(19)Ullillfid SIHIES
`<12)Patent Application
`Dry
`
`Publication
`
`(10)Pub.N0.:US 2004/0141326A1
`(43)Puh. Date:
`Jul. 22, 2004
`
`US 20040141326A1
`
`(54)
`
`(75)
`
`LIGHT EMITTING DIODE LIGHT SOURCE
`
`Inventor:
`
`Joel M. Dry, New Orleans, l,A (US)
`
`Correspondence Address:
`DONALD J. LENKSZUS
`PO BOX 3064
`CAREFREE, AZ 85377-3064 (US)
`
`No. ltI,»‘156‘8l0,filed on May 29, 2002, now Pat. No.
`6.573530.
`
`Pllhlimtlon Classification
`
`Int.CI.’
`(st)
`(52) u.s.c|.
`
`B60Q 1/06
`..........sa2/svs
`
`(73)
`
`Assignee: OPTOLUM,
`
`lNC., Scottsdale, AZ
`
`(57)
`
`ABSTRACT
`
`(31)
`
`Appl. No;
`
`10/631,027
`
`(23)
`
`Filed:
`
`Jul. 30, 2003
`
`Related U.S. Application Data
`
`(63)
`
`(Tontinuation of application No. l0s'430,732, filed on
`May 5, 2003, which is a continuation of application
`
`A light or radiation emitting source that utilizes radiation
`emitting solid state or semiconductor devices is disclosed.
`The devices are mounted on an elongate member having at
`least two surfaces upon which the light emitting diodes are
`mounted. The elongate member is thermally conductive and
`is utilized to cool the devices.
`ln the illustrative embodi­
`ment, the elongate memhcr is a tubular member through
`which a heat transfer medium flows.
`
`102
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`102
`
`­
`

`

`Patent Application Publication
`
`Jul. 22, 2004 Sheet 1 0f 2
`II3
`
`US 2004/0141326 A1
`
`09
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`­
`

`

`Patent Application Publication
`
`Jul. 22, 2004 Sheet 2 of 2
`
`US 2004/0141326Al
`
`4
`
`100
`
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`

