, base401may be an intermediary which upon shaping, bending, and/or pressing arrives at base301. In some embodiments, the plurality of fingers403may be an intermediary which upon shaping, bending, and/or pressing arrives at the plurality of fingers303.

Continuing discussingFIG. 4AandFIG. 4B, in some embodiments, base401may be a substantially elongate member. In some embodiments, base401may be a substantially planar member. In some embodiments, base401may be substantially shaped as a rectangular prism. In some embodiments, base401may be substantially semi-rigid.

Continuing discussingFIG. 4AandFIG. 4B, in some embodiments, each finger403of the plurality of fingers403may extend substantially perpendicularly away from a longitude of base401. In some embodiments where each such finger403extends away from base401, adjacent fingers403may have a predetermined spacing; i.e., adjacent fingers403may be spaced. In some embodiments, each finger403may be a substantially elongate member. In some embodiments, each finger403may be a substantially planar member. In some embodiments, each finger403may be substantially shaped as a rectangular prism. In some embodiments, each finger403may be substantially semi-rigid.

Continuing discussingFIG. 4AandFIG. 4B, in some embodiments, along the longitude of base401(i.e., along a length of base401) may be a first-end415. In some embodiments, disposed opposite of first-end415, at ends of each finger403, may be second-end417. In some embodiments, to form each finger303, second-end417may be shaped, bent, and/or press to curve around in a direction to approach first-end415.

Continuing discussingFIG. 4B, in some embodiments, the longitude of base401may comprise a predetermined length of base-length421. In some embodiments, each finger403may comprise a length of finger-length423. In some embodiments, base-length421may be longer than each finger-length423. In some embodiments, a ratio of base-length421to finger-length423may be from 1.5 to 2.7.

Note, in some embodiments, forming heat-dispersion-element100may not require forming intermediary heat-dispersion-element400. In such embodiments, heat-dispersion-element100may be formed by molding and/or 3D printing.

FIG. 5Amay depict a longitudinal cross-sectional view through housing180; wherein housing180may house heat-dispersion-elements100and light-module-insert190.FIG. 5Aalso show region of DETAIL5B.FIG. 5Bmay depict an enlarged (close-up) view of the region DETAIL5B. As shown inFIG. 5Aand inFIG. 5B, in some embodiments, heat-dispersion-elements100may be disposed between housing180and light-module-insert190.

FIG. 5AandFIG. 5Bmay show that exterior and outer arc101portions of base301may be in physical contact with housing-inside-surface281. Such regions of physical contact may permit desirable heat transfer, such as via conduction to housing180.

FIG. 5AandFIG. 5Bmay show that exterior and inner arc103portions of heat-dispersion-elements100may be in physical contact with light-module-insert-outside-surface591. In some embodiments, these inner arc103portions of heat-dispersion-elements100may be engagement-region307. Such regions of physical contact may permit desirable heat transfer, such as via conduction from light-module-insert190. In some embodiments, light-module-insert190may comprise light-module-insert-outside-surface591. In some embodiments, light-module-insert-outside-surface591may be outside surfaces of light-module-insert190. In some embodiments, light-module-insert-outside-surface591may comprise fins191of light-module-insert190.

FIG. 6may depict a cross-sectional view through an embodiment of heat-dispersion-element100. In some embodiments, along a top edge of base301may be a first-end615. In some embodiments, first-end615may be located along the longitudinal outside edge of base301. In some embodiments, at ends of each finger303, may be a second-end617. In some embodiments, to form each finger303, second-end617may be shaped, bent, and/or pressed to curve around in a looping direction to approach base301and/or to approach first-end615. In some embodiments, second-end617may be separated from base301by separation-gap625. When no load may be placed upon heat-dispersion-element100, separation-gap625may be predetermined; however, when heat-dispersion-element100may be physically contacting housing180and/or light-module-insert190, separation-gap625may vary according to the load and semi-rigidity of fingers303and base301.

Continuing discussingFIG. 6, in some embodiments, the plurality of fingers303and base301may partially circumscribe void-space-region627which is the region of void space; wherein void-space-region627may facilitate desirable heat transfer via radiation and convection.

