Heat sink structures, lighting elements and lamps incorporating same, and methods of making same

Patent metadata

Field	Value
Publication number	US-10030863-B2
Application number	US-201113089807-A
Country	US
Kind code	B2
Filing date	Apr 19, 2011
Priority date	Apr 19, 2011
Publication date	Jul 24, 2018
Grant date	Jul 24, 2018

Abstract

In some embodiments, a lighting element comprising at least first and second solid state light emitters, a first heat sink structure with a fold region between first and second heat sink regions, and at least one light emitter on each of the heat sink regions, and methods of making. In some embodiments, a lighting element, comprising plural heat sink regions on respective regions of a flexible circuit board, and plural light emitters on respective regions of the flexible circuit board, and methods of making. In some embodiments, heat sink structures comprising plural heat sink regions and a circuit board with plural regions, and lighting elements comprising them. In some embodiments, a heat sink structure, comprising plural heat sink regions and an internal flow guide structure, and lighting elements comprising same. Also, other lighting elements, lamps and heat sink structures.

First claim

The invention claimed is:

1. A lighting element, comprising:
at least a first heat sink structure; and
at least a first group of solid state light emitters and a second group of solid state light emitters,
the first heat sink structure a one-piece structure that comprises at least first and second heat sink regions integral with one another and at least a first fold region between the first and second heat sink regions, the fold region of rigidity that is lower than the rigidity of the first heat sink region and lower than the rigidity of the second heat sink region,
at least a first solid state light emitter on the first heat sink region, at least a second solid state light emitter on the second heat sink region,
the first heat sink structure defining a first internal space defined at least in part by the first and second heat sink regions,
an entirety of the first internal space between a first plane and a second plane, the first plane substantially parallel to the second plane,
the first internal space comprising at least one plenum extending from the first plane to the second plane,
each plenum extending from the first plane to the second plane having no path through which air can pass along a straight line from the first plane to the second plane,
each of the first group of solid state light emitters, when supplied with electricity, emitting light having a first color point,
each of the second group of solid state light emitter, when supplied with electricity, emitting light having a second color point,
the first color point different from the second color point,
at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a first string,
at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a second string,
a first ratio equal to (1) a number of solid state light emitters in said second group of solid state light emitters and in said first string, divided by (2) a number of solid state light emitters in said first group of solid state light emitters and in said first string,
a second ratio equal to (3) a number of solid state light emitters in said second group of solid state light emitters and in said second string, divided by (4) a number of solid state light emitters in said first group of solid state light emitters and in said second string,
the first ratio different from the second ratio.

2. A lighting element as recited in claim 1 , wherein the first fold region is substantially linear and has a thickness that is less than a thickness of every portion of each of the first and second heat sink regions.

3. A lighting element as recited in claim 1 , wherein the first heat sink structure further comprises at least a third heat sink region and a second fold region between the second and third heat sink regions.

4. A lighting element as recited in claim 3 , wherein the first internal space is defined at least in part by the first, second and third heat sink regions.

5. A lighting element as recited in claim 3 , wherein the first, second and third heat sink regions are substantially flat.

6. A lighting element as recited in claim 3 , wherein:
a major surface of the first heat sink region has a plane of symmetry in a first plane,
a major surface of the second heat sink region has a plane of symmetry in a second plane,
a major surface of the third heat sink region has a plane of symmetry in a third plane,
the first plane defines an angle of at least 20 degrees relative to each of the second plane and the third plane,
the second plane defines an angle of at least 20 degrees relative to the third plane.

7. A lamp comprising a lighting element as recited in claim 1 , wherein the lamp fits within an envelope of an A lamp.

8. A lighting element as recited in claim 1 , wherein at least the first solid state light emitter comprises a light emitting diode.

9. A lighting element as recited in claim 1 , wherein the first heat sink structure comprises at least a first heat dissipation element attached to the first heat sink region.

10. A lighting element as recited in claim 9 , wherein the first heat dissipation element comprises at least a first fin element.

11. A lighting element as recited in claim 1 , wherein the lighting element further comprises at least a first circuit board that extends across the first fold region.

12. A method of making a lighting element, comprising:
mounting first and second groups of solid state light emitters on a first heat sink structure, said mounting comprising mounting at least a first solid state light emitter on a first heat sink region of the first heat sink structure; and mounting at least a second solid state light emitter on a second heat sink region of the first heat sink structure,
the first heat sink structure a one-piece structure that comprises at least a first fold region between the first and second heat sink regions, the first and second heat sink regions integral with one another, the fold region of rigidity that is lower than the rigidity of the first heat sink region and lower than the rigidity of the second heat sink region,
the first heat sink structure defining a first internal space defined at least in part by the first and second heat sink regions,
an entirety of the first internal space between a first plane and a second plane, the first plane substantially parallel to the second plane,
the first internal space comprising at least one plenum extending from the first plane to the second plane,
each plenum extending from the first plane to the second plane having no path through which air can pass along a straight line from the first plane to the second plane,
each of the first group of solid state light emitters, when supplied with electricity, emitting light having a first color point,
each of the second group of solid state light emitter, when supplied with electricity, emitting light having a second color point,
the first color point different from the second color point,
at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a first string,
at least one of the first group of solid state light emitters and at least one of the second group of solid state light emitters on a second string,
a first ratio equal to (1) a number of solid state light emitters in said second group of solid state light emitters and in said first string, divided by (2) a number of solid state light emitters in said first group of solid state light emitters and in said first string,
a second ratio equal to (3) a number of solid state light emitters in said second group of solid state light emitters and in said second string, divided by (4) a number of solid state light emitters in said first group of solid state light emitters and in said second string,
the first ratio different from the second ratio.

13. A method as recited in claim 12 , wherein the method further comprises bending the first heat sink structure substantially along the first fold region.

14. A method as recited in claim 13 , wherein the method further comprises testing the first and second solid state light emitters before bending the first heat sink structure.

15. A method as recited in claim 12 , wherein:
the first heat sink structure further comprises at least a second fold region, and
the method further comprises bending the first heat sink structure at least along the first fold region and bending the first heat sink structure along the second fold region

Assignees

• Pickard Paul Kenneth
• Progl Curt
• Gray Joshua N
• Cree Inc

Inventors

• Pickard Paul Kenneth
• Progl Curt
• Gray Joshua N

Classifications

• F21V29/75

  with fins or blades having different shapes, thicknesses or spacing · CPC title

• F21Y2115/10

  Light-emitting diodes [LED] · CPC title

• F21V29/85

  characterised by the material (liquid coolants F21V29/56) · CPC title

• F21V23/02

  the elements being transformers, impedances {or power supply units, e.g. a transformer with a rectifier} · CPC title

• F21V29/777

  the planes containing the fins or blades having directions perpendicular to the light emitting axis · CPC title