Patent Publication Number: US-8529100-B1

Title: Modular extruded heat sink

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of and claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 12/471,575, filed May 26, 2009 now U.S. Pat. No. 8,123,382, titled “Modular Extruded Heat Sink,” which claims priority to U.S. Provisional Patent Application No. 61/104,444, titled “Light Emitting Diode Post Top Light Fixture” filed on Oct. 10, 2008, the entire contents of each of which are hereby incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to heat sinks, and more particularly, to a modular heat sink for removing heat from electronic components such as light emitting diode (“LED”) components. 
     BACKGROUND 
     LEDs are widely used in various applications including, but not limited to, area lighting, indoor lighting, and backlighting. LEDs are more efficient at generating visible light than many traditional light sources. However, the implementation of LEDs for many traditional light source applications has been hindered by the amount of heat build-up occurring within the electronic circuits of the LEDs. Heat build-up reduces the LEDs light output, shortens the LEDs lifespan and can eventually cause LEDs to fail. 
     Heat sinks are being used with LEDs and provide a pathway for absorbing the heat generated from the LEDs and for dissipating the heat directly or radiantly to the surrounding environment. Exemplary methods for manufacturing heat sinks include the casting process and the extrusion process. The casting process involves a series of steps including building a mold with specific dimensions and allowances, melting a base metal and adding a degasser component, machining the heat sink to obtain the proper dimensions, and polishing to provide a finish to the surface. The extrusion process, however, involves pushing or drawing a material through a die of the desired cross-section. Exemplary materials that can be extruded include, but are not limited to, metals, such as aluminum, copper, lead, tin, magnesium, zinc, steel, and titanium, polymers, and ceramics. 
     The extrusion process provides several benefits over other manufacturing processes. The extrusion process is capable of creating very complex cross-sections. The extrusion process also is able to work materials that are brittle because the material only encounters compressive and shear stresses. The process further forms finished parts having an excellent surface finish. The extrusion process also is more cost effective than other manufacturing processes. 
     One limitation when using an extrusion process to form a heat sink is that hollows cannot be formed without machining the heat sink to produce the hollow once the material has been extruded. A hollow is an area in the interior of the extruded product that is devoid of material but otherwise surrounded by the extruded material. Thus, an extra more costly step is involved to form the hollow within the extruded material or the hollow can be formed using the more costly casting process. 
     In view of the foregoing, there is a need in the art for providing a modular heat sink. There is a further need in the art for providing a modularly extruded heat sink that can be interconnected to form a shape that cannot be formed by directly from the extrusion process. Furthermore, there is a need for providing a method to form heat sink shapes having a hollow during the extrusion process. 
     SUMMARY 
     In one exemplary embodiment, the modular heat sink includes one or more heat sink sections that are interconnected sequentially to each other. The heat sink sections form a polar array once assembled. Each heat sink section includes a base having a first connecting part at one end and a second connecting part at an opposing end. The first connecting part of each heat sink section is interconnected with the second connecting part of an adjacent heat sink section. 
     In another exemplary embodiment, the LED mounting structure includes a modular heat sink and one or more LEDs coupled to the outer surface of the modular heat sink. The modular heat sink includes one or more heat sink sections that are interconnected sequentially to each other. The heat sink sections form a polar array once assembled. Each heat sink section includes a base having a first connecting part at one end and a second connecting part at an opposing end. The first connecting part of each heat sink section is interconnected with the second connecting part of an adjacent heat sink section. 
     In another exemplary embodiment, a method for forming a modular heat sink includes extruding a plurality of heat sink sections and interconnecting each of the heat sink sections together to form the modular heat sink. The modular heat sink is formed in a polar array. Each heat sink section has a first connecting part and a second connecting part, wherein the first connecting part is configured to couple with the second connecting part. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other features and aspects of the invention may be best understood with reference to the following description of certain exemplary embodiments, when read in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a top view of a heat sink section in accordance with an exemplary embodiment; 
         FIG. 2  is a perspective view of a modular heat sink including several interconnected heat sink sections of  FIG. 1  in accordance with an exemplary embodiment; 
         FIG. 3  is a top view of the modular heat sink of  FIG. 2  in accordance with an exemplary embodiment; 
         FIG. 4  is a perspective view of an LED mounting structure utilizing the modular heat sink of  FIG. 2  in accordance with an exemplary embodiment; 
         FIG. 5  is an elevational view of the LED mounting structure of  FIG. 4  in accordance with an exemplary embodiment; 
         FIG. 6  is a perspective view of an alternative modular heat sink in accordance with another exemplary embodiment; 
         FIG. 7  is a perspective view of another alternative modular heat sink in accordance with yet another exemplary embodiment; and 
         FIG. 8  is a perspective cutaway view of a luminaire utilizing the LED mounting structure of  FIG. 4  in accordance with an exemplary embodiment. 
     
    
    
     The drawings illustrate only exemplary embodiments of the invention and are therefore not to be considered limiting of its scope, as the invention may admit to other equally effective embodiments. 
     BRIEF DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     The present invention is directed to heat sinks. In particular, the application is directed to a modular heat sink for removing heat from electronic components such as LED components. Although the description of exemplary embodiments is provided below in conjunction with LEDs, alternate embodiments of the invention may be applicable to other types of electronic components needing heat removal or other types of light sources including, but not limited to, incandescent lamps, fluorescent lamps, high intensity discharge lamps (“HID”), or a combination of lamp types known to persons of ordinary skill in the art. 
     The invention may be better understood by reading the following description of non-limiting, exemplary embodiments with reference to the attached drawings, wherein like parts of each of the figures are identified by like reference characters, and which are briefly described as follows. 
