WO2014041470A2 - Heat sink structure and method of manufacturing the same - Google Patents

Heat sink structure and method of manufacturing the same Download PDF

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Publication number
WO2014041470A2
WO2014041470A2 PCT/IB2013/058346 IB2013058346W WO2014041470A2 WO 2014041470 A2 WO2014041470 A2 WO 2014041470A2 IB 2013058346 W IB2013058346 W IB 2013058346W WO 2014041470 A2 WO2014041470 A2 WO 2014041470A2
Authority
WO
WIPO (PCT)
Prior art keywords
heat sink
sheet material
sink structure
plastic material
mould
Prior art date
Application number
PCT/IB2013/058346
Other languages
French (fr)
Other versions
WO2014041470A3 (en
Inventor
Reinier Imre Anton DEN BOER
Original Assignee
Koninklijke Philips N.V.
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
Application filed by Koninklijke Philips N.V. filed Critical Koninklijke Philips N.V.
Publication of WO2014041470A2 publication Critical patent/WO2014041470A2/en
Publication of WO2014041470A3 publication Critical patent/WO2014041470A3/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V19/00—Fastening of light sources or lamp holders
    • F21V19/001—Fastening of light sources or lamp holders the light sources being semiconductors devices, e.g. LEDs
    • F21V19/003—Fastening of light source holders, e.g. of circuit boards or substrates holding light sources
    • F21V19/004—Fastening of light source holders, e.g. of circuit boards or substrates holding light sources by deformation of parts or snap action mountings, e.g. using clips
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/85—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems characterised by the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0013—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/747—Lightning equipment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING 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
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • the present invention generally relates to the field of heat sink structures for a dissipation of heat from heat-generating elements.
  • the present invention also relates to methods of manufacturing such heat sink structures.
  • Lighting devices comprising solid state light sources, such as light emitting diodes (LEDs), are known in the art. Lighting devices comprising LEDs may be used for a general lighting or even for a more specific lighting, as the colour and the output power of the LEDs may be tuned.
  • LEDs light emitting diodes
  • Light-emitting arrangements comprising a plurality of light sources, e.g. for use in a display or in an illumination device, may generate a quick rise of the temperature of the light-emitting arrangement, especially if many light sources are driven at the same time.
  • the effect of heat may be detrimental to the light sources, and their operation may become erratic and unstable. As a consequence, the light from the light source may flicker, causing degradation of the quality of the display or illumination.
  • lighting devices may comprise heat sinks (heat dissipators) which are in thermal contact with the heat-generating light sources(s) and/or electronics.
  • Heat sinks for lighting devices comprising LEDs may be produced e.g. by overmoulding, wherein a material (generally plastics) is formed over a heat sink insert (e.g. a piece of metal).
  • a material generally plastics
  • a heat sink insert e.g. a piece of metal
  • an insert moulding process may be performed, wherein a heat sink insert is placed in a mould and the material (e.g. plastics) is provided into the mould, and is thereafter cooled.
  • the heat sink inserts usually need to have a geometry that both facilitates the correct positioning of the heat sink inserts into the mould, and that may resist the clamping force of the mould. To meets these demands, the geometry of the heat sink inserts needs to be relative stiff and/or thick.
  • the heat sink inserts are often overdimensioned, which is disadvantageous, as the heat sink inserts thereby consist of a relatively large amount of material. This results in more costly heat sinks and/or that the heat sinks become more bulky. Overdimensioned heat sink inserts are especially undesired when considering the development of lighting devices comprising LEDs which become more and more efficient, as the heat sink inserts thereby use more material than needed.
  • the present invention has been made with respect to the above considerations. It is an object of the present invention to provide a method of manufacturing a heat sink structure, as well as a heat sink structure, which is cost-effective.
  • a method of manufacturing a heat sink structure comprises the steps of providing a heat- conductive sheet material and arranging the sheet material in a mould. Further, a plastic material is provided in a fluid state and injected into the mould. The method further comprises the step of moulding the plastic material and the sheet material, such that the plastic material and the sheet material are formed by the mould, and wherein the plastic material and the sheet material bond to each other. The method further comprises the step of solidifying the plastic material, such that the plastic material and the sheet material form a heat sink structure wherein the plastic material and the sheet material are thermally connected to each other.
  • a heat sink structure comprising a heat-conductive sheet material and a plastic material.
  • the sheet material and the plastic material have been moulded by means of a method according to the first aspect of the invention to form the heat sink structure, in which the plastic material and the sheet material are thermally connected to each other.
  • fluid state it is here meant a state of the plastic material which is able to conform to the form of the mould, e.g. a melt.
  • solidifying it is here meant to make a material solid, for example through hardening, curing and/or tempering.
  • the present invention is based on the idea of providing a method of manufacturing a heat sink structure, wherein a heat-conductive sheet material and a plastic material are bonded to each other by means of a moulding process.
  • the sheet material and the plastic material are formed by the mould into a heat sink structure, and after
  • the present invention thereby provides an efficient and cost-effective method of manufacturing a heat sink structure, wherein the heat sink structure is arranged to efficiently dissipate heat generated by one or more heat-generating elements (e.g. LEDs, carriers, etc.) when in operation.
  • the heat sink structure is arranged to efficiently dissipate heat generated by one or more heat-generating elements (e.g. LEDs, carriers, etc.) when in operation.
  • An advantage of various embodiments of the present invention is that the method provides an efficient way of manufacturing a heat sink structure, especially as the method comprises few and efficient process steps.
  • the present method avoids the process of holding and/or precisely positioning a heat sink insert in the mould, which is needed in some prior art processes such as the insert moulding process.
  • Processes of this kind are further disadvantageous in that auxiliary means are often needed, such as vibrating sorting machines, insert repositories, etc.
  • the convenient and straightforward method of the present invention avoids any awkward and troublesome holding and/or positioning of inserts, and thereby provides an efficient method of manufacturing a heat sink structure.
  • the method is advantageous in that the sheet material is applied as the heat sink structure is manufactured. Moreover, no adhesive material is necessary for adhering the sheet material to the plastic material, and the sheet material becomes permanently bonded to the plastic material.
  • Another advantage of the method of the present invention is that less heat sink material is needed compared to methods in the prior art. For example, if a insert moulding process is applied, the heat sink insert often needs to have a geometry that both facilitates a precise positioning of the heat sink insert into the mould, and that the heat sink insert must further resist the clamping force of the mould. This results in relatively stiff and/or thick heat sink inserts, which consequently leads to a troublesome manufacturing process as well as a (material) expensive and/or bulky heat sink structure.
  • the present invention provides a heat-conductive sheet (i.e. relatively thin/flat) material, resulting in an efficient manufacturing of a heat sink structure as well as an inexpensive and convenient (relatively thin) heat sink structure. Furthermore, as less heat sink material is used when manufacturing the heat sink structure, the method (and the heat sink structure) of the present invention provides a more environmental- friendly approach compared to prior art methods.
  • the heat- conductive sheet material is formed by the mould, wherein the sheet material easily adapts (i.e. forms, bends and/or shapes) according to the shape of the mould.
  • the sheet material is relatively thin, the sheet material is easily formed/shaped by the mould, and the sheet material thereby conforms to the shape of the heat sink structure.
  • the overall form/shape of the heat sink structure becomes thinner and more conveniently handled.
  • the feature of the easily formed sheet material of the method of the present invention is especially advantageous when moulding a heat sink structure with a non-flate shape, i.e. curved shape, as the sheet material is formed into (conforms to) the curved shape of the heat sink structure.
  • the moulding of the method provides good thermal contact between the plastic material and the heat-conductive sheet material in a rational and production- friendly way.
  • the present method is thereby more efficient compared to methods wherein a heat sink insert is held in a mould, and material is filled into the mould to surround the heat sink insert, as the holding and/or positioning of the heat sink insert may intervene with the thermal bonding between insert and material, thereby deteriorating the thermal bond after
  • the method of the present invention prevents the occurrence of any air gap between the plastic material and the heat-conductive sheet material, which even further improves the thermal contact.
  • the present invention provides a more efficient thermal contact between the plastic material and the heat-conductive sheet material.
  • the step of arranging the sheet material in a mould more specifically comprises arranging the sheet material in a female mould portion. Furthermore, a male mould portion is inserted into the female mould portion.
  • the method further comprises the step of injecting the plastic material into the mould.