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`US 2004/0141326 Al
`
`Jul. 22, 2004
`
`LIGHT l<IMl'l"l‘IN(ll)l()l)l<I LIGHT SOURCE
`
`RELATED APPLICATIONS
`
`[0001] This application is a continuation of my co-pending
`application Ser. No. 10/430,732, filed May 5, 2003 Which is
`a continuation of application Ser. No. 10/156,810 filed May
`29, 2002, now US. Pat. No. 6,573,536 issued .Iun. 3, 2003.
`
`FIELD OF THE INVENTION
`
`[0002] This invention pertains to lighting sources, in gen­
`eral, and to a lighting source that utilizes Light Emitting
`Diodes (LED’s), in particular.
`
`BACKGROUND OF THE INVENTION
`
`[0003] LED’s have many advantages as light sources.
`However, in the past LED’s have found application only as
`specialized light sources such as for vehicle brake lights, and
`other vehicle related lighting, and recently as flashlights. In
`these prior applications, the I.ED’s are typically mounted in
`a planar fashion in a single plane that is disposed so as to be
`perpendicular to the viewing area. Typically the LED planar
`array is not used to provide illumination, but to provide
`signaling.
`
`[0004] Recent attempts to provide LED light sources as
`sources of illt|mination have been few, and generally unsat­
`isfactory from a general lighting standpoint.
`
`is highly desirable to provide a light source
`It
`[0005]
`utilizing LED’s that provides sufficient light output so as to
`be used as a general lighting source rather than as a signaling
`source.
`
`[0006] One problem that has limited the use of LED’s to
`specialty signaling and limited general illumination sources
`is that I.ED’s typically generate significant amounts of heat.
`The heat is such that unless the heat is dissipated, the LED
`internal
`temperature will
`rise causing degradation or
`destruction of the LED.
`
`It is therefore further desirable to provide an LED
`[0007]
`light source that efficiently conducts heat away from the
`I.ED’s.
`
`SUMMARY OF THE INVENTION
`
`In accordance with the principles of the invention,
`[0008]
`an improved light source is provided. The light source
`includes an elongate thermally conductive member having
`an outer surface. A plurality of light emitting diodes is
`carried on the elongate member outer surface. At least some
`of the light emitting diodes are disposed in a first plane and
`others of said light emitting diodes are disposed in a second
`plane not coextensive with the first plane. Electrical con­
`ductors are carried by the elongate thermally conductive
`member and are connected to the plurality of light emitting
`diodes to supply electrical power thereto. The elongate
`thermally conductive member conducts heat away from the
`light emitting diodes.
`
`In accordance with one aspect of the invention, an
`[0009]
`illustrative embodiment of the invention utilizes light emit­
`ting diodes that emit white light. However, other embodi­
`ments of the invention may utilize light emitting diodes that
`are of different colors to produce monochromatic light or the
`colors may be chosen to produce white light or other colors.
`
`In accordance with another aspect of the invention
`[0010]
`the elongate thermally conductive member transfers heat
`from the light emitting diodes to a medium within said
`elongate thermally conductive member. In the illustrative
`embodiment of the invention, the medium is air.
`
`In accordance with another aspect of the invention,
`[0011]
`the elongate thermally conductive member has one or more
`Ilns to enhance heat transfer to the medium.
`
`In accordance with another aspect of the invention
`[0012]
`the elongate thermally conductive member comprises a tube.
`In one embodiment of the invention, the tube has a cross­
`section in the shape of a polygon. In another embodiment of
`the invention, the tube has a cross-section having flat por­
`tions.
`
`In accordance with another embodiment of the
`[0013]
`invention, the elongate thermally conductive member com­
`prises a channel.
`
`In accordance with the principles of the invention,
`[0014]
`the elongate thermally conductive member may comprise an
`extrusion, and the extrusion can be highly thermally con­
`ductive material such as aluminum.
`
`In one preferred embodiment of the invention the
`[0015]
`elongate thermally conductive member is a tubular member.
`The tubular member has a polygon cross-section. However,
`other embodiments my have a tubular member of triangular
`cross-section.
`
`In one embodiment of the invention, a flexible
`[0016]
`circuit is carried on a surface of said elongate thermally
`conductive member; the flexible circuit includes the electri­
`cal conductors.
`
`the flexible
`In another aspect of the invention,
`[0017]
`circuit comprises a plurality of apertures for receiving said
`plurality of light emitting diodes. Each of the light emitting
`diodes is disposed in a corresponding one of the apertures
`and aflixed in thermally conductive contact with said elon­
`gate thermally conductive member.
`
`conductive member
`thermally
`elongate
`[0018] The
`includes a thermal transfer media disposed therein in a flow
`channel.
`
`[0019] At least one clip for mounting the elongate ther­
`mally conductive member in a fixture may be included.
`
`BRIEF DESCRIPTION OF THE DRAWING
`
`[0020] The invention will be better understood from a
`reading of the following detailed description of a preferred
`embodiment of the invention taken in conjunction with the
`drawing figures, in which like reference indications identify
`like elements, and in which:
`
`[0021] FIG. 1 is a planar side view of a light source in
`accordance with the principles of the invention;
`
`[0022] FIG. 2 is a top planar view of the light source of
`FIG. 1;
`
`FIG. 3 is a perspective view of the light source of
`[0023]
`FIG. 1 with mounting clips;
`
`[0024] FIG. 4 is a planar side view of the light source of
`FIG. 3 showing mounting clips separated from the light
`source;
`
`