       FIG. 1  is a top view of a heat sink section  100  in accordance with an exemplary embodiment. Referring to  FIG. 1 , the heat sink section  100  includes a base  110 , a primary extension  130 , a secondary extension  141 , a first outer extension  140 , a second outer extension  160 , and one or more fins  180 . Although one exemplary embodiment of a heat sink section  100  is described below, alternative shapes for the heat sink section  100  are possible without departing from the scope and spirit of the exemplary embodiment. 
     The base  110  is substantially concave curve-shaped when viewed from the center of the heat sink and extends along a length downward to create a curved member. In one exemplary embodiment, the radius of curvature for the base  110  is ⅜ inch. However, in alternate exemplary embodiments, the radius of curvature for the base  110  ranges between about 1/10 inch to about twenty inches. The base  110  includes a female connecting part  112  running along the length of one end of the base  110  and a male connecting part  114  running along the length of the opposing end of the base  110 . In one exemplary embodiment, the female connecting part  112  is a sliding rail, and the male connecting part  114  is a protrusion extending from the base  110 . In this exemplary embodiment, the female connecting part  112  has a substantially cylindrical aperture extending the length of the base capable of receiving the male connecting part  114 . In one exemplary embodiment, the female connecting part  112  and the male connecting part  114  are both positioned along the same or substantially similar radius of curvature as the base  110 , however, in alternative embodiments, the male  114  and female  112  connecting parts are not in line with the radius of curvature of the base  110 . The male connecting part  114  is configured to couple with, or be slidably received within, the female connecting part  112  of another heat sink section  100 . In one exemplary embodiment, the male connecting part  114  has a rounded end capable of being disposed within the substantially cylindrical female connecting part  112 . Although one example of male and female connecting parts is provided, alternative connecting parts known to persons of ordinary skill in the art can be used without departing from the scope and spirit of the exemplary embodiment. 
     Although the exemplary embodiment of  FIG. 1  has a base  110  with a radius of curvature, an alternative exemplary embodiment includes the base being substantially straight without departing from the scope and spirit of the exemplary embodiment. According to this alternative exemplary embodiment, one of the connecting parts, either male or female, is positioned linearly in the direction of the base at one end of the base, while the other connecting part is positioned in a direction away from the primary extension  130  at the other end of the base. According to this alternative exemplary embodiment, four heat sink sections are interconnected to one another, thereby forming a square-shaped hollow in the center of the modular heat sink. 
     The primary extension  130  is a substantially planar member that extends radially outwardly from the base  110  at an orthogonal or substantially orthogonal angle and extends longitudinally along the vertical length of the base  110 . The primary extension  130  includes an adjacent end  132  positioned along the length of the base  110  and opposing end  133  distal and opposite of the adjacent end  132 . In one exemplary embodiment, the primary extension is integrally coupled to and integrally formed with the base  110 . 
     A secondary extension  141  is coupled to the primary extension  130  at an orthogonal or substantially orthogonal angle along the opposing end  133 . The secondary extension  141  is a substantially planar member that extends orthogonally from the planar primary extension  130  in two directions and extends vertically along the length of the primary extension  130 . The secondary extension  141  includes a first distal end  134 , and a second distal end  136 . In one exemplary embodiment, the secondary extension  141  is integrally coupled to and integrally formed with the primary extension  130 . Furthermore, in this exemplary embodiment, the secondary extension  141  is integrally formed with the base  110 . Although this exemplary embodiment has a T-shaped beam combination primary extension  130  and secondary extension  141 , alternative exemplary embodiments can have the combination of the primary extension  130  and secondary extension  141  formed into other shapes without departing from the scope and spirit of the exemplary embodiment. For example, in an alternative exemplary embodiment, the secondary extension  141  is concave-shaped or convex-shaped depending upon the desired illumination. In another alternative exemplary embodiment, the primary extension  130  is V-shaped without departing from the scope and spirit of the exemplary embodiment. Further, while one exemplary embodiment teaches the primary extension  130  being integrally coupled to the base  110 , alternatively, the primary extension  130  is removably coupled to substantially the middle portion of the base  110  without departing from the scope and spirit of the exemplary embodiment. In yet another alternative embodiment, the primary extension is either integrally or removably coupled to the base adjacent to the male  114  or female  112  connecting part. 
     The first outer extension  140  is a substantially planar member that extends from the first distal end  134  of the secondary extension  141  at an obtuse angle to the outer surface  233  ( FIG. 2 ) of the secondary extension  141 . The first outer extension  140  includes a first end  142  disposed along the first distal end  134  and a second end  144  opposite the first end  142 . In one exemplary embodiment, the first end  142  of the first outer extension  140  is integrally coupled to the first distal end  134  of the secondary extension  141 . Although the first end  142  of the first outer extension  140  is disclosed as being integrally coupled in  FIG. 1  to the first distal end  134  of the secondary extension  141 , in an alternative exemplary embodiment, the first outer extension  140  is removably coupled to the first distal end  134  without departing from the scope and spirit of the exemplary embodiment. In one exemplary embodiment, the first outer extension  140  forms an angle of about 120 degrees with the outer surface  233  ( FIG. 2 ) of the secondary extension  141 . Although this exemplary embodiment utilizes about a 120 degree angle between the first outer extension  140  and the outer surface  233  ( FIG. 2 ) of the secondary extension  141 , alternate angles ranging from about ninety degrees to about 180 degrees can be used. The first outer extension  140  extends radially outward and away from the base  110  to increase the amount of potential surface area for the overall heat sink section  100  and further enhance heat distribution that is generated from one or more LEDs  410  ( FIG. 4 ) coupled to the heat sink section  100 . The heat is distributed to the surrounding atmosphere by convection of air through the heat sink section  100  so that the heat is not trapped along the secondary extension  141 . Additionally, although the first outer extension  140  of  FIG. 1  is substantially planar, alternate exemplary embodiments can have different shapes for the first outer extension  140  including, but not limited to, convex-shaped, concave-shaped, zig-zag-shaped, curvilinear, or a combination of different shapes. 