  • the step of solidifying the plastic material comprises forming a curved heat sink structure wherein the sheet material is provided on an outer, convex portion of the heat sink structure.
  • the method is able to provide a heat sink structure having a curved (arched) shape, wherein the sheet material is provided on an outer, convex portion of the heat sink structure.
  • the heat sink structure may more specifically be single curved, i.e.
  • the heat sink structure is only curved in one dimension, e.g. in a shape of a tray, a trough, a vessel or the like.
  • the present embodiment is advantageous in that the curved heat sink structure provides a shape which may be even more suitable and efficient for dissipating heat from heat-generating elements.
  • the curved heat sink structure may be arranged to (at least partially) enclose one or more heat-generating elements, wherein the curvature results in a shorter, more effective thermal path between the heat sink structure and the heat generating elements.
  • the sheet material, provided on an outer, convex portion of the heat sink structure provides an even more efficient dissipation of heat from the heat-generating element into the surrounding environment outside the outer portion of the heat sink structure.
  • the method comprises the step of arranging the sheet material on a male mould portion.
  • the male mould portion is thereafter inserted into a female mould portion.
  • the method further comprises the step of injecting the plastic material into the mould.
  • the step of solidifying the plastic material comprises forming a curved heat sink structure wherein the sheet material is provided on an inner, concave portion of the heat sink structure.
  • the method is able to provide a heat sink structure having a curved (arched) shape, wherein the sheet material is provided on an inner, concave portion of the heat sink structure.
  • the heat sink structure may more specifically be single curved, i.e. curved in only one dimension.
  • the present embodiment is advantageous in that the curved heat sink structure may (at least partially) enclose one or more heat-generating elements, wherein the curvature results in bringing the heat sink structure nearer (or even contacting) the heat-generating elements, resulting in a short, effective thermal path between the heat sink structure and the heat-generating elements.
  • the present embodiment is further advantageous in that the sheet material, provided on an inner, concave portion of the heat sink structure, may dissipate heat from the heat-generating elements by spreading the heat throughout the heat sink structure, and the heat may thereafter be dissipated into the surrounding environment of the heat sink structure.
  • the step of providing the sheet material more specifically comprises providing the sheet material from a roll- fed process.
  • roll-fed process it is here meant a process wherein the sheet material is rolled up, e.g. provided on a roll, and that the sheet material is fed from the roll and into a mould.
  • the present embodiment is advantageous in that the sheet material may be provided in a highly efficient way.
  • a manual placement of heat sink inserts, a provision of vibrating sorting machines and/or a repository of heat sink inserts is often needed in the process, which leads to a circumstantial operation.
  • the method of manufacturing a heat sink structure becomes even faster, easier and more efficient, thereby allowing even larger production volumes of heat sink structures.
  • providing the sheet material comprises providing the sheet material as a pre-cut sheet material.
  • pre-cut it is here meant that the sheet material is cut/formed into sheet material portions in advance.
  • the sheet material may be provided e.g. from a stack of sheet material.
  • the sheet material may be picked from the stack of sheet materials and placed into a mould, e.g. by a robot using a vacuum handling technique.
  • the provision of sheet material as a pre-cut sheet material is advantageous in that it leads to an even faster, easier and more efficient method of manufacturing a heat sink structure.
  • the sheet material may be provided with at least one label.
  • label it is here meant information (e.g. text), colours, patterns, images and/or textures, wherein the label may provide any kind of information such as branding, trademarks, advertising, type (model) numbers, patent numbers, warning texts, pictures, etc.
  • the sheet material may both serve the purpose of providing a dissipation of heat and also provide information and/or aesthetical decorations (i.e. design features) to a user of the heat sink structure.
  • the present embodiment is especially advantageous when the sheet material comprising the label is arranged visibly inside a transparent material of the heat sink structure according to embodiments of the present invention, as the label thereby is encapsulated and will not be abraded during use of the heat sink structure.
  • the present embodiment is further advantageous in that the integration of the information of the label to the heat-conductive sheet material may be provided at a low additional cost.
  • the sheet material may be a metal foil.
  • the present embodiment is advantageous in that the metal material provides a very high heat conductivity, which further improves the heat dissipation properties of the heat sink structure.
  • the present embodiment is further advantageous in that the metal foil is able to provide an improved thermal contact between the metal foil and the plastic material of the heat sink structure.
  • the relatively thin metal foil provides several advantages in the method of manufacturing a heat sink structure, e.g. in that the metal foil is easily provided (e.g. rolled up before being fed to a mould), easily arranged in a mould and/or easily formed by the mould, resulting in an even more efficient method.
  • the relatively thin metal saves material and handling costs, thereby leading to a even more cost-effective method as well as an even more cost-effective heat sink structure.
  • the metal foil may have a thickness of ⁇ 0.35 mm, preferably ⁇ 0.25 mm, and most preferably ⁇ 0.15 mm.
  • the present embodiment is advantageous in that a relatively small metal foil thickness between 0.15 mm and 0.35 mm (or even less) leads to an even easier provision, handling and/or arrangement of the metal foil by the method, which even further improves the efficiency of the method.
  • the relatively small metal foil thickness saves material and handling costs even further, resulting in an even more cost-effective method and heat sink structure, respectively.
  • a relatively small metal foil thickness contributes to a relatively small thickness of the total heat sink structure, which results in a lighter, more convenient and/or more easily arranged heat sink structure.
  • a heat sink structure comprising a heat-conductive sheet material and a plastic material, wherein the sheet material and the plastic material have been moulded according to any method previously disclosed to form the heat sink structure.
  • the plastic material and the sheet material of the heat sink structure are formed by the mould, and the plastic material and the sheet material are bonded and thermally connected to each other.
  • the heat sink structure according to the present embodiment is advantageous in that it is relatively inexpensive, e.g. in that the relatively thin sheet material saves material costs compared to more bulky heat sink inserts. Furthermore, the relatively thin sheet material leads to an efficient
  • the sheet material of the heat sink structure easily adapts (i.e. forms, bends and/or shapes) according to the shape of the mould, and thereby adapts to the desired shape of the heat sink structure.
  • the heat sink structure may be curved and the sheet material may be provided on an outer, convex portion of the plastic material.
  • the heat sink structure may be curved and the sheet material may be provided on an inner, concave portion of the plastic material.
  • a lighting module comprising at least one light source and a carrier arranged to support the at least one light source. Furthermore, there is provided a heat sink structure according to any embodiment previously disclosed, wherein the heat sink structure is arranged in thermal contact with the carrier and is arranged for dissipating heat from the carrier.
  • carrier substantially any element for mechanical support (e.g. a substrate), thermal support and/or electrical support (e.g. an electrically conductive element for supplying electricity) of one or more light sources.
  • the present embodiment is advantageous in that the heat sink structure, as manufactured by the method of the present invention, provides an efficient dissipation of heat from the carrier and/or from the at least one light source, leading to a maintained reliability of the lighting module and a prevention of a premature failure of the light sources. More specifically, the heat sink structure provides an efficient thermal path from the at least one light source and/or the carrier, via the heat sink structure comprising the heat-conductive sheet material and the plastic material, into the surrounding environment of the lighting module.
  • the manufacture of heat sinks for the dissipation of heat for lighting modules or lighting arrangements is associated with relatively high costs, and a large fraction of the cost of light- emitting modules or arrangements is related to the heat sinks and the procedure of assembling together the light sources with the heat sink.
  • the present embodiment is advantageous in that the lighting module significantly reduces the mentioned costs. This is realized as the efficient methods steps of moulding a heat-conductive sheet material with the plastic material into a heat sink structure lead to a cost-efficient manufacture of the heat sink structure (as well as the resulting heat sink structure itself) which is comprised in the lighting module.
  • the heat sink structure may further comprise at least one snap connection arranged for connecting the heat sink structure to the carrier.
  • snap connection it is here meant substantially any releasable (friction) connection, e.g. a click feature, between the heat sink structure and the carrier.
  • the present embodiment is advantageous in that the snap connection provides an easy mounting and/or removal of the heat sink structure to the carrier, which is specifically advantageous in case of a handling of the lighting module such as mounting of the lighting module to a wall or a ceiling, a repair and/or a storage of the lighting module, etc.
  • the heat sink structure may be easily replaced if another heat sink structure is desired, e.g. having a different geometry.
  • the heat sink structure further comprises at least one resilient portion arranged for pressing the heat sink structure towards the carrier.
  • resilient portion it is here meant a portion of the heat sink structure which is able to apply a biased force between the heat sink structure and the carrier.
