Vehicle LED lamp having recirculating air channels

Patent metadata

Field	Value
Publication number	US-10415787-B2
Application number	US-201815868467-A
Country	US
Kind code	B2
Filing date	Jan 11, 2018
Priority date	Jan 11, 2018
Publication date	Sep 17, 2019
Grant date	Sep 17, 2019

Abstract

Lamp module 32 contains solid-state light source 17 and has mounting flange 42 coupleable to headlamp reflector 12. Lamp module 32 has base 2 defining central post 4, post 4 defining internal first air passage 401. Base and post act are heat sinks. Fan 8 is disposed within base 2. Circuit board 14 having LED arrays 17 is mounted inside post 4 in fluid communication with first air passage 401. Base 2 defines second air flow passage 405 exterior of post 4, second air passage 405 being oriented to direct air past mounting flange 42. Base 2 further defines third air passage 410 rearward of mounting flange 42 and radially outward from second air passage 405. Mounting flange 42 may be keys coupleable to slots 15. A method of directing an air stream through slots 15 in reflector socket 121 is described.

First claim

What is claimed is:

1. An automotive solid-state lamp module ( 32 ), comprising:
a base ( 2 ) defining a central post ( 4 ) having an outer peripheral surface ( 44 ), the post defining an internal first air flow passage ( 401 ) in an interior of the post,
a circuit board ( 14 ) bearing at least one solid-state light source ( 17 );
the post ( 4 ) defining a mounting surface for the circuit board ( 14 ) bearing the at least one solid-state light source ( 17 );
a mounting flange ( 42 ) disposed on the base ( 2 ), the mounting flange configured to be coupleable to a lamp-receiving reflector socket ( 121 ) of a reflector ( 12 );
the base ( 2 ) further defining at least one exterior second air flow passage ( 405 ) exteriorly adjacent the post ( 4 ), the second air flow passage ( 405 ) being oriented to direct air exiting the second air flow passage past the mounting flange ( 42 ) and adjacent the post outer peripheral surface ( 44 );
the base ( 2 ) further defining a third air flow passage ( 410 ) having an air outlet disposed axially rearward of the mounting flange ( 42 ) and radially outward from the second air flow passage ( 405 ); and
an air-moving fan ( 8 ) disposed in the base ( 2 ) arranged to, when energized, move air to the first, second and third air flow passages ( 401 , 405 , 410 );
wherein a post interior surface defines a first datum surface ( 403 ) and a second datum surface ( 402 ), the first datum surface ( 403 ) abutting an edge ( 140 ) of the circuit board ( 14 ) and the second datum surface ( 402 ) abutting a locator feature ( 13 ) on the circuit board ( 14 ).

2. The lamp module ( 32 ) of claim 1 , further comprising a gasket ( 64 ) surrounding the post ( 4 ) and disposed in an axial direction away from the mounting flange ( 42 ); and
wherein the second air flow passage ( 405 ) is disposed radially inward of the gasket ( 64 ).

3. The lamp module ( 32 ) of claim 2 , wherein the gasket ( 64 ) surrounds the second air flow passage ( 405 ).

4. The lamp module ( 32 ) of claim 1 , wherein the second air flow passage ( 405 ) comprises a plurality of passages.

5. The lamp module ( 32 ) of claim 3 , wherein the second air flow passage ( 405 ) comprises a plurality of passages.

6. The lamp module ( 32 ) of claim 1 , wherein the base ( 2 ) is formed of thermally conductive material forming a heat sink.

7. The lamp module ( 32 ) of claim 1 , wherein the mounting flange ( 42 ) comprises a plurality of radially extending keys.

8. An automotive solid-state lamp module ( 32 ) adapted to be selectively secured to a reflector ( 12 ) having a lamp-receiving socket ( 121 ), said lamp module in combination with the reflector ( 12 ) disposed in a headlamp housing ( 601 ) forming a headlamp assembly ( 6 ), said lamp module comprising:
a base ( 2 ) defining a central post ( 4 ) having an outer peripheral surface ( 44 ), the post defining an internal first air flow passage ( 401 ) in an interior of the post,
a circuit board ( 14 ) bearing at least one solid-state light source ( 17 );
the post ( 4 ) defining a mounting surface for the circuit board ( 14 ) bearing the at least one solid-state light source ( 17 );
a mounting flange ( 42 ) disposed on the base ( 2 ), the mounting flange configured to be coupleable to the reflector socket ( 121 );
the base ( 2 ) further defining at least one exterior second air flow passage ( 405 ) exteriorly adjacent the post ( 4 ), the second air flow passage ( 405 ) being oriented to direct air exiting the second air flow passage past the mounting flange ( 42 ) and adjacent the post outer peripheral surface ( 44 );
the base ( 2 ) further defining a third air flow passage ( 410 ) having an air outlet disposed axially rearward of the mounting flange ( 42 ) and radially outward from the second air flow passage ( 405 ); and
an air-moving fan ( 8 ) disposed in the base ( 2 ) arranged to, when energized, move air to the first, second and third air flow passages ( 401 , 405 , 410 ); wherein
the first air flow passage ( 401 ) and the second air flow passage ( 405 ) direct air received from the fan ( 8 ) into an interior ( 122 ) within the reflector ( 12 ); and
the third air flow passage ( 410 ) directs air received from the fan ( 8 ) towards an exterior region ( 123 ) rearward of the reflector ( 12 ).

