US20140020882A1 - Heat sink for led lighting - Google Patents
Heat sink for led lighting Download PDFInfo
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- US20140020882A1 US20140020882A1 US14/034,696 US201314034696A US2014020882A1 US 20140020882 A1 US20140020882 A1 US 20140020882A1 US 201314034696 A US201314034696 A US 201314034696A US 2014020882 A1 US2014020882 A1 US 2014020882A1
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- fin
- heat
- base plate
- heat sink
- extends
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
- F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
- F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
- F21S41/141—Light emitting diodes [LED]
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
- F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
- F21S41/19—Attachment of light sources or lamp holders
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
- F21S45/40—Cooling of lighting devices
- F21S45/47—Passive cooling, e.g. using fins, thermal conductive elements or openings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
- F21S45/40—Cooling of lighting devices
- F21S45/47—Passive cooling, e.g. using fins, thermal conductive elements or openings
- F21S45/48—Passive cooling, e.g. using fins, thermal conductive elements or openings with means for conducting heat from the inside to the outside of the lighting devices, e.g. with fins on the outer surface of the lighting device
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
- F21S45/40—Cooling of lighting devices
- F21S45/49—Attachment of the cooling means
-
- 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
- F21V29/50—Cooling arrangements
- F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
- F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
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- 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
- F21V29/50—Cooling arrangements
- F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
- F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
- F21V29/76—Cooling 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
- F21V29/763—Cooling 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 the direction of the light emitting axis
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- 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
- F21V29/89—Metals
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/64—Heat extraction or cooling elements
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/64—Heat extraction or cooling elements
- H01L33/642—Heat extraction or cooling elements characterized by the shape
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
- F21S43/10—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by the light source
- F21S43/13—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by the light source characterised by the type of light source
- F21S43/14—Light emitting diodes [LED]
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- 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
- F21Y2105/00—Planar light sources
- F21Y2105/10—Planar light sources comprising a two-dimensional array of point-like light-generating elements
-
- 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]
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Computer Hardware Design (AREA)
- Power Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Thermal Sciences (AREA)
- Mechanical Engineering (AREA)
- Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
- Led Device Packages (AREA)
- Cooling Or The Like Of Electrical Apparatus (AREA)
Abstract
A heat sink for LED lighting formed of an aluminum material includes: a mounting face part having an LED element mounted on a surface thereof; a first fin part extending in a direction perpendicular to the mounting face part; and a second fin part extending in a direction perpendicular to the mounting face part and extending in a direction intersecting the first fin part.
Description
- This application is a continuation of International Patent Application No. PCT/JP2012/057691, filed Mar. 26, 2012, the disclosure of which is incorporated herein by reference in its entirety. This application claims priority to Japanese Patent Application No. 2011-080432, filed Mar. 31, 2011, Japanese Patent Application No. 2011-066326, filed Mar. 24, 2011, Japanese Patent Application No. 2011-066327, filed Mar. 24, 2011, Japanese Patent Application No. 2011-280062, filed Dec. 21, 2011, and Japanese Patent Application No. 2012-065237, filed Mar. 22, 2012, the disclosures of which are incorporated herein by reference in their entireties.
- The present invention relates to a heat sink for LED lighting in which LED lighting having a light emitting diode (LED) element as a light emitting source dissipates heat generated at the time of emitting light into a surrounding space.
- Lighting having a light emitting diode (LED) element as a light emitting source is low in power consumption and is long in life and hence gradually begins to prevail in the market. Among the lighting, it is a vehicle-mounted LED lighting such as a headlight of an automobile that especially gets much attention in recent years, and it has been started to replace embedded lighting in buildings and other fields with the LED lighting as an application of the vehicle-mounted LED.
- However, the LED element of the light emitting source of the LED has the following problems: the LED element is very weak against heat; and when temperature is higher than an allowable temperature, the LED element is reduced in light emitting efficiency and has its life affected. In order to solve these problems, the heat generated when the LED element emits light needs to be dissipated into a space surrounding the LED element and hence the LED lighting is provided with a large heat sink.
- An aluminum die-cast heat sink using aluminum or aluminum alloy as a raw material has been widely used as a heat sink for LED lighting. In
patent literatures 1 to 4 have been disclosed heat sinks having typical constructions of these heat sinks. Each of these heat sinks has a base plate part having an LED light source arranged and fixed on a front side thereof and a plurality of fin parts arranged in parallel to each other on the back side of the base plate part in such a way as to protrude separately from each other and uses the base plate part and the fin parts as heat dissipating surfaces and hence can acquire a large heat dissipating area, which makes it possible to think that the heat sink has a given heat dissipation capability. - However, in a case where a
heat sink 4 for LED lighting that has abase plate part 2 having anLED light source 1 arranged and fixed on a front side thereof and a plurality offin parts 3 in parallel to each other on the back side of thebase plate part 2 in such a way as to protrude separately from each other, as shown inFIG. 47 , is used for dissipating heat generated by a vehicle-mounted lighting such as a headlight of an automobile and by an embedded lighting of a building, theheat sink 4 is fixed, as shown inFIG. 48 , in the state where thebase plate part 2 constructs a back part of ahousing 5 of a case of the LED lighting. In the case where theheat sink 4 is fixed in the vehicle body of an automobile or the wall surface or the ceiling of a building in the state where theheat sink 4 is built in thehousing 5, thefin parts 3 are protruded in a closed space on the back side of the LED lighting in which the convection of air is not caused. - In this way, in the case where the
heat sink 4 is used in the state where thefin parts 3 of theheat sink 4 are protruded into the closed space on the back side, heat dissipation from theheat sink 4 becomes heat dissipation into the closed space in which the convection of air is not caused. Hence, theheat sink 4 having the plurality of fin parts arranged in parallel to each other cannot dissipate heat efficiently. - That is, heat dissipation from a heat sink in a closed space is mainly done not by convection but by radiation. For this reason, it can be thought that increasing all projected areas in an x-axis direction, a y-axis direction, and a z-axis direction, that is, in three directions of the heat sink is more effective for enhancing a heat dissipation capability than providing the heat sink with a plurality of fin parts to simply increase their surface areas.
- Patent literature 1: JP-A No. 2007-172932
- Patent literature 2: JP-A No. 2007-193960
- Patent literature 3: JP-A No. 2009-277535
- Patent literature 4: JP-A No. 2010-278350
- An object of the present invention is to provide a heat sink for LED lighting that can efficiently dissipate heat even in a closed space.
- In order to solve the problems, a heat sink for LED lighting according to the present invention is a heat sink for LED lighting formed of an aluminum material and is constructed of: a mounting face part having an LED element mounted on a surface thereof; a first fin part extending in a direction perpendicular to the mounting face part; and a second fin part extending in a direction perpendicular to the mounting face part and extending in a direction intersecting the first fin part.
- In this heat sink for LED lighting, the first fin part and the second fin part extend in a direction perpendicular to the mounting face part mounted with the LED element and the first fin part extends in a direction intersecting the second fin part. Hence, the heat sink for LED lighting can increase all projected areas in three dimensional directions of an x-axis direction, a y-axis direction, and a z-axis direction. Therefore, even when the heat sink dissipates heat in a closed space in which the convection of air is hardly caused, the heat sink can efficiently dissipates heat.
- In the heat sink for LED lighting according to the present invention, it is preferable that: the mounting face part has the first fin part or/and the second fin part formed integrally with any one or both of top and bottom faces thereof, each of the first fin part and the second fin part being shaped like a plate; the respective fin parts are formed in such a way as to erect outward and separately from each other; and the number of the fin parts extending in a same direction is two or less at an arbitrary section perpendicular to any one of the top and bottom faces of the mounting face part.
- In this case, it is preferable that the respective fin parts are formed at positions between which the LED element is mounted.
- Further, it is preferable that the first fin part and the second fin part are formed by a total of 2 to 8.
- In this way, the object of the present invention can be achieved without complicating the shape and structure of the heat sink, especially, the shape and structure of the fin part for dissipating heat and without increasing the number of fin parts. On the contrary, the object of the present invention can be achieved by simplifying the shape and structure of the fin part and by decreasing the number of fin parts. Further, in the present invention, the base plate and the heat dissipating fins of the heat sink are integrally formed, so that the face of the base plate and the faces of the heat dissipating fins are continuous with each other and hence the path of heat conduction by the surfaces or materials of these parts is continuously formed. Hence, since there is no impediment such as a slit for cutting the path of heat conduction, the path of heat condition in the heat sink is not cut and heat from the LED element can be transferred to the respective parts constructing the heat sink. Therefore, an extremely high heat dissipation capability of the heat sink can be ensured
- Further, in the heat sink for LED lighting according to the present invention, it is preferable that the mounting face part and the first fin part are formed in a continuous stepped shape.
- In this case, it is preferable that the mounting face part, the first fin part, and the second fin part are integrally formed by bending a blank of aluminum material.
- Further, it is preferable that the first fin part has the second fin part further formed on an end portion thereof, the second fin part extending in a direction intersecting the first fin part.
- Still further, it is preferable that the mounting face part or/and the first fin part is/are larger in thickness than the second fin part.
- Still further, it is preferable that the second fin parts, or the second fin part and the mounting face part or/and the first fin part are overlaid on each other.
- Still further, it is preferable that a portion at which the LED element is mounted of the mounting face part is partially increased in thickness.
- The heat sink for LED lighting constructed in this way is a heat sink which is formed of an aluminum material and has a simple structure, so that the heat sink can be comparatively easily manufactured by bending a blank acquired by punching and cutting a rolled plate such as sheet or coil or an extruded plate and is lightweight. Hence, the heat sink for LED lighting according to the present invention is most suitable for a heat sink for LED lighting for a vehicle.
- Further, in the heat sink for LED lighting according to the present invention, it is preferable that the mounting face part has the LED element arranged and fixed on a front side thereof and has a plurality of the first fin parts formed on a back side thereof in such a way as to protrude separately from each other and in parallel to each other, and that of the first fin parts, at least one first fin part has a portion thereof bent at a right angle, whereby the portion is made the second fin part, and that the second fin part has a heat dissipating surface in a direction which is perpendicular to a heat dissipating surface of the first fin part and to a heat dissipating surface of the mounting face part, respectively.
- The heat sink for LED lighting constructed in this way can be manufactured from an aluminum material by a comparatively simple working method such as cutting and bending and the number of parts constructing the heat sink is not increased.
- In the heat sink for LED lighting according to the present invention, it is preferable that the mounting face part has the LED element arranged and fixed on a front side thereof and has a plurality of the first fin parts formed on a back side thereof in such a way as to protrude separately from each other and in parallel to each other, and that the mounting face part is bent in a direction perpendicular to a longitudinal direction of the first fin part and hence is formed in a shape of a letter L, and that the second fin part is formed by bending the mounting face part in this manner.
- In this way, the heat sink for LED lighting can be manufactured from an aluminum material by the use of a comparatively simple working method such as slitting and bending and the number of parts constructing the heat sink is not increased. In addition, the heat sink for LED lighting can be fixed even in a narrow limited space and in an indented space, which hence makes it possible to ensure a sufficient amount of heat dissipation from LED lighting even in such a limited space.
- In this case, it is preferable that the first fin part is protruded to an outside of the mounting face part bent in the shape of the letter L and has a linear slit formed in a bent portion thereof at the time of bending and hence is divided, the slit reaching an outside surface of the mounting face part.
- In this way, the heat sink for LED lighting can be fixed even in a concave corner of a narrow limited space, and when the base plate part is bent, it is not caused that the fin part has an effect on bending, and an amount of protrusion of the fin part does not need to be made small, which hence further makes it possible to further ensure a sufficient amount of heat dissipation from LED lighting.
- Alternatively, it is preferable that the first fin part is protruded to an inside of the mounting face part bent in the shape of the letter L and has a slit formed in a bent portion thereof at the time of bending and hence is divided, the slit reaching an inside surface of the mounting face part and being formed in a shape of a letter V having an angle of 90 degrees or more.
- In this way, the heat sink for LED lighting can be fixed even in a narrow limited space and can ensure a sufficient heat dissipating space by the surface areas of the base plate part and the fin parts, which hence makes it possible to further ensure a sufficient amount of heat dissipation from LED lighting. Further, the heat sink for LED lighting can be fixed even in a convex corner of a limited indented space. Still further, it is not caused that when the base plate part is bent, the fin part has an effect on the bending, and an amount of protrusion of the fin part does not need to be made small, which hence makes it possible to still further ensure a sufficient amount of heat dissipation from LED lighting.
- Further, in the heat sink for LED lighting according to the present invention, it is preferable that the first fin part and the second fin part are formed in a shape of continuous wavy heat dissipating fins by corrugating and have a part thereof pressed into a stepped part, the stepped part constructing the mounting face part.
- In this case, before the corrugating, the first fin part and the second fin part have their surfaces previously subjected to pre-coating having an emissivity ε of 0.7 or more.
- According to the heat sink for LED lighting constructed in this way, by forming the whole shape of the heat dissipating fins of the continuous wavy shapes by corrugating, it is possible to form many thin fins at comparatively narrow intervals and hence to increase a heat transfer area and to enhance a heat dissipation capability.
- Further, by using an aluminum alloy thin plate as a raw material, as a treatment for enhancing a heat dissipation capability, it is possible to previously apply pre-coating to the aluminum alloy thin plate as the raw material before corrugating. This makes it possible to omit or shorten processes that are necessary for a conventional heat sink manufactured by an aluminum alloy die casting, for example, a process of buffing the surface of a die casting, a cleaning process, a degreasing process, and a surface treatment process for enhancing the emissivity of a surface and hence to significantly reduce the manufacturing cost of the heat sink.
- Still further, when a raw material plate is corrugated, the part on which the LED element is fixed and the stepped part such as a depression and a protrusion for reinforcing rigidity can be formed by a series of corrugating processes including a forming process of the whole shape of the heat dissipating fins of continuous wavy shapes and a crushing process following the forming process. At this time, it is possible to design and form a portion to become the stepped part partially in a larger width than the width of the fin. Hence, it is possible to integrally manufacture a heat sink, which ensures an LED element mounting area and has many fins to ensure a heat dissipation capability, from the same raw material plate. The heat sink for LED lighting of the present invention can increase all projected areas in the three dimensional directions of the x-axis direction, the y-axis direction, and the z-axis direction and hence can efficiently dissipate heat even in a closed space in which the convection of air is not caused.