  • the present embodiment is advantageous in that the pressing/pushing of the resilient portion even further increases the thermal contact between the heat sink structure and the carrier, which leads to an even more efficient heat dissipation of the heat from the carrier by means of the heat sink structure.
  • the lighting module may further comprise at least one collimating means.
  • the collimating means may be arranged at a front portion of the lighting module for collimating light emitted from the at least one light source, wherein the heat sink structure may be arranged at the front portion of the lighting module.
  • the heat sink structure may hereby provide a thermal path for heat dissipation from a (central) portion of the lighting module to a front portion.
  • the present embodiment is advantageous in that the arrangement of the heat sink structure enables the use of the front portion (surface) of the lighting module for even further increasing the dissipation of heat from the lighting module.
  • the thermal path from the light sources and/or the carrier may proceed via the collimating means and via the heat sink structure, in thermal contact with the collimating means, into the surrounding environment.
  • FIGs. 1-5 are schematic illustrations of a method of manufacturing a heat sink structure according to embodiments of the present invention.
  • Figs. 6-9 are schematic illustrations of a lighting device comprising a heat sink structure according to embodiments of the present invention.
  • Figs, la-c are schematic illustrations of a method 100 of manufacturing a heat sink structure 150.
  • the method 100 comprises the step of providing a heat-conductive sheet material 110, wherein the sheet material 110 may be a relatively flat, thin material such as a sheet, a foil, or the like.
  • the foil may have a thickness of 0.15 mm to 0.35 mm (or even less), whereby the relatively small thickness leads to an even easier handling and/or arrangement of the metal foil.
  • the relatively small foil thickness saves material and handling costs even further, resulting in an even more cost-effective method 100 and heat sink structure 150, respectively.
  • the relatively small metal foil thickness further contributes to a relatively small thickness of the total heat sink structure 150, which consequently results in a lighter, more convenient and/or more easily arranged heat sink structure.
  • the sheet material 110 may comprise one or more metals, e.g. aluminium. As aluminium is both inexpensive and possesses high heat-conductive properties, it is highly advantageous for the use as a cost- effective sheet material 110.
  • the method 100 further comprises the step of arranging 120 the sheet material 110 in a mould 130, and closing the mould 130.
  • the method 100 further comprises the step of providing a plastic material 140 in a fluid state (e.g. a plastic melt) and injecting 125 the plastic material 140 into the mould 130, which is shown in Fig. lb.
  • the plastic material 140 may be substantially any kind of synthetic or semi- synthetic organic material, e.g. comprising one or more of polyethylene, polypropylene, polystyrene, polyvinyl chloride, etc. In its fluid state, the plastic material 140 is able to conform to the shape of the mould 130.
  • the method 100 further comprises the step of moulding the plastic material 140 and the sheet material 110, such that the plastic material 140 and the sheet material 110 are formed by the mould 130, and wherein the plastic material 140 and the sheet material 110 bond to each other.
  • the method 100 further comprises the step of solidifying the plastic material 140, e.g. by cooling, hardening, curing and/or tempering. In Fig.
  • the mould 130 is shown as a mould comprising a male and a female part, but it will be appreciated that it may be feasible to use virtually any kind of mould 130 in the present method 100.
  • the sheet material 110 is relatively thin, it is also easily formed/shaped by the mould 130. Hence, the sheet material 100 is thereby able to conform to the desired shape of the heat sink structure 150.
  • the plastic material 140 and the sheet material 110 together form a heat sink structure 150 which may be ejected from the mould 130.
  • An example of a heat sink structure 150 is shown in Fig. lc in an elongated and curved form, but it will be appreciated that virtually any form/shape of the heat sink structure 150 may be feasible, e.g. a flat and/or a round shape.
  • the plastic material 140 and the sheet material 110 of the heat sink structure 150 are thermally connected to each other, such that heat sink structure 150 is able to provide a thermal path between the plastic material 140 and the sheet material 110.
  • the efficient and cost-effective method of manufacturing the heat sink structure 150 likewise results in a cost-ombive heat sink structure 150 which is arranged to efficiently dissipate heat generated by one or more heat-generating elements.
  • Fig. 2a-d are schematic illustrations of an embodiment of the method 105 of manufacturing a heat sink structure 150.
  • the sheet material 1 10 is arranged 120 in a female mould portion 210, and in Fig. 2b, and a male mould portion 220 is inserted into the female mould portion 210.
  • the plastic material 140 is thereafter injected into the mould (comprising the female mould portion 210 and the male mould portion 220), as shown in Fig. 2c.
  • the plastic material 140 is thereby injected in the cavity of the mould, formed by the female and the male mould portions 210, 220, such that the plastic material is formed over the sheet material 1 10.
  • the plastic material 140 and the sheet material 110 bond to each other.
  • the male mould portion 220 and the female mould portion 210 have spherical shapes, but it will be appreciated that substantially any shape of the conforming female and male mould portions 210, 220 are feasible for a desired shape of the heat sink structure 155.
  • the plastic material 140 is thereafter solidified, such that the plastic material 140 and the sheet material 110 form a curved heat sink structure 155, as shown in Fig. 2d.
  • the sheet material 110 is provided on an outer, convex portion of the heat sink structure 150.
  • Fig. 3a-d are schematic illustrations of a further embodiment of the method 106 of manufacturing a heat sink structure 150. In Fig. 3a, the sheet material 110 is arranged on a male mould portion 320.
  • the male mould portion 320 comprises two vacuum chambers 330 for holding the sheet material 110, but it will be appreciated that substantially any technique may be applied for holding the sheet material 110 to the male mould portion 320.
  • the male mould portion 320 is thereafter inserted into the female mould portion 310, as shown in Fig. 3b.
  • the plastic material 140 is injected into the mould (comprising the female mould portion 310 and the male mould portion 320).
  • the plastic material 140 is thereby injected in the cavity of the mould, formed by the female and the male mould portions 310, 320, such that the plastic material 140 is formed under the sheet material 110 held by the male mould portion 320.
  • the plastic material 140 and the sheet material 110 bond to each other.
  • the plastic material 140 is thereafter solidified, whereby the plastic material 140 and the sheet material 110 form a curved heat sink structure 156, which is shown in Fig. 3d.
  • the sheet material 110 is provided on an inner, concave portion of the heat sink structure 156.
  • Fig. 4a is a schematic illustration of an embodiment of the method 107, wherein the step of providing the sheet material 110 comprises providing the sheet material 110 from a roll- fed process.
  • the sheet material 110 is provided from a roller 410 in which the sheet material 110 is rolled up, and the sheet material 110 is thereafter supplied/provided from the roller 410 and arranged into the mould 420.
  • the sheet material 110 may be provided as a pre-cut sheet material.
  • the sheet material 110 may be picked from a stack of sheet materials 430 and placed into the mould 420, e.g. by a robot using a vacuum handling technique (not shown).
  • Figs. 5a-b are schematic illustrations of an embodiment of the method, wherein the sheet material 115 is provided as a die cut.
  • the die cut sheet material 115 has a substantially round, flat form, and further comprises a plurality of slits 510 which run from the periphery of the sheet material 115 into a centre portion of the sheet material 1 15 to define a plurality of foldable tongues 520.
  • the sheet material 115 may thereby be arranged into a mould (not shown), whereby the mould is able to form the sheet material 115 such that the tongues 520 fold, and thereby protrude from the flat form of the sheet material 115.
  • the sheet material 1 15 is formed into a cup-shaped form as shown in Fig. 5b.
  • Fig. 5c shows an embodiment of a method 108 of manufacturing a heat sink structure comprising the sheet material 110 as shown in Figs. 5a-b.
  • the sheet material 115 is inserted into a female mould portion 540.
  • a male mould portion 530 is inserted into the female mould portion 540, such that the sheet material forms into the cup- shape form as shown in Fig. 5b.
  • the plastic material 140 is injected into the mould. More specifically, the plastic material 140 is injected such that it becomes distributed on the periphery of the sheet material 115 and distributed into the slits 510, which is shown in Fig. 5e for an enhanced understanding.
  • the sheet material as disclosed in any one of the preceding embodiments of the present invention may be provided with at least one label, wherein the label may provide any kind of information such as branding, trademark, advertising, type (model) number, patent number, warning text, pictures, etc.
  • a sheet material 110 comprising a label may be arranged visibly on the outer, convex portion of the heat sink structure 150 in Fig. 2d.
