Patent Abstract:
Methods and systems are provided for a lighting module and related components for efficiently directing dissipated heat and/or heated air away from the lighting module. Deflectors are often used to funnel heat away from solid-state light emitters and channel airflow away from a curing surface, but the risk of constrained airflow may negatively affect emitter output as well as disturb the curing process of a workpiece emitted light is directed towards. To efficiently remove heat as well as not disturb the curing process or shape of the lighting module, louvered vents are provided that extend into an interior of a housing of the lighting module for guiding heated air in a deflecting direction away from the emitted light direction.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 61/837,098, entitled “Internal Deflection Venting,” filed Jun. 19, 2013, the entirety of which is hereby incorporated by reference for all purposes. 
    
    
     BACKGROUND AND SUMMARY 
     Solid-state light emitters, such as light-emitting diodes (LEDs) and laser diodes, have several advantages over using more traditional arc lamps during curing processes, such as ultraviolet (UV) curing processes. Solid-state light emitters generally use less power, generate less heat, produce a higher quality cure, and have higher reliability than traditional arc lamps. While solid-state light emitters emit less heat than their arc lamp counterparts, the temperatures emitted from the solid-state light emitters can still be very high and can cause overheating of the solid-state light emitters during use and damage to the components of the solid-state light emitters over time. Overheating and damage to components of the solid-state light emitters may cause downtime for repair and loss of revenue. 
     Some solid-state light emitters incorporate cooling systems to remove some of the heat that is generated when the solid-state light emitter emits light. Often, these cooling systems include one or more heat sinks that help remove heat generated by the solid-state light emitters from the housing through openings or other heat exits in the housing, which results in air being expelled from the housing. These openings or heat exits in the housing are generally located near the medium on which the curing process occurs and can cause air to be expelled onto the medium, which can disturb the curing process, and which can increase manufacturing costs and decrease quality and efficiency. 
     External air deflectors have been used to effectively funnel heat away from solid-state light emitters and channel airflow away from a curing surface. A deflector may be secured to the housing and positioned to extend below some portion of the heat exit, the deflector guiding airflow and waste heat away from the housing. However, the constrained airflow due to an external deflector may negatively affect solid-state light emitter output as the deflector may block heat escape, raise the temperature of a heat sink, and lower LED efficiency. Furthermore, a deflector placed external to a housing for a lighting module may enlarge the housing and/or create an awkward shape that is not conducive to a particular curing system. This enlarged format may cause problems for integration, fitting, or arranging of the lighting module into existing systems. 
     One approach that may at least partially address the aforementioned issues includes a lighting module, comprising: an array of light-emitting elements thermally and/or electrically coupled to a heat sink and a housing having a plurality of heat exits. The heat exits may be covered over by louvered venting. For example, the louvered venting may guide airflow and waste heat away from the housing in a direction opposite to the direction in which the array of light-emitting elements emit light. In this manner, disturbance of the curing process at the medium by heat expelled from the lighting module can be substantially reduced, thereby increasing the reliability of the curing process, decreasing manufacturing costs, and increasing quality and efficiency. Furthermore, the louvered vents may be punched out of material comprising the housing and may not extend outwardly beyond the plane of the exterior of the housing. In this way, the cost and manufacture of additional components may be saved and the shape and size of the lighting module may remain substantially unaltered. 
     It will be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a front perspective view of an example lighting module having louvered vents. 
         FIG. 2  shows a back perspective view of the example lighting module with the louvered vents shown in  FIG. 1 . 
         FIG. 3  shows a side view of the example lighting module illustrated in  FIG. 1 . 
         FIG. 4  shows a partial exploded view of example louvered vents and the portion of the lighting module to which it is secured. 
         FIGS. 5A and 5B  show underside views of a top surface of a lighting module housing comprising louvered vents. 
         FIG. 6  shows a partial cross-sectional plan view of an example lighting module with louvered vents and heat exits adjacent to a heat sink. 
         FIG. 7  shows an example flow chart for an example method of irradiating a curable workpiece surface with the lighting module illustrated in  FIG. 1 . 
         FIG. 8  shows an example schematic of a lighting system. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     The present description relates to a lighting module comprising a heat sink for dissipating heat generated from an array of light-emitting elements, and louvered vents for guiding the dissipated heat and airflow away from the lighting module in a deflecting direction away from the emitted light direction.  FIGS. 1-2  are front and rear perspective views of an example lighting module comprising louvered vents for guiding airflow and waste heat away from the lighting module.  FIG. 3  illustrates a side view of a lighting module showing a deflecting direction of the heated air away from the lighting module.  FIG. 4  shows a partial exploded view of components comprising a lighting module with louvered vents of the present disclosure.  FIGS. 5A and 5B  show a top surface of the housing of a lighting module comprising louvered vents. The louvered vents may be positioned adjacent to the heat sink as shown in  FIG. 6 .  FIGS. 4-6  are drawn to scale while it is appreciated that other suitable scales may be used. A method of irradiating a curable workpiece surface with the lighting module is illustrated in  FIG. 7 . Finally,  FIG. 8  shows an example schematic of a lighting system. 