     A first male connector  146  extends angularly from the second end  144  of the first outer extension  140 . In one exemplary embodiment, the first male connector  146  is a substantially C-shaped member that extends longitudinally along the length of the first outer extension  140 . In this exemplary embodiment, the first male connector  146  is integrally coupled to the second end  144  of the first outer extension  140 ; however, the first male connector  146  can be removably coupled to the second end  144  of the first outer extension  140  without departing from the scope and spirit of the exemplary embodiment. According to this exemplary embodiment, the first male connector  146  includes a substantially planar member extending between the first male connector  146  and second end  144 . In an alternative embodiment, the first male connector  146  is positioned immediately adjacent the second end  144 . In yet another alternative embodiment, the first female connector  146  extends further from the second end  144  of the first outer extension  140 , as shown and described with respect to  FIG. 7 , thereby providing a different profile shape to the modular heat sink  200  ( FIG. 2 ) once the several heat sink sections  100  are interconnected to each other. Although a first male connector  146  extends from the second end  144 , other connectors described above or known to persons of ordinary skill in the art can be used without departing from the scope and spirit of the exemplary embodiment. 
     The second outer extension  160  is a substantially planar member that extends from the second distal end  136  of the secondary extension  141  at an obtuse angle to the outer surface  233  ( FIG. 2 ) of the secondary extension  141 . The second outer extension  160  includes a first end  162  disposed along the second distal end  136  and a second end  164  opposite the first end  162 . In one exemplary embodiment, the first end  162  of the second outer extension  160  is integrally coupled to the second distal end  136  of the secondary extension  141 . Although the first end  162  of the second outer extension  160  is disclosed as being integrally coupled in  FIG. 1  to the second distal end  136  of the secondary extension  141 , in an alternative exemplary embodiment, the second outer extension  160  is removably coupled to the second distal end  136  without departing from the scope and spirit of the exemplary embodiment. 
     In one exemplary embodiment, the second outer extension  160  forms an angle of about 120 degrees with the outer surface  233  ( FIG. 2 ) of the secondary extension  141 . Although this exemplary embodiment utilizes about a 120 degree angle between the second outer extension  160  and the outer surface  233  ( FIG. 2 ) of the secondary extension  141 , alternate angles ranging from about ninety degrees to about 180 degrees can be used. The second outer extension  160  extends radially outward and away from the base  110  to increase the amount of potential surface area for the overall heat sink section  100  and further enhance heat distribution that is generated from one or more LEDs  410  ( FIG. 4 ) coupled to the heat sink section  100 . The heat is distributed to the surrounding atmosphere by convection of air through the heat sink section  100  so that the heat is not trapped along the secondary extension  141 . Additionally, although the second outer extension  160  of  FIG. 1  is substantially linear, alternate exemplary embodiments include a second outer extension  160  having different shapes, including, but not limited to, convex-shaped, concave-shaped, zig-zag-shaped, curvilinear, or a combination of different shapes. 
     A second female connector  166  extends angularly from the second end  164  of the second outer extension  160 . In one exemplary embodiment, the second female connector  166  is a substantially C-shaped member that extends longitudinally along the length of the second outer extension  160 . In this exemplary embodiment, the second female connector  166  is integrally coupled to the second end  164  of the second outer extension  160 ; however, the second female connector  166  can be removably coupled to the second end  164  of the second outer extension  160  without departing from the scope and spirit of the exemplary embodiment. The second female connector  166  is configured to be slightly larger than the first male connector  146 , such that the first male connector  146  slidably couples within the second female connector  166 . However, the location of the first male connector  146  and the second female connector  166  may be switched so that the second female connector  166  extends from the first outer extension  140  and the first male connector  146  extends from the second outer extension  160 . According to this exemplary embodiment, the second female connector  166  includes a substantially planar member extending between the second female connector  166  and the second end  164  of the second outer extension  160 . In an alternative embodiment, the second female connector  166  is positioned immediately adjacent the second end  164 . In yet another alternative embodiment, the second female connector  166  extends further from the second end  164  of the second outer extension  160 , as shown and described with respect to  FIG. 7 , thereby providing a different profile shape to the modular heat sink  200  ( FIG. 2 ) once the several heat sink sections  100  are interconnected to each other. Although a second female connector  166  extends from the second end  164 , other connectors described above or known to persons of ordinary skill in the art can be used without departing from the scope and spirit of the exemplary embodiment. 
     One or more fins  180  are configured to extend from at least one of the primary extension  130 , the secondary extension  141 , the first outer extension  140 , and the second outer extension  160 . In one exemplary embodiment, each fin  180  is a substantially planar member that extends radially inward at an angle towards the radius of curvature of the base  110  and extends longitudinally along the length of the member from which the fin  180  extends. In certain alternative embodiments, one or more of the fins  180  extends a distance longitudinally that is greater than or equal to the longitudinal distance of the member to which the particular fin  180  is coupled. According to this exemplary embodiment, the fins  180  extend substantially linearly and parallel to each other; however, in alternate embodiments, the fins  180  can be configured to be non-linear and/or non-parallel to each other. 