  • a sheet material 110 comprising a label on the inner, concave portion of the heat sink structure 150 may be visible if the plastic material 140 of the heat sink structure 150 is transparent.
  • Fig. 6a is a schematic side-view illustration of a lighting module 600 according to an embodiment of the present invention.
  • the lighting module 600 comprises at least one light source 610, exemplified in the figure as three LEDs 610.
  • the lighting module 600 further comprises a carrier 620 arranged for mechanical and/or electrical support of the light sources 610, e.g. a printed circuit board (PCB).
  • the lighting module 600 comprises a heat sink structure 157 according to any of the previously described
  • the heat sink structure 157 comprises a sheet material 110 and a plastic material 140.
  • the heat sink structure 157 is arranged in thermal contact with the carrier 620 and is arranged for dissipating heat from the carrier 620.
  • the heat sink structure 157 provides a thermal path, indicated by arrows 650, on an outer side of the lighting module 600, from the light sources 610 and/or the carrier 620 to the heat sink structure 157.
  • the plastic material 140 of the heat sink structure 157 which is in thermal contact with the sheet material 110 provided on an outer portion of the heat sink structure 157, conveys the heat to the sheet material 110 which in turn dissipates the heat into the surrounding environment of the heat sink
  • the sheet material 110 of the heat sink structure 157 may alternatively be provided on an inner portion of the heat sink structure 157.
  • the sheet material 110 may be arranged to convey the heat from the light sources 610 and/or the carrier 620 to the plastic material 140 which in turn dissipates the heat into the surrounding environment of the heat sink structure 157.
  • Fig. 6b is a schematic side-view illustration of a lighting module 605, showing an alternative example to the lighting module 600 of Fig. 6a.
  • the lighting module 605 has a heat sink structure 158 comprising a die-cut sheet material 110 as exemplified in Figs. 5a-b, wherein the sheet material 110 is provided on an inner, concave portion of the heat sink structure 158.
  • the thermal path (indicated by arrows 650) is provided from the light sources 610 and/or the carrier 620 to the sheet material 110 on the inner, concave portion of the to the heat sink structure 158, and into the surrounding environment through the plastic material 140 of the heat sink structure 158.
  • Fig. 6c shows an alternative lighting module 606 to that of Fig. 6a-b, wherein the sheet material 1 10 is provided on an outer, convex portion of the heat sink structure 159, and having a shape as exemplified in Figs. 5a-b.
  • the thermal path 650 is hereby provided from the light sources 610 and/or the carrier 620 to the sheet material 110 on the outer, concave portion of the to the heat sink structure 159, and into the surrounding environment of the heat sink structure 159.
  • the at least one light source 610 and/or the carrier 620 of the lighting module of any of the exemplifying embodiments may be mounted directly on the sheet material 110 of the heat sink structure 150.
  • An example of this is disclosed by the lighting module 607 in Fig. 6d, wherein sheet material 110 is arranged on an outer, convex portion of the heat sink structure 160, and wherein the carrier 620, arranged for mechanical and/or electrical support of the light sources 610, is mounted on the sheet material 1 10.
  • the carrier 620 may be integrated into the sheet material 110.
  • Fig. 7a is a schematic illustration of a heat sink structure 165 comprising a plastic material 140 and a sheet material 110 (not indicated), wherein the heat sink structure 165 has a round, substantially flat shape. Furthermore, a plurality of snap connections 710 are arranged on a periphery of the heat sink structure 165.
  • the heat sink structure 165 is connected to a lighting module 700 comprising at least one light source (e.g. LEDs) 720 and a carrier 750 arranged to mechanically and/or electrically support the light sources. More specifically, the heat sink structure 150 is connected to the carrier 750 of the lighting module 700, wherein the snap connections 710 are received by the carrier 750.
  • a lighting module 700 comprising at least one light source (e.g. LEDs) 720 and a carrier 750 arranged to mechanically and/or electrically support the light sources.
  • the heat sink structure 150 is connected to the carrier 750 of the lighting module 700, wherein the snap connections 710 are received by the carrier 750.
  • Fig. 8a is a schematic illustration of a heat sink structure 170 having a relatively flat, rectangular shape, and wherein the heat sink structure 170 comprises at least one resilient portion 810.
  • two resilient portions 810 are arranged on opposite sides of the heat sink structure 170, and are arranged for pressing the heat sink structure 170 towards a carrier 850 of a lighting module 800.
  • the resilient portions 810 in Fig. 8a each comprises three resilient (flexible) clamps, but it will be appreciated that substantially any shape of the resilient portions 810 is feasible.
  • the heat sink structure 170 is connected to a lighting module 800 comprising at least one light source 820 (e.g. LEDs) and a carrier 850.
  • the resilient portions 810 are arranged to press the heat sink structure 150 towards the carrier 850 of the lighting module 800 to optimize thermal contact.
  • the heat sink structure 170 may comprise one or more snap connections for connecting the heat sink structure 170 to the carrier 850.
  • Fig. 9 is a schematic illustration of a lighting module 900 comprising at least one collimating means 910.
  • the collimating means 910 are arranged at a front portion of the lighting module 900 for collimating light emitted from at least one light source (not shown) of the lighting module 900.
  • the heat sink structure 175 has a relatively flat form, and is provided with holes such that the collimating means 910 may project through the heat sink structure 175 upon arrangement of the heat sink structure 175 at the front portion of the lighting module 900.
  • the sheet material 110, the plastic material 140 and/or the resulting heat sink structures may have different dimensions and/or sizes than those depicted/described.
  • the elongated, (single) curved heat sink structures e.g. as disclosed in Figs. 3-4, are shown as examples of the form/shape of the heat sink structures.
  • the heat sink structures may have substantially any desired form, such as flat (i.e. not curved), round, short, etc.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
  • Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

A method (100) of manufacturing a heat sink structure (150), and the heat sink structure (150), wherein the method comprises the steps of providing a heat-conductive sheet material (110) and arranging (120) the sheet material in a mould (130). Further, a plastic material (140) is provided in a fluid state and injected (125) into the mould. The method further comprises the step of moulding the plastic material and the sheet material, such that the plastic material and the sheet material are formed by the mould, and wherein the plastic material and the sheet material bond to each other. The method further comprises the step of solidifying the plastic material, such that the plastic material and the sheet material form a heat sink structure (150) wherein the plastic material and the sheet material are thermally connected to each other.

Description

Heat sink structure and method of manufacturing the same
FIELD OF THE INVENTION
The present invention generally relates to the field of heat sink structures for a dissipation of heat from heat-generating elements. The present invention also relates to methods of manufacturing such heat sink structures.
BACKGROUND OF THE INVENTION
Lighting devices comprising solid state light sources, such as light emitting diodes (LEDs), are known in the art. Lighting devices comprising LEDs may be used for a general lighting or even for a more specific lighting, as the colour and the output power of the LEDs may be tuned.
Common to light sources such as LEDs, light bulbs, laser diodes and lamps is that the light sources emit heat. Light-emitting arrangements comprising a plurality of light sources, e.g. for use in a display or in an illumination device, may generate a quick rise of the temperature of the light-emitting arrangement, especially if many light sources are driven at the same time. The effect of heat may be detrimental to the light sources, and their operation may become erratic and unstable. As a consequence, the light from the light source may flicker, causing degradation of the quality of the display or illumination. Hence, thermal management is an important issue to prevent thermal damage of the light sources, and it is necessary to dissipate excess heat in order to maintain the reliability of the light-emitting arrangement and to prevent premature failure of the light sources. For this purpose, lighting devices may comprise heat sinks (heat dissipators) which are in thermal contact with the heat-generating light sources(s) and/or electronics.
Heat sinks for lighting devices comprising LEDs may be produced e.g. by overmoulding, wherein a material (generally plastics) is formed over a heat sink insert (e.g. a piece of metal). Alternatively, an insert moulding process may be performed, wherein a heat sink insert is placed in a mould and the material (e.g. plastics) is provided into the mould, and is thereafter cooled. The heat sink inserts usually need to have a geometry that both facilitates the correct positioning of the heat sink inserts into the mould, and that may resist the clamping force of the mould. To meets these demands, the geometry of the heat sink inserts needs to be relative stiff and/or thick. Consequently, the heat sink inserts are often overdimensioned, which is disadvantageous, as the heat sink inserts thereby consist of a relatively large amount of material. This results in more costly heat sinks and/or that the heat sinks become more bulky. Overdimensioned heat sink inserts are especially undesired when considering the development of lighting devices comprising LEDs which become more and more efficient, as the heat sink inserts thereby use more material than needed.