- A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
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FIG. 1 is a perspective view showing a heat sink for LED lighting of a first embodiment according to the present invention. -
FIG. 2 is a perspective view showing a first modified example of the heat sink of the first embodiment. -
FIG. 3 is a perspective view showing a second modified example of the heat sink of the first embodiment. -
FIG. 4 is a perspective view showing a third modified example of the heat sink of the first embodiment. -
FIG. 5 is a perspective view showing a fourth modified example of the heat sink of the first embodiment. -
FIG. 6 is a perspective view showing a fifth modified example of the heat sink of the first embodiment. -
FIG. 7 is a perspective view showing a sixth modified example of the heat sink of the first embodiment. -
FIG. 8 is a perspective view showing a heat sink for LED lighting of a second embodiment according to the present invention. -
FIG. 9 illustrates a method for manufacturing the heat sink for LED lighting of the second embodiment and is perspective views, one of which shows a plate-shaped aluminum material made of a coil material and a blank, and the other of which shows a mode of a blank after coining. -
FIG. 10 is a perspective view illustrating the principle and function of heat dissipation in the heat sink for LED lighting of the second embodiment. -
FIG. 11 is a perspective view of such a mode of a blank after coining that illustrates a method for manufacturing a heat sink for LED lighting of a first modified example of the second embodiment, the first modified example being common in a whole shape to the second embodiment. -
FIG. 12 is a perspective view of such a mode of a blank after coining that illustrates a method for manufacturing a heat sink for LED lighting of a second modified example of the second embodiment, the second modified example being common in a whole shape to the second embodiment. -
FIG. 13 is a perspective view that shows a heat sink for LED lighting of a third modified example of the second embodiment, the third modified example being different in a whole shape from the second embodiment. -
FIG. 14 illustrates a method for manufacturing the heat sink for LED lighting of the third modified example of the second embodiment and is perspective views, one of which shows a plate-shaped aluminum material made of a coil material and a blank, and the other of which shows a mode of a blank after coining. -
FIG. 15 is a perspective view showing a heat sink for LED lighting of a third embodiment according to the present invention. -
FIG. 16 is a plan view ofFIG. 15 . -
FIG. 17 is a side section view of an aluminum plate showing an example of a case in which an aluminum plate (horizontal plane part) of an LED element mounting part in the heat sink for LED lighting of the third embodiment is made partially larger in thickness. -
FIG. 18 is a perspective view showing a setting state in a case where the heat sink for LED lighting of the third embodiment is applied to a headlight of an automobile. -
FIG. 19 is a section view taken on a line a-a inFIG. 18 . -
FIG. 20 is a section view taken on a line b-b inFIG. 18 . -
FIG. 21 is a section view taken on a line c-c inFIG. 18 . -
FIG. 22 is a perspective view showing a heat sink for LED lighting of a fourth embodiment according to the present invention. -
FIGS. 23( a), 23(b) and 23(c) show a heat sink for LED lighting of the fourth embodiment.FIG. 23( a) is a plan view andFIG. 23( b) is a front view andFIG. 23( c) is a side view. -
FIGS. 24( a), 24(b) and 24(c) show plan views showing modified examples of the heat sink for LED lighting of the fourth embodiment. -
FIG. 25 is a lateral section view showing a usage state in which the heat sink for LED lighting of the fourth embodiment is built in LED lighting as a part of housing. -
FIG. 26 is a vertical section view showing a usage state in which the heat sink for LED lighting of the fourth embodiment is built in LED lighting as a part of housing. -
FIG. 27 is a perspective view showing a heat sink for LED lighting of a fifth embodiment according to the present invention. -
FIG. 28 is a perspective view showing a heat sink for LED lighting of a first modified example of the fifth embodiment. -
FIG. 29 is a perspective view showing a heat sink for LED lighting of a second modified example of the fifth embodiment. -
FIG. 30 is a perspective view showing a heat sink for LED lighting of a third modified example of the fifth embodiment. -
FIG. 31 is a lateral section view showing a usage state in which the heat sink for LED lighting of the fifth embodiment shown inFIG. 29 is built in LED lighting as a part of a housing. -
FIG. 32 is a section view taken along a line B-B inFIG. 31 . -
FIG. 33 is a lateral section view showing a usage state in which the heat sink for LED lighting of the fifth embodiment shown inFIG. 30 is built in LED lighting as a part of a housing. -
FIG. 34 is a section view taken along a line B-B inFIG. 33 . -
FIG. 35 is a perspective view showing a heat sink for LED lighting of a sixth embodiment according to the present invention. -
FIG. 36 is a plan view ofFIG. 35 . -
FIG. 37 is a perspective view showing a heat sink for LED lighting of a first modified example of the sixth embodiment. -
FIG. 38 is a plan view of aFIG. 37 . -
FIG. 39 is a perspective view showing a heat sink for LED lighting of a second modified example of the sixth embodiment. -
FIG. 40 is a perspective view showing a heat sink for LED lighting of a third modified example of the sixth embodiment. -
FIG. 41 is a perspective view showing a heat sink for LED lighting of a fourth modified example of the sixth embodiment. -
FIGS. 42( a) and 42(b) show a heat sink for LED lighting of a fifth modified example of the sixth embodiment, andFIG. 42( a) is a perspective view andFIG. 42( b) is a section view taken on a line X-X′ inFIG. 42( a). -
FIG. 43 is a perspective view showing a heat sink for LED lighting of a sixth modified example of the sixth embodiment. -
FIGS. 44( a), 44(b), and 44(c) are perspective views showing the heat sinks for LED lighting of a seventh modified example of the sixth embodiment. -
FIGS. 45( a) and 45(b) illustrate a mode in which the heat sink of the sixth embodiment is mounted in a vehicle-mounted LED lamp. -
FIG. 46 illustrates an outline of an emissivity measurement device. -
FIG. 47 is a perspective view showing a conventional heat sink for LED lighting. -
FIG. 48 is a longitudinal section view showing a usage state in which the conventional heat sink for LED lighting is built in LED lighting as a part of a housing. -
FIGS. 49( a), 49(b), and 49(c) show the conventional heat sink for LED lighting, andFIG. 49( a) is a plan view andFIG. 49( b) is a front view andFIG. 49( c) is a side view. -
FIG. 50 is a perspective view showing a mode of a heat sink so as to make a comparison. -
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- 100—LED element
- 101—heat sink for LED lighting
- 102—base plate (mounting face part)
- 103, 105—heat dissipating fin (first fin part)
- 104, 106—heat dissipating fin (second fin part)
- 201—heat sink for LED lighting
- 211, 212—horizontal plane part (mounting face part)
- 221, 222—vertical front part (first fin part)
- 231-236, 2331-2334—vertical side part (second fin part)
- 300—LED element
- 301—heat sink for LED lighting
- 311, 312—horizontal plane part (mounting face part)
- 321, 322—vertical front part (first fin part)
- 331-338—vertical side part (second fin part)
- 400—LED light source (LED element)
- 401—heat sink for LED lighting
- 402—base plate part (mounting face part)
- 403—fin part (first fin part)
- 403 a—fin main body (first fin part)
- 403 b—fin bent piece (second fin part)
- 500—LED light source (LED element)
- 501—heat sink for LED lighting
- 502—base plate part (mounting face part)
- 503—fin part
- 503 a—first fin part
- 503 b—second fin part
- 601—heat sink for LED lighting
- 600, 600 a, 600 b—element
- 602, 603—wavy shape (first fin part and second fin part)
- 604 a, 604 b—stepped part (mounting face part)
- Hereinafter, the present invention will be further described in detail on the basis of embodiments shown in the accompanying drawings.
-
FIG. 1 shows aheat sink 101 for LED lighting of a first embodiment. Theheat sink 101 for LED lighting is characterized in that: abase plate 102 having anLED element 100 mounted on any one of top and bottom faces 1021, 1022 thereof has plate-shapedheat dissipating fins heat dissipating fins base plate 102 and to be separate from each other; and the number of theheat dissipating fins base plate 102. Of these parts, thebase plate 102 constructs a mounting face part of the present invention, and theheat dissipating fin 103 constructs a first fin part of the present invention, and theheat dissipating fin 104 constructs a second fin part of the present invention. - Specifically, a first embodiment of the
heat sink 101 for LED lightning of the present invention will be shown by a perspective view inFIG. 1 , and a first modified example to a sixth modified example of the first embodiment of theheat sink 101 for LED lightning of the present invention will be shown inFIGS. 2 to 7 . - Basic Structure of a Heat Sink:
- First, there will be described a basic structure common to the
heat sink 101 for LED lightning of the first embodiment of the present invention inFIGS. 1 to 7 . In theseFIGS. 1 to 7 , theheat sink 101 for LED lightning of the present invention commonly has the plate-shapedbase plate 102 having theLED element 100 mounted thereon. Thebase plate 102 has two top and bottom faces 1021, 1022 in a y direction (up and down direction) in each drawing, and thesefaces base plate 102 has theLED element 100 mounted on any one of these two top and bottom faces 1021, 1022, thereby supporting theLED element 100. InFIGS. 1 to 7 , for the sake of convenience, a face on a top side in each drawing is referred to as a mountingface 1021 of theLED element 100 and theLED element 100 is mounted in a central portion of the mountingface 1021. The other face on an under side in each drawing is referred to as thebottom face 1022 for the sake of convenience. - Further, the top and bottom faces 1021, 1022 of the
base plate 102 have the plate-shapedheat dissipating fins 103 to 106 which extend in the y direction (the up and down direction) in each drawing in such a way as to protrude perpendicularly to any one or both of the top and bottom faces 1021, 1022 (direction in which the face extends=perpendicular to the x direction and the z direction in each drawing). These plate-shapedheat dissipating fins 103 to 106 are erected on the top and bottom faces 1021, 1022 of thebase plate 102 in such a way as to direct to the outside. However, in the plate-shapedheat dissipating fins 103 to 106, their plate-shaped heat dissipation side surfaces do not necessarily need to be perpendicular to the top and bottom faces 1021, 1022 of thebase plate 102 at an angle of 90 degrees as shown inFIGS. 1 to 7 . For example, the plate-shapedheat dissipating fins 103 to 106 may be erected in such a way that the plate-shaped heat dissipating side surfaces are inclined to the outside with respect to the top and bottom faces 1021, 1022 of thebase plate 102 at an angle smaller than 90 degrees or larger than 90 degrees. However, in any case, these plate-shapedheat dissipating fins 103 to 106 are formed integrally and continuously with thebase plate 102 in terms of material. In other words, at least the plated-shaped top and bottom faces of the plate-shapedheat dissipating fins 103 to 106 are formed in such a way as not to be separate from but to be continuous with the top and bottom faces 1021, 1022 of thebase plate 102. - For this reason, there are formed continuous heat transfer surfaces in which heat from the
LED element 100 is continuously transferred to thebottom face 1022, the side faces surrounding theheat dissipating fins 103 to 106, and faces in a thickness direction via the face (surface) 1021, on which the LED element is mounted, of thebase plate 102. Further, there are formed also continuous heat dissipating surfaces for continuously radiating heat from these continuous heat transfer surfaces. - In this regard, at to the shape of the
base plate 102, a rectangular (or square) plate shape or planar shape is shown inFIGS. 1 to 7 . However, as to the shape of thebase plate 102, a planar shape such as a circular shape, a triangular shape, a polygonal shape, or an indefinite shape, or a three dimensional shape such as a cylindrical shape, a rectangular cylindrical shape, or a stepped shape can be arbitrarily selected according to the usage of theheat sink 101 for LED lighting. - Feature of Heat Dissipating Fin:
- The above-mentioned basic structure of the
heat sink 101 forLED lighting 101 of the present invention, when glanced, seems to be not much different from the structure of aconventional heat sink 4 shown inFIG. 47 . However, the basic structure of theheat sink 101 for LED lighting of the present invention is much different from the structure of theconventional heat sink 4 in that ingenuity for dissipating heat from theLED element 100 mainly by heat radiation, which is required in a narrow space or a closed space of a housing for vehicle-mounted lighting, is exercised in the arrangement of the plate-shapedheat dissipating fins 103 to 106. - First, in the heat sink for
LED lighting 101 of thepresent invention 1, on the premise of the basic structure of the heat sink, the plate-shapedheat dissipating fins 103 to 106, preferably, a total of 2 to 8 heat dissipating fins to be mounted on the twofaces base plate 102, are formed continuously and integrally with thefaces base plate 102 and separately from each other. - Of these
heat dissipating fins 103 to 106, the number of the fins extending in the same direction (including a parallel state) is made two or less in an arbitrary section perpendicular to the twofaces base plate 102, in other words, two or less in any section of theheat sink 101 which is cut at an arbitrary section perpendicular to the twofaces base plate 102. - Meaning of Specification of Direction in which Heat Dissipating Fin Extends:
- Here, the meaning of “extending in the same direction”, which is described in the present invention, naturally includes a parallel state and includes not only a parallel state in the strict sense of the word but also a state in which angles in which the plate-shaped side faces of the heat dissipating fins extend are slightly different from each other. An object of the present invention is to eliminate the excessive overlap of the heat dissipating fins in any direction of the three dimensional directions of the heat sink, to reduce the waste of material, and to achieve high performance in heat radiation efficiency. Hence, even if the angles in which the plate-shaped side faces of the heat dissipating fins extend are slightly different from each other within a range not to impair the object and the effect of the invention, it is possible to regard the plate-shaped side faces of the heat dissipating fins as extending in the same direction. This is because even if the angles in which the plate-shaped side faces of the heat dissipating fins extend are slightly different from each other or are not different from each other because the plate-shaped side faces are strictly parallel to each other, there is not much difference in that the heat dissipating fins extend in the same direction and overlap each other, which is to be specified in the present invention.
- At to the degree of this difference in the angle, in the case where an angle formed by the directions in which the plate-shaped side faces of the heat dissipating fins extend is 30 degrees or less, the heat dissipating fins are regarded as extending in the same direction. On the contrary, in the case where the angle formed by the directions in which the plate-shaped side faces of the heat dissipating fins extend is more than 30 degrees, the heat dissipating fins are not regarded as extending in the same direction.