     The fins  180  extending on one side of the primary extension  130  are symmetrical or substantially symmetrical to the fins  180  extending on the opposing side of the primary extension  130  and forms a substantially inverted V-shape; however, other shapes may be formed. Further, in one exemplary embodiment, each fin  180  extending on one side of the primary extension  130  has a corresponding fin  180  extending on the opposing side of the primary extension  130  at the same respective radial distance along the primary extension  130 . Also, in this exemplary embodiment, each fin  180  extending on one side of the primary extension  130  has the same radial length as its respective corresponding fin  180  extending on the opposing side of the primary extension  130 . Further, in this exemplary embodiment, each fin  180  extending on one side of the primary extension  130  has the same longitudinal length as its respective corresponding fin  180  extending on the opposing side of the primary extension  130 . However, alternate exemplary embodiments have at least one fin  180  on one side of the primary extension  130  being a different radial length than its corresponding fin  180  on the opposing side of the primary extension  130  or one fin  180  on one side of the primary extension  130  having a different longitudinal length than its corresponding fin  180  on the opposing side of the primary extension  130 . For example, in an alternative embodiment, the fin  180  extending on one side of the primary extension  130  has a shorter radial or longitudinal length than its respective corresponding fin  180 . 
     According to the exemplary embodiment of  FIG. 1 , there are five positions  182  on the primary extension  130  from which a fin  180  extends. For each position  182 , there are two fins  180 , one extending on each planar side of the primary extension  130 . Although five positions  182  are shown on the primary extension  130 , there can be greater or fewer positions  182  on the primary extension  130 . Additionally, although one fin  180  extends from each planar side of the primary extension  130  at each position  182 , there can be greater or fewer fins  180  extending from each position  182 , either on one planar side of the primary extension  130  or on both planar sides of the primary extension  130 , without departing from the scope and spirit of the exemplary embodiment. 
     The fins  180  also extend on one side of the first outer extension  140  and one side of the second outer extension  160 . The first outer extension  140  has one or more positions  182  that corresponds to the number and location of the positions  182  on the second outer extension  160 . In one exemplary embodiment, the fins  180  extending on one side of the first outer extension  140  are symmetrical or substantially symmetrical to the fins  180  extending on one side of the second outer extension  160 . In this exemplary embodiment, each fin  180  extending from the first outer extension  140  has a corresponding fin  180  extending from the second outer extension  160 . Further, in this exemplary embodiment, each fin  180  extending from the first outer extension  140  has the same radial length and longitudinal length as its respective corresponding fin  180  extending from the second outer extension  160 . However, alternate exemplary embodiments can have at least one fin  180  extending from the first outer extension  140  being a different radial and/or longitudinal length than its corresponding fin  180  extending from the second outer extension  160 . For example, the fin  180  extending from the first outer extension  140  can have a shorter radial length than its respective corresponding fin  180  extending from the second outer extension  160 . 
     According to the exemplary embodiment of  FIG. 1 , the primary extension  130 , the secondary extension  141 , the first outer extension  140 , and the second outer extension  160  collectively form a substantially Y-shaped configuration. However, in alternate exemplary embodiments, the primary extension  130 , the secondary extension  141 , the first outer extension  140 , and the second outer extension  160  collectively form various other shapes without departing from the scope and spirit of the exemplary embodiment. Similarly, the outer profile of the heat sink section  100 , which is made up of the secondary extension  141 , the first outer extension  140  and the second outer extension  160  forms a substantially V-shaped configuration. According to this embodiment, the angle formed in the V-shaped configuration is about sixty degrees. However, in alternate exemplary embodiments, the angle formed in the V-shaped configuration can range from greater than zero degrees to about 180 degrees without departing from the scope and spirit of the exemplary embodiment. Additionally, in another alternative embodiment, the outer profile of the heat sink section  100  forms a substantially V-shaped configuration where the side profile is linear or non-linear without departing from the scope and spirit of the exemplary embodiment. 
       FIG. 2  is a perspective view of a modular heat sink  200  including several interconnected heat sink sections  100 A,  100 B,  100 C,  100 D,  100 E, and  100 F of  FIG. 1  in accordance with an exemplary embodiment.  FIG. 3  is a top view of the modular heat sink  200  of  FIG. 2  in accordance with an exemplary embodiment. Referring to  FIGS. 1 ,  2  and  3 , six heat sink sections  100 A,  100 B,  100 C,  100 D,  100 E, and  100 F are assembled together to form the modular heat sink  200 . 
     The base  110  of the heat sink section  100  includes the female connecting part  112  and the male connecting part  114  for coupling with the female connecting part  112  of another heat sink section. Additionally, the first outer extension  140  of the heat sink section  100  includes the first male connector  146  and the second outer extension  160  of the heat sink section  100  includes the second female connector  166  for coupling with the first male connector  146  of another heat sink section. 
     Two heat sink sections  100 A,  100 B are provided adjacent one another where the female connecting part  112 A of the first heat sink section  100 A is adjacent the male connecting part  114 B of the second heat sink section  100 B. Similarly, the first male connector  146 A of the first heat sink section  100 A is adjacent the second female connector  166 B of the second heat sink section  100 B. As previously described, the male connecting part  114  is configured to be coupled within the female connecting part  112  and the first male connector  146  is configured to be coupled within the second female connector  166 . 
     The male connecting part  114 B of the second heat sink section  100 B is inserted from the edge of the female connecting part  112 A of the first heat sink section  100 A. Similarly, the first male connector  146 A of the first heat sink section  100 A is inserted from the edge of the second female connector  166 B of the second heat sink section  100 B. This positioning allows the second heat sink section  100 B to move relative to the first heat sink section  100 A. Once the first heat sink section  100 A is aligned accordingly with the second heat sink section  100 B, the male connecting part  114 B slides within the female connecting part  112 A and the second female connector  166 B slides exteriorly around the first male connector  146 A. The assembler slides the second heat sink section  100 B with respect to the first heat sink section  100 A until the top surface and the bottom surface of the base  110  are aligned. 