       FIGS. 1 and 2  show a lighting module  100  including a housing  102 , an array of light-emitting elements  104 , and a plurality of heat exits  106 . The housing  102  is a rectangular box-shaped structure in this example, but the example housing illustrated in  FIGS. 1-2  is not meant to be limiting. As such, housing  102  can be any other suitable size and shape in other lighting module configurations. The housing  102  is a protective structure for housing the array of light-emitting elements  104  and may include any suitable protective materials. The housing  102  in  FIGS. 1 and 2  has a front surface  108 , a back surface  110 , two opposing side surfaces  112 ,  114 , a top surface  116 , and a bottom surface (not shown). The front surface  108  includes a window  118  through which the array of light-emitting elements  104  emits light. The window  118  may be positioned on another suitable surface of the housing  102  in other configurations. The window  118  may comprise a glass, plastic or other material suitable to transmit or focus light from the light emitting elements. The window may take on other structural configurations than that shown in  FIG. 1 . Another structural configuration is shown in the example embodiment of  FIGS. 4 and 6 . 
     The window  118  of the lighting module  100  is positioned such that the array of light-emitting elements  104  emit light in an emitted light direction  111  toward a medium with some type of light-curable material, such as a curable workpiece surface. For example, the lighting module  100  is positioned vertically and a substrate, such as paper or plastic, is positioned below the lighting module  100 , such that the front surface  108  of the lighting module  100  having the window  118  through which the light is emitted faces the substrate. The curable workpiece surface of the light-curable material is positioned on the substrate so that the emitted light cures the light-curable material when light is emitted through the window  118 . The lighting module  100  is movable with respect to the medium in some configurations and may be adjustable in any suitable direction to cure the light-curing material to the medium. The array of light-emitting elements  104  may include light-emitting diodes (LEDs). These LEDs may emit light in a range of wavelengths. For example, the LEDs may emit visible light and ultraviolet light in the range of wavelengths between 10-400 nanometers. Other types of devices may be used as the light-emitting diodes, emitting light of different wavelength ranges depending on the curable workpiece surface. 
     During the curing process, the array of light-emitting elements  104  may generate a substantial amount of heat when the elements emit light, wherein the heat can damage the lighting module  100 . Various heat management systems have been developed to help control the heat generated during this process, such as including one or more heat sinks  120  in the lighting module  100 , as seen in  FIG. 3  and described later in further detail. The one or more heat sinks  120  included in the lighting module  100  are often positioned to dissipate the heat generated within the housing  102  so that the heat can be expelled through one or more heat exits  106  or other types of openings in the housing  102  of the lighting module  100 . For example, the heat sinks  120  may be thermally and/or electrically coupled to the array of light-emitting elements  104 . In this manner, heat generated by the array of light-emitting elements may be dissipated by conduction through the heat sinks  120  and by convection and radiation to the air surrounding the external surfaces of heat sinks  120 . As an example, the external surface of the heat sinks  120  may be finned, wherein one or more raised fins  123  (seen in  FIG. 4 ) extend from the external surface of the heat sinks  120 . The fins  123  increase the external heat transfer surface area of the heat sinks and may help to increase the heat dissipation from the heat sinks  120  as compared to the case of a heat sink with a smooth, unfinned surface. 
     Furthermore, one or more heat exits  106  may be positioned adjacent to the heat sinks  120 , wherein the heat exits  106  comprise openings in top surface  116  of the housing  102 . In some examples, the heated air containing the heat dissipated by the heat sink(s)  120  is expelled through the heat exits  106  by a fan or other expulsion device. In other configurations, the heated air is expelled through the heat exits  106  in a passive manner without the use of a fan or any other type of expulsion device. Reference to the expulsion of heat from the housing  102  of the lighting module  100  includes both the active expulsion of the heat by an expulsion device, such as a fan, and the passive expulsion of heat that may not include any type of assistive device to cause the heat to exit the housing  102 . Examples of heat exits  106  and an example heat sink  120  are shown in  FIGS. 3, 4, and 6 . 
     The heat sink(s)  120  dissipate warm or hot air generated within the housing  102  that then exits the housing  102  through the heat exits  106  or other suitable openings positioned on top surface  116  of the housing  102 , as shown in  FIGS. 1 and 2 . In some examples, the heat sink(s)  120  are spaced apart from, positioned adjacent to, or otherwise considered a discrete element from the heat exits  106 . Warm or hot heated air is expelled through the heat exits  106 . The combination of heat exits  106  and deflecting surfaces  124  may form a series of louvered vents  122 . Without the louvered vents  122  shown in  FIGS. 1 and 2 , the heated air may be expelled in various directions from the housing  102 , including toward the front surface  108  and the window  118  of the housing  102  and thus toward the medium where the curing occurs. When air is allowed to be expelled in the direction of the medium where the curing occurs, it may disrupt the curing process. The louvered vents  122  shown in  FIGS. 1 and 2  guide the heated air away from the housing  102  in a direction away from the medium upon which the curing occurs. In these examples, the louvered vents  122  guide the airflow and waste heat away from the housing  102  in a deflecting direction away from the window  118  through which the light is emitted in an emitted light direction  111 . Therefore, the heat is expelled away from the medium since the medium is positioned adjacent or otherwise near the window  118 . In this way, even if the heat exits are placed near the window  118  of front surface  108 , as shown in  FIGS. 1-2 , disturbances to the curing workpiece surface by the heated air may be substantially reduced by directing the heated air through louvered vents  122 . 
