WO2008093978A1 - Led assembly including cooler having heat pipe - Google Patents

Led assembly including cooler having heat pipe Download PDF

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Publication number
WO2008093978A1
WO2008093978A1 PCT/KR2008/000521 KR2008000521W WO2008093978A1 WO 2008093978 A1 WO2008093978 A1 WO 2008093978A1 KR 2008000521 W KR2008000521 W KR 2008000521W WO 2008093978 A1 WO2008093978 A1 WO 2008093978A1
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WO
Grant status
Application
Patent type
Prior art keywords
tube member
heat pipe
heat
inner
space
Prior art date
Application number
PCT/KR2008/000521
Other languages
French (fr)
Inventor
Sun-Gyu Yoon
Young-Woo Nam
Min-Whan Seo
Sang-Woong Park
Original Assignee
Zalman Tech Co., Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/002Cooling arrangements
    • F21V29/004Natural cooling, i.e. by natural convection, conduction or radiation
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21KNON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20Light sources comprising attachment means
    • F21K9/23Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50Cooling arrangements
    • F21V29/51Cooling arrangements using condensation or evaporation of a fluid, e.g. heat pipes
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50Cooling arrangements
    • F21V29/70Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/71Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks using a combination of separate elements interconnected by heat-conducting means, e.g. with heat pipes or thermally conductive bars between separate heat-sink elements
    • F21V29/717Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks using a combination of separate elements interconnected by heat-conducting means, e.g. with heat pipes or thermally conductive bars between separate heat-sink elements using split or remote units thermally interconnected, e.g. by thermally conductive bars or heat pipes
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50Cooling arrangements
    • F21V29/70Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/74Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
    • F21V29/76Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section
    • F21V29/767Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section the planes containing the fins or blades having directions perpendicular to the light emitting axis
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50Cooling arrangements
    • F21V29/70Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F21V29/74Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
    • F21V29/77Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section
    • F21V29/773Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section the planes containing the fins or blades having the direction of the light emitting axis
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V23/00Arrangement of electric circuit elements in or on lighting devices
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/85Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems characterised by the material
    • F21V29/89Metals
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21YINDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2105/00Planar light sources
    • F21Y2105/10Planar light sources comprising a two-dimensional array of point-like light-generating elements
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21YINDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00Light-generating elements of semiconductor light sources
    • F21Y2115/10Light-emitting diodes [LED]

Abstract

Provided is a light emitting diode (LED) assembly including a cooler having a heat pipe. The LED assembly includes: a heat pipe, which includes working fluid inside a sealed space, has a cylindrical form having a heat absorbing surface, a sealing surface, and a side, and has a through hole for an inner tube member penetrating the heat absorbing surface and the sealing surface; an LED combination, which includes at least one LED, and is combined to the heat absorbing surface of the heat pipe so as to transmit heat generated during operation of the LED to the heat pipe, wherein a wire is connected to the LED passes through the heat pipe through the through hole; a radiator, which is combined to the side of the heat pipe so as to externally radiate heat received from the heat pipe; and an electrical connector, which is combined to the wire passing through the through hole of the heat pipe and to an external power source.

Description

Description

LED ASSEMBLY INCLUDING COOLER HAVING HEAT PIPE

Technical Field

[1] This application claims the benefit of Korean Patent Application No.

10-2007-0010134, filed on January 31, 2007, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference

[2] The present invention relates to a light emitting diode (LED) assembly including a cooler having a heat pipe, and more particularly, to a LED assembly which can effectively cool down via a heat pipe heat generated by a LED .

[3] The present invention also relates to a heat pipe used in the LED assembly, and a method of manufacturing the heat pipe. Background Art

[4] A light emitting diode (LED) is a type of semiconductor that converts electrical energy in response to an applied voltage into light energy. A lighting apparatus using such LED consumes less power than an incandescent lamp that is mainly used as a current lighting apparatus, and also can realize light in various colors. Disclosure of Invention Technical Problem

[5] However, the lighting apparatus cannot effectively cool down heat generated by the

LED. Technical Solution

[6] The present invention provides a light emitting diode (LED) assembly including a cooler having a heat pipe, which can effectively cool down heat generated in an LED via the cooler including the heat pipe having a new structure.