`

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`US 2004/0141326 Al
`
`Jul. 22, 2004
`
`FIG. 5 is a top View of the light source and
`[0025]
`mounting clips of FIG. 4; and
`
`134 for receiving I.EDs 109 such that the backs ofI.EDs 109
`are in thermal contact with the tube surfanx: 107.
`
`[0026] FIG. 6 is a partial cross-section of the light source
`of FIG. 1.
`
`DETAILED DESCRIPTION
`
`[0027] Alight source in accordance with the principles of
`the invention may be used as a decorative lighting element
`or may be utilized as a general
`illumination device. As
`shown in FIG. 1, a light source 100 in accordance with the
`invention includes an elongate thermally conductive mem­
`ber or heat sink 101. Elongate heat sink 101 is formed of a
`material that provides excellent thermal conductivity. Elon­
`gate heat sink 101 in the illustrative embodiment of the
`invention is a tubular aluminum extrusion. To improve the
`heat dissipative properties of light source 100, elongate heat
`sink 101 is configured to provide convective heat dissipation
`and cooling. As more clearly seen in FIG. 2, tubular heat
`sink 101 is hollow and has an interior cavity 103 that
`includes one or more heat dissipating fins 105. Fins 105 are
`shown as being triangular in shape, but may take on other
`shapes. Fins 105 are integrally formed on the interior of
`elongate heat sink 101. In the illustrative embodiment con­
`vective cooling is provided by movement of a medium 102
`through elongate heat sink 101. The medium utilized in the
`illustrative embodiment is air, but may in some applications
`be a fluid other than air to provide for greater heat dissipa­
`tion and cooling
`
`[0028] The exterior surface 107 of elongate heat sink 101
`has a plurality of Light Emitting Diodes 109 disposed
`thereon. Each LED 109 in the illustrative embodiment
`comprises a White light emitting LED of a type that provides
`a high light output. Each LED 109 also generates significant
`amount of heat that must be dissipated to avoid thermal
`destruction of the LED. Ry combining a plurality of I.EDs
`109 on elongate heat sink 101, a high light output
`light
`source that may be used for general lighting is provided.
`
`[0029] Conductive paths 129 are provided to connect
`I.EDs 109 to an electrical connector 111. The conductive
`paths may be disposed on an electrically insulating layer 131
`or layers disposed on exterior surface 107. In the illustrative
`embodiment shown in the drawing figures, the conductive
`paths and insulating layer are provided by means of one or
`more flexible printed circuits 113 that are permanently
`disposed on surface 107. As more easily seen in FIG. 6,
`printed circuit 113 includes an electrically insulating layer
`131 that carries conductive paths 129. As will be appreciated
`by those skilled in the art, other means of providing the
`electrically wnductive paths on the
`
`Flexible printed circuit 113 has LED’s 109
`[0030]
`mounted to it in a variety of orientations ranging from 360
`degrees to 180 degrees and possibly others depending on the
`application. Electrical connector 111 is disposed at one end
`of printed circuit 113. Connector 113 is coupleable to a
`separate power supply to receive electrical current. Flexible
`printed circuit 113, in the illustrative embodiment is coated
`with a non-electrically conductive epoxy that may be
`infused with optically reflective materials. Flexible printed
`circuit 113 is adhered to the tube 101 with a heat conducting
`epoxy to aid in the transmission of the heat from LEDs 109
`to tube 101. Flexible printed circuit 113 has mounting holes
`
`[0031] Tubular heat sink 101 in the illustrative embodi­
`ment is formed in the shape of a polygon and may have any
`number of sides. Although tubular heat sink 101 in the
`illustrative embodiment is extruded aluminum, tubular heat
`sink 101 may comprise other thermal conductive material.
`Fins 105 may vary in number and location depending on
`particular LED layouts and wattage. In some instances, fins
`maybe added to the exterior surface of tubular heat sink 101.
`In addition, apertures may be added to the tubular heat sink
`to enhance heat flow.
`
`[0032] Light source 100 is mounted into a fixture and
`retained in position by mounting clips 121, 123 as most
`clearly seen in FIGS. 3, 4, and 5. Each of the clips is shaped
`so as to engage and retain light source 100. Each clip is
`afhxed on one surface 122, 124 to a light fixture.
`
`[0033] Although light source 100 is shown as comprising
`an elongate tubular heat sink, other extruded elongate mem­
`bers may be used such as channels.
`
`In the illustrative embodiment shown, convection
`[0034]
`cooling by [low of air through tubular heat sink 101 is
`utilized such that cool or unheated air enters tubular heat
`sink 101 at its lower end and exits from the upper end as
`heated air. In higher wattage light sources,
`rather
`than
`utilizing air as the cooling medium, other fluids may be
`utilized. In particular, convective heat pumping may be used
`to remove heat from the interior of the heat sink.
`
`In one particularly advantageous embodiment of
`[0035]
`the invention, the light source of the invention is configured
`to replace compact lluorescent lighting in decorative appli­
`cations.
`
`[0036] As will be appreciated by those skilled in the art,
`the principles of the invention are not limited to the use of
`light emitting diodes that emit white light. Different colored
`light emitting diodes may be used to produce monochro­
`matic light or to produce light that is the combination of
`different colors.
`
`[0037] Although the invention has been described in terms
`of illustrative embodiments,
`it
`is not
`intended that
`the
`invention be limited to the illustrative embodiments shown
`and described. It will be apparent to those skilled in the art
`that various changes and modifications may be made to the
`embodiments shown and described without departing from
`the spirit or scope of the invention. lt is intended that the
`invention be li.mited only by the claims appended hereto.
`
`What is claimed is:
`1. A light source comprising:
`
`an elongate thermally conductive member having an outer
`surface;
`
`at least one solid state light source carried on said elongate
`member outer surface;
`
`one or more electrical conductors carried by said elongate
`thermally conductive member and connected to said at
`least one solid state light source to supply electrical
`power thereto; and
`
`said elongate thermally conductive member being con­
`figured to conduct heat away from said at least one
`
`

