FIELD OF THE INVENTION

Embodiments of the invention relate generally to light-emitting diodes, thermal management for light-emitting diodes, and heat sinks and heat spreaders.

BACKGROUND INFORMATION

Light sources that use light-emitting diodes (LEDs) for light production consume less power than incandescent and halogen lights. Unlike fluorescent lights, LEDs contain no mercury. LEDs are typically built on a semiconductor chip. In operation, however, LED chips see temperature increases that can limit the usability and. lifetime of the LED chip. Temperature increases can also cause color shifts in the emitted LED light. Even a small shift in light color can cause color mis-matches between otherwise identical LEDs that are visible to the human eye. Unlike incandescent lights, LED-based lights do not give off excess heat as light and natural convection cooling is minimal The heat production associated with LEDs during operation presents challenges for lighting sources that seek to employ LED chips. Challenges include, producing light bulbs that employ LED chips that are reliable, efficient, and cost-effective at higher wattages, and providing heat management solutions for LED light bulbs that are used in confined spaces.

BRIEF DESCRIPTION OF THE FIGURES FIGURES 1A-D are schematic diagrams illustrating cross-sectional views of lighting systems employing LED chips as light producing elements.

FIGURES 2A-D are schematic diagrams illustrating cross-sectional views of additional lighting systems employing LET) chips as light producing elements.

FIGURES 3A-B are schematic diagrams illustrating views of an additional lighting system employing LED chips as light producing elements.

FIGURE 4 is a schematic diagram illustrating a further additional lighting system employing LED chips as light producing elements

FIGURES 5A-E are schematic diagrams illustrating views of additional lighting systems employing LED chips as light producing elements.

DETAILED DESCRIPTION OF THE INVENTIO

Embodiments of the invention provide lighting systems that employ light-emitting diode (LED) chips as active lighting elements. Additionally, heat management components for the LED chips employed in the lighting systems are provided. The lighting systems can be, for example, in the form of traditional light bulbs, recessed lighting fixtures, strip lighting fixtures, back lighting units, or other enclosed/encased LED lighting configurations. In embodiments of the invention, LED chips are cooled by one or more of heatspreaders and/or heat sinks attached to a substrate for the LED chip and the topside of the LED chip itself.

Figures 1A-B illustrate lighting structures in which LED chips are employed as light-producing elements. In Figure 1 A, a LED chip 105 is mounted on a substrate 1 10. In embodiments of the invention, the substrate 1 10 provides electrical interconnections between the LED chip 105 and additional electronic components (not shown) and a power source (not shown). Substrate 1 10 is a circuit board or other type of substrate, such as, for example, a board or a metal backed board. Additional electronics can include LED driver and dimmer control circuits and can be housed on an IC chip mounted, on a substrate or circuit board located for example, inside conical heat spreader 1 15. Optionally, the IC chip comprising additional electronics can be mounted on substrate 1 10. Alternately, some or all of these additional electronics can be housed on the LED chip 105 itself. Optionally, more than one LED chip 105 is mounted on substrate 110. Conical heat spreader 1 15 comprises radial fins 120. Conical heat spreader 1 15 and radial fins 120 can be separate joined pieces. Figures IB and C illustrate alternate cross-sectional views of a cut along the line 1 - 1 of Figure 1A. Different geometries and patterns for radial fins are possible. Additionally, although ten radial fins 120 are illustrated in Figure IB, and twenty radial fins are illustrated in Figure IC, other numbers of radial fins 120 are also possible, including larger and smaller numbers of fins. Figure IC shows a plurality of double radial fins 120. Other numbers of associated radial fins 120 are also possible such as triple or quadruple radial fins. Plural radial fins, such as double, triple, and quadruple radial fins are fins that originate from the same location on the conical heat spreader. Radial fins 120 can have sizes, shapes, geometries, relative angles, and/or orientations that are different from the embodiments depicted in Figures 1A-D. Conical heat spreader 1 15 is thermally coupled to substrate 1 10 though optional thermal interface material 125. Conical heat spreader 1 15 and fins 120 are comprised of a heat conductive material, such as, for example, a metal, such as for example, copper and/or aluminum, or a thermally conductive plastic, although other materials are also possible. Thermal interface material 125 is comprised of, for example, indium, a phase change material, a ceramic -polymer composite, a metal-polymer composite, or a graphite- polymer composite, where a polymer can be a grease, a gel, an elastomer, or a thermosetting plastic. In alternate embodiments, conical heat spreader 115 is thermally coupled to