     Turning to  FIG. 2 , lighting module  100  may further comprise an air intake  103  on its back surface  110 , wherein the air intake  103  comprises one or more openings in the housing for convecting air into the lighting module. Furthermore, lighting module  100  may also include an intake cover plate  105 . Intake cover plate  105  may define the one or more air intakes  103  for guiding intake air into the housing  102 . The intake cover plate may comprise the back surface  110  of the housing  102 . As examples, intake air may be convected into housing  102  actively via a fan (not shown) or passively via natural convection. 
     In alternative embodiments, a fan direction may be reversed and air may be convected out of the lighting module housing, exiting through the back surface  110 . The back surface  110  of the housing  102  may further comprise electrical or other inputs. In other embodiments, the back surface  110  may comprise an open grating to allow air access to internal fans (not pictured). Furthermore, different patterns and positioning of the air intake  103  may be possible while remaining within the scope of the present disclosure. 
       FIG. 3  illustrates a side view of the example lighting module of  FIG. 1 . As shown by arrow  127 , air may enter the lighting module  100  via are intakes  103  at back surface  110 . Inside the lighting module, the air may then flow over the heat sinks  120 , thereby dissipating the heat generated from the array of light-emitting elements. Although heat sink  120  is located inside housing  102 , it is shown with a dashed outline in  FIG. 3  to illustrate its positioning inside the housing. The heated air then exits the lighting module via the heat exits  106 . The top surface  116  of the housing  102  may be substantially planar as the deflecting surface  124  of the louvered vents  122  is punched into the internal space of the housing  102 , leaving the outer shape of the housing substantially unaltered. This generally rectangular exterior shape of the housing  102  may allow for ease of attaching or aligning the lighting module  100  with existing systems. 
     The louvered vents  122  may guide the heated air away from the housing  102  of the lighting module  100  in a direction that is approximately 180° away from the window  118 , essentially in a direction directly opposite the direction of emitted light  111 , as shown by the arrow  129  in  FIG. 3 . This configuration causes the least amount of air to disrupt the curing process because the air flow path directs the air in the opposite direction of the emitted light direction  111  through window  118  on the front surface  108  of the lighting module  100 , and thus away from the medium upon which the curing process occurs. However, in alternative examples, the louvered vents  122  may guide the air and waste heat in a direction that is at an angle of at least 90° with respect to the emitted light direction  111  through the window  118 , and in other examples, the louvered vents may guide the air and waste heat in a direction that is at an angle of at least 120° with respect to emitted light direction  111  through the window  118 . Other angles may be possible while remaining within the scope of the present disclosure. 
     In another embodiment, air flow through the louvered vents  122  may be intake air that is vented through the back surface  110  by fans that are run in a reverse direction to push air out back surface  110  as opposed to draw it in. In such an embodiment, the direction of airflow through the louvered vents  122  would be opposite to that indicated at  129  in  FIG. 3 . Furthermore, in the reverse airflow case, the direction of airflow through the air intakes  103  would also be opposite to that indicated at  127 . 
     The louvered vents  122  may have any suitable shape that guides the airflow and waste heat away from the housing  102  of the lighting module  100 . The louvered vents  122  may comprise a deflecting surface extending interior to the outer form of the lighting module  100 . In other words, the deflecting surface may extend from top surface  116  in the direction of a bottom surface, and may be further angled in the direction of a front surface  108 . The louvered vents may each comprise a deflecting surface  124 , the deflecting surface extending inward from a plane of top surface  116  of the housing  102  in a diagonal direction toward the window  118  and down toward the heat sink  120 . As presented above, louvered vents  122  may include both the solid material of one or more deflecting surfaces  124  and the heat exits  106  that define the lack of material through which air may flow out of lighting module  100 , as indicated by arrow  129 . This configuration is shown in  FIG. 3 . 
     In  FIGS. 1-3 , the lighting module  100  includes four heat exits  106  and four corresponding louvered vents  122  that direct heat from their respective heat exits  106 . In this example, the louvered vents  122  are positioned to extend below each heat exit  106 . However, in alternative configurations, the number of louvered vents may vary. The louvered vents may extend along a greater extent of the top surface  116  of the housing  102 . The louver vents may further comprise a different shape or dimensions or may be extend from sides  112  and  114  of the housing in multiple segments such that a short un-punched segment may extend from the front surface  108  to the back surface  110  along the length of the louvered vents. Such an embodiment may provide additional structural support to the housing  102  of the lighting module  100  without substantially interfering with air flow through the louvered vents. 
     Furthermore, the heat exits  106  may be positioned on any surface of the housing  102  of the lighting module  100  in any suitable arrangement. For instance, heat exits  106  and corresponding louvered vents  122  may be placed on front surface  108 , back surface  110 , two opposing side surfaces  112 ,  114 , top surface  116 , and the bottom surface (not shown) of housing  102 . As an example, heat exits  106  paired with corresponding louvered vents  122  may be placed very near the array of light-emitting elements  104  because the louvered vents  122  aid in guiding the air and waste heat away from the emitted light direction and the medium or curable workpiece surface. As such, this configuration may reduce the disturbance to the curable workpiece surface caused by the dissipated heat. Furthermore, by placing the heat exits  106  in close proximity to the array of light-emitting elements  104 , the heat generated from the array of light-emitting elements may be more expediently dissipated since the heat can be removed via dissipation over a shorter distance as compared to the case where the heat exits  106  are located farther away from the array of light-emitting elements. 