[7] According to an aspect of the present invention, there is provided light emitting diode

(LED) assembly including a cooler having a heat pipe, the LED assembly comprising: a heat pipe, which includes working fluid inside a sealed space, has a cylindrical form having a heat absorbing surface, a sealing surface, and a side, and has a through hole by an inner tube member penetrating the heat absorbing surface and the sealing surface; an LED combination, which includes at least one LED, and is combined to the heat absorbing surface of the heat pipe so as to transmit heat generated during operation of the LED to the heat pipe, wherein a wire connected to the LED passes through the heat pipe via the through hole; a radiator, which is combined to the side of the heat pipe so as to externally radiate heat received from the heat pipe; and an electrical connector, which is combined to the wire passing through the through hole of the heat pipe and to an external power source. [8] The radiator comprises: a cylindrical body, in which the heat pipe is inserted; and a plurality of cooling pins, which are formed in the vertical length direction on the cylindrical body and spaced apart from each other along the peripheral direction of the cylindrical body.

[9] The cylindrical body and the plurality of cooling pins are formed in one body.

[10] The radiator includes a plurality of cooling pins separated from each other and vertically inserted to the side of the heat pipe. [11] The LED combination includes a metallic printed circuit board (PCB), wherein the

LED is installed in one side of the PCB and the heat absorbing surface of the heat pipe is combined to another side of the PCB so as to transmit the heat generated in the LED to the heat pipe through the PCB

Description of Drawings [12] The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which: [13] FIG. 1 is a perspective view of a light emitting diode (LED) assembly including a cooler having a heat pipe according to an embodiment of the present invention; [14] FIG. 2 is a cross-sectional view taken along a line II - II of FIG. 1;

[15] FIG. 3 is a plan view of the LED assembly illustrated in FIG. 1;

[16] FIG. 4 is a perspective view of an LED assembly including a cooler having a heat pipe according to another embodiment of the present invention; [17] FIG. 5 is a perspective view of an LED assembly including a cooler having a heat pipe according to another embodiment of the present invention; [18] FIG. 6 is a cross-sectional view taken along a line VI - VI of FIG. 5;

[19] FIG. 7 is a diagram illustrating a radiator having a different shape than a radiator included in the LED assembly illustrated in FIG. 5; [20] FIG. 8 is a perspective view of a heat pipe according to an embodiment of the present invention;

[21] FIG. 9 is a cross-sectional view taken along a line IX - IX of FIG. 8;

[22] FIGS. 10 through 16 are diagrams for describing a method of manufacturing the heat pipe illustrated in FIG. 8; [23] FIG. 17 is a perspective view of a body of a heat pipe according to an embodiment of the present invention; and [24] FIG. 18 is a vertical cross-sectional view of the body illustrated in FIG. 17.

Best Mode [25] Hereinafter, the present invention will be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. [26] FIG. 1 is a perspective view of a light emitting diode (LED) assembly 1 including a cooler using a heat pipe 10 according to an embodiment of the present invention, FIG. 2 is a cross-sectional view taken along a line II - II of FIG. 1, and FIG. 3 is a plan view of the LED assembly 1 illustrated in FIG. 1.

[27] The LED assembly 1 according to the current embodiment of the present invention includes the heat pipe 10, an LED combination 20, a radiator 30, and an electrical connector 40.

[28] The heat pipe 10 quickly transmits heat generated in a plurality of LEDs 21 of the

LED assembly 20 to the radiator 30. A cross-sectional view of the heat pipe 10 is illustrated in FIG. 2, but the heat pipe 10 will now be described with reference to FIGS. 8 and 9, which only illustrate the heat pipe 10. In comparison to FIGS. 1 and 2, the heat pipe 10 is shown in an upside-down position in FIGS. 8 and 9.

[29] A working fluid is filled in the heat pipe 10 and the heat pipe 10 is sealed so that an inner space of the heat pipe 10 is in a vacuum state. The heat pipe 10 has a cylindrical form, and includes a heat absorbing surface 12, a sealing surface 14, and a side 16.

[30] Referring to FIG. 9, the heat absorbing surface 12 denotes a bottom surface of a heat absorbing cap 50, and the sealing surface 14 denotes a top surface of a sealing cap 52.

[31] A through hole 11 is formed in the heat absorbing surface 12 and the sealing surface

14. In other words, the through hole 11 is formed in the center of the heat pipe 10 from top to bottom. Thus, the heat pipe 10 in such shape may be referred to as a hollow heat pipe.

[32] The through hole 11 is formed by using an inner tube member 18. Referring to FIG.