substrate 1 10 though physical contact or through a grease, a gel, an elastomer, a thermosetting plastic, or other material. A second, thermal management component shown in Figures 1A and D, includes surface fins 130 and heat transfer collar 132 are thermally associated with substrate 1 10 and LED chip 105. The surface fins 130 can be thermally associated with substrate 1 10 and LED chip 105 through, for example, a thermal interface material (not shown) or other material located between them, through physical contact, or a combination thereof. A view of a cut through the line 2-2 in Figure 1A is shown in Figure I D. For simplicity, in Figure ID, the conical heat spreader 115 and fins 120 and transparent cover 135 are not depicted. LED chip 05 can also have other shapes to which the heat transfer collar 132 conforms, such as circular. Although ten surface fins 130 are shown in Figure I D, other numbers of surface fins are possible, such as, larger numbers and smaller numbers of surface fins 130. Surface fins 130 are comprised of a material capable of conducting heat, such as, for example, copper, aluminum, or glass. In embodiments of the invention, the surface fins have a thickness that is less than 1 mm, although other thicknesses are also possible. Optionally, the surface fins 130 are coated with a reflective material. The surface fins 130 can be in other relative orientations. The first thermal management component of Figures 1A-C, which includes the conical heat spreader 115 and fins 120, and the second thermal management component shown in Figures 1 A and D, which includes surface fins 30, can optionally be used separately from each other or they can be employed together in a lighting structure.

The lighting structure of Figures 1A-D additionally comprises transparent cover 135. Optionally, transparent cover 135 comprises vent holes 140 that are capable of allowing gases (air) to flow between the regions inside and outside of the transparent cover 135. Transparent cover 135 is comprised of a material that is partially or completely transparent to the light emitted by the LED chip, for example, glass, such as the glasses currently used in lighting sources, or plastic. When vent holes 140 are present, gas can flow through the lighting structure as illustrated, for example, by arrow 145 (the direction of flow depicted assumes the device is oriented as shown although other orientations are also possible). The lighting structures additionally comprise plug region 150 that is capable of making an electrical connection with a socket. Plug region 150 can have a shape designed for the socket into which it will fit in order to make an electrical connection and the shape and size of plug region 150. In general, dimensions of the elements of the lighting structures of Figures 1 A-D can vary based on the use to which the lighting structure will be put. Electrical connections (not shown) can extend through the conical heat spreader 1 15 between the LED chips 105, the optional additional electronic components, and the plug region 150. Figures 2A-D illustrate additional embodiments of lighting structures in which LED chips are employed as light-producing elements. In Figures 2A-B, a LED chip 205 is mounted on a substrate 210. Substrate 210 is a circuit board or other type of substrate, such as, for example, a board, or a metal backed, board. In embodiments of the invention, the substrate 210 provides electrical interconnections between the LED chip and optional additional electronics (not shown) and a power source (not shown). Optionally, more than one LED chip 205 is mounted on substrate 210. Additional electronics can include LED driver and dimmer control circuits and can be housed on an IC chip mounted on a substrate located, for example, inside conical heat spreader 215. Optionally, an IC chip comprising additional electronic components is housed on the substrate 210. Alternately, some or all of these additional electronics can be housed, on the LED chip 205 itself. Conical heat spreader 215 comprises radial fins 220. Figures 2B and C illustrate alternate cross-sectional views of a cut along the line 3-3 of Figure 2 A. Different geometries and. patterns for radial fins are possible. Additionally, although ten radial fins 220 are illustrated in Figure 2B, and twenty radial fins are illustrated in Figure 2C, other numbers of radial fins 220 are also possible, including larger and smaller numbers of fins. Figure 2C shows a plurality of double radial fins 220. Other numbers of associated radial fins 220 are also possible such as triple or quadruple radial fins. Plural radial fins, such as double, triple, and quadruple radial fins are fins that originate from the same location on the conical heat spreader. Radial fins 220 can have sizes, shapes, geometries, relative angles, and/or orientations that are different from the embodiments depicted in Figures 2A-D. Comparing Figures 1A and 2A-B, two different of a large number of possible shapes for the radial fins 120 and 220 are illustrated. Conical heat spreader 215 is optionally thermally coupled to substrate 210 though thermal interface material 225. Conical heat spreader 215 and fins 220 are comprised of a heat conductive material, such as, for example, a metal, such as for example, copper and/or aluminum, or a thermally conductive plastic, although other materials are also possible. Thermal interface material 225 is comprised of, for example, indium, a phase change material, a ceramic- polymer composite, a metal-polymer composite, or a graphite-polymer composite, where a polymer can be a grease, a gel, an elastomer, or a thermosetting plastic. In alternate

embodiments, conical heat spreader 215 is thermally coupled to substrate 210 though physical contact or through a grease, a gel, an elastomer, a thermosetting plastic, or other material.