     The heat exits  106  along with louvered vents  122  may be arranged to most effectively dissipate heat from heat sinks  120  and to expel the heat and air from the housing  102  when the array of light-emitting elements  104  generate heat during use. In some examples, one heat sink  120  is positioned within the housing  102  to dissipate heat generated within the housing, and the dissipated heat may be then expelled during use of the light-emitting elements  104  via the heat sink  120  through heat exits  106 . 
       FIG. 4  shows a partial exploded view of louvered vents  122  within the top surface  116  and the portion of the lighting module  100  to which the top surface  116  is secured. Top surface  116  may be created from a single piece of sheet metal, as an example. The top surface  116  may be formed so that the edges curve down to create corners  140 . These corners may serve as attachment points to the sides  114  and  112  (not visible) of the housing  102 . Furthermore, the corners may serve as a portion of the sides themselves. Additionally, the louvered vents  122  may be punched out of the raw material forming the top surface  116 . 
     The window  118  may extend fully from one side  112  to the opposite side  114  across the housing  102  of the lighting module  100 . With this embodiment of window  118 , it may be possible to place multiple lighting module units side by side to create a seamless, elongated light source. In the example of an extended, long curable workpiece surface, such an embodiment may be advantageous. In other examples embodiments, the opposite orientation may be possible where louvered vents  122  are features on the sides  112  and  114  of the housing  102  and window  118  may extend fully from top surface  116  to the bottom surface so that multiple lighting module units may be stacked in a top to bottom fashion to create an extended light emitting surface. 
     Furthermore, a mounting piece  126  is shown to extend the width of the lighting module  100  from side  112  to side  114 . The mounting piece  126  may provide an attachment point between the front surface  108  and the top surface  116  of the housing  102 . The mounting piece  126  may provide an airtight seal such that air convected from the heat sink  120  may not be convected onto a workpiece surface through the seam between front surface  108  and top surface  116 . The mounting piece  126  may be shaped as shown in  FIG. 4  with various indents and ridges  155  to provide a secure structural attachment between the top surface  116  (which includes integral corners  140 ) and front surface  108 . 
     The mounting piece  126  may have an angled back side that is angled parallel with the louvered vents so that an equivalent vent is created symmetric with the other vents, while at the same time enabling a structural attachment and connection between the top surface  116  and the front surface  108 , array and remaining housing portions. The mounting piece  126  may be located on top of heat sink  120  such that the mounting piece is substantially parallel to the top surface of heat sink  120 . Furthermore, when lighting module  100  is assembled with mounting piece  126  included, the mounting piece may be in direct contact with front surface  108 , top surface  116 , side surface  112 , side surface  114 , and/or the top surface of heat sink  120 . As seen in  FIG. 4 , mounting piece  126  may also include several holes  156  for fixing the mounting piece within housing  102 . In this way, mounting piece  126  provides both structural attachment in housing  102  and may also be angled to provide an additional louvered vent to the rest of vents  122 . With an angle similar to the angle of louvered vents  122 , the mounting piece  126  may contribute to removing heated air from housing  102  generated by light-emitting elements  104  to outside the housing  102  in the deflecting direction. 
     Turning now to  FIG. 5A , an underside of an example component forming the top surface  116  of the housing  102  is illustrated. Corners  140  can be seen positioned at right angles (substantially 90°) to the top surface  116 . The deflecting surfaces  124  of the louvered vents  122  extend into what would be an interior space of the housing  102  when top surface  116  is attached to the rest of housing  102 . A leading edge  128  of the louvered vents extends in the same direction as the deflecting surfaces  124 , but the leading edge may also create an airtight seam with mounting piece  126  (shown in  FIG. 4 ). 
       FIG. 5B  shows a closer view of a portion of  FIG. 5A . The width  125  of the deflecting surface  124  is less than or equal to the width  131  of the heat exits  106  as the deflecting surfaces may be formed by punching, pressing, or otherwise forming the deflecting surfaces of the louvered vents out of the raw material that forms the top surface  116  of the housing  102 . In other words, top surface  116  may be formed from a continuous piece of sheet metal that is bent to form several geometrical features. For example, corners  140  may be bent from an originally planar position to positions that are substantially 90° to the middle portion of top surface  116 . Similarly, the deflecting surfaces  124  may be partially cut from the originally continuous top surface  116  and bent to the angles shown in  FIGS. 5A and 5B . In this way, deflecting surfaces  124  include solid material while the empty space left by bending the deflecting surfaces  124  is labeled as heat exits  106 . 
     Leading edge  128  may also be originally part of the continuous piece of sheet metal, wherein cuts and bends are performed to allow leading edge  128  (as well as deflecting surfaces  124 ) to protrude into the interior of housing  102  when the lighting module  100  is assembled. As seen in  FIGS. 5A and 5B , each deflecting surface  124  may be substantially identical in shape and size, while it is appreciated that other configurations are possible. For example, the width  125  of deflecting surfaces  124  may gradually increase with each deflecting surface that is farther away from leading edge  128 . Furthermore, bolt holes  130  may be cut into the sheet metal forming top surface  116  for ease of assembly. Other methods of attaching the components of the housing  102  are possible such as gluing, nailing, welding, and riveting, provided as examples. 