Hence, alternative solutions for the manufacture of heat sink structures are of interest, such that a more cost-effective manufacture, as well as the heat sink structures resulting from the manufacture, is provided.
SUMMARY OF THE INVENTION
The present invention has been made with respect to the above considerations. It is an object of the present invention to provide a method of manufacturing a heat sink structure, as well as a heat sink structure, which is cost-effective.
This and other objects are achieved by providing a method and a heat sink structure having the features defined in the independent claims. Preferred embodiments are defined in the dependent claims.
Hence, according to a first aspect of the invention, there is provided a method of manufacturing a heat sink structure. The method comprises the steps of providing a heat- conductive sheet material and arranging the sheet material in a mould. Further, a plastic material is provided in a fluid state and injected into the mould. The method further comprises the step of moulding the plastic material and the sheet material, such that the plastic material and the sheet material are formed by the mould, and wherein the plastic material and the sheet material bond to each other. The method further comprises the step of solidifying the plastic material, such that the plastic material and the sheet material form a heat sink structure wherein the plastic material and the sheet material are thermally connected to each other.
According to a second aspect of the present invention, there is provided a heat sink structure comprising a heat-conductive sheet material and a plastic material. The sheet material and the plastic material have been moulded by means of a method according to the first aspect of the invention to form the heat sink structure, in which the plastic material and the sheet material are thermally connected to each other.
By the term "fluid state", it is here meant a state of the plastic material which is able to conform to the form of the mould, e.g. a melt. Furthermore, by the term "solidifying", it is here meant to make a material solid, for example through hardening, curing and/or tempering.
Thus, the present invention is based on the idea of providing a method of manufacturing a heat sink structure, wherein a heat-conductive sheet material and a plastic material are bonded to each other by means of a moulding process. The sheet material and the plastic material are formed by the mould into a heat sink structure, and after
solidification, the sheet material and the plastic material become thermally connected to each other. The present invention thereby provides an efficient and cost-effective method of manufacturing a heat sink structure, wherein the heat sink structure is arranged to efficiently dissipate heat generated by one or more heat-generating elements (e.g. LEDs, carriers, etc.) when in operation.
An advantage of various embodiments of the present invention is that the method provides an efficient way of manufacturing a heat sink structure, especially as the method comprises few and efficient process steps. By arranging (placing) the sheet material in a mould before injecting the plastic material in the fluid state, the present method avoids the process of holding and/or precisely positioning a heat sink insert in the mould, which is needed in some prior art processes such as the insert moulding process. Processes of this kind are further disadvantageous in that auxiliary means are often needed, such as vibrating sorting machines, insert repositories, etc. In contrast, the convenient and straightforward method of the present invention avoids any awkward and troublesome holding and/or positioning of inserts, and thereby provides an efficient method of manufacturing a heat sink structure. Furthermore, the method is advantageous in that the sheet material is applied as the heat sink structure is manufactured. Moreover, no adhesive material is necessary for adhering the sheet material to the plastic material, and the sheet material becomes permanently bonded to the plastic material.
Another advantage of the method of the present invention is that less heat sink material is needed compared to methods in the prior art. For example, if a insert moulding process is applied, the heat sink insert often needs to have a geometry that both facilitates a precise positioning of the heat sink insert into the mould, and that the heat sink insert must further resist the clamping force of the mould. This results in relatively stiff and/or thick heat sink inserts, which consequently leads to a troublesome manufacturing process as well as a (material) expensive and/or bulky heat sink structure. The present invention, on the other hand, provides a heat-conductive sheet (i.e. relatively thin/flat) material, resulting in an efficient manufacturing of a heat sink structure as well as an inexpensive and convenient (relatively thin) heat sink structure. Furthermore, as less heat sink material is used when manufacturing the heat sink structure, the method (and the heat sink structure) of the present invention provides a more environmental- friendly approach compared to prior art methods.
Another advantage of the method of the present invention is that the heat- conductive sheet material is formed by the mould, wherein the sheet material easily adapts (i.e. forms, bends and/or shapes) according to the shape of the mould. Hence, as the sheet material is relatively thin, the sheet material is easily formed/shaped by the mould, and the sheet material thereby conforms to the shape of the heat sink structure. As a result, the overall form/shape of the heat sink structure becomes thinner and more conveniently handled. This is highly advantageous compared to methods in the prior art, wherein stiff and/or thick heat sink inserts are often used. Furthermore, the feature of the easily formed sheet material of the method of the present invention is especially advantageous when moulding a heat sink structure with a non-flate shape, i.e. curved shape, as the sheet material is formed into (conforms to) the curved shape of the heat sink structure.
Another advantage achievable through various embodiments of the present invention is that the moulding of the method provides good thermal contact between the plastic material and the heat-conductive sheet material in a rational and production- friendly way. The present method is thereby more efficient compared to methods wherein a heat sink insert is held in a mould, and material is filled into the mould to surround the heat sink insert, as the holding and/or positioning of the heat sink insert may intervene with the thermal bonding between insert and material, thereby deteriorating the thermal bond after
solidification. Furthermore, the method of the present invention prevents the occurrence of any air gap between the plastic material and the heat-conductive sheet material, which even further improves the thermal contact. Hence, the present invention provides a more efficient thermal contact between the plastic material and the heat-conductive sheet material.
According to an embodiment of the present invention, the step of arranging the sheet material in a mould more specifically comprises arranging the sheet material in a female mould portion. Furthermore, a male mould portion is inserted into the female mould portion. The method further comprises the step of injecting the plastic material into the mould. Furthermore, the step of solidifying the plastic material comprises forming a curved heat sink structure wherein the sheet material is provided on an outer, convex portion of the heat sink structure. Hence, in the present embodiment, the method is able to provide a heat sink structure having a curved (arched) shape, wherein the sheet material is provided on an outer, convex portion of the heat sink structure. It will be appreciated that the heat sink structure may more specifically be single curved, i.e. that the heat sink structure is only curved in one dimension, e.g. in a shape of a tray, a trough, a vessel or the like. The present embodiment is advantageous in that the curved heat sink structure provides a shape which may be even more suitable and efficient for dissipating heat from heat-generating elements. For example, the curved heat sink structure may be arranged to (at least partially) enclose one or more heat-generating elements, wherein the curvature results in a shorter, more effective thermal path between the heat sink structure and the heat generating elements. The present embodiment is further advantageous in that the sheet material, provided on an outer, convex portion of the heat sink structure, provides an even more efficient dissipation of heat from the heat-generating element into the surrounding environment outside the outer portion of the heat sink structure.
According to an embodiment of the present invention, the method comprises the step of arranging the sheet material on a male mould portion. The male mould portion is thereafter inserted into a female mould portion. The method further comprises the step of injecting the plastic material into the mould. Furthermore, the step of solidifying the plastic material comprises forming a curved heat sink structure wherein the sheet material is provided on an inner, concave portion of the heat sink structure. Hence, in the present embodiment, the method is able to provide a heat sink structure having a curved (arched) shape, wherein the sheet material is provided on an inner, concave portion of the heat sink structure. Analogously with the previous embodiment, the heat sink structure may more specifically be single curved, i.e. curved in only one dimension. The present embodiment is advantageous in that the curved heat sink structure may (at least partially) enclose one or more heat-generating elements, wherein the curvature results in bringing the heat sink structure nearer (or even contacting) the heat-generating elements, resulting in a short, effective thermal path between the heat sink structure and the heat-generating elements. The present embodiment is further advantageous in that the sheet material, provided on an inner, concave portion of the heat sink structure, may dissipate heat from the heat-generating elements by spreading the heat throughout the heat sink structure, and the heat may thereafter be dissipated into the surrounding environment of the heat sink structure.
According to an embodiment of the present invention, the step of providing the sheet material more specifically comprises providing the sheet material from a roll- fed process. By "roll-fed process", it is here meant a process wherein the sheet material is rolled up, e.g. provided on a roll, and that the sheet material is fed from the roll and into a mould. The present embodiment is advantageous in that the sheet material may be provided in a highly efficient way. In the prior art, a manual placement of heat sink inserts, a provision of vibrating sorting machines and/or a repository of heat sink inserts is often needed in the process, which leads to a circumstantial operation. In contrast, by providing the sheet material from a roll- fed process, as in the present embodiment, the method of manufacturing a heat sink structure becomes even faster, easier and more efficient, thereby allowing even larger production volumes of heat sink structures.