A second thermal management component shown in Figure 2A, includes transparent plate 230 that is thermally associated with LED chip 205. The transparent plate 230 can be thermall associated with LED chip 205 through, for example, phy sical contact. The transparent plate 230 can be bonded to the substrate 210 with a bonding material 235, which is, for example, a thermal interface material (as described herein). Transparent plate 230 has associated protruding members 232, that can have arty shape, such as conical, cylindrical, pyramidal, fin-like, or triangular, rectangular, pentagonal, or hexagonal prismatic, or other shape. The protruding members 232 can extend various distances from the transparent plate 230. In Figure 2B, for example, the protruding members 232 are shown extending to the transparent cover 240. Various numbers of protruding members 232 are also possible. Transparent plate 230 and protruding members 232 are comprised of a material capable of conducting heat such as, for example, glass or plastic, and are transparent to some or all of the light emitted, by LED chip 205. In alternate embodiments, protruding members 232 are thin metal fins having a thickness of 0.5 to I mm or less than 0.5 mm. The first thermal management component of

Figures 2A-D, which includes the conical heat spreader 215 and fins 220, and the second thermal management component shown in Figures 2A-B, which includes transparent plate 230 and protruding members 232, can optionally be used, separately from each other or they can be employed together in a fighting structure.

The lighting structures of Figures 2A-D additionally comprise transparent cover 240.

Optionally, transparent cover 240 comprises vent holes 244 that are capable of allowing gases (air) to flow between the regions inside and. outside of the transparent cover 240. When vent holes 244 are present, gas can flow through the lighting structure as illustrated, for example, by arrow 245. Transparent cover 240 is comprised of a material that is partially or completely transparent to the light emitted by the LED chip, for example, glass or plastic. The lighting structures additionally comprise plug region 250 that is capable of making an electrical connection with a socket. Plug region 250 can have a shape designed for the socket into which it will fit in order to make an electrical connection. In general, the shape and size of the elements of the lighting structures of Figures 2A-D can vary based, on the use to which the lighting stracture will be put. Electrical connections (not shown) can extend through the conical heat spreader 215 between the LED chips 205 and the plug region 250.

Figures 3A-B show additional lighting structures in which LED chips are employed as light-producing elements. Figure 3 A is an exploded diagram of the elements of the lighting structure and Figure 3 A is an assembled structure. Substrate 310 is a circuit board or other type of substrate, such as, for example, a board or a metal backed board. In Figures 3A-B two LED chips 305 are mounted on a substrate 310 that optionally provides electrical interconnections between the LED chip and additional electronics (not shown) and. a power source (not shown). Optionally, more or less than two LED chips 305 are mounted on substrate 310. Additional electronics can include LED driver, optional dimmer control circuits, and other components, and can be housed on a substrate located inside a space within heat sink 315 or on substrate 310. Alternately, some or all of these additional electronics can be housed on the LED chip 105 itself. Annular heat dissipater 320 comprises fins 325. Although a number of fins 325 are illustrated, in Figure 3A, the number of fins in the lighting structure of Figures 3A-B can be smaller or larger than the number illustrated. Plural radial fins, such as double, triple, and quadruple radial fins which are fins that originate from the same location on the conical heat spreader, and different patterns of fins, are also possible. The heat sink 315 and heat dissipater 320 are comprised of a heat conductive material, such as, for example, a metal, such as for example, aluminum and/or copper or a thermally conductive plastic, although other materials are also possible. Heat spreader 311 can have a flat disk shape or a conical shape.

The lighting structures of Figures 3A-B additionally comprise transparent cover 330. Transparent cover 330 is comprised of a material that is partially or completely transparent to the light emitted by the LED chip, for example, glass or plastic. The lighting structure additionally comprises plug region 340 that is capable of making an electrical connection with a socket Plug region 340 can have a shape designed, for the socket into which it will fit in order to make an electrical connection. In general, the shape and size of elements of the lighting structure of Figures 3A-B can vary based on the use to which the lighting structure will be put. Electrical connections (not shown) can extend through the annular heat sink 315 between the LED chips 305, additional electronic components, and the plug region 340.