     Turning now to  FIG. 6 , a partial cross-sectional view of a lighting module  100  is shown. The cross section is taken parallel to sides  112  and  114  as viewed from side  114 . As shown in  FIG. 6 , louvered vents  122  may extend over at least a portion of heat exits  106 , and heat exits  106  are positioned adjacent to heat sink  120 . Heat sink  120  may include a plurality of fins  123  and may be thermally and/or electrically coupled to an array of light-emitting elements (not visible). A reflector clamp  136  may be used to hold the light-emitting elements to the heat sink  120 . The width  139  of heat exits  106  may be the same as the width  138  of the portions of top surface  116  segregating the heat exits. 
     The fins  123  of the heat sink  120  may be arranged so that the ridges and grooves of the fins extend from front surface  108  to a back surface (not shown) of the housing. In other words, the fins  123  of the heat sink  120  may be parallel to sides  112  and  114  of the housing. The array of light-emitting elements may emit light in an emitted light direction  111 , and louvered vents  122  may guide dissipated heat and/or heated air in a deflecting direction  129  at least 90° from the emitted light direction  111 . 
     Mounting piece  126  is also visible in  FIG. 6 , wherein the mounting piece is shown in the assembled configuration providing structural support for housing  102 . It can be seen that recesses and ridges  155  of mounting piece  126  may maintain face-sharing contact with tabs and other features of top surface  116  in order to form a rigid assembly as well as an air-tight seal between the interior of housing  102  and the exterior of the housing. Furthermore, fasteners  157  may be inserted through the holes of top surface  116  as well holes  156  of the mounting piece  126  in order to secure the assembly of lighting module  100 . In one example, fasteners  157  may thread into only mounting piece  126  while in another example fasteners  157  may thread into heat sink  120  in order to fix top surface  116  and the mounting piece to heat sink  120 . The end surfaces of mounting piece  126  may be coplanar with the end surfaces of heat sink  120 . 
     Mounting piece  126  has a cross-sectional geometry as seen in  FIG. 6 , wherein a horizontal edge  137  is substantially planar to the top surface  116 . Also, a leading edge  141  is angled, extending from horizontal edge  137  to top surface  116 . Leading edge  141  may have an angle ranging between 0° and 90°. In some examples, leading edge  141  may be substantially parallel to deflecting surfaces  124 , as seen in  FIG. 6 . In other words, leading edge  141  may share the same angle as deflecting surfaces  124 . In this way, leading edge  141  further guides heated air from heat sink  120  out of the interior of housing  102  in the deflecting direction  129 . As one function, mounting piece  126  may aid in providing structural support for housing  102  and provide connection between top surface  116 , front surface  108 , and heat sink  120 , among other components. Additionally, as a second function, mounting piece  126  may act as another deflecting surface of louvered vents  122  by angling leading edge  141  in a similar fashion to the other deflecting surfaces  124 . In this sense, leading edge  141  is the first deflecting surface closest to front surface  108 , and leading edge  141  is located prior to the start of louvered vents  122  and fins  123 . 
     As seen in  FIG. 6 , four louvered vents  122  are included in top surface  116 , wherein each louvered vent includes four heat exits  106  and four deflecting surfaces  124 . As seen, the louvered vents  122  do not extend beyond the end of heat sink  120  farther away from front surface  108 . In particular, the fourth deflecting surface  124  from front surface  108  may be proximate to the ends of fins  123 . In other words, most rearward of the louvered vents  122  may have its deflecting surface  124  substantially aligned with the rearward end of the heat sink  120 . This alignment may allow for heated air vented by the heat sink  120  to escape the heat exits  106 . In some configurations, the louvered vents  122  may not extend further in the direction of the back surface than the rearward end of heat sink  120 . With this configuration of alignment between the deflecting surface  124  and heat sink  120 , air flown into housing  102  may be directed into heat sink  120  before exiting the housing via louvered vents  122 . If additional louvered vents  122  extended beyond fins  123 , then air flown into housing  102  may exit prior to transferring heat from heat sink  120 , which may degrade heat exchange performance. 
     In the present configuration shown in  FIG. 6 , substantially all of the intake air may be directed through fins  123  without letting air escape through louvered vents  122  before interaction with heat sink  120 , thereby increasing heat exchange efficiency. Additionally, deflecting surfaces  124  may be in close proximity to fins  123  such that a small gap is present between the deflecting surfaces and fins. As such, intake air may flow through fins  123  and directly out through heat exits  106  without recirculating through heat sink  120 . In this way, heat exchange between the intake air and heat sink  120  may be optimized to increase overall performance of lighting module  100 . Alternatively, if large spaces were present between fins  123  and deflecting surfaces  124 , then air may flow along the tops of fins  123  and recirculate away from front surface  108 . This air flow may decrease heat exchange performance and efficiency of the lighting module  100 . 
     Also shown in  FIG. 6  is an example of a curable workpiece surface  610 . The lighting module  100  may be positioned so that window  118  faces the curable workpiece surface  610 . In this manner, light emitted from the array of light-emitting elements in an emitted light direction  111  may irradiate the curable workpiece surface  610 . 