9. The headlamp assembly of claim 8 , further comprises an end cap ( 602 ) attached to the headlamp housing ( 601 ) rearward of the reflector ( 12 ) and in overlying relation to the base ( 2 ) of the lamp module ( 32 ).

10. A method of cooling a solid-state vehicle lamp module ( 32 ) retained in a vehicle headlamp reflector ( 12 ), comprising
inserting a lamp module ( 32 ) having a solid-state light source ( 17 ) into a reflector interior ( 122 ) of a vehicle headlamp reflector ( 12 ) having a lamp-receiving socket ( 121 ) configured to receive the lamp module ( 32 ), the reflector ( 12 ) defining adjacent the socket ( 121 ) a plurality of circumferentially disposed slots ( 15 );
latching the lamp module ( 32 ) to the headlamp reflector ( 12 );
directing a first flow of air (F 1 ) from an exterior region ( 123 ) exterior the reflector ( 12 ) through the lamp module ( 32 ) and adjacent the solid-state light source ( 17 );
directing a second flow of air (F 2 ) from the exterior region ( 123 ) exterior the reflector ( 12 ) through the lamp module ( 32 ) and through the plurality of slots ( 15 ) and thereby into the reflector interior ( 122 ); and
directing a third flow of air (F 3 ) from the lamp module ( 32 ) away from the reflector interior ( 122 ) to the exterior region ( 123 ) exterior the reflector ( 12 ).

11. A method of cooling a solid-state vehicle lamp module ( 32 ) retained in a vehicle headlamp reflector ( 12 ), comprising
inserting a lamp module ( 32 ) having a solid-state light source ( 17 ) into a reflector interior ( 122 ) of a vehicle headlamp reflector ( 12 ) having a lamp-receiving socket ( 121 ) configured to receive the lamp module ( 32 ), the reflector ( 12 ) defining adjacent the socket ( 121 ) a plurality of circumferentially disposed slots ( 15 );
latching the lamp module ( 32 ) to the headlamp reflector ( 12 );
directing a first flow of air (F 1 ) from an exterior region ( 123 ) exterior the reflector ( 12 ) through the lamp module ( 32 ) and adjacent the solid-state light source ( 17 );
directing a second flow of air (F 2 ) from the exterior region ( 123 ) exterior the reflector ( 12 ) through the lamp module ( 32 ) and through the plurality of slots ( 15 ) and thereby into the reflector interior ( 122 ); and
directing a third flow of air (F 3 ) from the lamp module ( 32 ) rearward of the reflector ( 12 ) thereby bypassing the reflector interior ( 122 ).

12. The method of claim 10 , further comprising spatially separating the third flow of air (F 3 ) from the second flow of air (F 2 ) by a barrier ( 64 ).

13. The method of claim 10 , wherein the latching comprises rotating the lamp module ( 32 ) relative the plurality of slots ( 15 ).

14. The method of claim 10 , wherein a principal direction of the second flow of air (F 2 ) is directed laterally displaced from the first flow of air (F 1 ).

Assignees

• Lessard Jason
• Weiss Blair
• Holland Richard
• Osram Sylvania Inc

Inventors

• Lessard Jason
• Weiss Blair
• Holland Richard

Classifications

• F21S45/33

  specially adapted for headlamps · CPC title

• F21S45/43 Primary

  using gas · CPC title

• F21S41/141

  Light emitting diodes [LED] · CPC title

• F21S45/20

  Promoting gas flow in lighting devices, e.g. directing flow toward the cover glass for demisting (ventilation F21S45/30; forced cooling F21S45/42) · CPC title

• F21S45/49

  Attachment of the cooling means · CPC title