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`US 2004/0141326 Al
`
`Jul. 22, 2004
`
`solid state light source to fluid contained by said
`elongate thermally conductive member.
`2. A light source comprising:
`
`an elongate thermally conductive member having an outer
`surface;
`
`a plurality of solid state light sources carried on said
`elongate member outer surface at least some of said
`solid state light sources being disposed in a first plane
`and others of said solid state light sourws being dis­
`posed in a second plane not coextensive With said first
`plane;
`
`electrical conductors carried by said elongate thermally
`conductive member and connected to said plurality of
`solid state light sources to supply electrical poWer
`thereto; and
`
`said elongate thermally conductive member being con­
`figured to conduct heat away from said solid state light
`sources to fluid contained by said elongate thermally
`conductive member.
`3. A light source in accordance With claim 2, Wherein:
`
`said fluid comprises air.
`4. A light source in accordance With claim 3, Wherein:
`
`said elongate thermally conductive member comprises
`one or more heat dissipation protrusions.
`5. A light source in accordance With claim 2, Wherein:
`
`said elongate thermally conductive member comprises a
`tube.
`6. A light source in accordance With claim 5, Wherein:
`
`16. A light source in accordance With claim l5, Wherein:
`
`each of said solid state light sources is disposed in a
`corresponding one of said apertures and afiixed in
`thermally conductive contact With said elongate ther­
`mally conductive member.
`17. A light source in accordance with claim 2, Wherein:
`
`a thermal transfer media disposed therein.
`18. A light source in accordance with claim 17, wherein:
`
`said elongate thermally conductive member comprises a
`floW channel for said thermal transfer media.
`19. A light source in accordance Withclaim 2, comprising:
`
`at least one clip for mounting said elongate thermally
`conductive member in a fixture.
`20. A light source in accordance Withclaim 2, comprising:
`
`an electrically insulating layer disposed on said elongate
`thermally conductive member outer surface and carry­
`ing said electrical conductors thereon.
`21. A light source in accordance with claim 20, wherein:
`
`said electrically insulating layer comprises a plurality of
`apertures, each aperture receiving one of said solid state
`light sources; and
`
`each solid state light source of said plurality of solid state
`light sources being mounted in a corresponding one of
`said apertures and in thermally conductive contact with
`said elongate thermally conductive member.
`22. A radiation emitting source comprising:
`
`an elongate thermally conductive member having an outer
`surface;
`
`said tube has a cross-section in the shape of a polygon.
`7. A light source in accordance With claim 5,wherein:
`
`at least one radiation emitting semiconductor device car­
`ried on said elongate member outer surface;
`
`said tube has a cross-section having fiat portions.
`8. A light source in accordance With claim 2, Wherein:
`
`said elongate thermally conductive member comprises a
`channel.
`9. A light sournx:in accordance with claim 2, wherein:
`
`said elongate thermally conductive member comprises an
`extrusion.
`10. A light source in accordance With claim 9, Wherein:
`said extrusion is an aluminum extrusion.
`Ll. A light source in accordance With claim 10, Wherein:
`
`said elongate thermally conductive member is a tubular
`member.
`12. A light source in accordance with claim 11, wherein:
`
`said tubular member has a polygon cross-section.
`13. A light source in accordance With claim 11, Wherein:
`
`said tubular member has a triangular cross-section.
`l4. A light source in accordance With claim 2, comprising:
`
`a flexible circuit carried on a surface of said elongate
`thermally conductive member, said flexible circuit
`comprising said electrical conductors.
`15. A light sournx:in accordance with claim 14, wherein:
`
`said flexible circuit comprises a plurality of apertures for
`receiving said plurality of light emitting diodes.
`
`one or more electrical conductors carried by said elongate
`thermally conductive member and connected to said at
`least one radiation emitting semiconductor device to
`supply electrical poWer thereto; and
`
`said elongate thermally conductive member being con­
`figured to conduct heat away from said at least one
`radiation emitting semiconductor device to fluid con­
`tained by said elongate thermally conductive member.
`23. A radiation emitting source comprising:
`
`an elongate thermally conductive member having an outer
`surface;
`
`a plurality of radiation emitting semiconductor devices
`carried on said elongate member outer surface at least
`some of said radiation emitting semiconductor devices
`being disposed in a first plane and others of said
`radiation emitting semiconductor devices being dis­
`posed in a second plane not coextensive with said first
`plane;
`
`electrical conductors carried by said elongate thermally
`conductive member and connected to said plurality of
`light emitting diodes to supply electrical poWerthereto;
`and
`
`said elongate thermally conductive member being con­
`figured to wnduct heat away from said radiation emit­
`ting semiconductor devices to fluid contained by said
`elongate thennally conductive member.
`
`