     Turning now to  FIG. 7 , an example method  700  of irradiating a curable workpiece surface with the lighting module  100  of previous figures is shown. For ease of understanding, reference will be made to labeled components of  FIGS. 1-6 . Method  700  begins at  710  where a lighting module is positioned opposite a curable workpiece surface. For example, lighting module  100  may be placed so that window  118  faces the curable workpiece surface. As shown in  FIG. 6 , light may be emitted from the array of light-emitting elements in an emitted light direction  111  to irradiate the curable workpiece surface at  740 . Next, at  750 , air may be actively or passively convected through the air intakes  103  as seen by direction  127  in  FIG. 3 . The convected air is then passed into the housing  102  and over the one or more heat sinks  120  at  760 . Heat generated from the array of light-emitting elements  104  is dissipated via conduction to the heat sinks  120  and then further dissipated by conduction and radiation to the air convected over the external surface of the heat sinks  120 . If the heat sinks  120  are finned, then the heat transfer area and the heat transfer dissipation rate may be increased as compared to when the heat sinks  120  are not finned. 
     Next, method  700  continues at  770  where the heat and/or heated air is convected out from the heat exits  106 . In cases where housing  102  comprises louvered vents  122  that may extend at least partially over the heat exits  106 , the heated air may be deflected away from the emitted light direction  111  in a deflecting direction  129  at  780  (as seen in  FIG. 3 ). As an example, the deflecting direction  129  may be at least 90° away from the emitted light direction. Upon completion of  780 , method  700  ends. 
     Turning now to  FIG. 8 , a block diagram for an example configuration of a lighting system  800  for a lighting module  100  is illustrated. In one example, lighting system  800  may comprise a lighting module  100  comprising a light-emitting subsystem  812 , a controller  814 , a power source  816 , and a cooling subsystem  818 . The light-emitting subsystem  812  may comprise a plurality of semiconductor devices  819 . The plurality of semiconductor devices  819  may be an array  820  of light-emitting elements such as a linear or two-dimensional array of LED devices, for example. The plurality of semiconductor devices  819  may provide radiant output  824 , represented by the arrows in  FIG. 8 . The radiant output  824  may be directed in an emitted light direction  111  to a workpiece  826  located at a fixed plane from lighting system  800 . 
     The radiant output  824  may be directed to the workpiece  826  via coupling optics  830 . The coupling optics  830 , if used, may be variously implemented. As an example, the coupling optics  830  may include one or more layers, materials or other structures interposed between the semiconductor devices  819  and window  864  in order to direct radiant output  824  to surfaces of the workpiece  826 . As an example, the coupling optics  830  may include a micro-lens array to enhance collection, condensing, or collimation of radiant output  824 , or otherwise enhance the quality or effective quantity of the radiant output. As another example, the coupling optics  830  may include a micro-reflector array. In employing such a micro-reflector array, each semiconductor device  819  providing radiant output  824  may be disposed in a respective micro-reflector, on a one-to-one basis. As another example, a linear array  820  of semiconductor devices  819  providing radiant output  824  may be disposed in macro-reflectors, on a many-to-one basis. In this manner, coupling optics  830  may include both micro-reflector arrays, wherein each semiconductor device  819  is disposed on a one-to-one basis in a respective micro-reflector, and macro-reflectors wherein the quantity and/or quality of the radiant output  824  from the semiconductor devices is further enhanced by macro-reflectors. 
     Each of the layers, materials, or other structure of coupling optics  830  may have a selected index of refraction. By properly selecting each index of refraction, reflection at interfaces between layers, materials, and other structures in the path of the radiant output  824  may be selectively controlled. As an example, by controlling differences in such indexes of refraction at a selected interface, for example window  864 , disposed between the semiconductor devices  819  and the workpiece  826 , reflection at that interface may be reduced or increased so as to enhance the transmission of radiant output  824  at that interface for ultimate delivery to the workpiece  826 . For example, the coupling optics may include a dichroic reflector wherein certain wavelengths of incident light are absorbed while other wavelengths are reflected and focused to the surface of workpiece  826 . 
     The coupling optics  830  may be employed for various purposes. Example purposes include, among others, to protect the semiconductor devices  819 , to retain cooling fluid associated with the cooling subsystem  818 , to collect, condense and/or collimate the radiant output  824 , or for other purposes, alone or in combination. As a further example, the lighting system  800  may employ coupling optics  830  so as to enhance the effective quality, uniformity, or quantity of the radiant output  824 , particularly as delivered to the workpiece  826 . 
     Several or all of the plurality of semiconductor devices  819  may be coupled to the controller  814  via coupling electronics  822  so as to provide data to the controller  814 . As described further below, the controller  814  may also be implemented to control such data-providing semiconductor devices  819 , e.g., via the coupling electronics  822 . The controller  814  may also be connected to, and may be implemented to control, the power source  816  and the cooling subsystem  818 . For example, the controller  814  may supply a larger drive current to light-emitting elements distributed in the middle portion of linear array  820  and a smaller drive current to light-emitting elements distributed in the end portions of linear array  820  in order to increase the useable width of light irradiated at workpiece  826 . Moreover, the controller  814  may receive data from power source  816  and cooling subsystem  818 . In one example, the irradiance at one or more locations at the workpiece  826  surface may be detected by sensors and transmitted to controller  814  in a feedback control scheme. In a further example, controller  814  may communicate with a controller of another lighting system (not shown in  FIG. 8 ) to coordinate control of both lighting systems. For example, controllers  814  of multiple lighting systems may operate in a master-slave cascading control algorithm, where the setpoint of one of the controllers is set by the output of the other controller. Other control strategies for operation of lighting system  800  in conjunction with another lighting system may also be used. As another example, controllers  814  for multiple lighting systems arranged side by side may control lighting systems in an identical manner for increasing uniformity of irradiated light across multiple lighting systems. 