9, sintering wicks 58 and 60 are respectively formed on the top surface of the heat absorbing cap 50 and an inner side 190 of an outer tube member 19. Also according to the current embodiment, an inner side 180 of the inner tube member 18 includes a sintering wick 62 formed by sintering metal powder. However, the sintering wick 62 of the inner tube member 18 may not be included. Here, the inner side 180 of the inner tube member 18 denotes a side facing an inner space 100 of the heat pipe 10 from among the sides of the inner tube member 18.

[33] The heat pipe 10 includes the inner space 100 surrounded by the inner tube member

18, the outer tube member 19, the heat absorbing cap 50, and the sealing cap 52. The inner space 100 is in a vacuum state, and contains the working fluid.

[34] Referring to FIGS. 1 and 2, the LED combination 20 includes the plurality of LEDs

21, a printed circuit board (PCB) 22, and a wire 26.

[35] In the current embodiment, the LEDs 21 have a device form instead of a bulb form, and are mounted with the PCB 22. Heat is generated when the LEDs 21 operate, and this heat is transmitted to the heat absorbing surface 12 of the heat pipe 10.

[36] In the current embodiment, the PCB 22 is formed of a metal with good thermal conductance, such as aluminum. Although it is not illustrated in detail, one side (top) of the metal PCB 22 in FIG. 2 is coated with an insulating layer for circuit formation, and is mounted with the plurality of LEDs 21.

[37] Also, another side (bottom) of the PCB 22 is combined to the heat absorbing surface

12 of the heat pipe 10. Accordingly, heat generated in the LEDs 21 is quickly and effectively transmitted to the heat absorbing surface 12 of the heat pipe through the metal PCB 22.

[38] Meanwhile, a thermal pad 24 is additionally included between the PCB 22 and the heat absorbing surface 12 of the heat pipe 10. Due to such thermal pad 24, the heat can be easily transmitted irrelevantly to roughness of a contacting surface of the PCB 22 and the heat absorbing surface 12.

[39] The wire 26 is used to supply power to the LEDs 21. One end of the wire 26 is combined to the center of the PCB 22, and is electrically connected to the LEDs 21 that are mounted on the PCB 22 by a circuit. As illustrated in FIG. 2, since the through hole 11 is included in the heat pipe 10, the wire 26 extends to the sealing surface 14 by passing through the inner space of the heat pipe 10 through the through hole 11. The one end of the wire 26 may be combined to the PCB 22 right above the through hole 11. Although not illustrated in FIG. 2, another end of the wire 26 is electrically connected to the electrical connector 40 that will be described later. In the current embodiment, the LEDs 21 are of a device type, but the LEDs 21 may be of any other type (including a bulb form).

[40] The radiator 30 is combined to the side 16 of the heat pipe 10, and cools down the

LEDs 21 by receiving heat from the LEDs 21 through the heat pipe 10 and externally radiating the received heat in the air.

[41] In the current embodiment, the radiator 30 includes a cylindrical body 32 and a cooling pin 34.

[42] Referring to FIGS. 1 through 3, the cylindrical body 32 is inserted to the side 16 of the heat pipe 10 in a cylindrical form. In other words, the inside diameter of the cylindrical body 32 in a pipe form is approximately equal to the external diameter of the heat pipe 10, and thus the cylindrical body 32 is forcibly fitted into the heat pipe 10. The cylindrical body 32 and the side 16 may be combined through separate welding or soldering.

[43] The cooling pin 34 is formed in a vertical length direction on the cylindrical body 32, and a plurality of cooling pins 34 are spaced apart from each other along the peripheral direction of the cylindrical body 32.

[44] According to the current embodiment in FIG. 3, the cylindrical body 32 and the cooling pins 34 are formed in one body. The cylindrical body 32 and the cooling pins 34 can be formed in one body by extruding the cylindrical body 32 and the cooling pins 34 by using a metal having good thermal conductance, such as aluminum, or by die-casting the cylindrical body 32 and the cooling pins 34.

[45] The electrical connector 40 is combined to another end of the wire 26 that passed through the through hole 11 of the heat pipe 10. The electrical connector 40 may be combined to an external power source (not shown), and provides power required for the LEDs 21 to emit light. In the current embodiment, the electrical connector 40 is of a screw base type, such as a general incandescent lamp, and thus can supply power by being combined to a socket to which the general incandescent lamp is tightened.

