Patent Publication Number: US-9429293-B2

Title: Vehicle light fixture having internal heatsink for LED lamp

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to external vehicular lighting fixtures, more specifically, an external vehicular lighting fixture having an internal heatsink attached to a light-emitting diode (LED) lamp. 
     BACKGROUND OF THE INVENTION 
     Many vehicles include the use of LED lighting for headlamps and other signal lighting on the exterior of the vehicle. The use of LED lighting within these fixtures tends to generate large amounts of heat that require heatsinks to be attached in order to dissipate the heat generated when the LED fixture is in operation. Conventional heatsinks for LED fixtures include heatsinks that attach to the back of an LED fixture and project directly rearward of the LED fixture. LED fixtures having such a configuration can occupy significant amounts of space within the engine compartment and various body panels of the vehicle. Additionally, conventional heatsinks can provide little to no heat transfer from the LED fixture to the outer areas of the light fixture proximate the lens. 
     SUMMARY OF THE INVENTION 
     According to one aspect of the present invention, a vehicle headlight includes a headlight housing including an external lens and an outer wall that define a headlight interior. A lighting element includes a light-emitting diode lamp and an internal heatsink is coupled to at least a portion of the lamp. The lamp is in thermal communication with the internal heatsink. The lighting element is disposed within the headlight interior and coupled to an element receptacle defined by the outer wall. The internal heatsink of the lighting element is in thermal communication with the external lens. 
     According to another aspect of the present invention, a vehicle headlight includes an internal heatsink defining a lamp receptacle. A lamp is disposed within the lamp receptacle and is in thermal communication with the internal heatsink. A headlight housing includes an external lens and an outer wall that define an interior volume. The internal heatsink and lamp are disposed within the interior volume. The internal heatsink is in thermal communication with the external lens. 
     According to yet another aspect of the present invention, an external vehicle lamp includes a heatsink defining an element receptacle. A lamp is disposed within the element receptacle and is in thermal communication with the heatsink. A light housing includes a lens and an outer wall that define an interior volume. The heatsink and lamp are disposed within the interior volume, wherein the heatsink is in thermal communication with the lens. 
     These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a front perspective view of a vehicle with an embodiment of the vehicle lighting element installed; 
         FIG. 2  is a detailed front perspective view of the headlight of the vehicle including the lighting element of  FIG. 1 ; 
         FIG. 3  is a cross-sectional view of the lighting element of  FIG. 2  taken along line III-III; 
         FIG. 4  is a perspective view of another embodiment of the vehicle lighting element; 
         FIG. 5  is an exploded perspective view of the lighting element of  FIG. 4 ; 
         FIG. 6  is a cross-sectional view of the lighting element of  FIG. 4 , taken at line VI-VI; 
         FIG. 7  is a top perspective view of another embodiment of the vehicle lighting element; 
         FIG. 8  is an exploded perspective view of the lighting element of  FIG. 7 ; 
         FIG. 9  is a top perspective view of another alternate embodiment of the vehicle lighting element; and 
         FIG. 10  is an exploded perspective view of the lighting element of  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     As shown in  FIGS. 1-3 , reference numeral  10  generally refers to a headlight  10  for a vehicle  12 . The headlight  10  includes a headlight housing  14  having an external lens  16  and an outer wall  18  that define a headlight interior  20 . A lighting element  22  includes a light-emitting diode (LED) lamp  24  and an internal heatsink  26  coupled to at least a portion of the LED lamp  24 . The LED lamp  24  is in thermal communication with the internal heatsink  26 . The lighting element  22  is disposed within the headlight interior  20  and coupled to an element receptacle  28  defined by the outer wall  18 . The internal heatsink  26  of the lighting element  22  is in thermal communication with the external lens  16 . 
     Referring now to the embodiment illustrated in  FIGS. 2 and 3 , the headlight  10  is disposed within a front portion  40  of the vehicle  12  and can include one or more lighting elements  22 . Where more than one lighting element  22  is included, typically, the headlight  10  will include a low-beam element  42  and a high-beam element  44 . Each lighting element  22  can be coupled to the headlight housing  14  at the outer wall  18  or a rear wall  46  of the headlight housing  14 . The exact connection method of the lighting element  22  to the headlight housing  14  within the headlight interior  20  can be determined, in part, by the geometry of the internal heatsink  26 , the configuration of the headlight  10 , the configuration of the LED lamp  24 , as well as other considerations. 