In some embodiments, first-end415may be an intermediary which upon shaping, bending, and/or pressing arrives at first-end615. In some embodiments, second-end417may be an intermediary which upon shaping, bending, and/or pressing arrives at second-end617.

FIG. 7may depict a cross-sectional view through an embodiment of heat-dispersion-element100(e.g., similar toFIG. 6) and that also may show various arrows indicating directions and/or types of heat transfer. Recall, in some embodiments, portions of engagement-region307may be in physical contact with portions of light-module-insert-outside-surface591, wherein conductive heat transfer is facilitated through such physical contact. Recall, in some embodiments, portions of base301may be in physical contact with portions of housing-inside-surface281, wherein conductive heat transfer is facilitated through such physical contact. InFIG. 7, arrows indicated as731may indicate radiant heat transfer, as in radiant-heat-direction731. Arrows indicated as733may indicate conductive heat transfer, as in conductive-heat-direction733. Arrow indicated as735may indicate convective heat transfer, as in convective-direction735.

Continuing discussingFIG. 7, in some embodiments, radiant-heat-direction731may be radiating away from the material(s) of construction of heat-dispersion-element100. In some embodiments, conductive-heat-direction733may be heat transfer through the material(s) of construction of heat-dispersion-element100. Portions of conductive-heat-direction733may result in heat transfer to exterior surfaces of heat-dispersion-element100, wherein heat may then radiate outwards and away from heat-dispersion-element100via radiant-heat-direction731. Radiant heat transfer may then heat ambient air disposed between light-module-insert190and housing180. Such heated ambient air may then result in further convective heat transfer and convective ambient air movement. That is, heated ambient air is less dense and will rise, creating a general updraft of ambient air movement, such as convective-direction735, which is further facilitated by the spaced arrangement of fingers303that permits ambient air movement through such spacing and of void-space-region627.

FIG. 8may depict a transverse width cross-sectional view (i.e., a top cross-sectional view) through housing180; wherein housing180may house heat-dispersion-elements100and light-module-insert190.FIG. 8may show some portions of some fins191being received by fin-engagement-regions305.

In some embodiments, a heat-dispersion-element may be shaped substantially as a torus or substantially as a portion of a torus; wherein the heat-dispersion-element may be comprised of a wool or a substantially elongate member of material suitable for heat transfer, such as, but not limited to, a metal wool. Such a metal wool, substantially shaped as a torus or portion thereof, may be disposed between housing180and light-module-insert190.

In some embodiments, heat-dispersion-elements (e.g.,100and/or400) may be substantially constructed from one or more materials suitable for heat transfer; such as, but not limited to, copper, aluminum, silver, steel, alloys thereof, combinations thereof, and/or the like.

In some embodiments, heat-dispersion-elements (e.g.,100and/or400) may act as a heat sink.

Note with respect to the materials of construction, it is not desired nor intended to thereby unnecessarily limit the present invention by reason of such disclosure.

In some embodiments, a method for transferring heat away from light-module-insert190may comprise locating one or more heat dispersion elements100between housing180and light-module-insert190. In some embodiments, light-module-insert190may be housed within housing180. In some embodiments, heat-dispersion-element100may comprise outer arc101and disposed opposite inner arc103. In some embodiments, at least portions of outer arc101may be in direct physical contact with at least some portions of housing-inside-surfaces281of housing180. In some embodiments, at least portions of inner arc103may be in direct physical contact with at least some portions of light-module-insert-outside-surfaces591of light-module-insert190. See e.g.,FIG. 1,FIG. 2B,FIG. 2C,FIG. 5A,FIG. 5B,FIG. 7, andFIG. 8.

In some embodiments, a system for cooling light-module-insert190may comprise at least one heat-dispersion-element (such as100) and light-module-insert190. In some embodiments, a system for cooling light-module-insert190may comprise at least one heat-dispersion-element (such as100) and housing180. In some embodiments, a system for cooling light-module-insert190may comprise at least one heat-dispersion-element (such as100) housing180, and light-module-insert190; wherein the at least one heat-dispersion-element (such as100) may be disposed between housing180and light-module-insert190.

Various heat-dispersion-elements have been described. The foregoing description of the various exemplary embodiments of the invention has been presented for the purposes of illustration and disclosure. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit of the invention.