According to an embodiment of the present invention, providing the sheet material comprises providing the sheet material as a pre-cut sheet material. By "pre-cut", it is here meant that the sheet material is cut/formed into sheet material portions in advance. In this embodiment of the method, the sheet material may be provided e.g. from a stack of sheet material. For example, the sheet material may be picked from the stack of sheet materials and placed into a mould, e.g. by a robot using a vacuum handling technique. The provision of sheet material as a pre-cut sheet material is advantageous in that it leads to an even faster, easier and more efficient method of manufacturing a heat sink structure.
According to an embodiment of the present invention, the sheet material may be provided with at least one label. By "label", it is here meant information (e.g. text), colours, patterns, images and/or textures, wherein the label may provide any kind of information such as branding, trademarks, advertising, type (model) numbers, patent numbers, warning texts, pictures, etc. The present embodiment is advantageous in that the sheet material may both serve the purpose of providing a dissipation of heat and also provide information and/or aesthetical decorations (i.e. design features) to a user of the heat sink structure. The present embodiment is especially advantageous when the sheet material comprising the label is arranged visibly inside a transparent material of the heat sink structure according to embodiments of the present invention, as the label thereby is encapsulated and will not be abraded during use of the heat sink structure. The present embodiment is further advantageous in that the integration of the information of the label to the heat-conductive sheet material may be provided at a low additional cost.
According to an embodiment of the present invention, the sheet material may be a metal foil. The present embodiment is advantageous in that the metal material provides a very high heat conductivity, which further improves the heat dissipation properties of the heat sink structure. The present embodiment is further advantageous in that the metal foil is able to provide an improved thermal contact between the metal foil and the plastic material of the heat sink structure. Furthermore, the relatively thin metal foil provides several advantages in the method of manufacturing a heat sink structure, e.g. in that the metal foil is easily provided (e.g. rolled up before being fed to a mould), easily arranged in a mould and/or easily formed by the mould, resulting in an even more efficient method. Furthermore, the relatively thin metal saves material and handling costs, thereby leading to a even more cost-effective method as well as an even more cost-effective heat sink structure.
According to an embodiment of the present invention, the metal foil may have a thickness of < 0.35 mm, preferably < 0.25 mm, and most preferably < 0.15 mm. The present embodiment is advantageous in that a relatively small metal foil thickness between 0.15 mm and 0.35 mm (or even less) leads to an even easier provision, handling and/or arrangement of the metal foil by the method, which even further improves the efficiency of the method. The relatively small metal foil thickness saves material and handling costs even further, resulting in an even more cost-effective method and heat sink structure, respectively. Furthermore, it will be appreciated that a relatively small metal foil thickness contributes to a relatively small thickness of the total heat sink structure, which results in a lighter, more convenient and/or more easily arranged heat sink structure.
According to an embodiment of the present invention, there is provided a heat sink structure comprising a heat-conductive sheet material and a plastic material, wherein the sheet material and the plastic material have been moulded according to any method previously disclosed to form the heat sink structure. The plastic material and the sheet material of the heat sink structure are formed by the mould, and the plastic material and the sheet material are bonded and thermally connected to each other. The heat sink structure according to the present embodiment is advantageous in that it is relatively inexpensive, e.g. in that the relatively thin sheet material saves material costs compared to more bulky heat sink inserts. Furthermore, the relatively thin sheet material leads to an efficient
manufacturing of the heat sink structure as well as a convenient (relatively thin) and easily mountable heat sink structure. Moreover, as the sheet material is formed by the mould, the sheet material of the heat sink structure easily adapts (i.e. forms, bends and/or shapes) according to the shape of the mould, and thereby adapts to the desired shape of the heat sink structure. These advantages, and even further advantages, of the heat sink structure have been presented in the previously described method of the present invention as well as in the previously described embodiments of the method, and it is referred to these sections of the text.
According to an embodiment of the present invention, the heat sink structure may be curved and the sheet material may be provided on an outer, convex portion of the plastic material. According to yet another embodiment of the present invention, the heat sink structure may be curved and the sheet material may be provided on an inner, concave portion of the plastic material. The advantages of providing the sheet material on an outer, convex portion and/or on an inner, concave portion of the plastic material are disclosed in the previously described embodiments of the method manufacturing heat sink structures with these respective features, and it is referred to these sections of the text.
According to an embodiment of the present invention, there is provided a lighting module comprising at least one light source and a carrier arranged to support the at least one light source. Furthermore, there is provided a heat sink structure according to any embodiment previously disclosed, wherein the heat sink structure is arranged in thermal contact with the carrier and is arranged for dissipating heat from the carrier. By the term
"carrier", it is here meant substantially any element for mechanical support (e.g. a substrate), thermal support and/or electrical support (e.g. an electrically conductive element for supplying electricity) of one or more light sources. The present embodiment is advantageous in that the heat sink structure, as manufactured by the method of the present invention, provides an efficient dissipation of heat from the carrier and/or from the at least one light source, leading to a maintained reliability of the lighting module and a prevention of a premature failure of the light sources. More specifically, the heat sink structure provides an efficient thermal path from the at least one light source and/or the carrier, via the heat sink structure comprising the heat-conductive sheet material and the plastic material, into the surrounding environment of the lighting module. Furthermore, it will be appreciated that the manufacture of heat sinks for the dissipation of heat for lighting modules or lighting arrangements is associated with relatively high costs, and a large fraction of the cost of light- emitting modules or arrangements is related to the heat sinks and the procedure of assembling together the light sources with the heat sink. The present embodiment is advantageous in that the lighting module significantly reduces the mentioned costs. This is realized as the efficient methods steps of moulding a heat-conductive sheet material with the plastic material into a heat sink structure lead to a cost-efficient manufacture of the heat sink structure (as well as the resulting heat sink structure itself) which is comprised in the lighting module.
According to an embodiment of the present invention, the heat sink structure may further comprise at least one snap connection arranged for connecting the heat sink structure to the carrier. By "snap connection", it is here meant substantially any releasable (friction) connection, e.g. a click feature, between the heat sink structure and the carrier. The present embodiment is advantageous in that the snap connection provides an easy mounting and/or removal of the heat sink structure to the carrier, which is specifically advantageous in case of a handling of the lighting module such as mounting of the lighting module to a wall or a ceiling, a repair and/or a storage of the lighting module, etc. Furthermore, the heat sink structure may be easily replaced if another heat sink structure is desired, e.g. having a different geometry.
According to an embodiment of the present invention, the heat sink structure further comprises at least one resilient portion arranged for pressing the heat sink structure towards the carrier. By "resilient portion", it is here meant a portion of the heat sink structure which is able to apply a biased force between the heat sink structure and the carrier. The present embodiment is advantageous in that the pressing/pushing of the resilient portion even further increases the thermal contact between the heat sink structure and the carrier, which leads to an even more efficient heat dissipation of the heat from the carrier by means of the heat sink structure.
According to an embodiment of the present invention, the lighting module may further comprise at least one collimating means. The collimating means may be arranged at a front portion of the lighting module for collimating light emitted from the at least one light source, wherein the heat sink structure may be arranged at the front portion of the lighting module. Hence, the heat sink structure may hereby provide a thermal path for heat dissipation from a (central) portion of the lighting module to a front portion. The present embodiment is advantageous in that the arrangement of the heat sink structure enables the use of the front portion (surface) of the lighting module for even further increasing the dissipation of heat from the lighting module. For example, the thermal path from the light sources and/or the carrier may proceed via the collimating means and via the heat sink structure, in thermal contact with the collimating means, into the surrounding environment.
It is noted that the invention relates to all possible combinations of features recited in the claims. Further, it will be appreciated that the various embodiments described for the heat sink structure are all combinable with the various embodiments described for the method of manufacturing a heat sink structure, as defined in accordance with the first aspect of the present invention.
Further objectives of, features of, and advantages with, the present invention will become apparent when studying the following detailed disclosure, the drawings and the appended claims. Those skilled in the art realize that different features of the present invention can be combined to create embodiments other than those described in the following. BRIEF DESCRIPTION OF THE DRAWINGS
This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing embodiments of the invention.
Figs. 1-5 are schematic illustrations of a method of manufacturing a heat sink structure according to embodiments of the present invention, and
Figs. 6-9 are schematic illustrations of a lighting device comprising a heat sink structure according to embodiments of the present invention.
