Patent ID: 8378322

Claim:
A lamp head module comprising: an optical macro-reflector including a window having an outer surface; an array of light emitting diodes (LEDs) positioned within the optical reflector, the array having a high fill factor and a high aspect ratio operable to provide a high irradiance output beam pattern having a peak irradiance of greater than 25 W/cm 2 at a work piece surface at least 1 mm away from the outer surface of the window of the optical reflector; a micro-channel cooler assembly operable to maintain a substantially isothermal state among p-n junctions of LEDs in the array at a temperature of less than or equal to 80° Celsius, the micro-channel cooler assembly also providing a common anode substrate for the array, wherein a thermally efficient electrical connection is formed between the array and the common anode substrate by mounting the array to the micro-channel cooler assembly; a flex-circuit, including a patterned cathode layer, to independently address a plurality of groups of one or more LEDs of the array; a thermally conductive lamp body having opposing thin outer walls and having formed therein deep and long coolant flow channels in fluid communication with the micro-channel cooler; and integrated LED drivers mounted to the outer walls of the lamp body, wherein the deep and long coolant flow channels serve to balance flow of coolant through the micro-channel cooler and create a sufficient surface area to reduce heat transfer coefficient to maintain operational temperature requirements of the integrated LED drivers and wherein the thin outer walls of the lamp body allow for the lamp head module to be narrow which (i) reduces length requirement of the patterned cathode layer and (ii) reduces thermal resistance between coolant in the coolant flow channels and the integrated LED drivers.