[46] Also in the current embodiment, if a power source is AC 220 volts, the LEDs 21 generally emit lights of approximately DC 12 volts. Accordingly, the electrical connector 40 may include a transformer (not shown) that converts AC to DC.

[47] According to the current embodiment, the electrical connector 40 is of screw base type, but the type of the electrical connector 40 is not limited thereto. In other words, the electrical connector 40 may be of a plug form combined to an outlet, or of a connector form.

[48] By using the LED assembly 1 according to the current embodiment of the present invention, the heat generated in the LEDs 21 can be quickly and effectively cooled down by using the heat pipe 10 and the radiator 30.

[49] Also, as the heat pipe 10 includes the through hole 11 that is perforated from top to bottom, the wire 26 extended from the LED combination 20 can pass through the through hole 11 so as to be connected to the electrical connector 40. Accordingly, the wire 26 is not exposed, and thus the appearance of the LED assembly 1 is excellent. Moreover, the radiator 30 can be designed to have various shapes and volumes without interference of the wire 26, and thus cooling performance of the radiator 30 is improved. As the cooling performance improves, the number of LEDs 21 in the LED assembly 1 can be increased, and thus a brighter LED assembly 1 can be realized. In addition, the durability of the LEDs 21 can be increased if the cooling is effectively performed.

[50] More amount of heat can be effectively and quickly transmitted as the sintering wick

62 is included in the inner side 180 of the inner tube member 18 as illustrated in FIG. 9. However, as occasion demands, the sintering wick 62 may not be included in the inner side 180 of the inner tube member 18.

[51] Meanwhile, in the LED assembly 1 according to the current embodiment of the present invention, the cylindrical body 32 and the cooling pins 34 of the radiator 30 are in one body, but the present invention is not limited thereto. In other words, the cylindrical body 32 and the cooling pins 34 may be separately manufactured, and then combined together. Mode for Invention [52] FIG. 4 is a perspective view of an LED assembly Ia including a cooler using a heat pipe according to another embodiment of the present invention. Comparing the LED assembly 1 of FIG. 1 and the LED assembly Ia of FIG. 4, only the shapes of a radiator 30a and cooling pin 34a are different.

[53] FIG. 5 is a perspective view of an LED assembly Ib including a cooler using a heat pipe according to another embodiment of the present invention, and FIG. 6 is a cross- sectional view taken along a line VI - VI of FIG. 5.

[54] Comparing the LED assembly 1 and the LED assembly Ib, only the configuration of the radiator 30b is different. Accordingly, only the configuration of the radiator 30b will be described, and the other elements are to the same as the elements of the LED assembly 1.

[55] The radiator 30b according to the current embodiment of the present invention includes a plurality of cooling pins 34b that are vertically spaced apart from each other on the side 16 of the heat pipe 10. Referring to FIG. 6, the thin metal cooling pins 34b are horizontally inserted in the side 16 of the heat pipe 10. Each cooling pin 34b has a circular plate form, and a combining hole 340b, to which the heat pipe 10 is inserted, is formed in the center of the cooling pin 34b. Also, burrs 342b, which protrude to one side, are formed along the circumference of the combining hole 340b. The cooling pin 34b can have a large contacting area against the side 16 of the heat pipe 10, and can be combined to the heat pipe 10 by the burrs 342b. The cooling pin 34b is forcibly fitted to the heat pipe 10. Alternatively, the cooling pins 34b can be combined to the side 16 of the heat pipe 10 through soldering.

[56] FIG. 7 is a diagram illustrating a radiator in different shape than the radiator 30b included in the LED assembly Ib illustrated in FIG. 5. In FIG. 7, cooling pins 34c having different shapes are combined to the heat pipe 10. The diameter of the cooling pin 34c on the bottom of the heat pipe 10 is smaller than the diameter of the cooling pin 34c on the top of the heat pipe 10. The shapes or locations of the cooling pins 34c may vary according to a space for installing an LED assembly or a desired amount of generated heat.

[57] FIG. 8 is a perspective view of the heat pipe 10 employed in the LED assembly 1 of

FIG. 1 described above, and FIG. 9 is a cross-sectional view taken along a line IX - IX of FIG. 8. Overlapping descriptions about the heat pipe 10 will be omitted herein.