     Once the second heat sink section  100 B is properly positioned with respect to the first heat sink section  100 A, the first heat sink section  100  A is fastened to the second heat sink section  100 B. According to this exemplary embodiment, the first heat sink section  100 A is fastened to the second heat sink section  100 B using a screw  290  and a bolt (not shown), where the screw  290  proceeds through a passageway  215  formed between the first male connector  146 A and the second female connector  166 B. In one exemplary embodiment, the perimeter of the head of the screw  290  is equal to or greater than the perimeter of the second female connector  166 B. In alternate exemplary embodiments, other fastening means are used without departing from the scope and spirit of the exemplary embodiment. For example, in one alternative embodiment, the first male connector  146 A is configured to be jammed within the larger second female connector  166 B so that the first heat sink section  100 A is no longer slidable with respect to the second heat sink section  100 B. In another alternative embodiment, one of the first male connector  146 A or the second female connector  166 B is threaded at its longitudinal ends so that a nut (not shown) can be screwed thereon to ensure that the first heat sink section  100 A is securely coupled to the second heat sink section  100 B. 
     The remaining heat sink sections  100 C,  100 D,  100 E, and  100 F are similarly assembled in a polar array with the previous heat sink sections  100 A,  100 B to form the modular heat sink  200 . Once the modular heat sink  200  is formed, a channel or hollow  220  is formed substantially at the center of the modular heat sink  200 . Using conventional forming methods, this channel  220  is not directly formable when manufacturing heat sinks using the extrusion process. Thus, the combined heat sink sections  100 A,  100 B,  100 C,  100 D,  100 E, and  100 F form the modular heat sink  200 , which could itself not be extruded by itself. Hence, this and other exemplary embodiments allow complex heat sinks to be directly formed which would normally not be possible when using a cost effective extrusion process. 
     In the exemplary embodiment of  FIGS. 2 and 3 , the profile of the modular heat sink  200  is star-shaped. The points on the star are where adjacent heat sink sections  100  interlock and provide for a surface area to extend beyond the thermal perimeter of the modular heat sink  200  and into much cooler air. However, alternate exemplary embodiments have profiles with other geometric shapes, including, but not limited to, square, circular, star-shaped with a different number of points on the star, and star-shaped with flat sides instead of points. Also, in the exemplary embodiment of  FIGS. 2 and 3 , once the modular heat sink  200  is assembled, the fins  180  extending from the primary extension  130 A,  130 B,  130 C,  130 D,  130 E, and  130 F form substantially concentric hexagonal shapes. However, alternate exemplary embodiments can have fins  180  forming other geometric shapes depending upon the number of heat sink sections  100  that are used to form the modular heat sink  200  and the angular disposition of those fins  180  along each primary extensions  130 A,  130 B,  130 C,  130 D,  130 E, and  130 F. The fins  180  form air channels  281  between the concentric hexagonal shapes that create a venturi effect, drawing air through the air channels  281 . The air travels from the bottom end  202  of the modular heat sink  200 , through the air channels  281 , and out the top end  204  of the modular heat sink  200 . This air movement assists in dissipating heat generated by one or more LEDs  410  ( FIG. 4 ) coupled to the modular heat sink  200  along the outer surface  233  of the secondary extension  141 . 
     This exemplary embodiment illustrates the modular heat sink  200  having six heat sink sections  100 A,  100 B,  100 C,  100 D,  100 E, and  100 F. However, alternate exemplary embodiments can have the number of heat sink sections  100  range from two to twenty and still form a channel  220  substantially at the center of the modular heat sink  200  without departing from the scope and spirit of the exemplary embodiment. 
     In one exemplary embodiment, the modular heat sink  200  has a longitudinal length  240  of about four inches. However, in alternate exemplary embodiments, the longitudinal length  240  ranges from about one inch to about ten feet. As the longitudinal length  240  of the modular heat sink  200  increases, more heat is capable of being collected from the LEDs  410  ( FIG. 4 ) and distributed to the surrounding environment through the fins  180 . Hence, more LEDs  410  ( FIG. 4 ) can be coupled to the modular heat sink  200  or LEDs  410  ( FIG. 4 ) emitting light having a greater intensity (as measured in watts) can be coupled to the modular heat sink  200 . Similarly, in alternative embodiments the diameter of the modular heat sink  200  is variable based on the desired end-use. As the diameter of the modular heat sink  200  increases, the modular heat sink&#39;s  200  ability to dissipate heat also increases. Hence, a greater lumen output is achievable from a lamp using the modular heat sink  200 . 
     In one exemplary embodiment, the outer surface  243  of the first outer extension  140  and the outer surface  263  of the second outer extension  160  of each heat sink section  100  are reflective. In another exemplary embodiment, the outer surface  243  of the first outer extension  140 , the outer surface  263  of the second outer extension  160 , and the outer surface  233  of the secondary extension  130  are reflective. Although polishing is one method available for making the outer surfaces  243 ,  263 , and  233  reflective, other methods known to persons of ordinary skill in the art can be used without departing from the scope and spirit of the exemplary embodiment. For example, the outer surfaces  243 ,  263 , and  233  can be metalized or a thin metallic surface can be applied over the outer surfaces to make them reflective. 
     In one exemplary embodiment, the materials used to manufacture the base  110 , the primary extension  130 , the secondary extension  141 , the first outer extension  140 , the second outer extension  160 , and the fins  180  of each heat sink section  100  include any suitable material capable of being extruded, including, but not limited to, metals, such as aluminum, copper, lead, tin, magnesium, zinc, steel, and titanium, metal alloys, polymers, and ceramics. In one exemplary embodiment, the components for each heat sink section  100  are manufactured as an integral unit and directly through the extrusion process; however, according to alternative embodiments, the components of each heat sink section  100  are manufactured separately and coupled to one another using the above described fastening means or any other fastening means known to persons of ordinary skill in the art, including, but not limited to, welding. 