- In
FIGS. 1 to 7 which will be described later, as a mode in which two heat dissipating fins extend in the same direction across theLED element 100, the two heat dissipating fins are arranged in such a way as to be parallel to each other and to surround the perimeter of theLED element 100 in a rectangular shape and to make the heat dissipating fins adjacent to each other perpendicular to each other (intersect each other at right angles). However, in the present invention, the heat dissipating fins are not necessarily arranged in this way but may be arranged separately from each other on a circumference or an arc, in which theLED element 100 is set at a center, in such a way as to surround the perimeter of theLED element 100, for example, in the arrangement of dominos in domino toppling in which the angles of the plate-shaped side faces are changed in sequence. - In addition, it is because of preventing the heat dissipating fins from overlapping each other excessively with respect to a certain direction in a three-dimensional space “that the number of the heat dissipating fins extending in the same direction is specified to be two or less in an arbitrary section perpendicular to the two
faces base plate 102 is made two or less, whereby the heat dissipating fins or the heat dissipating side surfaces of the heat dissipating fins can be prevented from overlapping each other in the same direction. That is, the above-mentioned specification is provided for the following purpose: regardless of whether or not the heat dissipating surfaces are of the same heat dissipating fin, the number of the heat dissipating surfaces (heat dissipating side surfaces) of the heat dissipating fins is regarded as the number of the heat dissipating fins and is specified to be two or less so as to prevent the heat dissipating surfaces of the heat dissipating fins from overlapping each other excessively in the same direction regardless of the positions of the twofaces base plate 102. - In this point, in the case where the number of the heat dissipating fins extending in the same direction is temporarily specified to be “two or less even in either of
faces base plate 102” as another expression different from the above-mentioned specification, the absolute number of the heat dissipating fins will be specified. For this reason, in this case, the number of the heat dissipating surfaces in different directions of the heat dissipating fin shaped like a letter L or C is not regarded as the number of heat dissipating fins, which presents the possibility that the heat dissipating surfaces of the heat dissipating fins will overlap each other excessively depending on the positions of the twofaces base plate 102. Hence, as described above, “the number of the heat dissipating fins is specified to be two or less in an arbitrary section perpendicular to the twofaces - As to the shape of the plate-shaped
heat dissipating fins 103 to 106, examples are shown inFIGS. 1 to 7 in which the whole shape or the plate-shaped side face is a rectangle (square). However, the shape is not limited to this rectangle but a planar shape or a three-dimensional shape can be selected. For example, in the case where a plurality of plate-shaped heat dissipating surfaces (heat dissipating side surfaces) are extended in different directions (which form, for example, 90 degrees or more), theheat dissipating fins 103 to 106 may be formed in the shape of a letter L in which theheat dissipating fins heat dissipating fins heat dissipating fins 103 to 106 may have not only these plate-shaped heat dissipating surfaces (heat dissipating side surfaces) but also an arc-shaped or a curved heat dissipating surfaces (heat dissipating side surfaces) or a whole shape. Further, theheat dissipating fins 103 to 106 extending in the outward direction may be made different in the shape of a section in a thickness direction or in a thickness at height positions, that is, may be formed in the shape of a letter L or in a stepped shape. In addition, theheat dissipating fins 103 to 106 may also have the heat dissipating surfaces selectively formed in a planar shape such as a circular shape, a triangular shape, a polygonal shape, or an indefinite shape. - Hereinafter, specific embodiments of the present invention shown in
FIGS. 1 to 7 will be described, and the meaning of specifying the number and the arrangement of the plate-shapedheat dissipating fins 103 to 106 of the present invention will be described. That is, the meaning of specifying the number of the plate-shapedheat dissipating fins 103 to 106 to be preferably 2 to 8 in total will be also described. Further, the meaning of specifying the number of the fins extending in the same direction of theseheat dissipating fins 103 to 106 to be two or less even in any section of theheat sink 101 cut at an arbitrary section in a direction perpendicular to either of thefaces base plate 102 will be also described. - First Embodiment Shown in
FIG. 1 : - In the plate-shaped
heat dissipating fins FIG. 1 , a total of four plate-shaped heat dissipating fins are formed on the side of the LEDelement mounting face 1021 of thebase plate 102 in such a way that their respective plate-shaped side faces are integral and continuous with theface 1021 of thebase plate 102, the LEDelement mounting face 1021 supporting theLED element 100. The heat dissipating fin is not formed on the other side of thebottom face 1022 but only the plate-shapedbottom face 1022 exists. - In the
heat dissipating fins element mounting face 1021, two of them are formed side by side in parallel to each other symmetrically across theLED element 100 as a mode in which theheat dissipating fins heat dissipating fins heat dissipating fins 103, 103 (or 104, 104) opposed to each other are formed on the top surface side of the LEDelement mounting face 1021 at positions between which theLED element 100 is mounted. Of theseheat dissipating fins faces heat sink 101 cut at a section in this direction). - The
heat dissipating fins LED element 100 is sandwiched (theLED element 100 is arranged at the center), and the respective plate-shaped side faces of theheat dissipating fins element mounting face 1021 and theother bottom face 1022, which are large in thermal emissivity, of thebase plate 102 are directed to the y direction. - In addition, the
respective faces base plate 102 are comparatively smaller in area than therespective faces heat dissipating fins 103, 104: that is, the respective faces are comparatively smaller in area than the plate-shaped side faces but are larger in the number of the faces; and in the top faces and the faces of both end portions, a total of four faces are directed to each of the x, y, z directions and become the heat radiating surfaces in these directions. - Hence, although of the plate-shaped side surfaces of the
heat dissipating fins LED element 100 is mounted overlap each other, the heat dissipating surfaces of the heat dissipating fins do not overlap each other excessively in any direction of the x, y, and z directions, which results in eliminating the waste of material. For this reason, a high heat radiation efficiency can be acquired by the synergistic effect of the effect of forming the continuous heat transfer faces to which the heat of theLED element 100 is continuously transferred to thebottom face 1022, the side faces surrounding the respectiveheat dissipating fins face 1021 of thebase plate 102 and the effect of forming the continuous heat dissipating surfaces for continuously radiating heat from the continuous heat transfer faces. - The Number of the Heat Dissipating Fins:
- In the case where the number of the heat dissipating fins extending in the same direction is further reduced to only two of a preferable limit even in an arbitrary section perpendicular to the
faces base plate 102, only two of both of theheat dissipating fins FIG. 1 , only two of both of theheat dissipating fins FIG. 1 , or only two of any one of theheat dissipating fins 103 and any one of theheat dissipating fins 104 are left and the other heat dissipating fins are eliminated. In this case, both of theheat dissipating fins FIG. 1 may be left, or both of theheat dissipating fins FIG. 1 may be left, or two of either of theheat dissipating fins heat dissipating fins - In contrast to this, in the case where the number of the plate-shaped heat dissipating fins is increased, the heat dissipating surfaces of the heat dissipating fins overlap each other in any one of the three dimensional directions of the x, y, z directions, which results in causing the waste of material and reducing the heat radiation efficiency of heat (heat dissipation efficiency) for a high spatial occupancy. Hence, the number of the heat dissipating fins to be mounted, that is, the number of the heat dissipating fins on two
faces base plate 102 is specified to be eight or less in total, preferably, within a range from two to eight. However, inFIGS. 1 to 7 , in the case of the mode in which one of the dissipatingfins 103 to 106 is only separated or divided into several parts or many small parts as they are in the directions in which the heat dissipating side surfaces extend, each of the separated or divided parts is not individually regarded as one heat dissipating fin but the separated or divided parts are collectively regarded as one heat dissipating fin. - A problem caused in the case where a total number of the plate-shaped heat dissipating fins is increased is caused similarly also in the case where the number of the heat dissipating fins extending in the same direction (in parallel to each other) is too large, as is the case with a comparative example shown in
FIG. 50 in which the number of the heat dissipating fins is three or more in an arbitrary section perpendicular to the two top and bottom faces 1021, 1022 of the base plate 102 (three or more also in any section of theheat sink 101 cut by an arbitrary section in a direction perpendicular to the two top and bottom faces 1021, 1022 of the base plate 102). In the comparative example shown inFIG. 50 , when four heat dissipating fins extending in parallel to each other are formed on each of the top and bottom faces 1021, 1022 of thebase plate 102, the number of the heat dissipating fins formed on thetop face 1021 is equal to the number of the heat dissipating fins arranged in parallel to each other of a conventional example shown inFIG. 47 , and the heat dissipating surfaces of the heat dissipating fins overlap each other in any one of the three dimensional directions of the x, y, z directions. Hence, the waste of material is caused and the heat radiation efficiency is reduced for a high spatial occupancy. - First Modified Example of the First Embodiment Shown in
FIG. 2 : - Plate-shaped heat dissipating fins shown in
FIG. 2 show a mode in which heat dissipatingfins base plate 102 as shown inFIG. 1 but also on theother bottom face 1022 side of thebase plate 102. Specifically, in addition to four plate-shapedheat dissipating fins LED mounting face 1021 of thebase plate 102 shown inFIG. 1 , two for each ofheat dissipating fins other bottom face 1022 symmetrically with respect to theLED mounting face 1021, that is, a total of eight (which is a preferable upper limit) ofheat dissipating fins base plate 102. - The
heat dissipating fins bottom face 1022 are arranged absolutely similarly to and symmetrically in the up and down direction in the drawing with respect to the four plate-shapedheat dissipating fins element mounting face 1021 of thebase plate 102. That is, as a mode in which the heat dissipating fins extend in the same direction, twoheat dissipating fins LED element 100, whereas twoheat dissipating fins LED element 100. That is, also on the side of thebottom face 1022, the plate-shapedheat dissipating fins LED element 100 is mounted, is sandwiched in a similar manner in which the plate-shapedheat dissipating fins element mounting face 1021 are formed. In other words, the plate-shaped heat dissipating fins are formed at the positions between which theLED element 100 is sandwiched on both of the top and bottom faces of thebase plate 102. Of theheat dissipating fins face 1022 of the base plate 102 (also at any section of theheat sink 101 cut at a section in this direction). - The
heat dissipating fins bottom face 1022 corresponding to the position of thetop face 1021 at which theLED element 100 is mounted is at the center in a manner in which the heat dissipating fins adjacent to each other are perpendicular to each other (intersect at right angles), and the respective plate-shaped side faces of theheat dissipating fins element mounting face 1021 and theother bottom face 1022, each of which has a large heat radiation efficiency, of thebase plate 102 are directed to the y direction. - In addition, not only the
respective faces base plate 102 and the respective faces (top faces and faces of the end portions) in the thickness direction of the four plate-shapedheat dissipating fins LED mounting face 1021 of thebase plate 102 but also the respective faces (bottom faces and faces of the end portions) in the thickness direction of the respectiveheat dissipating fins bottom face 1022 become the heat radiating surfaces. The respective faces in the thickness direction of the respective heat dissipating fins are comparatively small in area, but the number of faces of both of the top and bottom faces and the faces of the end portions becomes two times the number of those faces inFIG. 1 and a total of eight faces are directed to each of the x, y, z directions and become the heat radiating surfaces in these directions. - Hence, also in the case of
FIG. 2 , the heat dissipating surfaces of the heat dissipating fins do not overlap each other, especially, even in any direction of the three dimensional directions of these x, y, z directions, whereby the waste of material can be eliminated and a high heat radiation efficiency can be acquired for a low spatial occupancy. - Second, Third, and Fourth Modified Examples of the First Embodiment Shown in
FIGS. 3 , 4 and 5: - The plate-shaped heat dissipating fins of the modified examples shown in
FIGS. 3 , 4, and 5 show modes in which heat dissipating fins on either of one side of thebase plate 102, that is, the LEDelement mounting face 1021 or the other side of thebase plate 102, that is, thebottom face 1022 are omitted from the case shown inFIG. 2 in which the number of the heat dissipating fins is the upper limit. - In the second modified example shown in
FIG. 3 , as compared with the arrangement of the heat dissipating fins shown inFIG. 2 , on the side of the LEDelement mounting face 1021 of thebase plate 102, one heat dissipating fin on the lower side in the drawing of twoheat dissipating fins 104 is omitted, that is, the number of the heat dissipating fins is reduced to three. Also on the other side of thebottom face 1022, the heat dissipating fins are arranged asymmetrically in the up and down direction in the drawing, that is, one heat dissipating fin on the left side in the drawing of twoheat dissipating fins 105 is omitted and hence the number of heat dissipating fins is reduced to three. In other words, a total of six heat dissipating fins are formed. - In the third modified example shown in
FIG. 4 , as compared with the arrangement of the heat dissipating fins shown inFIG. 2 , on the side of the LEDelement mounting face 1021 of thebase plate 102, twoheat dissipating fins heat dissipating fins other bottom face 1022 side, the symmetric arrangement of the heat dissipating fins in the up and down direction in the drawing is kept and hence twoheat dissipating fins heat dissipating fins - The fourth modified example shown in
FIG. 5 is the same asFIG. 4 in that as compared with the arrangement of the heat dissipating fins shown inFIG. 2 , on the LEDelement mounting face 1021 side of thebase plate 102 on the LEDelement mounting face 1021 side of thebase plate 102, twoheat dissipating fins heat dissipating fins bottom face 1022, twoheat dissipating fins heat dissipating fins - Fifth and Sixth Modified Examples of the First Embodiment Shown in
FIGS. 6 , 7: - A
heat sink 101 for LED lighting shown inFIGS. 6 , 7 shows an embodiment in which the base plate 102 (faces 1021, 1022) and plate-shapedheat dissipating fins - In this case, the plate-shaped
heat dissipating fins base plate 102 in the y direction (in the up and down direction in the drawing), in which the respective heat dissipating surfaces extend, from the end portion sides of thebase plate 102. In the fifth modified example shown inFIG. 6 , theheat dissipating fins FIG. 7 , theheat dissipating fins heat dissipating fins heat dissipating fins FIG. 6 is the same as the case shown inFIG. 1 andFIG. 7 is the same as the case shown inFIG. 5 . However, theheat dissipating fins base plate 102 and hence the arrangement structures shown inFIG. 1 andFIG. 5 in which theheat dissipating fins base plate 102 are different from the arrangement structures shown inFIG. 6 andFIG. 7 . - Principle and Function of Heat Dissipation:
- There will be described the principle (function) of heat dissipation in the case where this
heat sink 101 of the present invention is set in a space in which the convention of air is not caused to thereby do the LED lighting. When theLED element 100 mounted on theLED mounting face 1021 is made to emit light, the heat (heat flux) Q emitted by theLED element 100 is transferred to the LEDelement mounting face 1021 of thebase plate 102 through a mounting part (not shown) of a bottom portion of theLED element 100. Subsequently, the heat Q transferred to the LEDelement mounting face 1021 is transferred (conducted) not only to theheat dissipating fins LED mounting face 1021 but also to thebottom face 1022 and theheat dissipating fins bottom face 1022 speedily (without delay) continuously with the respective heat dissipating surfaces described above and almost uniformly at a high level. For this reason, convection from the heat dissipating surfaces of these heat dissipating fins and, in particular, heat dissipation by radiation are performed uniformly at a given level or more, whereby the heat dissipation efficiency can be increased. - Here, as is specified by the present invention, in the
heat dissipating fins 103 to 106, the number of the heat dissipating fins extending in the same direction is specified to be two or less at an arbitrary section perpendicular to thefaces base plate 102 and hence theheat dissipating fins 103 to 106 do not overlap each other excessively in the same direction. Hence, the transferred heat Q is transmitted to the three dimensional directions of the x, y, z directions and is radiated speedily and efficiently to a closed space (heat dissipating space) around them from the surfaces of the LEDelement mounting face 1021 and thebottom face 1022 of thebase plate 102 and the respective heat dissipating surfaces of theheat dissipating fins 103 to 106. Hence, the heat emitted by theLED element 100 is dissipated in all directions of the three dimensional x, y, z directions at a high radiation efficiency in which the amount of heat dissipation is more than a given value. The reasons are as follows: although theheat sink 101 of the present invention is small in the number of theheat dissipating fins 103 to 106, theheat sink 101 is large in a projected area in any direction of the x, y, z directions also in a closed heat dissipating space in a lighting device in which the efficiency of heat dissipation is controlled by heat radiation and in which the convection of air is little caused. Theheat sink 101 of the present invention has an excellent characteristic such that although theheat sink 101 has a simple structure in which the number of theheat dissipating fins 103 to 106 is small, theheat sink 101 is excellent in the heat dissipation efficiency per unit heat dissipation area. - Here, in the case of heat dissipation by radiation, which is required in a narrow space or a closed space of a housing for a vehicle-mounted lighting device, the sizes of the projected areas in the x-axis, y-axis, z-axis directions (three dimensional directions) shown in the respective drawings influence the heat radiation efficiency of the vehicle-mounted lighting device, that is, as the total of the projected areas becomes larger, the heat radiation efficiency becomes larger.