[58] Referring to FIG. 9, a bypass 54 is an element for putting an inner space 100 in a vacuum state and for pouring working fluid into the inner space 100. After that, an end of the bypass 54 is sealed. An outer side and an inner side of a heat absorbing cap 50 respectively include welding rings 502 and 504. The welding rings 502 and 504 are inserted into pre-prepared grooves, melted by heat generated while sintering inner metal powder, and hardened in order to combine the heat absorbing cap 50 to one ends of an inner tube member 18 and an outer tube member 29.

[59] A heat pipe including a through hole employed in the LED assembly of the present invention and a method of manufacturing the heat pipe will now be described.

[60] The heat pipe includes working fluid inside a sealed space, and has a cylindrical form including a heat absorbing surface, a sealing surface, and a side. A through hole, which penetrates the heat absorbing surface and the sealing surface, is formed in the heat pipe.

[61] The through hole is formed by using an inner tube member that penetrates the heat absorbing surface and the sealing surface, and the inner tube member may include a sintering wick that is formed by sintering metal powder on an inner side of the inner space of the heat pipe.

[62] The method according to an embodiment of the present invention includes: a tube member preparing operation, wherein a tube member is prepared by cutting each of an outer tube member and an inner tube member, where a diameter of the outer tube member is relatively larger than that of the inner tube member; a heat absorbing cap combining operation, wherein a heat absorbing cap having a circular plate form and including a combining hole near the center to which the inner tube member can be inserted is prepared, the inner tube member is placed inside the outer tube member, and then the heat absorbing cap is combined to one end of the outer tube member and the inner tube member; a metal powder filling operation, wherein a mandrel, which has a cylindrical form including a space for receiving the inner tube member, is inserted to an inner space formed by the heat absorbing cap, the outer tube member, and the inner tube member, and then metal powder is filled in a space between the inner side of the outer tube member and the mandrel, and a space between the heat absorbing cap and the mandrel; a sintering operation, wherein a sintering wick is formed by sintering the metal powder; a sealing cap combining operation, wherein a sealing cap is prepared in a circular plate form including at least one of a combining hole to which the inner tube member can be inserted, and a bypass for forming a vacuum inside the inner space and pouring the working fluid, and then the sealing cap is combined to another end of the outer tube member and the inner tube member; and a vacuuming and working fluid pouring operation, wherein the inner space is placed in a vacuum state to a predetermined level by using the bypass in the sealing cap, the working fluid is poured in the inner space through the bypass, and then the bypass is sealed.

[63] In the metal powder filling operation, the metal powder may be filled in a space between the inner side of the inner space of the inner tube member and the mandrel.

[64] In the method according to the current embodiment of the present invention, the heat pipe includes working fluid inside a sealed space, has a cylindrical form having a heat absorbing surface, a sealing surface, and a side, and has a through hole for an inner tube member penetrating the heat absorbing surface and the sealing surface. In other words, the heat pipe is the same as the heat pipe described above with reference to the previous LED assembly, and is characterized by the through hole in its center.

[65] The method of FIGS. 8 and 9 will now be described with reference to FIGS. 10 through 16. Reference numerals in FIGS. 10 through 16 denote the same elements as in FIGS. 1 through 3, 8, and 9.

[66] The method according to the current embodiment of the present invention includes the tube member preparing operation, the heat absorbing cap combining operation, the metal powder filling operation, the sintering operation, the sealing cap combining operation, and the vacuuming and working fluid pouring operation.

[67] In the tube member preparing operation, the outer tube member 19 and the inner tube member 18 are prepared by cutting them to the same length. Here, the diameter of the outer tube member 19 is relatively large compared to that of the inner tube member 18. The tube member is formed of copper (Cu).

[68] Then, the heat absorbing cap combining operation is performed.

[69] Referring to FIG. 11, the heat absorbing cap 50 includes the combining hole 51 in the vicinity of the center of the heat absorbing cap 50. The combining hole 51 has a size appropriate for inserting the inner tube member 18. The heat absorbing cap 50 has a circular plate form and is formed of Cu.

[70] The inner tube member 18 is located inside the outer tube member 19, and the heat absorbing cap 50 is combined to ends of the outer tube member 19 and the inner tube member 18. This is illustrated in FIG. 10. Grooves are formed along the circumferential surfaces of an inner surface and an outer surface of the heat absorbing cap 50, and the welding rings 502 and 504 are combined to the grooves.

[71] The metal powder filling operation and the sintering operation will now be described with reference to FIGS. 12 through 14.