     Referring now to the embodiment illustrated in  FIGS. 3-6 , the lighting element  22  can include a bracket  60  that is coupled to the internal heatsink  26 , wherein the bracket  60  defines a lamp receptacle  62  configured to receive the LED lamp  24 . It is contemplated that the LED lamp  24  can be removed from the lamp receptacle  62  for repair and/or replacement of the LED lamp  24 . The bracket  60  can include a backplate  64 , wherein the backplate  64  can be fastened, attached, or otherwise coupled to a back wall  66  of the internal heatsink  26 . In the various embodiments, the bracket  60  can be attached to the internal heatsink  26  by mechanical fasteners that include, but are not limited to, screws, hooks, clasps, latches, and other similar fastening mechanisms. Other fastening methods for attaching the bracket  60  to the internal heatsink  26  can include adhesives, welding, and other similar methods. It is contemplated that the bracket  60  can include a plurality of tabs  68  that are configured to engage at least a portion of an outer surface  70  of the LED lamp  24 . The tabs  68  of the bracket  60  are configured to position the LED lamp  24  such that a back portion  72  of the LED lamp  24  engages the electrical components  74  of the lighting element  22  and connections through which electricity can be connected to the LED lamp  24 . The lighting element  22  is configured such that wiring and various electrical components  74  can be connected to the LED lamp  24  either through the back wall  66  of the internal heatsink  26  or through the bracket  60  to be delivered to the back portion  72  of the LED lamp  24 . Alternatively, electrical wiring components can be delivered to the LED lamp  24  around the internal heatsink  26  and through side portions  76  of the bracket  60  for connection to the LED lamp  24 . The exact location and path of the electrical components  74  can be determined, in part, by the configuration of the headlight  10 , the configuration of the internal heatsink  26 , the configuration of the LED lamp  24 , and other considerations. 
     In various embodiments, the electrical components  74  for the LED lamp  24  is disposed on the backplate  64  of the bracket  60 . The tabs  68  of the bracket  60  serve to position the back portion  72  of the LED lamp  24  having the electrical interface  90  of the LED lamp  24  in electrical engagement with the electrical components  74  of the bracket  60 . It is also contemplated that the electrical components  74  can be disposed on a portion of the internal heatsink  26 , such that the LED lamp  24  is installed in electrical engagement with the internal heatsink  26  when the LED lamp  24  is installed in the lamp receptacle  62 . 
     In the various embodiments, the tabs  68  of the bracket  60  are configured to selectively retain the LED lamp  24  in an installed position, wherein the LED lamp  24  is placed in electrical communication with the various electrical components  74  and wiring for the headlight  10 . In the event that an LED lamp  24  needs to be repaired and/or replaced, the LED lamp  24  can be removed from the bracket  60  manually, and without the use of tools. It is contemplated that various retaining structures in addition to, or other than, tabs  68  can be used to retain the LED lamp  24  within the lamp receptacle  62 . Such retaining structures can include, but are not limited by, hooks, clasps, detents, protrusions, and other similar interference-type mechanisms. It is further contemplated that in various alternate embodiments, the LED lamp  24  can be mechanically fastened to the bracket  60  such that tools are required to remove and/or replace an LED lamp  24  within the lamp receptacle  62 . It is further contemplated that in order to access the lighting element  22  within the headlight housing  14 , the headlight housing  14  can be removed, or, the headlight housing  14  can include an access aperture through which the lighting element  22  can be accessed and removed for repair and/or replacement of the LED lamp  24 . In the various embodiments, the headlight housing  14  can be configured such that user access to the headlight interior  20  for maintenance of the lighting element  22  can be accomplished manually, by hand, and without the use of tools. Alternatively, access to the headlight interior  20  can be configured such that tools are required in order to access the headlight interior  20  to maintain the lighting element  22 . 