All the figures are schematic, not necessarily to scale, and generally only show parts which are necessary in order to elucidate the invention, wherein other parts may be omitted or merely suggested.
DETAILED DESCRIPTION
In the following description, the present invention is described with reference to a method of manufacturing a heat sink structure.
Figs, la-c are schematic illustrations of a method 100 of manufacturing a heat sink structure 150. The method 100 comprises the step of providing a heat-conductive sheet material 110, wherein the sheet material 110 may be a relatively flat, thin material such as a sheet, a foil, or the like. The foil may have a thickness of 0.15 mm to 0.35 mm (or even less), whereby the relatively small thickness leads to an even easier handling and/or arrangement of the metal foil. Furthermore, the relatively small foil thickness saves material and handling costs even further, resulting in an even more cost-effective method 100 and heat sink structure 150, respectively. The relatively small metal foil thickness further contributes to a relatively small thickness of the total heat sink structure 150, which consequently results in a lighter, more convenient and/or more easily arranged heat sink structure. The sheet material 110 may comprise one or more metals, e.g. aluminium. As aluminium is both inexpensive and possesses high heat-conductive properties, it is highly advantageous for the use as a cost- effective sheet material 110. The method 100 further comprises the step of arranging 120 the sheet material 110 in a mould 130, and closing the mould 130. The method 100 further comprises the step of providing a plastic material 140 in a fluid state (e.g. a plastic melt) and injecting 125 the plastic material 140 into the mould 130, which is shown in Fig. lb. The plastic material 140 may be substantially any kind of synthetic or semi- synthetic organic material, e.g. comprising one or more of polyethylene, polypropylene, polystyrene, polyvinyl chloride, etc. In its fluid state, the plastic material 140 is able to conform to the shape of the mould 130. The method 100 further comprises the step of moulding the plastic material 140 and the sheet material 110, such that the plastic material 140 and the sheet material 110 are formed by the mould 130, and wherein the plastic material 140 and the sheet material 110 bond to each other. The method 100 further comprises the step of solidifying the plastic material 140, e.g. by cooling, hardening, curing and/or tempering. In Fig. lb, the mould 130 is shown as a mould comprising a male and a female part, but it will be appreciated that it may be feasible to use virtually any kind of mould 130 in the present method 100. As the sheet material 110 is relatively thin, it is also easily formed/shaped by the mould 130. Hence, the sheet material 100 is thereby able to conform to the desired shape of the heat sink structure 150.
After solidifying, the plastic material 140 and the sheet material 110 together form a heat sink structure 150 which may be ejected from the mould 130. An example of a heat sink structure 150 is shown in Fig. lc in an elongated and curved form, but it will be appreciated that virtually any form/shape of the heat sink structure 150 may be feasible, e.g. a flat and/or a round shape. The plastic material 140 and the sheet material 110 of the heat sink structure 150 are thermally connected to each other, such that heat sink structure 150 is able to provide a thermal path between the plastic material 140 and the sheet material 110. The efficient and cost-effective method of manufacturing the heat sink structure 150 likewise results in a cost-effetive heat sink structure 150 which is arranged to efficiently dissipate heat generated by one or more heat-generating elements.
Fig. 2a-d are schematic illustrations of an embodiment of the method 105 of manufacturing a heat sink structure 150. In Fig. 2a, the sheet material 1 10 is arranged 120 in a female mould portion 210, and in Fig. 2b, and a male mould portion 220 is inserted into the female mould portion 210. The plastic material 140 is thereafter injected into the mould (comprising the female mould portion 210 and the male mould portion 220), as shown in Fig. 2c. The plastic material 140 is thereby injected in the cavity of the mould, formed by the female and the male mould portions 210, 220, such that the plastic material is formed over the sheet material 1 10. Upon moulding, the plastic material 140 and the sheet material 110 bond to each other. Here, the male mould portion 220 and the female mould portion 210 have spherical shapes, but it will be appreciated that substantially any shape of the conforming female and male mould portions 210, 220 are feasible for a desired shape of the heat sink structure 155. The plastic material 140 is thereafter solidified, such that the plastic material 140 and the sheet material 110 form a curved heat sink structure 155, as shown in Fig. 2d. Here, the sheet material 110 is provided on an outer, convex portion of the heat sink structure 150. Fig. 3a-d are schematic illustrations of a further embodiment of the method 106 of manufacturing a heat sink structure 150. In Fig. 3a, the sheet material 110 is arranged on a male mould portion 320. Here, the male mould portion 320 comprises two vacuum chambers 330 for holding the sheet material 110, but it will be appreciated that substantially any technique may be applied for holding the sheet material 110 to the male mould portion 320. The male mould portion 320 is thereafter inserted into the female mould portion 310, as shown in Fig. 3b. In Fig. 3c, the plastic material 140 is injected into the mould (comprising the female mould portion 310 and the male mould portion 320). The plastic material 140 is thereby injected in the cavity of the mould, formed by the female and the male mould portions 310, 320, such that the plastic material 140 is formed under the sheet material 110 held by the male mould portion 320. The plastic material 140 and the sheet material 110 bond to each other. The plastic material 140 is thereafter solidified, whereby the plastic material 140 and the sheet material 110 form a curved heat sink structure 156, which is shown in Fig. 3d. In this embodiment, and in contrast to the embodiment as disclosed in Figs. 2a-d, the sheet material 110 is provided on an inner, concave portion of the heat sink structure 156.
Fig. 4a is a schematic illustration of an embodiment of the method 107, wherein the step of providing the sheet material 110 comprises providing the sheet material 110 from a roll- fed process. Here, the sheet material 110 is provided from a roller 410 in which the sheet material 110 is rolled up, and the sheet material 110 is thereafter supplied/provided from the roller 410 and arranged into the mould 420. Alternatively, as shown in Fig. 4b, the sheet material 110 may be provided as a pre-cut sheet material. In this embodiment of the method 100, the sheet material 110 may be picked from a stack of sheet materials 430 and placed into the mould 420, e.g. by a robot using a vacuum handling technique (not shown).
Figs. 5a-b are schematic illustrations of an embodiment of the method, wherein the sheet material 115 is provided as a die cut. Here, the die cut sheet material 115 has a substantially round, flat form, and further comprises a plurality of slits 510 which run from the periphery of the sheet material 115 into a centre portion of the sheet material 1 15 to define a plurality of foldable tongues 520. The sheet material 115 may thereby be arranged into a mould (not shown), whereby the mould is able to form the sheet material 115 such that the tongues 520 fold, and thereby protrude from the flat form of the sheet material 115. As a result, the sheet material 1 15 is formed into a cup-shaped form as shown in Fig. 5b. Fig. 5c shows an embodiment of a method 108 of manufacturing a heat sink structure comprising the sheet material 110 as shown in Figs. 5a-b. Here, the sheet material 115 is inserted into a female mould portion 540. A male mould portion 530 is inserted into the female mould portion 540, such that the sheet material forms into the cup- shape form as shown in Fig. 5b. In Fig. 5d, the plastic material 140 is injected into the mould. More specifically, the plastic material 140 is injected such that it becomes distributed on the periphery of the sheet material 115 and distributed into the slits 510, which is shown in Fig. 5e for an enhanced understanding.
It will be appreciated that the sheet material as disclosed in any one of the preceding embodiments of the present invention may be provided with at least one label, wherein the label may provide any kind of information such as branding, trademark, advertising, type (model) number, patent number, warning text, pictures, etc. In the embodiment of the method 100 as disclosed in Figs. 2a-d, a sheet material 110 comprising a label may be arranged visibly on the outer, convex portion of the heat sink structure 150 in Fig. 2d. Alternatively, in the embodiment of the method 100 as disclosed in Figs. 3a-d, a sheet material 110 comprising a label on the inner, concave portion of the heat sink structure 150 may be visible if the plastic material 140 of the heat sink structure 150 is transparent.