[72] A mandrel 102 is inserted in the inner space 100 formed by the heat absorbing cap

50, the outer tube member 19, and the inner tube member 18 as illustrated in FIG. 12. The mandrel 102 is used to limit a space in which metal powder 56 is to be filled. The mandrel 102 includes a space 104 of which center can receive the inner tube member 18. In other words, the mandrel 102 has a cylindrical form, and the space 104 is vertically formed inside the mandrel 102.

[73] The mandrel 102 is inserted into the inner space 100 in order to form a space between each inner side of the outer tube member 19, the inner tube member 18, and the heat absorbing cap 50, and the mandrel 102 so that the metal powder 56 can be filled in.

[74] Referring to FIG. 13, the metal powder 56 is filled in a space between the inner side

190 of the outer tube member 19 and the mandrel 102, a space between the inner side 180 of the inner tube member 18 and the mandrel 102, and a space between an inner space 500 of the heat absorbing cap 50 and the mandrel 102 (the metal powder filling operation).

[75] In the current embodiment, the metal powder 56 is filled in the space between the inner side 180 of the inner tube member 18 and the mandrel, but the metal powder 56 may not be filled in such space. In the latter case, the size of the space 104 is adjusted so that the space between the inner side 180 and the mandrel 102 is not formed.

[76] Then, while maintaining the location of the mandrel 102, the sintering operation is performed, wherein a sintering wick is formed by sintering the metal powder with heat. When the mandrel 102 is removed after the sintering operation, it can be seen that the sintering wicks 58, 60, and 62 are respectively formed on the inner sides 500, 190, and 180 as illustrated in FIG. 14. Meanwhile, when heat is applied in the sintering operation, the welding rings 502 and 504 of the heat absorbing cap 50 are melted, and thus welded.

[77] Then, the sealing cap combining operation is performed.

[78] In order to perform the sealing cap combining operation, the sealing cap 52 is prepared. The sealing cap 52 has a circular plate form, and the center thereof has the combining hole 53 to which the inner tube member 19 can be inserted. Also, a bypass 54 for extracting air from the inner space 100 to place the inner space 100 in a vacuum state at a predetermined level and pouring the working fluid into the inner space 100 is formed on one side of the sealing cap 52.

[79] The sealing cap 52 is inserted in other end of the outer tube member 19 and the inner tube member 18, and then combined thereto by applying heat. At this time, the welding rings 520 and 522 are formed in the sealing cap 52 like the heat absorbing cap 50, and thus the sealing cap 52 is welded to the other end of the outer tube member 19 and the inner tube member 18.

[80] Then, the inner space 100 is put in a vacuum state and the working fluid is poured into the inner space 100 by using the bypass 54 of the sealing cap 52. Here, the order of vacuuming and pouring is not important, and may be decided by an operator. Next, an end of the bypass 54 is sealed through welding or the like. Accordingly, the heat pipe according to the current embodiment of the present invention is manufactured.

[81] In the current embodiment, one bypass 54 is used for the vacuuming and working fluid pouring operation, but there two bypasses 54 may be used to separately perform a vacuuming operation and a working fluid pouring operation.

[82] Another method of manufacturing a heat pipe employed in the LED assembly of the present invention according to another embodiment will not be described.

[83] The method of manufacturing a heat pipe, which includes working fluid inside a sealed space, has a cylindrical form having a heat absorbing surface, a sealing surface, and a side, and a through hole for an inner tube member penetrating the heat absorbing surface and the sealing surface, includes: a body and inner tube member preparing operation for preparing a body, the body having one end that includes a heat absorbing surface including a combining hole, another end that is opened, and a side, and an inner tube member that is combined to the combining hole, and for combining one end of the inner tube member to the combining hole of the body; a metal powder filling operation for inserting a mandrel, which has a cylindrical form including a space that can receive the inner tube member, to an inner space of the body, and then filling a metal powder in a space between the inner side of the body and the mandrel; a sintering operation for forming a sintering wick by sintering the metal powder; a sealing cap combining operation for preparing a sealing cap, which has a circular plate form including at least one of a combining hole to which the inner tube member can be inserted, and a bypass for forming a vacuum inside the inner space and pouring the working fluid, removing the mandrel, and then combining the sealing cap to another end of the body; and a vacuuming and working fluid pouring operation for putting the inner space in a vacuum state at a predetermined level by using the bypass in the sealing cap, pouring the working fluid to the inner space through the bypass, and then sealing the bypass.