     Referring again to the embodiment as illustrated in  FIGS. 3-6 , the LED lamp  24  can include the back portion  72  and a lamp lens  100 , where one or more lamp sides  102  extend between the back portion  72  and the lamp lens  100 . The internal heatsink  26  includes a plurality of elongated members  110  that extend proximate at least a portion of the lamp sides  102  of the LED lamp  24 . In the various embodiments, the elongated members  110  of the internal heatsink  26  can be configured to engage the LED lamp  24  proximate the back portion  72  of the LED lamp  24 . In such an embodiment, the elongated members  110  of the internal heatsink  26  can extend from the back portion  72  of the LED lamp  24  to beyond the lamp lens  100  of the LED lamp  24 . In this manner, each of the elongated members  110  of the internal heatsink  26  includes a distal end  112  that is positioned in front of the LED lamp  24  such that the distal end  112  of each elongated member  110  is disposed proximate an internal surface  114  of the external lens  16  of the headlight housing  14 . 
     Referring again to the embodiment illustrated in  FIGS. 3-6 , as the headlight  10  of the vehicle  12  is being used, the LED lamp  24 , while emitting light, also emits heat  120  from various portions of the LED lamp  24 . In the various embodiments, heat  120  can be emitted from the lamp sides  102 , the front, or other portion of the outer surface  70  of the LED lamp  24 . As heat  120  is emitted from the LED lamp  24 , the internal heatsink  26  captures at least a portion of this heat  120 . The captured heat  120  is temporarily retained within the elongated members  110  of the internal heatsink  26 . The captured heat  120  within the internal heatsink  26  migrates to areas around the lighting element  22  that have a lower temperature than the internal heatsink  26 . Typically, the external lens  16  of the headlight housing  14  has a lower temperature than the internal heatsink  26  during operation of the headlight  10 . This lower temperature of the external lens  16  is generally the result of the high temperature of the LED lamp  24 , but can also be the result of environmental factors, such as air flowing across the external lens  16  during operation of the vehicle  12 . The cooler temperature of the external lens  16  may also be the result of weather conditions such as rain, condensation, ice, snow, and other various weather conditions. Where inclement weather is present, in particular, condensation, snow and ice, the heat  120  that migrates from the LED lamp  24  through the internal heatsink  26  and to the distal ends  112  of each of the elongated members  110 , can further migrate from the distal ends  112  of the elongated members  110  to the external lens  16  of the headlight housing  14 . As such, the internal heatsink  26 , after absorbing heat  120  from the LED lamp  24 , exchanges or transfers heat  120  to cooler regions in and around the headlight housing  14 , including the external lens  16 . The internal heatsink  26 , in this manner, serves as a heater to keep the external lens  16  clear of snow, ice, condensation, and other cold weather precipitation and accumulation. In this manner, the heat  120  transferred from the distal ends  112  of the elongated members  110  can serve to warm the external lens  16  above the freezing point of water to melt snow and ice that may collect on the outer surface  70  of the external lens  16 . Also, the heat  120  transferred to the external lens  16  from the distal ends  112  of the elongated members  110  can serve to raise the temperature of the external lens  16  above the dew point of the surrounding air, such that condensation that may collect on the external lens  16  of the headlight housing  14  can dissipate, evaporate, or otherwise be removed from the surface of the external lens  16  as a result of the heat  120  from the elongated members  110  of the internal heatsink  26 . 
     In the various embodiments, the elongated members  110  of the internal heatsink  26  can extend generally perpendicular from the back portion  72  of the internal heatsink  26 . In such an embodiment, the elongated members  110  can be substantially linear, or can include various angled and/or curved portions that extend toward the distal ends  112  of each of the elongated members  110 . It is contemplated that, in various embodiments, the elongated members  110  can extend in an angled configuration or a curved configuration, or both, relative to the back portion  72  of the internal heatsink  26 . It is further contemplated that each elongated member  110  can have configurations that can include, but are not limited to, linear, curved, angled, trapezoidal, among other configurations. Additionally, various cross members  128  can be included that extend across the elongated members  110  to add structure to the elongated members  110  and also add surface area through which heat  120  can be transferred from the LED lamp  24  to areas outside of the lighting element  22 , including the external lens  16 . It is also contemplated that the elongated members  110  may not have a consistent length, but may have a length that substantially matches the profile of the headlight housing  14 . Such configurations may include a triangular profile, a trapezoidal profile, a curved profile, an irregular profile, among other similarly shaped profiles. Various embodiments of the internal heatsink  26  may also include more than one row of elongated members  110 , such as an inner layer and outer layer of elongated members  110  that extend around the perimeter of the LED lamp  24 . 