- In this point, in a heat sink in a conventional example shown in
FIG. 47 or aheat sink 4 of a comparative example, a projected area in the y direction becomes the total of the plane of abase plate part 2 and the upper planes offin parts 3 and thefin parts 3 do not overlap each other, so that the waste of material is eliminated and the projected area is made large. However, the projected area in the z direction becomes the total of the side faces of thebase plate part 2 and the side faces of thefin parts 3 and a projection plane is shaped like a comb and has many spaces and the projected area becomes a small area that is smaller than 50% of a total area acquired by multiplying the length of thebase plate part 2 by the height of thefin part 3. Further, a projected area in the x direction becomes the total of the front of thebase plate part 2 and the front of thefin part 3, and although fourfin parts 3 are formed, these four fin parts overlap each other and hence the projected area of thefin parts 3 becomes equal to the projected area of onefin part 3, which results in causing the waste of material and reducing the heat radiation efficiency per unit heat radiation area. That is, although many fins overlap each other and occupy the space in the x direction, the projected are is small and the heat radiation efficiency is low for a large spatial occupancy. In addition, since the number of the heat dissipating fins in the x direction is excessive, there is presented also the problem of increasing the waste of material and the weight of the heat sink. - In other words, in the conventional heat sink shown in
FIG. 47 and theheat sink 4 of the comparative example, the heat radiation efficiency in any of the x, y, z directions (three dimensional directions) inevitably becomes low. As a result, the heat radiation efficiency in any direction of the three dimensional directions cannot be increased and hence an integrated heat radiation efficiency is decreased. Further, the number of the heat dissipating fins becomes excessive in the x direction or the like and hence the waste of material becomes large. In other words, these conventional techniques are common to each other in that a heat sink cannot be produced which is little in the waste of material and is high in the heat radiation efficiency in any direction of the three dimensional directions of the heat sink for a small spatial occupancy. - Incidentally, Japanese Patent Application Laid-Open No. 2010-146817 is the same in this point, and the heat radiation efficiency is low for a high spatial occupancy in the direction in which the heat dissipating parts of many ladle parts, each of which is shaped like a letter C, overlap each other and the waste of material is large, in particular, in the x direction in terms of the integrated heat radiation efficiency in three directions of the three dimensional directions. Further, the slit-shaped opening described above is greatly limited in width so as to ensure the size of a heat sink itself and an area on the heat dissipating part side and hence is inevitably made narrow, so that in the case where the heat sink is applied to a closed space, an improvement in the heat dissipation efficiency by the convection of air cannot be actually made as large as desired.
- The heat sink of the present invention is most suitable in a usage (installation) state in which a heat dissipating space around the heat sink is closed and is small in volume and is little in the convection of air, that is, in a usage (installation) environment in which heat dissipation by the convection of air is hardly expected. In this usage environment, in order to dissipate heat, heat dissipation by radiation needs to be made main. However, in the heat conventional heat sink structure in which heat dissipation performance is mainly enhanced by an increase in the convection of air which is made by increasing the surface areas of the heat dissipating surfaces of the heat dissipating fins or the like, the heat dissipation by the radiation becomes insufficient and hence heat dissipation cannot be efficiently achieved as a whole. In contrast to this, in the heat sink of the present invention, heat dissipation is mainly done by the radiation of heat from the heat dissipating surfaces of the heat dissipating side surfaces, so that the heat sink of the present invention can be said to be the most suitable heat sink for the usage (setting) environment in which heat dissipation by the convection of air can be hardly expected.
- In addition, in the heat sink of the present invention, the respective heat dissipating surfaces including the LED
element mounting face 1021 and the heat dissipating fins are of an integral structure in which each of the heat dissipating surfaces does not have a joint face between the LEDelement mounting face 1021 and the heat dissipating fin and hence do not cause a contact heat resistance caused in the case where the LEDelement mounting face 1021 and the heat dissipating fins are separately manufactured and then joined to each other. For this reason, heat conduction can be easily developed between the LEDelement mounting face 1021 and the respective heat dissipating fins, which results in markedly increasing the heat dissipation performance of the whole heat sink. Further, the structure of theheat sink 101 is a structure such that the heat dissipating fins are directed to all directions of the x, y, z directions of the three dimensional directions and hence has high rigidity. For this reason, even in the case of usage in which the heat sink suffers vibrations, for example, in the vehicle-mounted lighting device or the like, the heat sink can hold a shape without using a special reinforcing member and can achieve a maintenance-free heat sink and a long life. - Common Items of the First Embodiment Including the Respective Modified Examples:
- The LED
element mounting face 1021 and thebottom face 1022 of thebase plate 102 and the respective heat dissipating surfaces of theheat dissipating fins 103 to 106, which have been described above, may have a space, a slit, or a partial shape for fixing a component formed in a portion thereof, according to the usage of theheat sink 101 and to a member to which theheat sink 101 is fixed, by cutting out a portion of the face and the surfaces or by three-dimensionally forming a depressed part, a projected part, or a stepped part in the surfaces. In addition, the heat dissipating side surfaces may have a portion thereof omitted or changed in shape according to the need of fixing the component and the like. - The
heat sink 101 of the present invention can achieve an excellent heat dissipation effect without complicating the shape and structure of the heat sink, in particular, the shape and structure of the heat dissipating fins and without increasing the number of the heat dissipating fins, on the contrary, by simplifying the structure and by decreasing the number of heat dissipating fins. As a result, various kinds of raw materials, various manufacturing methods, or various manufacturing processes can be selected and hence a heat sink easily manufactured at low cost can be provided. As the raw material can be selected from various kinds of raw materials, for example, aluminum (pure aluminum) or aluminum alloy, copper (pure copper) or copper alloy, a steel plate, resin, or ceramics, and manufacturing methods or manufacturing processes such as drawing or bending of a plate, die casting or casting, forging, or extruding can be selected. - (Aluminum)
- In this regard, aluminum (pure aluminum) or an aluminum alloy is desired as a raw material having strength, rigidity, lightness, corrosion resistance, heat transfer capability, heat dissipation capability, and workability which are characteristics require of the
heat sink 101. The aluminum (pure aluminum) or the aluminum alloy is especially large in heat transfer characteristics and heat dissipation characteristics required of the heat sink and pure aluminum of 1000 series specified by the AA standard or the JIS standards can be preferably used. - The plate thickness (thickness) of the
base plate 102 and the thicknesses of theheat dissipating fins 103 to 106 or a plate thickness (thickness) in the case where a raw material is a metal thin plate can be preferably selected from a range from 0.4 mm to 4 mm in consideration of a reduction in weight, required strength and rigidity, and drawing (forming) capability of the heat sink. When the plate thickness is too thin, the required strength and rigidity or the drawing (forming) capability of the heat sink cannot be ensured. On the other hand, when the plate thickness is too thick, the reduction in weight of the heat sink is sacrificed. - (Surface Emissivity of Heat Dissipating Surface)
- In order to make the heat sink of the present invention acquire high heat dissipation capability, the surface emissivity ε of the metal thin plate is desired to be 0.6 or more. For this reason, before drawing the metal thin plate, a pre-coating processing (coating) of paint of black, gray, or white, which is high in heat dissipation rate, may be applied to the entire surface of the metal thin plate of the raw material. Alternatively, after drawing the metal thin plate, a post-coating processing (coating) of the paint which is high in thermal emissivity may be applied to a drawn product. In this way, the amount of heat transfer by radiation as the heat sink can be increased. When the pre-coating processing is previously applied to the metal thin plate of the raw material before the drawing, the coating processing serves as a lubricant in the drawing.
- The surface emissivity ε is the ratio of the heat radiation of an actual body to a theoretical value (heat radiation of a black body of an ideal heat radiator) and an actual surface emissivity E may be measured by the method described in Japanese Patent Application Laid-Open No. 2002-234460 or may be measured by the use of a portable thermal emissivity measuring device on the market.
- (Mounting Heat Sink of Present Invention in Vehicle-Mounted Lamp)
- The mounting of the heat sink of the present invention in a vehicle-mounted LED lamp or the like can be performed in the same way as the mounting of a heat sink generally used, which is also an advantage of the heat sink of the present invention. Usually, the vehicle-mounted LED lamp (lighting device for a vehicle) includes an LED substrate having an LED element as a light source mounted thereon, a reflector for reflecting light from the LED to the front in the direction in which light is emitted, a housing for wrapping the LED substrate and the reflector, an outer lens for closing the open front end of the housing and made of a transparent material, and a heat sink arranged in thermal contact with the LED substrate. The reflector is formed of a resin material and has a parabolic reflecting surface having a focal point near the LED on the LED substrate. Here, the heat sink of the present invention is used as a heat sink arranged on the LED substrate or in thermal contact with the LED substrate. Even in this case, the heat sink of the present invention used for the vehicle-mounted LED lamp is greatly different from the conventional heat sink in the following point: that is, heat dissipation by the convection of air to which heat is transferred to air as in the case of the conventional heat sink is not main but heat dissipation by the thermal radiation of heat is main.
- The heat sinks of the respective shapes of the fifth modified example (inventive example) shown in
FIG. 6 corresponding toFIG. 1 , the first modified example shown inFIG. 2 , the conventional example shown inFIG. 47 , and the comparative example shown inFIG. 50 were actually manufactured, and each of the heat sinks was mounted with an LED element and had electric current applied thereto to thereby emit light and the temperature of the LED element was measured. The measurement results will be shown in Table 1. - The heat sinks of the respective shapes of the first modified example shown in
FIG. 2 , the conventional example shown inFIG. 47 , and the comparative example shown inFIG. 50 were manufactured by machining or cutting an extruded bar of aluminum of 1100 series of the JIS as a raw material. The heat sink of the inventive example shown inFIG. 6 corresponding toFIG. 1 was manufactured by press-forming the end portions of a cold-rolled plate made of aluminum of 1100 series of the JIS to bend the end portions into heat dissipating fins. - The rectangular shape of the base plate of each example was of the size of 100 mm (z direction)×100 mm (x direction)×
thickness 2 mm, and the rectangular shape of the heat dissipating fin was of the size of 70 mm (length in the z direction of the plate-shaped side surface)×30 mm (height in the y direction of the plate-shaped side surface)×thickness 2 mm, which was common to the respective examples. The distance between the heat dissipating fins parallel to each other of the inventive example, that is, between 103 and 103 on the left and right sides and between 104 and 104 on the upper and lower sides was 80 mm or more (the distance from the center of the LED element was 35 mm or more). The distance between the heat dissipating fins in the conventional example and the comparative example was 10 mm. The base plate and the heat dissipating fins had cationic resin coating electrodeposited on the surfaces in the respective examples, the cationic resin coating being commercially available and black. When a surface thermal emissivity was measured for all examples by the use of a commercially available portable thermal emissivity measuring device developed by Japan Aerospace Exploration Agency, the surface thermal emissivity was 0.85 for all examples. - In all examples, the base plate was mounted with a commercially available LED element and then the LED element had an electric current of 3.7 V×0.85 A applied thereto from a direct current power supply to thereby emit light. At this time, the heat sink was set hermetically in a cylindrical wooden case simulating the closed space of a vehicle-mounted LED lamp in which the convection of air was not caused and having the size of 300 mm×300 mm×300 mm, and while monitoring the temperature of the LED element with a thermocouple, the LED element was made to emit light in the atmosphere set at a temperature of 20° C. After a given time passed, the temperature brought into a steady state in which the temperature was neither increased nor decreased was measured. The temperature was measured five times for each of the examples and an average value of the measured temperatures was found and evaluated.
- As shown in Table 1, in an inventive example 1 corresponding to the fifth modified example shown in
FIG. 6 corresponding toFIG. 1 and an inventive example 2 corresponding to the first modified example shown inFIG. 2 , even in the closed space of the vehicle-mounted LED lamp in which the convection of air is not caused, the temperature of the LED element in the steady state could be held at an extremely low temperature of 42° C. or less which is lower than 100° C. or less exemplified as the allowable temperature at which the light emission efficiency of the LED element is not decreased, so that it could be assured that the inventive examples 1,2 had an excellent heat dissipation performance (cooling performance) by the heat radiation. In this regard, naturally, the inventive example 2 shown inFIG. 2 , which had the heat dissipating fins of eight of a preferable upper limit, was more excellent in heat dissipation performance but was larger in weight than the inventive example 1 shown inFIG. 6 which had four heat dissipating fins, so that there was not much difference in terms of heat dissipation efficiency between the inventive example 2 and the inventive example 1. - On the other hand, in the heat sinks of the conventional example 1 shown in
FIG. 47 , the conventional example 2 similar to the conventional example 1, and the comparative example shown inFIG. 50 , the temperature of the LED element in the steady state was lower than 100° C. but was higher than the inventive examples, so that it could be assured that the heat sinks of the conventional examples 1, 2 and the comparative example were inferior to the inventive examples 1, 2 in the heat dissipation performance (cooling performance) by the heat radiation in the closed space of the vehicle-mounted LED lamp in which the convection of air was not caused. Here, in the bunch of tests, heat inputs from an engine, a heat exchanger, and various kinds of electric devices, which are thought when the heat sink is mounted in an actual vehicle, and a heat input from direct sunlight were not taken into account. For this reason, it is thought that the temperature of the LED element will be lower than the temperature of the LED element actually mounted in the vehicle (vehicle-mounted LED). However, the bunch of tests have sufficient accuracy and reproducibility in the performance comparison of the heat sinks. - The critical significance of the specifications, in particular, the number and the arrangement of the heat dissipating fins of the heat sink of the present invention can be supported by the facts described above.
-
TABLE 1 Number of heat Arrangement Average Corre- dissipating of heat temperature in spondence fins of base dissipating steady state Category to FIG. plate fins (° C.) Inventive FIG. 1 4 only on Perpendicular 37 example 1 one face to each other Inventive FIG. 2 a total of 8 Perpendicular 34 example 2 on both faces to each other Conventional FIG. 47 4 only on Parallel to 49 example 1 one face each other Conventional — 6 only on Parallel to 47 example 2 one face each other Comparative FIG. 50 a total of 8 Parallel to 43 example on both faces each other - As described above, in the heat sinks of the present invention, heat dissipation is done mainly by heat dissipation by heat radiation from the heat dissipating surfaces such as the heat dissipating side surfaces and the like, so that the heat sink of the present invention is most suitable for a narrow usage space (usage, setting environment) in which the convection of air is little caused (heat dissipation by the convection of air is hardly expected). For this reason, the heat sink of the present invention can be used as a heat dissipating component for a vehicular lighting device such as a vehicle-mounted LED lamp.
- In various exemplary embodiments, a heat sink for LED lighting according to the present invention includes: a base plate; a first heat-dissipating fin; and a second heat-dissipating fin. In some such embodiments: the base plate, the first fin, and the second fin are formed integrally from aluminum or an aluminum alloy; the base plate comprises a first surface suitable for mounting an LED element and a second surface opposite from the first surface; the first fin extends from the first surface or the second surface of the base plate; the second fin extends from the first surface or the second surface of the base plate; no more than one additional heat-dissipating fin extends from the surface of the base plate from which the first fin extends and is parallel or substantially parallel to the first fin; and no more than one additional heat-dissipating fin extends from the surface of the base plate from which the second fin extends and is parallel or substantially parallel to the second fin.