[84] T he body may be formed to have the heat absorbing surface by spinning one end of a material in a tube form.

[85] Alternatively, the body may formed by drawing a metal plate member, and then drilling the combining hole in the center of the heat absorbing surface.

[86] The metal powder filling operation may fill the metal powder in a space between the inner side of the inner space of the inner tube member and the mandrel.

[87] The method according to the current embodiment of the present invention will now be described with reference to FIGS. 17 and 18.

[88] The method according to the current embodiment is different from the method according to the previous embodiment, as the method according to the previous embodiment requires combining the outer tube member 19 and the heat absorbing cap 50 as they are separately prepared, but the method according to the current embodiment does not require such process since a body 80 corresponding to the combination of the outer tube member 19 and the heat absorbing cap 50 is used.

[89] Accordingly, descriptions of the metal powder filling operation, the sintering operation, the sealing cap combining operation, and the vacuuming and working fluid pouring operation of the method according to the current embodiment are omitted as they are the same as those of the method according to the previous embodiment. Thus, only the body and inner tube member preparing operation, which corresponds to the tube member preparing operation and the heat absorbing cap combining operation of the method according to the previous embodiment, will now be described. [90] In the body and inner tube member preparing operation, the body 80 and an inner tube member are required. Referring to FIGS. 17 and 18, the body 80 includes a heat absorbing surface 82 having a combining hole 84 in one side, and another side is opened. Also, the body 80 includes a side 86. The heat absorbing surface 82 and the side 86 are in one body and formed of Cu. [91] The inner tube member is equal to the inner tube member 19 used in the method according to the previous embodiment. [92] The inner tube member is inserted to the combining hole 84 of the body 80. Here, like the method of the previous embodiment, a welding ring is included in the combining hole 84. [93] Next, like the method of the previous embodiment, a mandrel is inserted to an inner space of the body 80, and then metal powder is filled in the inner space. Then, the sintering operation, the sealing cap combining operation, and the vacuuming and working fluid pouring operation are respectively performed so as to manufacture the heat pipe. [94] The body 80 may be prepared in a desired form through casting. However, the body

80 may be formed through other various methods, such as spinning and drawing. [95] In other words, the body 80 may be formed to have the heat absorbing surface by spinning one end of a tube shaped material [96] According to the spinning, a container having a conic shape or similar shape is prepared by rotating a material in a tube shape using a conventional spinning shelf according to a spinning mold frame in a conic shape or similar shape. Accordingly, one end of the material is closed up, and thus the body 80 as illustrated in FIG. 17 is formed. [97] Also during the spinning, the combining hole 84 can be simultaneously formed, and thus the combining hole 84 may not be separately formed through drilling. [98] Alternatively, the body 80 may be formed by drawing a metal plate member, and then drilling the combining hole 84 in the center of the heat absorbing surface. Here, the drawing is a process of extruding a flat metal circle plate in room temperate so as to form a container in a cup shape or a shape having a flat bottom. [99] In other words, a metal plate is processed to have a cup shape through several operations, and then the combining hole 84 is formed by drilling the center of the bottom surface so as to form the body 80 illustrated in FIG. 17. [100] As described above, according to the LED assembly including a cooler having a heat pipe of the present invention, heat generated in an LED can be effectively cooled down. [101] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.