     In the various embodiments, the internal heatsink  26  can be made of various materials that have a high thermal connectivity. Such materials can include, but are not limited to, aluminum, aluminum alloys, copper, composite materials that incorporate materials having a high thermal connectivity, combinations thereof, and other materials that are at least partially thermally conductive. 
     Referring now to the embodiments illustrated in  FIGS. 7-10 , the configuration of the elongated members  110  can be designed such that the elongated members  110  extend along only one side of the LED lamp  24 . In various alternate embodiments, the elongated members  110  can extend along some or all of the sides of the LED lamp  24 , such that the LED lamp  24  is substantially surrounded by a plurality of elongated members  110 . It is further contemplated that the distal ends  112  of the elongated members  110  can be connected by an edge member  130 , wherein the edge member  130  can add structure to the distal ends  112  of the elongated members  110  and also provide additional surface area through which heat  120  can be transferred from the LED lamp  24  to the external lens  16  of the headlight housing  14 . The elongated members  110 , in various embodiments, can include elongated plates  132  that extend across the length and width of a lamp side  102  of the LED lamp  24 . In the various embodiments, the configuration of the elongated members  110  can be determined, in part, by the configuration of the headlight housing  14 , the configuration of the LED lamp  24 , the configuration of the front portion  40  of the vehicle  12 , and other structural and aesthetic considerations. 
     In the various embodiments, it is contemplated that the lighting element  22  can be configured to exclude the bracket  60 , such that the lamp receptacle  62  is defined within an inner portion  140  of the internal heatsink  26 . In such an embodiment, the LED lamp  24  is coupled directly to the internal heatsink  26  and the internal heatsink  26  includes various tabbed features and/or interference members that are configured to selectively retain the LED lamp  24  within the internal heatsink  26 . Additionally, various electrical components  74  that are configured to engage the LED lamp  24  and place the LED lamp  24  in electrical communication with the electrical system of the vehicle  12  can be disposed on a portion of the internal heatsink  26 . 
     According to the various embodiments, the LED lamp  24  can be fixed to the internal heatsink  26 , either by direct connection, or by connection through a bracket  60  that engages the LED lamp  24  to the internal heatsink  26 . In such embodiments, replacement and/or repair of the LED lamp  24  can be accomplished through replacement of the entire lighting element  22 , including the internal heatsink  26 , the bracket  60  and the LED lamp  24 . 
     It is contemplated that the lighting element  22  can include a generally rectangular configuration, wherein the LED lamp  24 , the bracket  60  and the internal heatsink  26  can similarly include a generally rectangular shape. In various alternate embodiments, the lighting element  22  can include a generally curved configuration, wherein each component of the lighting element  22  is generally curved, circular, oval, elliptical, or other curved shape to generally match the shape of the headlight housing  14 . It is also contemplated that the various components of the lighting element  22  can have dissimilar shapes, where one or more component is generally rectilinear and other components are generally curved. 
     Referring again to the embodiment illustrated in  FIG. 1 , it is contemplated, that in various embodiments, the lighting element  22  can be disposed within portions of the car other than the headlight  10 . By way of explanation, and not limitation, an internal heatsink  26  can be disposed within a vehicle light fixture  150  or signal fixture  152 , such as turn signals, parking lights, brake lights, fog lamps, and other various external light and signal fixtures  150 ,  152 , where heat  120  may be transferred from an LED lamp  24  to an external lens  16  of a particular light and signal fixture  150 ,  152 , in which the internal heatsink  26  is disposed. In the various embodiments, it is further contemplated that the internal heatsink  26  can be visible from the exterior of the vehicle  12  through the external lens  16  of the headlight housing  14 . It is also contemplated that the heatsink  26 , in addition to the functional elements disclosed above, can also include various aesthetic features that may add to the visual appeal of the headlight  10 , light fixture  150  or signal fixture  152 . 
     In the various embodiments, the lighting element can incorporate an LED lamp  24  or some other lighting source. These lighting sources can include any source that gives off light and heat that can be transferred by the internal heatsink  26  during use. Such sources include, but are not limited to, incandescent, halogen, metal halide, or other similar heat emitting light source. 
     It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.