Figure 4 shows farther additional lighting structures in which LED chips are employed as light-producing elements. In Figure 4, LED chips 405 are mounted on a substrate 10. In embodiments of the invention, the substrate 410 is a metal pad or layer that is capable of transferring heat to heat sink 415. In further embodiments, substrate 410 is a circuit board or other type of substrate, such as, for example, a board or a metal backed board. Optionally, a thermal interface material 420 is disposed between the substrate 410 and the heat sink 415. In the alternative, the substrate 410 and the heat sink 415 can make thermal contact through physical contact or through a different material disposed between them. Optionally, one, three, or more LED chips 405 are mounted on substrate 410. Heat sink 415 is optionally beveled (as shown) to provide a greater heat diffusion area. Heat sink 415 comprises fins 425 and a cavity- inside that is capable of additional electronics, such as an IC chip comprising LED driver and dimmer circuits (not shown). Plural radial fins, such as double, triple, and quadruple radial fins which are fins that originate from the same location on the conical heat spreader, and different patterns of fins are also possible. Optionally, heat sink 415 also comprises channels and/or slots capable of allowing air flow as illustrated by arrows 430. Slots can allow air to enter the body of the heat sink 415, increasing air flow.

A second thermal management component shown in Figure 4A, includes transparent fin structure 435 that makes thermal contact with and is capable of removing heat from LED chips 405. The transparent fin structure 435 can be thermally associated with LED chips 405 through, for example, physical contact. Transparent fin structure 435 can extend various distances from the LED chips 405. In Figure 4, for example, the transparent fin structure 435 is shown extending to the transparent cover 440. Although four fins are shown in Figure 4. various other numbers of fins in transparent fin structure 435 are also possible. Transparent fin structure 435 is comprised of a material capable of conducting heat. In embodiments of the invention, the transparent fin structure 435 is transparent to some or all of the light emitted by LED chips 405. and is a material, such as, for example, glass or plastic. Optionally, the transparent fin structure 435 comprises a reflective coating on its surface. In other embodiments, the transparent fin structure 435 can be comprised of a metal having a highly reflective surface finish or coating. The first thermal management component of Figures 4, which includes the conical heat sin 415 and fins 425, and the second thermal management component shown in Figures 4, which includes transparent fin structure 435, can optionally be used separately from each other or they can be employed together in a lighting structure.

The lighting structure of Figure 4 additionally comprises transparent cover 440.

Transparent cover 440 is comprised of a material that is partially or completely transparent to the light emitted, by the LED chips, for example, glass or plastic. The lighting structure additionally comprises plug region 445 that is capable of making an electrical connection with a socket. Plug- region 445 can have a shape designed for the socket into which it will fit in order to make an electrical connection. In general, the shape and size of elements of the lighting structure of Figure 4 can vary based on the use to which the lighting structure will be put. Electrical connections (not shown) can extend through the heat sink 415 between the LED chips 405 and the plug region 445.

Figures 5A-E illustrate further lighting structures in which LED chips are employed as light-producing elements. Figure 5A is an exploded diagram of several of the elements of the lighting structures. Figure 5B shows the assembled elements of Figure 5A. In Figures 5A-B, a sectional heat sink is formed in two sections 505 and 507. In embodiments of the invention, the sections 505 and 507 of the heat sink are comprised of a material a metal such as, for example, aluminum and/or copper, or a thermally conductive plastic, although other materials are also possible. In embodiments of the invention, the sectional heat sink is an annular heat sink (as shown) although other shapes are also possible. Figure 5C show ^r s one of other possible shapes for a first section 508 of the sectional heat sink (the second section is the mirror image of the first section 508) having a tapered or semi-conical exterior and a semi-annular section. The sectional heat sink could also have other shapes such as an exterior having four (or more) sides when assembled and presenting a square or rectangular (or pentagon, hexagon, etc.} footprint rather than a circular one. In the assembled lighting structure, a heat spreader 510 is located between the first section 505 and the second 507 of the heat sink, makes contact with both sections 505 and 507 of the sectional heat sink, and is capable of transferring heat to the sectional heat sink. A section 51 1 of the heat spreader 510 extends beyond a surface of the sectional heat sink. One or more LED chip(s) 515 and substrate 520 are located on the section 51 1 of the heat spreader 510 that extends beyond the sectional heat sink 505 and 507. Optionally, additional LED chip(s) and substrate (not shown) are located on the opposite face of the heat spreader 510 in the region 51 1 that the heat spreader 510 extends beyond the sectional heat sink 505 and 507 in the assembled structure. Figure 5B, which shows the assembly of the elements of Figure 5A but omits the LED chip(s) 515 and substrate 520 for ease of illustration. The heat spreader 510 is comprised of, for example, a metal, such as aluminum and/or copper, or a thermally conductive plastic, although other materials are also possible. A circuit board 525 (or other substrate) comprising electronics, such as an IC chip comprising LED driver and optional dimmer control circuits is located inside sectional heat sink 505 and 507. Alternately, some or all of these additional electronics can be housed on a LED chip 515 itself. The circuit board 525 is operably coupled to the LED chip(s) 515 though, for example, wires that extend into the interior of sectional heat sink 505 and 507.