     In addition to the power source  816 , cooling subsystem  818 , and light-emitting subsystem  812 , the controller  814  may also be connected to and implemented to control internal element  832  and external element  834 . Element  832 , as shown, may be internal to the lighting system  800 , while element  834 , as shown, may be external to the lighting system  800 , but may be associated with the workpiece  826  (e.g., handling, cooling or other external equipment) or may be otherwise related to a photoreaction (e.g. curing) that lighting system  800  supports. 
     The data received by the controller  814  from one or more of the power source  816 , the cooling subsystem  818 , the light-emitting subsystem  812 , and/or elements  832  and  834 , may be of various types. As an example the data may be representative of one or more characteristics associated with coupled semiconductor devices  819 . As another example, the data may be representative of one or more characteristics associated with the respective light-emitting subsystem  812 , power source  816 , cooling subsystem  818 , internal element  832 , and external element  834  providing the data. As still another example, the data may be representative of one or more characteristics associated with the workpiece  826  (e.g., representative of the radiant output energy or spectral component(s) directed to the workpiece). Moreover, the data may be representative of some combination of these characteristics. 
     The controller  814 , in receipt of any such data, may be implemented to respond to that data. For example, responsive to such data from any such component, the controller  814  may be implemented to control one or more of the power source  816 , cooling subsystem  818 , light-emitting subsystem  812  (including one or more such coupled semiconductor devices), and/or the elements  32  and  34 . As an example, responsive to data from the light-emitting subsystem  812  indicating that the light energy is insufficient at one or more points associated with the workpiece  826 , the controller  814  may be implemented to either (a) increase the power source&#39;s supply of power to one or more of the semiconductor devices  819 , (b) increase cooling of the light-emitting subsystem via the cooling subsystem  818  (e.g., certain light-emitting devices, if cooled, provide greater radiant output), (c) increase the time during which the power is supplied to such devices, or (d) a combination of the above. 
     Individual semiconductor devices  819  (e.g., LED devices) of the light-emitting subsystem  812  may be controlled independently by controller  814 . For example, controller  814  may control a first group of one or more individual LED devices to emit light of a first intensity, wavelength, and the like, while controlling a second group of one or more individual LED devices to emit light of a different intensity, wavelength, and the like. The first group of one or more individual LED devices may be within the same linear array  820  of semiconductor devices, or may be from more than one linear array of semiconductor devices  820  from multiple lighting systems  800 . Linear array  820  of semiconductor devices  819  may also be controlled independently by controller  814  from other linear arrays of semiconductor devices in other lighting systems. For example, the semiconductor devices of a first linear array may be controlled to emit light of a first intensity, wavelength, and the like, while those of a second linear array in another lighting system may be controlled to emit light of a second intensity, wavelength, and the like. 
     As a further example, under a first set of conditions (e.g. for a specific workpiece, photoreaction, and/or set of operating conditions) controller  814  may operate lighting system  800  to implement a first control strategy, whereas under a second set of conditions (e.g. for a specific workpiece, photoreaction, and/or set of operating conditions) controller  814  may operate lighting system  800  to implement a second control strategy. As described above, the first control strategy may include operating a first group of one or more individual semiconductor devices (e.g., LED devices) to emit light of a first intensity, wavelength, and the like, while the second control strategy may include operating a second group of one or more individual LED devices to emit light of a second intensity, wavelength, and the like. The first group of LED devices may be the same group of LED devices as the second group, and may span one or more arrays of LED devices, or may be a different group of LED devices from the second group, but the different group of LED devices may include a subset of one or more LED devices from the second group. 
     The cooling subsystem  818  may be implemented to manage the thermal behavior of the light-emitting subsystem  812 . For example, the cooling subsystem  818  may provide for cooling of light-emitting subsystem  812 , and more specifically, the semiconductor devices  819 . For example, cooling subsystem  818  may comprise an air or other fluid (e.g., water) cooling system. Cooling subsystem  818  may also include cooling elements such as cooling fins attached to the semiconductor devices  819 , or linear array  820  thereof, or to the coupling optics  830 . For example, cooling subsystem may include blowing cooling air over the coupling optics  830 , wherein the coupling optics  830  are equipped with external fins to enhance heat transfer. Cooling subsystem  818  may further comprise one or more louvered vents  122  and/or one or air intakes  103 . As described above, louvered vents  122  may aid in guiding dissipated heat and/or heated air away from the housing  102  in a deflected direction  129  away from an emitted light direction  111 , for example, at least 90° away from an emitted light direction  111 . As described above, air intakes  103  may aid in guiding intake air into the housing  102 , wherein the intake air is subsequently guided in a deflected direction  129  away from the emitted light direction  111  and away from the curable workpiece surface or workpiece  826 . 