- In further exemplary embodiments, the heat sink according to the present invention includes: a third heat-dissipating fin; and a fourth heat-dissipating fin. In some such embodiments: the first fin is not parallel or substantially parallel to the second fin; the third fin is parallel or substantially parallel to the first fin; and the fourth fin is parallel or substantially parallel to the second fin.
- In further exemplary embodiments, in the heat sink according to the present invention, each of the first fin, the second fin, the third fin, and the fourth fin extends from the first surface of the base plate.
- In further exemplary embodiments, in the heat sink according to the present invention: the heat sink is formed by bending a blank of the aluminum or aluminum alloy; and each of the first fin, the second fin, the third fin, and the fourth fin is formed by bending the blank such that the base plate joins each of the first fin, the second fin, the third fin, and the fourth fin at a location of a respective bend.
- In further exemplary embodiments, the heat sink according to the present invention includes: a fifth heat-dissipating fin; a sixth heat-dissipating fin; a seventh heat-dissipating fin; and an eighth heat-dissipating fin. In some such embodiments: each of the fifth fin, the sixth fin, the seventh fin, and the eighth fin extends from the second surface of the base plate; the fifth fin is not parallel or substantially parallel to the sixth fin; the seventh fin is parallel or substantially parallel to the fifth fin; and the eighth fin is parallel or substantially parallel to the sixth fin.
- In further exemplary embodiments, in the heat sink according to the present invention, each of the first fin, the second fin, the third fin, and the fourth fin extends from the second surface of the base plate.
- In further exemplary embodiments, the heat sink according to the present invention includes: a third heat-dissipating fin; a fourth heat-dissipating fin; and a fifth heat-dissipating fin. In some such embodiments, each of the first fin, the third fin, and the fourth fin extends from the first surface of the base plate; each of the second fin and the fifth fin extends from the second surface of the base plate; the first fin is not parallel or substantially parallel to the second fin; the third fin is parallel or substantially parallel to the first fin; the fourth fin is not parallel or substantially parallel to the first fin; and the fifth fin is parallel or substantially parallel to the second fin.
- In further exemplary embodiments, the heat sink according to the present invention includes: a third heat-dissipating fin; and a fourth heat-dissipating fin. In some such embodiments: each of the first fin and the third fin extends from the first surface of the base plate; each of the second fin and the fourth fin extends from the second surface of the base plate; the first fin is parallel or substantially parallel to the second fin; the third fin is parallel or substantially parallel to the first fin; and the fourth fin is parallel or substantially parallel to the second fin.
- In further exemplary embodiments, in the heat sink according to the present invention: each of the first fin and the third fin extends from the first surface of the base plate; and each of the second fin and the fourth fin extends from the second surface of the base plate.
- In further exemplary embodiments, in the heat sink according to the present invention: the heat sink is formed by bending a blank of the aluminum or aluminum alloy; and each of the first fin, the second fin, the third fin, and the fourth fin is formed by bending the blank such that the base plate joins each of the first fin, the second fin, the third fin, and the fourth fin at a location of a respective bend.
-
FIG. 8 shows aheat sink 201 for LED lighting of a second embodiment. Theheat sink 201 for LED lighting is theheat sink 201 for LED lighting made of plate-shaped aluminum material and is integrally formed by bending ablank material 241 made of aluminum and is characterized by including a steppedbase plate part 202 in which ahorizontal plane part 211 and verticalfront parts LED mounting part 203 formed on the surface of thehorizontal plane part 211 and/or the verticalfront parts base plate part 202. Of these parts, thehorizontal plane part 211 constructs a mounting face part of the present invention and the verticalfront parts side surface parts 231 to 236 construct a second fin part of the present invention - Specifically, the
heat sink 201, as shown inFIG. 8 , is constructed of thebase plate part 202 formed of a plate-shaped aluminum (including aluminum alloy) material having a given uniform thickness and having a stepped shape as a whole. That is, thebase plate part 202 has a shape (structure) in which the horizontal plane part and the vertical plane parts are integrally formed at right angle, in more detail, thevertical plane part 221, thehorizontal plane part 211 and thevertical plane part 222, each of which has a same rectangular shape, are alternately formed continuously with each other in this order from the top portion of the stepped shape. TheLED mounting part 203 is mounted in a bulging manner at the center of the surface of thehorizontal plane part 211 of the base plate part. - The
base plate part 202 of theheat sink 201 has aside plate part 204 further formed integrally with the end portions on both sides thereof, theside plate part 204 being vertical to thebase plate part 202. That is, the verticalfront part 221 on the top of thebase plate part 202 has avertical side part 231 and avertical side part 232 which are continuously arranged on both sides of and at right angles with the verticalfront part 221 in such a way as to extend backward. Further, thehorizontal plane part 211 of thebase plate part 202 has avertical side part 233 and avertical side part 234 which are continuously arranged on both sides of and at right angles with thehorizontal plane part 211 in such a way as to extend downward. Still further, the verticalfront part 222 on the bottom of thebase plate part 202 has avertical side part 235 and avertical side part 236 which are continuously arranged on both sides of and at right angles with the verticalfront part 222 in such a way as to extend forward. - Depending on the whole size of the
heat sink 201, it is generally desired that the thickness of thebase plate part 202 and theside plate part 204 constructing theheat sink 201 is 0.5 to 5 mm from the viewpoint of rigidity, heat dissipation capability, and weight reduction. - In this regard, although the aluminum material is not limited to a special kind of aluminum, it is desired to use pure aluminum of JIS 1000 series, aluminum alloy of JIS 3000 series, and aluminum alloy of JIS 5000 series, which are excellent in thermal conductivity and formability.
- A method for manufacturing the
heat sink 201 of the second embodiment will be described below on the basis ofFIG. 9 . - First, one blank 241 which corresponds to a plane shape of a development view matching the three dimensional shape of the
heat sink 201 shown inFIG. 8 is acquired by punching a plate-shapedaluminum coil material 240 produced by rolling, as shown in an upper figure ofFIG. 9 . The blank 241, as shown in a lower figure ofFIG. 9 , has a rectangular shape as a whole and hascutouts 242 at two portions respectively on both sides, that is, at a total of four portions. Thecutouts 242 are made at positions at which the length of the blank 241 is trisected, and each of thecutouts 242 is made in the shape of a belt extending from an end on the long side of the blank 241 to the center of the blank 241, and thecutouts 242 extend in parallel to each other. Here, in place of thealuminum coil material 240, a sheet material produced by rolling may be used. - Next, the LED
element mounting part 203, which is formed in a rectangular parallelepiped bulged upward, is formed at the center position of the surface of the blank 241 by coining. - Next, the respective parts of the blank 241 are bent. In the lower figure of
FIG. 9 , the same reference numerals as the reference numerals corresponding to the names of the respective parts constructing the three-dimensional shape of theheat sink 201 shown inFIG. 8 are shown in respective sections of the plane of the blank 241. Thereference numeral 202 designates the base plate part and thereference numerals 204 designate the side plate parts. The broken lines are the boundary lines of the respective continuous parts and show the bend lines (fold lines) when the blank 241 is bent. - First, a 221 face part of the blank 241 is bent up integrally with a 231 face part and a 232 face part at a right angle with a center on a
bend line 243 of a boundary with a 211 face part, and a 222 face part is bent down integrally with a 235 face part and a 236 face part at a right angle with a center on thebend line 243 of a boundary with the 211 face part. In this way, there is formed thebase plate part 202, shown inFIG. 8 , in which the verticalfront part 221 of the top, thehorizontal plane part 211 of the middle, and the verticalfront part 222 of the bottom are continuous with each other in the stepped shape. Next, the 231 face part and the 232 face part are bent back (down inFIG. 9 ) at a right angle respectively with centers on thebend lines 243 of the boundaries with the 221 face part. In this way, thevertical side part 231 and thevertical side part 232 continuous with the verticalfront part 221 shown inFIG. 8 are formed at the end portions on both sides of the verticalfront part 221. Next, the 235 face part and the 236 face part are bent forth (down inFIG. 9 ) at a right angle respectively with centers on thebend lines 243 of the boundaries with the 222 face part. In this way, thevertical side part 235 and thevertical side part 236 continuous with the verticalfront part 222 shown inFIG. 8 are formed at the end portions on both sides of the verticalfront part 222. Still further, a 233 face part and a 234 face part are bent down at a right angle with centers on thebend lines 243 of the boundaries with the 211 face part. In this way, thevertical side part 233 and thevertical side part 234 continuous with thehorizontal plane part 211 shown inFIG. 8 are formed at the end portions on both sides of thehorizontal plane part 211. - The manufacturing of the
heat sink 201 for LED lighting of the embodiment shown inFIG. 8 is finished by bending the blank 241 in the manner described above. In this regard, the order of bending the respective parts in the bending process of the blank 241 for manufacturing theheat sink 201 of the present embodiment is not especially limited to the method described above. Even if the order of bending processes is interchanged as appropriate, thepresent heat sink 201 can be manufactured in the same way. - In this way, the
heat sink 201 for LED lighting of the embodiment shown inFIG. 8 can be easily manufactured only by punching, coining, and bending the raw material of the aluminum plate produced by working such as rolling. Further, theheat sink 201 has the combined structure of the thin plate and hence is very light and has sufficient rigidity. Still further, as compared with a conventional heat sink manufactured by die casting, theheat sink 201 can be greatly reduced in the manufacturing cost. - Next, the principle and function of heat dissipation in the case where the
heat sink 201 according to the present invention is set in a closed space in which the convection of air is not caused and where the LED lighting is done will be described with reference toFIG. 10 by taking the embodiment shown inFIG. 8 as an example. Here, the directions in which the heat Q is emitted from the respective parts are denoted by arrows and a surrounding closed space is denoted by S. - First, when the LED element mounted on the LED
element mounting part 203 of thehorizontal plane part 211 is made to emit light, heat generated by the LED element is transferred to thehorizontal plane part 211 through the LEDelement mounting part 203. Subsequently, the heat transferred to thehorizontal plane part 211 is conducted to the verticalfront parts vertical side parts horizontal plane part 211 is radiated in directions at right angles with the horizontal plane part 211 (an arrow of the heat Q radiated from the bottom surface in the up and down direction in the drawing will be omitted), that is, into the surrounding closed space S (heat dissipation space) from the top and bottom surfaces of thehorizontal plane part 211. Further, the heat Q conducted to the verticalfront parts front parts 221, 222 (arrows of the heat Q radiated from the bottom surfaces of the verticalfront part 222 in the back and forth directions in the drawing will be omitted), that is, into the surrounding closed space S from the top and bottom surfaces of the verticalfront parts vertical side parts vertical side parts 233, 234 (arrows of the heat Q radiated from the bottom surfaces of thevertical side parts vertical side parts - On the other hand, a part of the heat Q conducted to the vertical
front part 221 is conducted to thevertical side parts vertical side parts 231, 232 (in the right and left directions in the drawing), that is, into the surrounding closed space S from the top and bottom surfaces of thevertical side parts front part 222 is conducted to thevertical side parts vertical side parts 235, 236 (in the right and left directions in the drawing), that is, into the surrounding closed space S from the top and bottom surfaces of thevertical side parts - In this regard, in the
vertical side parts 231 to 236, thevertical side parts vertical side parts 231 to 236 are smaller in heat dissipation by heat radiation than thehorizontal plane part 211 and the verticalfront parts vertical side parts vertical side part 231 and the heat Q from the top face (left face in the drawing) of thevertical side part 232 are directly radiated in the directions at right angles with thevertical side parts vertical side part 231 from the bottom face (left face in the drawing) of thevertical side part 231 and the heat Q radiated in the direction at a right angle with thevertical side part 232 from the bottom face (right face in the drawing) of thevertical side part 232 pass each other; so that thevertical side parts - In this way, the
heat sink 201 shown inFIG. 8 is formed of the steppedbase plate part 202 in which thehorizontal plane part 211 and the verticalfront parts vertical side parts 231 to 236 on both side ends of thebase plate part 202. Hence, it can be understood that since theheat sink 201 shown inFIG. 8 has very large projected areas in the x, y, z directions, that is, in the three dimensional directions, theheat sink 201 has a high heat radiation efficiency and an excellent heat dissipation capability even in the closed heat dissipation space in which the heat dissipation efficiency is subjected mainly to heat radiation and in which the convection of air is hardly caused. - Next, a first modified example of the second embodiment will be described which is common to the second embodiment shown in
FIG. 8 in the whole shape. The heat sink itself of the first modified example of the second embodiment, although not illustrated, is different from the second embodiment shown inFIG. 8 only in the thicknesses of the stepped base plate part 202 (horizontal plane part 211, the verticalfront part 221 and the vertical front part 222) shown inFIG. 8 and the vertical side parts (231, 232, 233, 234, 235, 236) formed on the end portions on both sides of thebase plate part 202 and is absolutely same as the second embodiment shown inFIG. 8 in the other portions. - The first modified example of the second embodiment will be specifically described with reference to
FIG. 11 showing the shape of a blank after a coining process. - A blank 241 is a blank which has a rectangular shape as a whole and which has two cutouts respectively on both side portions thereof, that is, a total of four
cutouts 242 and which includes abase plate part 202 formed in the center portion and having a thick thickness andside parts 204 formed on both sides and having a thin thickness, that is, a blank whose thickness is varied in a width direction. - When describing a method for manufacturing the blank 241, two kinds of plate-shaped aluminum coil materials produced by rolling and having different thicknesses are prepared, and one thick plate and one thin plate which are acquired by punching or cutting the respective plate-shaped aluminum coil materials are welded to each other, thereby being integrated. A
reference numeral 244 designates welded bead portions. Then,cutouts 242 extending in parallel to each other in the shape of a belt from an end side to a center side in a given length are made in the integrated aluminum plate at the positions at which the length is trisected. - By bending the blank 241 in the manner described in the second embodiment, a
heat sink 201 according to the first modified example of the second embodiment can be easily manufactured. Theheat sink 201 according to the first modified example of the second embodiment has the same three-dimensional shape as shown inFIG. 8 but is characterized in that the thickness of thebase plate part 202 constructing a stepped shape (that is, the verticalfront part 221, thehorizontal plane part 211, and the vertical front part 222) is larger than the thickness of the side plate part 204 (that is,vertical side parts base plate part 202 is 0.5 to 5 mm and the thickness of theside part 204 is 0.25 to 2.5 mm. - According to the first modified example of the second example, as compared with the second embodiment shown in
FIG. 8 , the rigidity of the steppedbase plate part 202 of the backbone of theheat sink 201 can be further increased and at the same time the thermal conductivity can be held higher, whereby the heat dissipation capability can be further improved. - Next, a second modified example of the second embodiment which is common to the second embodiment shown in