`

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`US 2004/0141326 Al
`
`Jul. 22, 2004
`
`24. A radiation emitting source in accordance with claim
`23, wherein:
`
`39. A radiation source in accordance with claim 38,
`wherein:
`
`said fluid comprises air.
`25. A radiation emitting source in accordance with claim
`24, wherein:
`
`said elongate thermally conductive member comprises
`one or more heat dissipation p1'OlItJSlOI1S.
`26. A radiation emitting source in accordance with claim
`23, wherein:
`
`said elongate thermally conductive member comprises a
`tube.
`27. A radiation emitting source in accordance with claim
`26, wherein:
`
`said tube has a cross-section in the shape of a polygon.
`28. A radiation emitting source in accordance with claim
`26,wherein:
`
`said tube has a cross-section having flat portions.
`29. A radiation emitting source in accordance with claim
`23, wherein:
`
`said elongate thermally conductive member comprises a
`channel.
`30. A radiation source in accordance with claim 23,
`wherein:
`
`said elongate thermally conductive member comprises an
`extrusion.
`31. A radiation emitting source in accordance with claim
`30, wherein:
`said extrusion is an aluminum extrusion.
`32. A radiation emitting source in accordance with claim
`31, wherein:
`
`said elongate thermally conductive member is a tubular
`member.
`33. A radiation emitting source in accordance with claim
`32, wherein:
`
`said tubular member has a polygon cross-section.
`34. A radiation emitting source in accordance with claim
`32, wherein:
`
`said tubular member has a triangular cross-section.
`35. A radiation emitting source in accordance with claim
`23, comprising:
`
`a flexible circuit carried on a surface of said elongate
`thermally conductive member, said flexible circuit
`comprising said electrical conductors.
`36. A radiation source in accordance with claim 35,
`wherein:
`
`said flexible circuit comprises a plurality of apertmes for
`receiving said plurality of light emitting diodes.
`37. A radiation source in accordance with claim 36,
`wherein:
`
`said elongate thermally conductive member comprises a
`flow channel for said thermal transfer media.
`40. A radiation emitting source in accordance with claim
`23, comprising:
`
`at least one clip for mounting said elongate thermally
`conductive member in a fixture.
`41. A radiation emitting source in accordance with claim
`23, comprising:
`
`an electrically insulating layer disposed on said elongate
`thermally conductive member outer surface and carry­
`ing said electrical conductors thereon.
`42. A radiation emitting source in accordance with claim
`41, wherein:
`
`said electrically insulating layer comprises a plurality of
`apertures, each aperture receiving one of said radiation
`emitting semiconductor devices; and
`
`each radiation emitting semiconductor device of said
`plurality of radiation emitting semiconductor devices
`being mounted in a corresponding one of said apertures
`and in thermally conductive contact with said elongate
`thermally conductive member.
`43. A radiation emitting source comprising:
`
`an elongate thermally conductive member having an outer
`surface;
`
`at least one radiation emitting solid state device carried on
`said elongate member outer surface;
`
`one or more electrical conductors carried by said elongate
`thermally conductive member and connected to said at
`least one radiation emitting solid state device to supply
`electrical power thereto; and
`
`said elongate thermally conductive member being con­
`figured to conduct heat away from said at least one
`radiation emitting solid state device to fluid contained
`by said elongate thermally conductive member.
`44. A radiation emitting source comprising:
`
`an elongate thermally conductive member having an outer
`surface;
`
`a plurality of radiation emitting solid state devices carried
`on said elongate member outer surface at least s