       FIG. 4  is a perspective view of an LED mounting structure  400  utilizing the modular heat sink  200  of  FIG. 2  in accordance with an exemplary embodiment.  FIG. 5  is an elevational view of the LED mounting structure  400  of  FIG. 4  in accordance with an exemplary embodiment. Now referring to  FIGS. 1 ,  2 ,  4 , and  5 , the LED mounting structure  400  includes the modular heat sink  200 , one or more LEDs  410 , electrical wiring  414 , a wire-way tube  420 , and a mounting plate  430 . In some exemplary embodiments, the LED mounting structure  400  also includes wire management clips  416 . In alternate exemplary embodiments, the LED mounting structure  400  further includes a junction box (not shown) and a junction cap  440 . In still other alternate embodiments, the LED mounting structure  400  further includes a driver mounting bracket  450  and one or more LED drivers  455 . 
     The modular heat sink  200  includes several heat sink sections  100  interlocked with one another and its features and some of its potential modifications have been described above in detail. The modular heat sink  200  is configured to disperse the maximum amount of heat created by one or more LEDs  410  coupled thereon. In one exemplary embodiment, one or more LEDs or one or more LED packages, each package including one or more LED die, is disposed on the outer surface  233  of the secondary extension  141  of one or more of the heat sink sections  100 . For purposes of this discussion, the use of the term LED includes both individual LEDs and LED packages that include and LED array that includes a chip on board and one or multiple LED dies on each package. In certain exemplary embodiments, the number of LEDs capable of being disposed on an LED package ranges from 1-312, however, greater numbers of LEDs are capable of being disposed on an individual package based on the particular application of the luminaire using the LED mounting structure  400 . 
     Each LED  410  is coupled to the outer surface  233  of the secondary extension  141 . The LEDs  410  are oriented such that each emits light in a direction that is substantially perpendicular to the axis of the channel  220 . Although not illustrated in this exemplary embodiment, the LEDs can also be coupled to one or both of the outer surfaces  243 ,  263 . For simplicity, each outer surface  233  of the secondary extension  141  is referred to as a “facet.” The LEDs  410  are mounted to the facets  233  using thermal tape (not shown). The thermal tape accomplishes a two-fold purpose of both adhering the LEDs  410  to the facet  233  and assisting in the transmission of heat from the LEDs  410  to the facet  233 . In alternative embodiments, the LEDs  410  are mounted to the facet  233  using solder, braze, welds, glue, plug-and-socket connections, epoxy, rivets, clamps, fasteners, or other means known to persons of ordinary skill in the art having the benefit of the present disclosure. 
     In the exemplary embodiment of  FIGS. 4 and 5 , the modular heat sink  200  includes six longitudinally extending facets  233 . The number of facets  233  can vary depending on the size of the LEDs  410 , the diameter and shape of the modular heat sink  200 , the number of heat sink sections  100 , cost considerations, and other financial, operational, and/or environmental factors known to persons of ordinary skill in the art having the benefit of the present disclosure. Each facet  233  is configured to receive one or more LEDs  410  in one or more positions longitudinally along the length of the facet  410 . The greater the number of facets  233  or the longer the facet  233 , the greater the number of LED  410  positions available, and thus more optical distributions become available. 
     In one exemplary embodiment, each facet  233  is configured to receive one or more columns of LEDs  410  extending longitudinally along the length of the facet  233 , in which each column includes one or more LEDs  410 . The term “column” is used herein to refer to an arrangement or a configuration whereby one or more LEDs  410  are disposed approximately in or along a line. LEDs  410  in a column are not necessarily in perfect alignment with one another. For example, one or more LEDs  410  in a column might be slightly out of alignment due to manufacturing tolerances or assembly deviations. In addition, LEDs  410  in a column can be purposefully staggered in a non-linear arrangement. Each column extends along a longitudinal axis of its associated facet  233 . 
     In certain exemplary embodiments, each LED  410  is mounted to its corresponding facet  233  using a substrate  412 A. In one exemplary embodiment, the substrate  412 A is a printed circuit board or a metal core printed circuit board. Each substrate  412 A includes one or more sheets of ceramic, metal, laminate, or another material. Each LED  410  is attached to its respective substrate  412 A using a solder joint, a plug, epoxy, a bonding line, or another suitable provision for mounting an electrical/optical device on a surface. Each substrate  412 A is connected to electrical wiring  414  for supplying electrical power to the associated LEDs  410  on that substrate  412 A. 
     In certain exemplary embodiments, the LEDs  410  include semiconductor diodes configured to emit incoherent light when electrically biased in a forward direction of a p-n junction. For example, each LED  410  can emit blue or ultraviolet light. The emitted light can excite a phosphor that in turn emits red-shifted light. The LEDs  410  and the phosphors can collectively emit blue and red-shifted light that essentially matches black-body radiation. The emitted light approximates or emulates incandescent light to a human observer. In certain exemplary embodiments, the LEDs  410  and their associated phosphors emit substantially white light that may seem slightly blue, green, red, yellow, orange, or some other color or tint. Exemplary embodiments of the LEDs  410  include indium gallium nitride (“InGaN”) or gallium nitride (“GaN”) for emitting blue light; however, other color lights can be emitted using alternate types of LEDs. 
     In certain exemplary embodiments, one or more of the LEDs  410  include multiple LED elements mounted together on a single substrate  412 A, also referred to as a package. Each of the LED elements, or groups therein, can produce the same or a distinct color of light. In one exemplary embodiment, the LED elements collectively produce substantially white light or light emulating a black-body radiator. In certain exemplary embodiments, some of the LEDs  410  produce one color of light while others produce another color of light. Thus, in certain exemplary embodiments, the LEDs  410  provide a spatial gradient of colors. 