     The lighting system  800  may be used for various applications. Examples include, without limitation, curing applications ranging from ink printing to the fabrication of DVDs and lithography. The applications in which the lighting system  800  may be employed can have associated operating parameters. That is, an application may have associated operating parameters as follows: provision of one or more levels of radiant power, at one or more wavelengths, applied over one or more periods of time. In order to properly accomplish the photoreaction associated with the application, optical power may be delivered at or near the workpiece  826  at or above one or more predetermined levels of one or a plurality of these parameters (and/or for a certain time, times or range of times). 
     In order to follow an intended application&#39;s parameters, the semiconductor devices  819  providing radiant output  824  may be operated in accordance with various characteristics associated with the application&#39;s parameters, e.g., temperature, spectral distribution and radiant power. At the same time, the semiconductor devices  819  may have certain operating specifications, which may be associated with the semiconductor devices&#39; fabrication and, among other things, may be followed in order to preclude destruction and/or forestall degradation of the devices. Other components of the lighting system  800  may also have associated operating specifications. These specifications may include ranges (e.g., maximum and minimum) for operating temperatures and applied electrical power, among other parameter specifications. 
     Accordingly, the lighting system  800  may support monitoring of the application&#39;s parameters. In addition, the lighting system  800  may provide for monitoring of semiconductor devices  819 , including their respective characteristics and specifications. Moreover, the lighting system  800  may also provide for monitoring of selected other components of the lighting system  800 , including its characteristics and specifications. 
     Providing such monitoring may enable verification of the system&#39;s proper operation so that operation of lighting system  800  may be reliably evaluated. For example, lighting system  800  may be operating improperly with respect to one or more of the application&#39;s parameters (e.g. temperature, spectral distribution, radiant power, and the like), any component&#39;s characteristics associated with such parameters and/or any component&#39;s respective operating specifications. The provision of monitoring may be responsive and carried out in accordance with the data received by the controller  814  from one or more of the system&#39;s components. 
     Monitoring may also support control of the system&#39;s operation. For example, a control strategy may be implemented via the controller  814 , the controller  814  receiving and being responsive to data from one or more system components. This control strategy, as described above, may be implemented directly (e.g., by controlling a component through control signals directed to the component, based on data respecting that components operation) or indirectly (e.g., by controlling a component&#39;s operation through control signals directed to adjust operation of other components). As an example, a semiconductor device&#39;s radiant output may be adjusted indirectly through control signals directed to the power source  816  that adjust power applied to the light-emitting subsystem  812  and/or through control signals directed to the cooling subsystem  818  that adjust cooling applied to the light-emitting subsystem  812 . 
     Control strategies may be employed to enable and/or enhance the system&#39;s proper operation and/or performance of the application. In a more specific example, control may also be employed to enable and/or enhance balance between the linear array&#39;s radiant output and its operating temperature, so as, e.g., to preclude heating the semiconductor devices  819  beyond their specifications while also directing sufficient radiant energy to the workpiece  826 , for example, to carry out a photoreaction of the application. 
     In some applications, high radiant power may be delivered to the workpiece  826 . Accordingly, the light-emitting subsystem  812  may be implemented using a linear array  820  of light-emitting semiconductor devices  819 . For example, the light-emitting subsystem  812  may be implemented using a high-density, light-emitting diode (LED) array. Although LED arrays may be used and are described in detail herein, it is understood that the semiconductor devices  819 , and linear arrays  820  thereof, may be implemented using other light-emitting technologies without departing from the principles of the invention; examples of other light-emitting technologies include, without limitation, organic LEDs, laser diodes, other semiconductor lasers. 
     It will be appreciated that variations of the above-disclosed lighting modules and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, methods, or applications. For example, methods of guiding air or heat away from a lighting module may use anyone or more of the above disclosed louvered vents. Also various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which also are intended to be encompassed by the following claims. Thus, although there has been described to this point a particular embodiment for a method and apparatus for lighting modules with louvered vents, it is not intended that such specific references be considered as limitations upon the scope of this invention except in-so-far as set forth in the following claims. 
     Various alternative scopes of coverage may be desired. In example, a lighting module, comprises a housing with a surface perpendicular to a vertical axis of the module, the surface including a plurality of lateral louvered vents; an array of light-emitting elements arranged on a planar substrate and positioned behind a planar window, the planar window optionally including one or more lenses or other light-modifying features, the window extending fully across the housing such that the window extend laterally at least as wide as a widest part of the housing; and a heat sink thermally coupled to the array of light-emitting elements, the heat sink including a plurality of extending longitudinal fins with vertical spaces therebetween, the plurality of louvered vents optionally all positioned vertically above the longitudinally extending fins. 
     The lighting module may further comprise a fan positioned immediately behind the fins and facing the window, the fan positioned longitudinally behind a last of the vents. The lighting module may further comprise power electronics positioned behind the fan. The lighting module may further have the vents include an extension into an inside of the housing. The lighting module may further have the array of light-emitting elements being a single linear array of LEDs. The lighting module may further have no components between a top surface of the heat sink fins and the louvered vents. The lighting module may further have the substrate is mounted directly to the heat sink with no components therebetween, and wherein the substrate is powered by power electronics. The lighting module may further have the module positioned in an ink-curing system, such as a printer, or a sterilization system, or a fiber-curing system. For example, the lighting module may be positioned proximate to a fiber optic cable for generating UV light to cure the cable as it passes by the module. As another example, the lighting module may be positioned proximate to components to be sterilized, such as blood containers, etc.

Technology Classification (CPC): 5