Claims

Claims
[1] A light emitting diode (LED) assembly including a cooler having a heat pipe, the
LED assembly comprising: a heat pipe, which includes working fluid inside a sealed space, has a cylindrical form having a heat absorbing surface, a sealing surface, and a side, and has a through hole by an inner tube member penetrating the heat absorbing surface and the sealing surface; an LED combination, which includes at least one LED, and is combined to the heat absorbing surface of the heat pipe so as to transmit heat generated during operation of the LED to the heat pipe, wherein a wire connected to the LED passes through the heat pipe via the through hole; a radiator, which is combined to the side of the heat pipe so as to externally radiate heat received from the heat pipe; and an electrical connector, which is combined to the wire passing through the through hole of the heat pipe and to an external power source.
[2] The LED assembly of claim 1, wherein the radiator comprises: a cylindrical body, in which the heat pipe is inserted; and a plurality of cooling pins, which are formed in the vertical length direction on the cylindrical body and spaced apart from each other along the peripheral direction of the cylindrical body.
[3] The LED assembly of claim 2, wherein the cylindrical body and the plurality of cooling pins are formed in one body.
[4] The LED assembly of claim 1, wherein the radiator includes a plurality of cooling pins separated from each other and vertically inserted to the side of the heat pipe.
[5] The LED assembly of claim 1, wherein the LED combination includes a metallic printed circuit board (PCB), wherein the LED is installed in one side of the PCB and the heat absorbing surface of the heat pipe is combined to another side of the PCB so as to transmit the heat generated in the LED to the heat pipe through the PCB.
[6] A heat pipe, which includes working fluid inside a sealed space, has a cylindrical form having a heat absorbing surface, a sealing surface, and a side, and has a through hole penetrating the heat absorbing surface and the sealing surface.
[7] The heat pipe of claim 6, wherein the through hole is formed by an inner tube member that penetrates the heat absorbing surface and the sealing surface, wherein the inner tube member comprises a sintering wick that is formed by sintering a metal powder on an inner side of an inner space of the heat pipe. [8] A method of manufacturing a heat pipe, which includes working fluid inside a sealed space, has a cylindrical form having a heat absorbing surface, a sealing surface, and a side, and has a through hole by an inner tube member penetrating the heat absorbing surface and the sealing surface, the method comprising: a tube member preparing operation for preparing a tube member by cutting each of an outer tube member and an inner tube member, wherein a diameter of the outer tube member is relatively larger than that of the inner tube member; a heat absorbing cap combining operation for preparing a heat absorbing cap in a circular plate form including a combining hole near the center to which the inner tube member can be inserted, placing the inner tube member inside the outer tube member, and then combining the heat absorbing cap to one end of the outer tube member and the inner tube member; a metal powder filling operation for inserting a mandrel, which has a cylindrical form including a space for receiving the inner tube member, to an inner space formed by the heat absorbing cap, the outer tube member, and the inner tube member, and then filling a metal powder in a space between the inner side of the outer tube member and the mandrel, and a space between the heat absorbing cap and the mandrel; a sintering operation for forming a sintering wick by sintering the metal powder; a sealing cap combining operation for, preparing a sealing cap in a circular plate form, which includes at least one of a combining hole to which the inner tube member can be inserted, and a bypass for forming a vacuum inside the inner space and pouring the working fluid, and then combining the sealing cap to another end of the outer tube member and the inner tube member; and a vacuuming and working fluid pouring operation for putting the inner space in a vacuum state at a predetermined level by using the bypass in the sealing cap, pouring the working fluid into the inner space through the bypass, and then sealing the bypass.
[9] The method of claim 8, wherein the metal powder is filled in the metal powder filling operation in a space between the inner side of the inner space of the inner tube member and the mandrel.
[10] A method of manufacturing a heat pipe, which includes working fluid inside a sealed space, has a cylindrical form having a heat absorbing surface, a sealing surface, and a side, and has a through hole for an inner tube member penetrating the heat absorbing surface and the sealing surface, the method comprising: a body and inner tube member preparing operation for preparing a body, having one end that includes a heat absorbing surface including a combining hole, another end that is opened, and a side, and an inner tube member that is combined to the combining hole, and combining one end of the inner tube member to the combining hole of the body; a metal powder filling operation for inserting a mandrel, which has a cylindrical form including a space that can receive the inner tube member, to an inner space of the body, and then filling a metal powder in a space between the inner side of the body and the mandrel; a sintering operation for forming a sintering wick by sintering the metal powder; a sealing cap combining operation for preparing a sealing cap, which has a circular plate form including at least one of a combining hole to which the inner tube member can be inserted, and a bypass for forming a vacuum inside the inner space and pouring the working fluid, removing the mandrel, and then combining the sealing cap to other end of the body; and a vacuuming and working fluid pouring operation for putting the inner space in a vacuum state at a predetermined level by using the bypass in the sealing cap, pouring the working fluid into the inner space through the bypass, and then sealing the bypass.
[11] The method of claim 10, wherein the body is formed to have the heat absorbing surface by spinning one end of a material in a tube form.
[12] The method of claim 10, wherein the body is formed by drawing a metal plate member, and then drilling the combining hole in the center of the heat absorbing surface.
[13] The method of claim 10, wherein the metal powder is filled in the metal powder filling operation in a space between the inner side of the inner space of the inner tube member and the mandrel.
PCT/KR2008/000521 2007-01-31 2008-01-29 Led assembly including cooler having heat pipe WO2008093978A1 (en)

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