     In certain exemplary embodiments, optically transparent or clear material (not shown) encapsulates each LED  410  and/or LED element, either individually or collectively. This material provides environmental protection while transmitting light. For example, this material can include a conformal coating, a silicone gel, cured/curable polymer, adhesive, or some other material known to persons of ordinary skill in the art having the benefit of the present disclosure. In certain exemplary embodiments, phosphors configured to convert a light of one color to a light of another color are coated onto or dispersed within the encapsulating material. 
     The wireway tube  420  is a hollow tube. At least a portion of the wireway tube  420  is slidably inserted into the channel  220  and coupled to the channel  220 . The hollow portion of the wireway tube  420  provides an area for which the electrical wiring  414  proceeds through it and for at least partially concealing the electrical wiring  414  when electrically coupling the LEDs  410  to a power supply source or one or more drivers  455 . The other end of the wireway tube  420  is securely coupled to the mounting plate  430 . In one exemplary embodiment, the wireway tube  420  has a cylindrical shape that is similar to the substantially cylindrical shape of the channel  220  and is configured for one end of the wireway tube  420  to be inserted through at least a portion of the channel  220 . According to this exemplary embodiment, the wireway tube  420  has a circular cross-section; however, the wireway tube  420  can be fabricated into other geometric shapes without departing from the scope and spirit of the exemplary embodiment. In an alternative embodiment, the wireway tube  420  extends through the entirety of the channel  220  and extends out from each end of the channel  220 . The wireway tube  420  is manufactured according to any method known to persons of ordinary skill in the art, including, but not limited to, extruding and machining the hollow therein, casting, and forging. In addition, the wireway tube  420  is fabricated from any suitable material including, but not limited to, aluminum, steel, polymers, and metal alloys. 
     The mounting plate  430  is a substantially circular plate that includes an opening  432 , one or more mounting holes  433 , and one or more mounting bracket holes  434  formed therein. In one exemplary embodiment, the opening  432  is positioned at or substantially near the center of the circular mounting plate  430 ; however, in alternate exemplary embodiments the opening  432  is positioned at any location on the mounting plate  430 . According to this exemplary embodiment, the opening  432  has a shape that is the same as or similar to the shape of the channel  220  and is configured to receive the other end of the wireway tube  420 . While the exemplary embodiment of  FIGS. 4 and 5  teaches the mounting plate  430  having a circular shape; in alternate exemplary embodiments, the mounting plate  430  takes other geometric shapes, including, but not limited to, square, rectangular, triangular, and oval. 
     The mounting holes  433  formed within the mounting plate  430  are used to mount the mounting plate  430  to a mounting structure, such as a post-top luminaire (not shown), thereby forming a post-top luminaire  800  ( FIG. 8 ). The mounting bracket holes  434  are used to releasably mount the driver mounting bracket  450  to the mounting plate  430  and are capable of receiving fasteners, such as screws, rivets, nails, and other fasteners known to persons of ordinary skill in the art, to releasably couple the driver mounting bracket  450  to the mounting plate  430 . In certain exemplary embodiments, the driver mounting bracket  450  is coupled to the mounting plate  430  on an opposing surface from which the wireway tube  420  extends. 
     In one exemplary embodiment, the driver mounting bracket  450  is substantially rectangular; however, in alternative embodiments, the driver mounting bracket  450  is another geometric shape, including, but not limited to, square, circular, triangular, and oval. The driver mounting bracket  450  provides a surface for which one or more drivers  455  are mounted. In this exemplary embodiment, the driver mounting bracket  450  is fabricated from aluminum; however, according to alternate exemplary embodiments, the driver mounting bracket  450  is fabricated from any other suitable material, including, but not limited to, steel, polymers, and metal alloys. The drivers  455  are mounted to the driver mounting bracket  450  and provide electrical power and control to the LEDs  410  using the electrical wiring  414 . In certain alternative embodiments, several drivers  455  are mounted to the driver mounting bracket  450  and each driver  455  provides electrical power to one or more LEDs  410  so that the direction and intensity of light emitted by each LED  410  is individually controlled by one of the drivers  455 . In some exemplary embodiments, the drivers  455  are capable of varying the amount of power delivered to the LEDs  410 , thereby having the LEDs emit more or less light. Also, in certain exemplary embodiments, the drivers  455  are configured to control the LEDs in such a way that the LEDs  410  turn on and off intermittently, thereby making the LEDs blink. 
     In addition, fasteners of the type described above releasably couple the mounting plate  430  to the mounting structure. In certain exemplary embodiments, the mounting plate  430  is fabricated from sand cast aluminum; however, according to alternate exemplary embodiments, the mounting plate  430  is fabricated from any suitable material, including, but not limited to, steel, polymers, and metal alloys. 
     In some exemplary embodiments, wire management clips  416  are coupled along at least a portion of the primary extension  130  and are positioned at the top end  204  and the bottom end  202  of the modular heat sink  200 . According to this exemplary embodiment, the wire management clips  416  extend the entire radial length of each of the primary extension  130 . The wire management clips  416  provide a pathway for the electrical wiring  414  from the junction cap  440  to the outer surface  233  of the secondary extension  141 . The wire management clips  416  maintain the positioning of the electrical wiring  414  and protect the electrical wiring  414  from heat and other types of damage. Although the wire management clips  416  are positioned at the top end  204  and the bottom end  202  of the modular heat sink  200 , alternate exemplary embodiments can have the wire management clips  416  positioned at one end of the modular heat sink  200 , either the top end  204  or the bottom end  202 . 
