Systems and methods for a heat sink

Patent metadata

Field	Value
Publication number	US-10488028-B2
Application number	US-201715636923-A
Country	US
Kind code	B2
Filing date	Jun 29, 2017
Priority date	May 3, 2017
Publication date	Nov 26, 2019
Grant date	Nov 26, 2019

Abstract

Embodiments may utilize a series of exposed fins, which increase the surface area of the heat sink creating additional air flow. As hotter air rises within the system, cooler is drawn into the heatsink. The fins may be exposed on both sides of the longitudinal axis, allowing cooler air to be drawn towards the longitudinal axis above the heatsink and flow upward. This process may cool the fins. Additionally, the spacing between the fins may have to be wide enough to allow for air to freely enter the heatsink.

First claim

What is claimed is:

1. A method for manufacturing a linear heat sink for a light source, comprising:
creating a die to form the heat sink;
forming a first plurality of fins by extruding a first unitary block of metal from an upper surface of the first unitary block of metal towards a lower surface of the first unitary block of metal via a negative of the die, wherein each of the plurality of fins includes an exposed upper edge;
forming a first base simultaneously while forming the first plurality of fins;
coupling a first rail to a first sidewall of a first base, the first base being positioned below the first plurality of fins,
coupling a second rail to a second sidewall of the first base, the first rail and the second rail extending along a central axis of the linear heat sink from a first end of the first base to a second end of the first base, wherein:
a width of each of the first plurality of fins extends across the central axis from the first rail to the second rail, the width of each of the first plurality of fins being smaller than a length of the linear heat sink;
the first rail and the second rail each comprise a planar external sidewall perpendicular to the first base and a tapered internal sidewall, wherein the tapered internal sidewall extends outward from a position below the first base toward the planar external sidewall; extending a second unitary block of metal to form a second plurality of fins and a second base; and coupling the first base and the second base via the first rail and the second rail.

2. The method of claim 1 , further comprising:
creating at least three exposed surfaces between a first fin of the first plurality of fins and a second fin of the first plurality of fins.

3. The method of claim 1 , wherein the first rail and the second rail are formed of a different material than the first unitary block of metal.

4. The method of claim 3 , wherein the first rail and the second rail are formed of aluminum and the first unitary block of metal is an aluminum block.

5. The method of claim 1 , further comprising:
extruding an entire height of the first unitary block of metal to create four exposed edges between adjacent fins of the first plurality of fins.

6. The method of claim 1 , wherein the extrusions are evenly spaced and uniformly shaped, the extrusions being perpendicular to the central axis.

7. The method of claim 6 , wherein the extrusions are spaced ⅓ rd of an inch from each other.

8. The method of claim 1 , further comprising:
coupling first ends of the first rail and the second rail to an outer sidewall of the first base; and
positioning second ends of the first rail and the second rail below the first base.

9. A linear heat sink for a light source comprising:
a first plurality of fins formed by a negative of a die by extruding through the die a first unitary block of metal from an upper surface of the first unitary block of metal towards a lower surface of the first unitary block of metal, the extrusions causing spacing between each of the first plurality of fins, wherein each of the plurality of fins includes an exposed upper edge;
a first base that is formed simultaneously while forming the first plurality of fins;
a first rail being coupled to a first sidewall of a first base, the first base being positioned below the first plurality of fins;
a second rail being coupled to a second sidewall of the first base, the first rail and the second rail extending along a central axis of the linear heat sink from a first end of the first base to a second end of the first base, wherein:
a width of each of the first plurality of fins extends across the central axis from the first rail to the second rail, the width of each of the first plurality of fins being smaller than a length of the linear heat sink;
the first rail and the second rail each comprise a planar external sidewall perpendicular to the first base and a tapered internal sidewall, wherein the tapered internal sidewall extends outward from a position below the first base toward the planar external sidewall; a second plurality of fins formed by extruding a second unitary block of metal to form a second plurality of fins; and a second base associated with the second plurality of fins, wherein the first rail and the second rail are configured to couple the first base and the second base.

10. The heat sink of claim 9 , wherein the extrusions create at least three exposed surfaces between a first fin of the first plurality of fins and a second fin of the first plurality of fins.

11. The heat sink of claim 9 , wherein the first rail and the second rail are formed of a different material than the first unitary block of metal.

12. The heat sink of claim 11 , wherein the first rail and the second rail are formed of aluminum and the first unitary block of metal is an aluminum block.

13. The heat sink of claim 9 , wherein the extrusions extending across an entire height of the first unitary block of metal to create four exposed edges between adjacent fins of the first plurality of fins.

14. The heat sink of claim 9 , wherein the extrusions are evenly spaced and uniformly shaped, the extrusions being perpendicular to the central axis.

15. The heat sink of claim 14 , wherein the extrusions are spaced ⅓ rd of an inch from each other.

16. The heat sink of claim 9 , wherein first ends of the first rail and the second rail are coupled to an outer sidewall of the first base, and second ends of the first rail and the second rail are positioned below the first base.

Assignees

• Fluence Bioengineering
• Fluence Bioengineering Inc

Inventors

• Duong Dung
• Johnson Randall
• Klase Nicholas

Classifications

• H10W40/22

  characterised by their shape, e.g. having conical or cylindrical projections · CPC title

• F21V29/763

  the planes containing the fins or blades having the direction of the light emitting axis · CPC title

• F21V29/83

  the elements having apertures, ducts or channels, e.g. heat radiation holes · CPC title

• F21Y2103/10

  comprising a linear array of point-like light-generating elements · CPC title

• H05K1/05

  Insulated {conductive substrates, e.g. insulated} metal substrate · CPC title