FIG. 8 in the whole shape will be specifically described with reference toFIG. 12 showing the shape of a blank subjected to the coining process in the same way as described above. The blank 241 has a rectangular shape as a whole and has two cutouts respectively on both sides, that is, a total of four cutouts and includes a thickbase plate part 202 in the center andthin side parts 204 on both sides, so that the blank 241 is the same as the blank described above in the shape of the blank. However, the blank 241 is different from the above-mentioned integrated blank made by welding two kinds of plate-shaped aluminum coil materials having different thicknesses. - That is, the blank 241 is formed of an aluminum extruded material having the thick
base plate part 202 in the center and thethin side parts 204 on both sides. The blank 241 can be manufactured by extruding an aluminum material by the use of a die corresponding to this sectional shape and then by forming thecutouts 242. Further, by bending the blank 241 in the manner described in the second embodiment, theheat sink 201 according to the second modified example of the second embodiment can be manufactured in the same way. - The
heat sink 201 of the second modified example of the second embodiment, as compared with the second embodiment shown inFIG. 8 , can further increase the rigidity of the steppedbase plate part 202 of the backbone of theheat sink 201 and at the same time can hold the thermal conductivity higher and can further enhance the heat dissipation capability. In addition, the blank 241, which is uniform in quality and is different in thickness in the width direction, can be manufactured not by the punching process and the welding process but by the extruding process, so that the process of manufacturing theheat sink 201 can be further simplified as compared with the process shown inFIG. 9 . - The heat sink shown in
FIG. 8 is a mode showing a basic whole shape and the second embodiment is not limited to this mode. For example, although the heat sink shown inFIG. 8 has a one-stepped shape constructed of three plane parts of the upper and lower verticalfront parts horizontal plane part 211 formed between the verticalfront parts FIG. 8 , all of thehorizontal plane part 211 and the verticalfront parts horizontal plane part 211 and the verticalfront parts horizontal plane part 211 and the verticalfront parts horizontal plane part 211 and the verticalfront parts - Further, in
FIG. 8 is shown the heat sink having the verticalfront part 221, thehorizontal plane part 211, and the verticalfront part 222 which have thevertical side parts vertical side parts vertical side parts vertical side parts vertical side parts vertical side parts - Next, a third modified example of the second embodiment which is different from the second embodiment shown in
FIG. 8 in the whole shape will be described with reference toFIG. 13 . - Here, a heat sink for LED lighting of the third modified example of the second embodiment is constructed of a
base plate part 202 which is formed of a plate-shaped aluminum (including aluminum alloy) having a given uniform thickness and which is formed in the stepped shape as a whole, as is the case with the second embodiment shown inFIG. 8 . A first different point from the second embodiment shown inFIG. 8 is that thebase plate part 202 further has ahorizontal plane part 212 arranged continuously backward on the top of the verticalfront part 221 at a right angle with the verticalfront part 221, in other words, is formed in a two-stepped shape. - Next, the heat sink of the third modified example of the second embodiment is greatly different from the heat sink shown in
FIG. 8 in the structure of theside plate parts 204 formed at both side ends of thebase plate part 202. Ahorizontal plane part 212 hasvertical side parts vertical side parts horizontal plane part 212. Further, the verticalfront part 221 hasvertical side parts vertical side parts horizontal plane part 211 at right angle with thehorizontal plane part 211. Still further, thehorizontal plane part 211 hasvertical side parts vertical side parts horizontal plane part 211. - Still further, the
vertical side parts flange parts flange parts vertical side parts vertical side parts flange parts flange parts vertical side parts 235, 236 (rear side portions) respectively in such a way as to be in outer contact with the surfaces. - A method for manufacturing the
heat sink 201 of the third modified example of the second embodiment will be described below on the basis ofFIG. 14 . - First, one blank 241 which corresponds to a plane shape of a development view matching the three-dimensional shape of the
heat sink 201 shown inFIG. 13 is acquired by punching a plate-shapedaluminum coil material 240 produced by rolling is punched as shown in an upper figure ofFIG. 14 . The blank 241, as shown in a lower figure ofFIG. 14 , has a shape of a letter T as a whole and has a total of sixcutouts 2421 to 2423 in the perimeter thereof. That is, the blank 241 hascutouts 2421 at one position respectively on both lower sides (both near sides in the drawing) of ahead part 241 a thereof and hascutouts 2422, 2433 at two positions respectively on both sides of abody part 241 b. Thecutout 2421 is formed in the shape of a two-stepped key, thecutout 2422 is formed in the shape of a belt, and the cutout 2433 is formed in the shape of a one-stepped key. - Next, an LED
element mounting part 203, which is formed in a rectangular parallelepiped and is bulged upward, is formed at the center position of the surface of the blank 241 by the coining process. - Next, the respective parts of the blank 241 are bent. In the lower figure of
FIG. 14 , the same reference numerals as the reference numerals corresponding to the names of the respective parts constructing the three-dimensional shape of theheat sink 201 shown inFIG. 13 are shown in respective partitions of the plane of the blank 241. Thereference numeral 202 designates the base plate part and thereference numeral 204 designates the side plate part. The broken lines are the boundary lines of the respective continuous parts and show the bend lines (fold lines) when the blank 241 is bent. - First, a 221 face part of the blank 241 is bent up with a 2331 face part, a 2332 face part, a 212 face part, a 231 face part, and a 232 face part at a right angle with a center on the
bend line 243 of a boundary with a 211 face part. Further, a 222 face part is bent down integrally with a 235 face part and a 236 face part at a right angle with a center on thebend line 243 of a boundary with the 211 face part. Still further, the 212 face part is bent down (down inFIG. 14 ) integrally with the 231 face part and the 232 face part at a right angle with a center on thebend line 243 of a boundary with the 221 face part. In this way, thebase plate part 202 is formed in which thehorizontal plane part 212, the verticalfront part 221, thehorizontal plane part 211, and the verticalfront part 222 are continuously formed one after the other in this order in the stepped shape from the top inFIG. 13 . - After the stepped
base plate part 202 is formed, the 235 face part and the 236 face part are bent forth (up inFIG. 14 ) with a center on thebend line 243 of a boundary with the 235 face part and with a center on thebend line 243 of a boundary with the 236 face part, respectively, whereby thevertical side part 235 and thevertical side part 236 which are continuous with the verticalfront part 222 shown inFIG. 13 are formed on both side ends of the verticalfront part 222. Next, a 2333 face part and a 2334 face part are bent down with a center on thebend line 243 of a boundary with the 211 face part and with a center on thebend line 243 of a boundary with the 211 face part, respectively, whereby thevertical side part 2333 and thevertical side part 2334 which are continuous with thehorizontal plane part 211 shown inFIG. 13 are formed on both side ends of thehorizontal plane part 211. - By forming the blank 241 in this way, the overlapping
flange parts 253 of the 2333 face part and the 2334 face part overlap the surfaces of the 235 face part and the 236 face part and are bonded to the surfaces, respectively. That is, as shown inFIG. 13 , the overlappingflange parts 253 of thevertical side part 2333 and thevertical side parts 2334 cover portions (rear portions) of thevertical side part 235 and thevertical side part 236 and are bonded to the portions, respectively, whereby these portions are formed in a double structure. - Next, the 2331 face part and the 2332 face part are bent forth (up in
FIG. 14 ) at a right angle with a center on thebend line 243 of a boundary with the 221 face part and with a center on thebend line 243 of a boundary with the 221 face part, respectively, whereby thevertical side part 2331 and thevertical side part 2332 which are continuous with the verticalfront part 221 shown inFIG. 13 are formed on both side ends of the verticalfront part 221. - Subsequently, the 231 face part and the 232 face part are bent down at a right angle with a center on the
bending line 243 of a boundary with the 212 face part and with a center on thebending line 243 of a boundary with the 212 face part, respectively, whereby thevertical side part 231 and thevertical side part 232 which are continuous with thehorizontal plane part 212 shown inFIG. 13 are formed on both side ends of thehorizontal plane part 212. - By forming the blank 241 in this way, the overlapping
flange parts 251 of the 231 face part and the 232 face part are overlaid on the 2331 face part and the 2332 face part in contact with the surfaces thereof, whereas the overlappingflange parts 252 of the 231 face part and the 232 face part are overlaid on the 2333 face part and the 2334 face part in contact with the surfaces thereof. In other words, as shown inFIG. 13 , the upper overlappingflange parts 251 of thevertical side part 231 and thevertical side part 232 cover portions (rear portions) of thevertical side part 2331 and thevertical side part 2332 and are overlaid on the portions, whereas the lower overlappingflange portions 252 of thevertical side part 231 and thevertical side part 232 cover portions (rear portions) of thevertical side part 2333 and thevertical side part 2334 and are overlaid on the portions. In this way, all of these flange parts are formed in the double structure. - By bending the blank 241 in the above-mentioned way, the manufacturing of the
heat sink 201 for LED lighting of the third modified example of the second embodiment shown inFIG. 13 is finished. The order of working processes of the respective parts in the bending process of the blank 241 for manufacturing theheat sink 201 is not especially limited to the method described above, as is the case with the second embodiment shown inFIG. 8 . However, in the case of the third modified example of the second embodiment is more complicated than the heat sink shown inFIG. 8 , so that in order to prevent the respective parts from interfering with each other at the time of bending the respective parts, it is necessary to pay attention to the order of working processes: for example, a vertical side part having the overlapping flange part is bent after a vertical side part to be bonded thereto is bent. - According to the third modified example of the second embodiment, as compared with the heat sink of the second embodiment shown in
FIG. 8 , a heat sink of the third modified example is additionally provided with thehorizontal plane part 212, thevertical side parts vertical side part flange parts 251 to 253 are formed on thevertical side parts vertical side pat FIG. 8 and hence can enhance strength, durability, and stability. - In this regard, the third modified example of the second embodiment is an example in which the vertical side parts are overlaid on each other via the overlapping flange parts. However, not only this structure but also a structure such that the vertical side parts and the horizontal plane parts and/or the vertical front parts of the
base plate part 202 are overlaid on each other can be also employed. - Further, in the double structure parts of the vertical side parts in the third modified example of the second embodiment, the double materials may be integrally bonded to each other by the use of a bonding method such as screw fastening, rivet fastening, swage fastening, welding, or soldering, whereby the rigidity of the heat sink can be greatly increased.
- In various exemplary embodiments, the heat sink for LED lighting according to the present invention includes: a base plate; a first heat-dissipating fin; and a second heat-dissipating fin. In some such embodiments: the base plate, the first fin, and the second fin are formed integrally from aluminum or an aluminum alloy; the base plate comprises a first surface suitable for mounting an LED element and a second surface opposite from the first surface; the first fin comprises a first surface and a second surface opposite from the first surface; the first fin extends from the first surface or the second surface of the base plate; and the second fin extends from the first surface or the second surface of the first fin.
- In further exemplary embodiments, the heat sink according to the present invention includes: a third heat-dissipating fin; a fourth heat-dissipating fin; a fifth heat-dissipating fin; a sixth heat-dissipating fin; a seventh heat-dissipating fin; and an eighth heat-dissipating fin. In some such embodiments: the first fin extends from the first surface of the base plate; the second fin extends from the second surface of the first fin; the third fin extends from the second surface of the first fin; the fourth fin extends from the second surface of the base plate; the fifth fin extends from the second surface of the base plate; the sixth fin comprises a first surface and a second surface opposite from the first surface; the sixth fin extends from the second surface of the base plate; the seventh fin extends from the first surface of the sixth fin; and the eighth fin extends from the first surface of the sixth fin.
- In further exemplary embodiments, in the heat sink according to the present invention: the heat sink is formed by bending a blank of the aluminum or aluminum alloy; each of the first fin, the fourth fin, the fifth fin, and the sixth fin is formed by bending the blank such that the base plate joins each of the first fin, the fourth fin, the fifth fin, and the sixth fin at a location of a respective bend; each of the second fin and the third fin is formed by bending the blank such that the first fin joins each of the second fin and the third at a location of a respective bend; and each of the seventh fin and the eighth fin is formed by bending the blank such that the sixth fin joins each of the seventh fin and the eighth fin at a location of a respective bend.
- In further exemplary embodiments, in the heat sink according to the present invention, the blank comprises a thick portion corresponding to the base plate, the first fin, and the sixth fin and a thin portion corresponding to corresponding to the second fin, the third fin, the fourth fin, the fifth fin, the seventh fin, and the eighth fin.
- In further exemplary embodiments, in the heat sink according to the present invention, the blank is prepared by welding sheets of the aluminum or aluminum alloy.
- In further exemplary embodiments, in the heat sink according to the present invention, the blank is prepared by coining.
- In further exemplary embodiments, the heat sink according to the present invention includes: a third heat-dissipating fin; a fourth heat-dissipating fin; a fifth heat-dissipating fin; a sixth heat-dissipating fin; a seventh heat-dissipating fin; an eighth heat-dissipating fin; a ninth heat-dissipating fin; a tenth heat-dissipating fin; and an eleventh heat-dissipating fin. In some such embodiments: the first fin extends from the first surface of the base plate; the second fin comprises a first surface and a second surface opposite from the first surface; the second fin extends from the second surface of the first fin; the third fin extends from the first surface of the first fin; the fourth fin extends from the first surface of the first fin; the fifth fin extends from the second surface of the surface of the second fin; the sixth fin extends from the second surface of the surface of the second fin; the seventh fin extends from the second surface of the base plate; the eighth fin extends from the second surface of the base plate; the ninth fin comprises a first surface and a second surface opposite from the first surface; the ninth fin extends from the second surface of the base plate; the tenth fin extends from the first surface of the ninth fin; and the eleventh fin extends from the first surface of the ninth fin.
- In further exemplary embodiments, in the heat sink according to the present invention: a portion of the fifth fin overlaps and contacts a portion of the fourth fin; a portion of the fifth fin overlaps and contacts a portion of the seventh fin; a portion of the sixth fin overlaps and contacts a portion of the third fin; a portion of the sixth fin overlaps and contacts a portion of the eighth fin; a portion of the seventh fin overlaps and contacts a portion of the eleventh fin; and a portion of the eighth fin overlaps and contacts a portion of the tenth fin.
- In further exemplary embodiments, in the heat sink according to the present invention: the heat sink is formed by bending a blank of the aluminum or aluminum alloy; each of the first fin, the seventh fin, the eighth fin, and the ninth fin is formed by bending the blank such that the base plate joins each of the first fin, the seventh fin, the eighth fin, and the ninth fin at a location of a respective bend; each of the second fin, the third fin, and the fourth fin is formed by bending the blank such that the first fin joins each of the second fin, the third fin, and the fourth fin at a location of a respective bend; each of the fifth fin and the sixth fin is formed by bending the blank such that the second fin joins each of the fifth fin and the sixth fin at a location of a respective bend; and each of the tenth fin and the eleventh fin is formed by bending the blank such that the ninth fin joins each of the tenth fin and the eleventh fin at a location of a respective bend.