     In certain exemplary embodiments, a junction box (not shown) is disposed over the channel  220  at the top end  204  of the modular heat sink  200 . The junction box receives the electrical wiring  414  from the channel  220  and provides electrical junctions for distributing the electrical power to the several LEDs  410  using additional electrical wiring  414 . The junction box cap  440  is disposed over and rotatably coupled to the junction box to visually conceal the electrical junctions, provide protection to the electrical junctions, and provide one or more pathways  442  for the several electrical wirings  414  extending from the junction box to the LEDs  410 . These pathways  442  surround the perimeter of the junction box cap  440 . In one exemplary embodiment, the pathways  442  are substantially aligned with the axis of the primary extension  130 . Although the pathways  442  are substantially aligned with the axis of each of the primary extensions  130 , alternate exemplary embodiments have pathways that are not substantially aligned with the axis of each of the primary extensions  130  without departing from the scope and spirit of the exemplary embodiment. Further, in one exemplary embodiment, the junction box cap  440  is substantially circular; however, in alternative embodiments the junction box cap  440  takes other geometric shapes including, but not limited to, square, rectangular, triangular, and oval. In certain exemplary embodiments, the junction box and the junction box cap  440  are fabricated from spun aluminum; however, in alternate exemplary embodiments, the junction box and the junction box cap  440  are fabricated from any other suitable material, including, but not limited to, steel, polymers, and metal alloys. 
       FIG. 6  is a perspective view of a modular heat sink  600  in accordance with an alternative exemplary embodiment. The modular heat sink  600  is similar to the modular heat sink  200  of  FIGS. 1 ,  2  and  3 , except for the configuration of the fins  180 . Modular heat sink  600  includes the features and potential modifications that can be implemented to it as described with respect to the modular heat sink  200  of  FIGS. 1 ,  2 , and  3 . 
     According to the alternative exemplary embodiment of  FIG. 6 , the fins  180  extend outwardly from both planar sides of the primary extension  130 . At least a portion of that extension of the fins  180  is orthogonal or substantially orthogonal to the radial direction of the primary extension  130 . Fins  180  also extend from the secondary extension  141 . In addition, fins  180  do not extend from the first outer extension  140  or the second outer extension  160 . Some of the fins  180  positioned closer to the first outer extension  140  and the second outer extension  160  extend outwardly from the primary extension  130  and/or secondary extension  141  and angle radially away from the base  110  in a manner that is parallel with either the first outer extension  140  or the second outer extension  160 . This configuration results in the fins  180  being configured in a hexagonal shape with outwardly formed conical shaped points at each junction of the hexagonal sides. This configuration provides for additional surface area of the fins  180  to extend beyond the thermal perimeter of the modular heat sink  600  and into cooler air. 
     The exemplary embodiment of  FIG. 6  also depicts two fins  180  extending from a single position  182  on one side of the secondary extension  141 . This position  182  is located at both edges of the secondary extension  141 . 
     Although the exemplary embodiment of  FIG. 6  teaches there being no fins  180  extending from either the first outer extension  140  or the second outer extension  160 , some alternative exemplary embodiments include fins  180  extending from the first outer extension  140  and the second outer extension  160 . Also, although some fins  180  extend outwardly from the primary extension  130  and/or the secondary extension  141  and angle radially away from the base  110  in a manner that is parallel with either the first outer extension  140  or the second outer extension  160 , all fins  180  can extend outwardly from the primary extension  130  and/or secondary extension  141  and angle away from the base  110  in a manner that is parallel with either the first outer extension  140  or the second outer extension  160 . In certain other exemplary embodiments, the fins  180  are disposed in any other configuration that is capable of being directly extruded as part of a heat sink section  100 . 
       FIG. 7  is a perspective view of a modular heat sink  700  in accordance with yet another alternative exemplary embodiment. The modular heat sink  700  is similar to the modular heat sink  200  of  FIGS. 1 ,  2  and  3 , except for the exterior shape of the modular heat sink  700 . Modular heat sink  700  includes the features and potential modifications that can be implemented to it as described with respect to the modular heat sink  200  of  FIGS. 1 ,  2 , and  3 . 
     Turning now to  FIG. 7 , the shape of the modular heat sink  700  has been altered by extending the distance between the first male connector  146  and the substantially planar portion of the first outer extension  140  and by extending the distance between the second female connector  166  and the substantially planar portion of the second outer extension  160 . This configuration results in the modular heat sink  700  having a star-shaped exterior perimeter with substantially flat sides  750  instead of points. These substantially flat sides  750  provide greater surface area along the perimeter of the modular heat sink  700  and into much cooler air than the star shape with points embodiment. 
       FIG. 8  is a perspective cutaway view of a post-top luminaire  800  utilizing the LED mounting structure  400  of  FIG. 4  in accordance with an exemplary embodiment. Luminaire  800  includes a transparent cover  810  surrounding the LEDs  410  and the modular heat sink  200 . Although a transparent cover  810  is shown in this exemplary embodiment, some exemplary embodiments have no transparent cover surrounding the LEDs  410  and the modular heat sink  200 . Although one exemplary luminaire  800  is illustrated in  FIG. 8 , the luminaire can be any shape or size that accommodates the modular heat sink  200 . 
     Although each exemplary embodiment has been described in detail, it is to be construed that any features and modifications that are applicable to one embodiment are also applicable to the other embodiments. 
     Although the invention has been described with reference to specific embodiments, these descriptions are not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention will become apparent to persons of ordinary skill in the art upon reference to the description of the exemplary embodiments. It should be appreciated by those of ordinary skill in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures or methods for carrying out the same purposes of the invention. It should also be realized by those of ordinary skill in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. It is therefore, contemplated that the claims will cover any such modifications or embodiments that fall within the scope of the invention.