Fig. 6a is a schematic side-view illustration of a lighting module 600 according to an embodiment of the present invention. The lighting module 600 comprises at least one light source 610, exemplified in the figure as three LEDs 610. The lighting module 600 further comprises a carrier 620 arranged for mechanical and/or electrical support of the light sources 610, e.g. a printed circuit board (PCB). Further, the lighting module 600 comprises a heat sink structure 157 according to any of the previously described
embodiments, wherein the heat sink structure 157 comprises a sheet material 110 and a plastic material 140. The heat sink structure 157 is arranged in thermal contact with the carrier 620 and is arranged for dissipating heat from the carrier 620. In other words, during operation of the lighting module 600, the heat sink structure 157 provides a thermal path, indicated by arrows 650, on an outer side of the lighting module 600, from the light sources 610 and/or the carrier 620 to the heat sink structure 157. The plastic material 140 of the heat sink structure 157, which is in thermal contact with the sheet material 110 provided on an outer portion of the heat sink structure 157, conveys the heat to the sheet material 110 which in turn dissipates the heat into the surrounding environment of the heat sink
structure 157. It will be appreciated that the sheet material 110 of the heat sink structure 157 may alternatively be provided on an inner portion of the heat sink structure 157. In this embodiment, the sheet material 110 may be arranged to convey the heat from the light sources 610 and/or the carrier 620 to the plastic material 140 which in turn dissipates the heat into the surrounding environment of the heat sink structure 157.
Fig. 6b is a schematic side-view illustration of a lighting module 605, showing an alternative example to the lighting module 600 of Fig. 6a. Here, the lighting module 605 has a heat sink structure 158 comprising a die-cut sheet material 110 as exemplified in Figs. 5a-b, wherein the sheet material 110 is provided on an inner, concave portion of the heat sink structure 158. During operation of the lighting module 605, the thermal path (indicated by arrows 650) is provided from the light sources 610 and/or the carrier 620 to the sheet material 110 on the inner, concave portion of the to the heat sink structure 158, and into the surrounding environment through the plastic material 140 of the heat sink structure 158.
Fig. 6c shows an alternative lighting module 606 to that of Fig. 6a-b, wherein the sheet material 1 10 is provided on an outer, convex portion of the heat sink structure 159, and having a shape as exemplified in Figs. 5a-b. The thermal path 650 is hereby provided from the light sources 610 and/or the carrier 620 to the sheet material 110 on the outer, concave portion of the to the heat sink structure 159, and into the surrounding environment of the heat sink structure 159.
It will be appreciated that the at least one light source 610 and/or the carrier 620 of the lighting module of any of the exemplifying embodiments may be mounted directly on the sheet material 110 of the heat sink structure 150. An example of this is disclosed by the lighting module 607 in Fig. 6d, wherein sheet material 110 is arranged on an outer, convex portion of the heat sink structure 160, and wherein the carrier 620, arranged for mechanical and/or electrical support of the light sources 610, is mounted on the sheet material 1 10. Alternatively, the carrier 620 may be integrated into the sheet material 110.
Fig. 7a is a schematic illustration of a heat sink structure 165 comprising a plastic material 140 and a sheet material 110 (not indicated), wherein the heat sink structure 165 has a round, substantially flat shape. Furthermore, a plurality of snap connections 710 are arranged on a periphery of the heat sink structure 165. In Fig. 7b, the heat sink structure 165 is connected to a lighting module 700 comprising at least one light source (e.g. LEDs) 720 and a carrier 750 arranged to mechanically and/or electrically support the light sources. More specifically, the heat sink structure 150 is connected to the carrier 750 of the lighting module 700, wherein the snap connections 710 are received by the carrier 750.
Fig. 8a is a schematic illustration of a heat sink structure 170 having a relatively flat, rectangular shape, and wherein the heat sink structure 170 comprises at least one resilient portion 810. In the embodiment of Fig. 8a, two resilient portions 810 are arranged on opposite sides of the heat sink structure 170, and are arranged for pressing the heat sink structure 170 towards a carrier 850 of a lighting module 800. The resilient portions 810 in Fig. 8a each comprises three resilient (flexible) clamps, but it will be appreciated that substantially any shape of the resilient portions 810 is feasible. In Fig. 8b, the heat sink structure 170 is connected to a lighting module 800 comprising at least one light source 820 (e.g. LEDs) and a carrier 850. The resilient portions 810 are arranged to press the heat sink structure 150 towards the carrier 850 of the lighting module 800 to optimize thermal contact. Optionally, the heat sink structure 170 may comprise one or more snap connections for connecting the heat sink structure 170 to the carrier 850.
Fig. 9 is a schematic illustration of a lighting module 900 comprising at least one collimating means 910. The collimating means 910 are arranged at a front portion of the lighting module 900 for collimating light emitted from at least one light source (not shown) of the lighting module 900. Here, the heat sink structure 175 has a relatively flat form, and is provided with holes such that the collimating means 910 may project through the heat sink structure 175 upon arrangement of the heat sink structure 175 at the front portion of the lighting module 900.
The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. For example, the sheet material 110, the plastic material 140 and/or the resulting heat sink structures may have different dimensions and/or sizes than those depicted/described. For example, it will be appreciated that the elongated, (single) curved heat sink structures, e.g. as disclosed in Figs. 3-4, are shown as examples of the form/shape of the heat sink structures. Hence, the heat sink structures may have substantially any desired form, such as flat (i.e. not curved), round, short, etc.

Claims

CLAIMS:
1. A method (100) of manufacturing a heat sink structure, comprising the steps of:
providing a heat-conductive sheet material (110);
arranging (120) said sheet material in a mould (130);
providing a plastic material (140) in a fluid state and injecting (125) said plastic material into the mould;
moulding said plastic material and said sheet material, such that said plastic material and said sheet material are formed by the mould, and wherein said plastic material and said sheet material bond to each other; and
solidifying said plastic material, such that said plastic material and said sheet material form a heat sink structure (150) wherein said plastic material and said sheet material are thermally connected to each other.
2. The method as claimed in claim 1, comprising the steps of:
arranging said sheet material in a female mould portion (210), inserting a male mould portion (220) into the female mould portion;
injecting said plastic material into the mould; and
solidifying said plastic material, such that said plastic material and said sheet material form a curved heat sink structure wherein said sheet material is provided on an outer, convex portion of the heat sink structure.
3. The method as claimed in claim 1, comprising the steps of:
arranging said sheet material on a male mould portion (320),
inserting the male mould portion into a female mould portion (310);
injecting said plastic material into the mould; and
solidifying said plastic material, such that said plastic material and said sheet material form a curved heat sink structure wherein said sheet material is provided on an inner, concave portion of the heat sink structure.
4. The method as claimed in claim 1, wherein the step of providing said sheet material comprises providing said sheet material from a roll-fed process.
5. The method as claimed in claim 1, wherein the step of providing said sheet material comprises providing said sheet material as a pre-cut sheet material.
6. The method as claimed in claim 1, wherein said sheet material is provided with at least one label.
7. A heat sink structure (150), comprising:
a heat-conductive sheet material (110), and
a plastic material (140);
wherein said sheet material and said plastic material have been moulded by means of a method as claimed in any one of the preceding claims to form said heat sink structure, wherein said plastic material and said sheet material are formed by the mould, and wherein said plastic material and said sheet material are bonded and thermally connected to each other.
8. The heat sink structure as claimed in claim 7, wherein said heat sink structure is curved and wherein said sheet material is provided on an outer, convex portion of said plastic material.
9. The heat sink structure as claimed in claim 7, wherein said heat sink structure is curved and wherein said sheet material is provided on an inner, concave portion of said plastic material
10. The heat sink structure as claimed in claim 7, wherein said sheet material is a metal foil.
11. The heat sink structure as claimed in claim 10, wherein said metal foil has a thickness of < 0.35 mm, preferably < 0.25 mm, and most preferably < 0.15 mm.
12. A lighting module (600, 605, 606, 607, 700, 800, 900), comprising:
at least one light source (610, 720, 820), a carrier (620, 850) arranged to support said at least one light source, and a heat sink structure (150) as claimed in claim 9, wherein said heat sink structure is arranged in thermal contact with said carrier and is arranged for dissipating heat from said carrier.
13. The lighting module as claimed in claim 12, wherein said heat sink structure further comprises at least one snap connection (710) arranged for connecting said heat sink structure to said carrier.
14. The lighting module as claimed in claim 12, wherein said heat sink structure further comprises at least one resilient portion (810) arranged for pressing said heat sink structure towards said carrier.
15. The lighting module as claimed in claim 12, further comprising at least one collimating means (910) arranged at a front portion of said lighting module for collimating light emitted from said at least one light source, wherein said heat sink structure is arranged at the front portion of said lighting module.
PCT/IB2013/058346 2012-09-11 2013-09-06 Heat sink structure and method of manufacturing the same WO2014041470A2 (en)

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