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FIG. 15 shows aheat sink 301 for LED lighting of a third embodiment. Theheat sink 301 for LED lighting is theheat sink 301 for LED lighting formed of analuminum plate 302 and is characterized by including a stepped shape such thathorizontal plan parts front parts LED element 300 is mounted on the surface of the horizontal plane part and/or the vertical front part. Of these parts, thehorizontal plane part 312 constructs a mounting face part of the present invention and the verticalfront parts vertical side parts 331 to 338 to be described later construct a second fin part. - Specifically, the
heat sink 301 of the third embodiment, as shown inFIG. 15 , is formed of an aluminum (including aluminum alloy)plate 302 having a given thickness and has a stepped shape as a whole. That is, in the case of theheat sink 301 shown inFIG. 15 , theheat sink 301 is formed of thealuminum plate 302 and has a whole basis shape formed in a two-stepped shape. In other words, in the case of theheat sink 301 shown inFIG. 15 , theheat sink 301 is formed in the two-stepped shape and is formed in a shape (structure) in which horizontal plane parts and vertical front parts, which meet each other at a right angle, are continuously formed one after the other from the top portion of a step in the order of ahorizontal plane part 311, a verticalfront part 321, ahorizontal plane part 312, and a verticalfront part 322. - Each of the
horizontal plane parts front parts aluminum plate 302 forming the stepped shape and a short side of a width acquired by dividing the length of thealuminum plate 302 into equal quarters. - A
reference numeral 300 designates an LED element mounted on the center of thehorizontal plane part 312. - Of the horizontal plane parts and the vertical front parts, the
horizontal plane part 312 and the verticalfront part 321 havevertical side parts vertical side parts horizontal plane parts front parts - Next, the principle and function of heat dissipation in the case where the
heat sink 301 having such a stepped shape is set in a space in which the convection of air is not caused and where LED lighting is done will be described. When theLED element 300 mounted on thehorizontal plane part 312 is made to emit light, the heat generated by theLED element 300 is conducted to thehorizontal plane part 312 through a part having theLED element 300 mounted thereon. Subsequently, the heat conducted to thehorizontal plane part 312 is conducted to the verticalfront part 321, the verticalfront part 322, and thevertical side parts horizontal plane part 312 is conducted to the two or more vertical front parts or the vertical side parts which are continuous with thehorizontal plane part 312. Then, the heat Q conducted to thehorizontal plane part 312 is radiated at right angles with the horizontal plane part 312 (up and down directions inFIG. 15 ) into the surrounding closed space (heat dissipation space) S from the whole top and bottom surfaces of thehorizontal plane part 312, and the heat Q conducted to the verticalfront part 321 is radiated at a right angle with the vertical from part 321 (left and right directions inFIG. 15 ) into the surrounding closed space S from the whole top and bottom surfaces of the verticalfront part 321, and the heat Q conducted to thevertical side parts vertical side parts 331, 332 (right and left directions inFIG. 16 ) into the surrounding closed space S from the whole surfaces of thevertical side parts FIG. 15 ) facing theLED element 300 of thevertical side part 331 and the side (right surface inFIG. 15 ) facing theLED element 300 of thevertical side part 332, but the heat dissipated to the left from thevertical side part 331 is absorbed by the right surface of thevertical side part 332 and the heat dissipated to the right from thevertical side part 332 is absorbed by the left surface of thevertical side part 331 and hence the heat dissipation by radiation from these both surfaces is a little. - Further, a portion of the heat Q conducted to the vertical
front part 321 is conducted to thehorizontal plane part 311 and is radiated at right angles with the horizontal plane part 311 (up and down directions inFIG. 15 ) into the surrounding closed space S from the whole top and bottom surfaces of thehorizontal plane part 311. Here, the heat conducted to thehorizontal plane part 312, the verticalfront part 321, thevertical plane part 322, thehorizontal plane part 311, and thevertical side parts - In this way, the heat sink having the stepped shape shown in
FIG. 15 and further having the vertical side parts on both sides of the horizontal plane part and the vertical front part constructing the stepped shape has a very large projected area in the x, y, z directions, that is, three dimensional directions. Hence, it can be understood that the heat sink has a high heat radiation efficiency and an excellent heat dissipation capability even in the closed heat dissipation space in which the efficiency of heat dissipation is subjected to radiation and in which the convection of air is not caused. The heat sink is excellent in heat dissipation efficiency per unit heat dissipation area and is formed in a simple structure. Still further, since the heat sink has two or more vertical front parts and vertical side parts which are continuous from thehorizontal plane part 312 mounted with the LED element, the heat generated by the LED element is conducted in many directions from the LED mounting surface and hence is speedily dissipated to accelerate heat radiation from the respective surfaces. Hence, the heat sink has an excellent heat dissipation capability. - Next, a method for manufacturing a heat sink formed in a shape shown in
FIG. 15 will be described. - First, a pure aluminum plate or an aluminum alloy plate (which is simply referred to as an aluminum plate in the present invention) having a given thickness is produced from a raw material of pure aluminum or aluminum alloy by rolling or the like. The aluminum plate produced has a length L of four times a short side of the rectangle of the horizontal plane part 311 (which is the same as the
horizontal plane part 312, and verticalfront parts 321 and 322) shown inFIG. 15 and a width W acquired by adding two times a side of a square of the vertical side part 331 (which is the same as the vertical side part 332) to a long side of the rectangle of thehorizontal plane part 311. - Next, of four rectangles acquired by dividing the aluminum plate, which is produced by the rolling and has a size of L×W, into four equal quarters in the length direction, three rectangles of the first, second, and fourth quarters except for the third quarter from an end have both side portions thereof cut off by a length corresponding to a side of the square of the vertical side part 331 (which is the same as the vertical side part 332). By cutting the aluminum plate in this way, an
aluminum plate 302 can be acquired which has three rectangles having a width (long side) corresponding to thehorizontal plane part 311 and the verticalfront parts vertical side part 331 and a side of thevertical side part 332 to a width of thehorizontal plane part 312. - In the
aluminum plate 302, a short-width rectangular part which is to be thehorizontal plane part 311 is bent at a right angle with a rectangular part which is to be the verticalfront part 321 with a center on a boundary with the rectangular part which is to be the verticalfront part 321; next, a same rectangular part which is to be thehorizontal plane part 312 is further bent on a side opposite to thehorizontal plane part 311 at a right angle with the rectangular part which is to be the verticalfront part 321 with a center on a boundary with the rectangular part which is to be the verticalfront part 321; subsequently, a same rectangular part which is to be the verticalfront part 322 is still further bent on a side opposite to a same rectangular part of the verticalfront part 321, which is bent, at a right angle with the same rectangular part of thehorizontal plane part 312 with a center on a boundary with the same rectangular part of thehorizontal plane part 312. In this way, a stepped shape of a base shape can be formed. - Then, finally, square parts of the
vertical side part 331 and thevertical side part 332 which are positioned on both sides in a width direction of a long-width rectangular part which is to be (thehorizontal plane part 312+thevertical side part 331+the vertical side part 332) is bent to the side of the face of the verticalfront part 321 at a right angle with the rectangular part of thehorizontal plane part 312 with a center on a boundary with thehorizontal plane part 312, respectively. In this way, theheat sink 301 of the present invention shown inFIG. 15 can be easily manufactured from the raw material of thealuminum plate 302 by the use of comparatively easy working processes of cutting and bending. - A method for manufacturing the
aluminum plate 302 has been described by taking the rolling method as an example. However, not only the rolling method but also other working method such as an extruding method can be used. - The
heat sink 301 shown inFIG. 15 is an embodiment showing a basic whole shape and the third embodiment is not limited to this embodiment. For example, the heat sink shown inFIG. 15 has a two-stepped shape but the heat sink may have three or more steps so as to increase a projected area to the heat dissipation space. Further, in the heat sink shown inFIG. 15 , thehorizontal plane parts front parts - Further, in
FIG. 15 is shown the heat sink having thevertical side parts horizontal plane part 312 and the verticalfront part 321. However, thevertical side parts vertical side parts horizontal plane part 312 and the verticalfront part 321 but may be formed on one side or both sides of thehorizontal plane part 312 and the verticalfront part 322 and on one side or both sides of thehorizontal plane part 311 and the verticalfront part 321. Still further, the vertical side parts may be vertically arranged on both side ends (or one side end) of any one of the horizontal plane parts and the vertical front parts, that is, may be vertically protruded up from the both side ends of thehorizontal plane part 311 shown inFIG. 15 and may be vertically protruded forth from the both side ends of the verticalfront part 322. - Still further, the
vertical side parts FIG. 15 , as described above, are formed by bending the rectangular aluminum plate including (thehorizontal plane part 312+thevertical side part 331+the vertical side part 332) in the same direction at right angles and are integral and continuous with thehorizontal plane part 312. Hence, thevertical side parts vertical side parts front part 321 forming a stepped main body in a state where the separate parts are arranged vertically on both side ends of the verticalfront part 321. - Further, in the heat sink shown in
FIG. 15 , the thickness of the aluminum plate forming therespective parts horizontal plane part 312 mounted with theLED element 300.FIG. 17 shows this example and is a section view of a part of thehorizontal plane part 312 on which theLED element 300 is mounted. - Here, the thickness of the
horizontal plane part 312 except for the part having theLED element 300 mounted thereon is the same as the thickness of theother parts LED element 300 mounted thereon has athicker part 3121 formed on the bottom side thereof in such a way as to bulge downward. In this way, by increasing the thickness of the part having theLED element 300 mounted thereon of thehorizontal plane part 312, a large amount of heat generated by thehorizontal plane part 312 at the time of lighting is speedily conducted to a surroundingthin part 3122 and is radiated into the upper and lower heat dissipation space from the whole top and bottom surfaces of thehorizontal plane part 312 and at the same time is conducted also to therespective face parts horizontal plane part 312 and is radiated also from these parts. Hence, the heat sink can further enhance the heat dissipation efficiency and can be easily manufactured in the case where the heat sink is formed in such a shape. - A setting state in the case where the above-mentioned
heat sink 301 for an LED light is applied to a headlight for an automobile will be described with reference toFIG. 18 toFIG. 21 .FIG. 18 is a perspective view to show a state where theheat sink 301 is set in the headlight,FIG. 19 is a section view taken along a line a-a inFIG. 18 ,FIG. 20 is a section view taken along a line b-b inFIG. 18 , andFIG. 21 is a section view taken along a line c-c inFIG. 18 . - Here, the
heat sink 301 is formed of thealuminum plate 302 and has a stepped (two-stepped) shape constructed of the verticalfront part 321, thehorizontal plane part 311, the verticalfront part 322, and thehorizontal plane part 312 in this order from the top and has thevertical side parts horizontal plane part 311 and the verticalfront part 322 and has thevertical side parts horizontal plane part 312 and the verticalfront part 322 and has thevertical side parts horizontal plane part 312 and the verticalfront part 322. Further, theheat sink 301 has thevertical side parts horizontal plane part 312 and hasvertical side parts front part 321. Here, thevertical side parts horizontal plane part 311 at a right angle and are flush with the side surfaces of ahousing 340, the extensions being extended to both sides of thehorizontal part 311, whereas thevertical side parts front part 322 at a right angle and are arranged in the state where the parts are overlaid on the outside surfaces of thehousing 340, the extensions being extended to both sides of the verticalfront part 322. Thevertical side parts horizontal plane part 312 at a right angle, the extensions being extended to both sides of thehorizontal plane part 312. Thevertical side parts vertical plane part 321 at a right angle, the extensions being extended to both sides of thevertical plane part 321. - A
reference numeral 300 designates an LED element of a light emitting source and theLED elements 300 are mounted on the upper faces of thehorizontal plane parts reference numeral 350 designates reflectors (which is omitted inFIG. 18 ) set on the insides of the verticalfront parts reference numeral 360 designates an outer lens. - The
heat sink 301 is set in thehousing 340 formed in the shape of a frame body, whose both sides have tope ends formed nearly in the shape of an arc and have bottom ends formed in the stepped shape and whose front portion has a curved opening corresponding to the shape of the arc, in the state where thehousing 340 is disposed on theheat sink 301 formed in the stepped shape. Thevertical side parts heat sink 301 integrated with thehousing 340 are fixed and supported by a fixing part (not shown) of a vehicle body. In the curved opening of thehousing 340 is fitted anouter lens 360 formed in the same shape as the curved opening and of transparent glass. - The respective outside surfaces of the vertical
front part 321, thehorizontal plane part 311, the verticalfront part 322, and thehorizontal plane part 312 of theheat sink 301 are opposed to the closed space S in a vehicle body and the inside surfaces and outside surfaces of thevertical side parts - In the case where the
LED element 300 is made to emit light and to do illumination as the headlight of the automobile in this setting state, the heat generated when theLED element 300 emits light is dissipated by radiation to the surrounding closed space (heat dissipation space) S opposite to these parts from the outside surfaces of theseface parts vertical side parts 331 to 338 on both side ends of these face parts. The heat is dissipated by the heat sink having a heat dissipating surface of a very large projected area in the three dimensional directions of the x, y, and z directions and having a high heat radiation efficiency and hence can be dissipated very effectively to a narrow space in which the convection of air is hardly caused. - In various exemplary embodiments, the heat sink for LED lighting according to the present invention includes: a base plate; a first heat-dissipating fin; and a second heat-dissipating fin. In some such embodiments: the base plate, the first fin, and the second fin are formed integrally from aluminum or an aluminum alloy; the base plate comprises a first surface suitable for mounting an LED element and a second surface opposite from the first surface; the first fin comprises a first surface and a second surface opposite from the first surface; the first fin extends from the first surface or the second surface of the base plate; and the second fin extends from the first surface or the second surface of the first fin.
- In further exemplary embodiments, the heat sink according to the present invention includes: a third heat-dissipating fin; a fourth heat-dissipating fin; and a fifth heat-dissipating fin. In some such embodiments: the first fin extends from the first surface of the base plate; the second fin extends from the second surface of the first fin; the third fin extends from the first surface of the base plate; the fourth fin extends from the first surface of the base plate; and the fifth fin extends from the second surface of the base plate.
- In further exemplary embodiments, in the heat sink according to the present invention: the heat sink is formed by bending a blank of the aluminum or aluminum alloy; each of the first fin, the fourth fin, the fifth fin, and the sixth fin is formed by bending the blank such that the base plate joins each of the first fin, the fourth fin, the fifth fin, and the sixth fin at a location of a respective bend; each of the second fin and the third fin is formed by bending the blank such that the first fin joins each of the second fin and the third at a location of a respective bend; and each of the seventh fin and the eighth fin is formed by bending the blank such that the sixth fin joins each of the seventh fin and the eighth fin at a location of a respective bend.