Figure D provides additional embodiments of the invention for the heat spreader 510. Other shapes for heat spreader 510 are also possible. In Figure 5D structures (i)-(iii), LET) chips 515 and substrates 520 are located on regions 512 of the heat spreader 510 that are disposed at an angle relative to the main body of the heat spreader 510 and/or on separate armlike structures. In Structure (iii), the LED chips 515 and structures 520 can be located on both sides of the arms. The heat spreader 510 of can be formed, for example, from two separate parts located, next to each as shown in structure (ii). In alternate embodiments, the heat spreader 510 is formed from two or more parts. Regions of the parts of the heat spreaders that extend beyond the sectional heat sink can be disposed at different relative angles to the regions that are located between the sections of the heat sink. Heat spreaders 510 of Figure 5D can provide the ability to direct or aim light emitted from the LED chip in desired direction(s) thus providing light output having a shape other than a conical one. Figure 5E shows an assembly for the lighting structure in which the assembled structure of Figure 5B additionally comprises transparent cover 530 and plug region 535. Plug region 535 can have a shape designed for the socket into which it will fit in order to make an electrical connection and the shape and size of plug region 535 can vary based on the use to which the lighting source of Figures 5A-E will be put. Electrical connections (not shown) can be made between circuit board 525 and the plug region 535. Additionally, in embodiments of the invention, the plug region is designed to fit over a bottom section of the assembled heat sink 505 and 507. Transparent cover 530 is comprised of a material that is partially or completely transparent to the light emitted by the LED chip, for example, glass or plastic.

In general, a LED chip can comprise one light-emitting diode or an array of light-emitting diodes. Embodiments of the invention are not limited to LED chips having a particular type, size, wattage, color spectrum, and/or number of LEDs and embodiments of the in vention are capable of being used with various types of LED chips or LED arrays in general. LED chips can also comprise additional electronics, such as LED drivers and dimmer circuits.

In embodiments of the invention, the substrate can be a substrate that provides connections between and among electronic components, such as chips, and power supplies. Semiconductor chips can be attached to one or both sides of the substrate. Substrates can be used, to provide electrical connections between small-scale semiconductor chips and larger-scale power sources. Substrates can be, for example, wireboards or circuitboards.

Persons skilled in the relevant art appreciate that modifications and variations are possible throughout the disclosure as are substitutions for various components shown and described. Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included, in at least one embodiment of the invention, but does not necessarily denote that they are present in every embodiment. Furthermore, the particular features, structures, materials, or characteristics disclosed in the embodiments may be combined in any suitable manner in one or more embodiments. For example, second thermal management components shown in Figure 1 A can be used in the lighting structures of Figure 2A-D (in place of the second thermal management components of Figures 2A-D), Figure 3A--B, Figure 4, and some of the embodiments of Figures 5A-E; the second thermal management components of Figures 2A-B can be used with the fighting structures of Figures 1A-D (in place of the second thermal management components of Figures 1A-D), Figures 3A--B, Figure 4 (in place of the second thermal management components of Figure 4), and some of the embodiments of Figures 5A-E; and the second thermal management component of Figure 4 can be used with the lighting structures of Figures 1A-D (in place of the second thermal management components of Figures 1 A-D), Figure 2A-D (in place of the secorsd thermal management components of Figures 2A-D), Figures 3A-B, and some of the embodiments of Figures 5A-E. Various additional stractures may be included and/or described features may be omitted in other embodiments.