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FIG. 22 shows aheat sink 401 for LED lighting of a fourth embodiment. Theheat sink 401 for LED lighting is a heat sink for LED lighting formed of an aluminum extrusion material and is constructed of: abase plate part 402 having anLED light source 400 arranged and fixed on a front side thereof; and a plurality offin parts 403 arranged on the back side of thebase plate part 402 in such a way as to protrude in parallel to each other and separately from each other. Theheat sink 401 is characterized in that: of therespective fin parts 403, at least onefin part 403 has a portion thereof bent at a right angle from a finmain body 403 a, whereby the portion is made the finbent piece 403 b; and the finbent piece 403 b has a heat dissipating surface in a direction which is perpendicular to a heat dissipating surface of the finmain body 403 a and to a heat dissipating surface of thebase plate part 402. Of these parts, thebase plate part 402 constructs a mounting face part of the present invention and thefin part 403 and the finmain body 403 a construct a first fin part of the present invention and the finbent piece 403 b constructs a second fin part of the present invention. - Specifically, the
heat sink 401 for LED lighting of the fourth embodiment (hereinafter simply referred to as theheat sink 401 in some cases) is manufactured by applying a comparatively simple working such as cutting and bending to an aluminum extrusion material made by extruding an aluminum material which is excellent in thermal conductivity and formability, such as pure aluminum of JIS 1000 series and an aluminum alloy of JIS 6000 series. Further, theheat sink 401 may be manufactured by the use of other aluminum alloy material such as an aluminum alloy material of JIS 5000 series. A manufacturing method will be described later. - As shown in
FIG. 22 , theheat sink 401 of the fourth embodiment is constructed of: for example, thebase plate part 402 having the LEDlight source 400 arranged and fixed on the front side thereof (shown on the lower side inFIG. 22 ); and the plurality offin parts 403 arranged on the back side of thebase plate part 402 in such a way as to protrude in parallel to each other and separately from each other. Of thesefin parts 403, at least onefin part 403 has a portion thereof bent at a right angle from the finmain body 403 a, whereby the portion is made the finbent piece 403 b. Here, the LEDlight source 400 is formed by mounting a plurality of light emitting diode (LED) elements on a substrate based on an aluminum alloy. - The fin bent
piece 403 b has the heat dissipating surface in the direction which is perpendicular to the heat dissipating surface of the finmain body 403 a and to the heat dissipating surface of thebase plate part 402. That is, the heat dissipating surface of thebase plate part 402, the heat dissipating surface of the finmain body 403 a, and the heat dissipating surface of the finbent piece 403 b are directed in different directions (y-axis direction, x-axis direction, z-axis direction) which are perpendicular to each other. - A plan view, a front view, and a side view of the
heat sink 401 of the fourth embodiment will be shown inFIG. 23 , whereas a plan view, a front view, and a side view of aconventional heat sink 4 will be shown inFIG. 49 . It can be understood that in theheat sink 401 shown inFIG. 23 , a sufficient projected area can be ensured in the plan view, the front view, and the side view, but it is clear that in theheat sink 4 shown inFIG. 49 , a sufficient projected area cannot be ensured only in the front view. - In the fourth embodiment shown in
FIG. 22 , fourfin parts 403 are formed in parallel to each other on the back side of thebase plate part 402 in such a way as to protrude separately from each other, and of these fourfin parts 403, twofin parts 403 on both sides have both end portions thereof bent at a right angle from the finmain body 403 a toward both side edges of thebase plate part 402, respectively, whereby the both end portions are made the fin bentpieces 403 b. - The number and shape of these
fin parts 403 do not need to be the same as those of the embodiment shown inFIG. 22 . It is only necessary that the number of thefin parts 403 is plural, that is, at least two or more, and in the case where the number of thefin parts 403 is three or more, thefin parts 403 having the finbent piece 403 b formed thereon do not need to be twofin parts 402 on both sides. For example, as shown inFIG. 24( c), the finbent piece 403 b can be formed on thefin part 403 at the center. InFIG. 24 will be shown modified examples of theheat sink 401, the modified examples being formed in various shapes. - Next, a method for manufacturing the
heat sink 401 for LED lighting of the fourth embodiment will be simply described. As described above, theheat sink 401 for LED lighting according to the present invention is manufactured from the aluminum extrusion material formed by extruding a metal material, which is excellent in thermal conductivity and formability, such as pure aluminum of JIS 1000 series and aluminum alloy of JIS 6000 series. - For example, in the case where the
heat sink 401 shown inFIG. 22 is manufactured, first, an aluminum extrusion material (of the same shape as a conventional heat sink for LED lighting shown inFIG. 47 ) produced by the use of an extrusion process is prepared, and slits of a given depth are made in lower ends of both sides (portions in contact with the base plate part 402) of thefin parts 403 on both sides of the aluminum extrusion material, in other words, slits each having a given depth are made at a total of four lower edges of thefin parts 403 on both sides from both side ends. Next, the portions having the slits made therein of thefin parts 403 are bent at a right angle in both side-edge directions (outward directions) of thebase plate part 402, whereby the fin bentparts 403 b are formed. Here, a middle portion, which does not have a slit made in lower edge thereof and is not bent, of thefin part 403 becomes the finmain body 403 a. - The
heat sink 401 for LED lighting described above is used as theheat sink 401 for vehicle-mounted lighting such as a headlight of an automobile or an embedded lighting of a building. InFIG. 25 andFIG. 26 will be shown a usage state in which theheat sink 401 for LED lighting of the fourth embodiment is used as a heat sink for LED lighting of a headlight of an automobile. Theheat sink 401, as shown inFIG. 25 andFIG. 26 , is mounted in the state where thebase plate part 402 constructs a back part of ahousing 410 of a case for LED lighting, that is, a part of thehousing 410. In the case where theheat sink 401 is mounted in the state where theheat sink 401 is set in thehousing 410, thefin parts 403 are protruded into a closed space which is located on the back side of the LED lighting and in which the convection of air is not caused. Here, areference numeral 420 designates an outer lens fixed to a front of the LED lighting and having transparency. - In this way, in the case the
heat sink 401 for LED lighting of the fourth embodiment is used as the heat sink for LED lighting in a state where thefin parts 403 of theheat sink 401 is protruded into the closed space, the heat generated when the LED light source emits light is dissipated from theheat sink 401 into the closed space in which the convection of air is not caused. Theheat sink 401 for LED lighting according to the present invention, as shown in the plan view, the front view, and the side view ofFIG. 23 , can ensure sufficient projected areas in all directions of the x-axis direction, the y-axis direction, and the z-axis direction, so that the heat can be efficiently dissipated even in this closed space. - In various exemplary embodiments, the heat sink for LED lighting according to the present invention includes: a base plate; a first heat-dissipating fin; a second heat-dissipating fin; and a third heat-dissipating fin. In some such embodiments: the base plate, the first fin, the second fin, and the third fin are formed integrally from aluminum or an aluminum alloy; the base plate comprises a first surface suitable for mounting an LED element and a second surface opposite from the first surface; the first fin extends from the second surface of the base plate; the second fin comprises a first surface and a second surface opposite from the first surface; the second fin extends from the second surface of the base plate; and the third fin extends from the first surface or the second surface of the second fin.
- In further exemplary embodiments, the heat sink according to the present invention includes: a fourth heat-dissipating fin; a fifth heat-dissipating fin; a sixth heat-dissipating fin; a seventh heat-dissipating fin; and an eighth heat-dissipating fin. In some such embodiments: the third fin extends from the first surface of the second fin; the fourth fin extends from the first surface of the second fin; the fifth fin extends from the second surface of the base plate; the sixth fin comprises a first surface and a second surface opposite from the first surface; the sixth fin extends from the second surface of the base plate; the seventh fin extends from the first surface of the sixth fin; and the eighth fin extends from the first surface of the sixth fin.
- In further exemplary embodiments, the heat sink according to the present invention includes: a fourth heat-dissipating fin; a fifth heat-dissipating fin; and a sixth heat-dissipating fin. In some such embodiments: the fourth fin extends from the second surface of the base plate; the fifth fin comprises a first surface and a second surface opposite from the first surface; and the sixth fin extends from the first surface or the second surface of the fifth fin.
- In further exemplary embodiments, the heat sink according to the present invention includes: a fourth heat-dissipating fin; a fifth heat-dissipating fin; a sixth heat-dissipating fin; a seventh heat-dissipating fin; and an eighth heat-dissipating fin. In some such embodiments: the third fin extends from the first surface of the second fin; the fourth fin extends from the second surface of the second fin; the fifth fin extends from the second surface of the base plate; the sixth fin comprises a first surface and a second surface opposite from the first surface; the sixth fin extends from the second surface of the base plate; the seventh fin extends from the first surface of the sixth fin; and the eighth fin extends from the second surface of the sixth fin.
- In further exemplary embodiments, the heat sink according to the present invention includes: a fourth heat-dissipating fin; and a fifth heat-dissipating fin. In some such embodiments: the third fin extends from the first surface of the second fin; the fourth fin extends from the second surface of the second fin; and the fifth fin extends from the second surface of the base plate.
-
FIG. 27 shows aheat sink 501 for LED lighting of a fifth embodiment. Theheat sink 501 for LED lighting is aheat sink 501 for LED lighting formed of an aluminum extrusion material and is constructed of: abase plate part 502 having anLED light source 500 arranged and fixed on a front side thereof; and a plurality offin parts 503 arranged in parallel to each other on the back side of thebase plate part 502 in such a way as to protrude separately from each other. Theheat sink 501 for LED lighting of the fifth embodiment is characterized in that thebase plate part 502 is bent in a direction perpendicular to the longitudinal direction of thefin part 503, that is, is formed in the shape of a letter L. Of these parts, thebase plate part 502 constructs a mounting face part of the present invention, and aside 503 a extending in one direction of thefin part 503 construct a first fin part of the present invention, and aside 503 b extending in other direction of thefin part 503 constructs a second fin part of the present invention. - Specifically, the
heat sink 501 for LED lighting of the fifth embodiment (hereinafter simply referred to as theheat sink 501 in some cases) is manufactured by applying a comparatively simple working such as cutting and bending to an aluminum extrusion material made by extruding an aluminum material, which is excellent in thermal conductivity and formability, such as pure aluminum of JIS 1000 series and aluminum alloy of JIS 6000 series. Further, theheat sink 501 for LED lighting may be manufactured by the use of other aluminum alloy material such as aluminum alloy material of JIS 5000 series. - As shown in
FIG. 27 , theheat sink 501 of the fifth embodiment is constructed of: thebase plate part 502 having the LEDlight source 500 arranged and fixed on the front side thereof (face on a right concave corner part inFIG. 27 ); and the plurality offin parts 503 arranged in parallel to each other on the back side of thebase plate part 502 in such a way as to protrude separately from each other. - The
base plate part 502 is a plate so-called shaped like a letter L, the plate being bent in a direction perpendicular to the longitudinal direction of thefin parts 503 arranged in parallel to each other. As thebase plate part 502 is bent in this manner, there is formed thefin part 503 having afirst fin part 503 a, which extends in a direction perpendicular to thebase plate part 502, and asecond fin part 503 b, which extends in the direction perpendicular to thebase plate part 502 and in a direction intersecting thefirst fin part 503 a. In the present embodiment, thefin part 503 is bent outside along with thebase plate part 502 and hence a bent part of thefin part 503 is pulled and extended, which hence is likely to have an effect on the bending of thebase plate part 502. Hence, the dimension of protrusion of thefin part 503 needs to be short not to interfere with the bending of thebase plate part 502. - Here, the LED
light source 500 is made, for example, by mounting a plurality of light emitting diode (LED) elements on a substrate based on an aluminum alloy. -
FIG. 28 shows a first modified example of theheat sink 501 of the fifth embodiment. Thisheat sink 501, like theheat sink 501 shown inFIG. 27 , is also constructed of: thebase plate part 502 having the LEDlight source 500 arranged and fixed on the front side thereof (face on a right convex corner part inFIG. 28 ); and the plurality offin parts 503 arranged in parallel to each other on the back side of thebase plate part 502 in such a way as to protrude separately from each other. - The
base plate part 502 is a plate so-called shaped like a letter L, the plate being bent in a direction perpendicular to the longitudinal direction of thefin parts 503 arranged in parallel to each other. In the present embodiment, thefin parts 503 are bent to the inside along with thebase plate part 502 and hence the bent parts of thefin parts 503 are compressed, which hence is likely to have an effect on the bending of thebase plate part 502. Hence, thefin parts 503 need to be short in the dimension of protrusion not to interfere with the bending of thebase plate part 502. -
FIG. 29 shows a second modified example of theheat sink 501 of the fifth embodiment. Thisheat sink 501, like theheat sink 501 shown inFIG. 27 , is also constructed of: thebase plate part 502 having the LEDlight source 500 arranged and fixed on the front side thereof (face on a right concave corner part inFIG. 29 ); and the plurality offin parts 503 arranged in parallel to each other on the back side of thebase plate part 502 in such a way as to protrude separately from each other. - The
base plate part 502 is a plate so-called shaped like a letter L, the plate being bent in a direction perpendicular to the longitudinal direction of thefin parts 503 arranged in parallel to each other. In the present embodiment, thefin parts 503 are bent to the outside along with thebase plate part 502 and, if thefin parts 503 are bent as they are, thefin parts 503 have an effect on the bending of thebase plate part 502, so that before bending thebase plate part 502, alinear slit 504 reaching the outside surface of thebase plate part 502 is formed in a portion to be bent of eachfin part 503. Since thebase plate part 502 is bent after the slit is formed in eachfin part 503 in this manner, as is the case with the embodiment shown inFIG. 27 , thefin part 503 does not need to be especially short in the dimension of protrusion and hence heat can be dissipated from the LED lighting more efficiently than in the embodiment shown inFIG. 27 . Further, each of thefin parts 503 is divided into onefirst fin part 503 a and the othersecond fin part 503 b by theslit 504. -
FIG. 30 shows a third modified example of theheat sink 501 of the fifth embodiment. Thisheat sink 501, like theheat sink 501 shown inFIG. 28 , is also constructed of thebase plate part 502 having the LEDlight source 500 arranged and fixed on the front side (face on a left convex corner side inFIG. 30 ) and the plurality offin parts 503 arranged in parallel to each other on the back side of thebase plate part 502 in such a way as to protrude separately from each other. - The
base plate part 502 is a plate so-called shaped like a letter L, the plate being bent in a direction perpendicular to the longitudinal direction of thefin parts 503 arranged in parallel to each other. In the present embodiment, thefin parts 503 are bent to the inside along with thebase plate part 502 and, if thefin parts 503 are bent as they are, thefin parts 503 have an effect on the bending of thebase plate part 502, so that before bending thebase plate part 502, aslit 505 is formed in a portion to be bent of each of thefin parts 503, theslit 505 reaching the outside surface of thebase plate part 502 and being shaped like a letter V of an angle of 90 degrees or more. Since theslit 505 shaped like a letter V is formed in each of thefin parts 503 in this manner and then thebase plate part 502 is bent, thefin parts 503 do not need to be especially short in the dimension of protrusion as is the case with the embodiment shown inFIG. 28 , so that the heat can be dissipated more efficiently from the LED lighting than in the embodiment shown inFIG. 28 . Further, each of thefin parts 503 is divided into onefirst part 503 a and the othersecond fin part 503 b by theslit 505. - The
heat sink 501 for LED lighting is used as aheat sink 501 for vehicle-mounted lighting such as the headlight of an automobile and the embedded lighting of a building.FIG. 31 andFIG. 32 show a usage state in which theheat sink 501 of the embodiment shown inFIG. 29 is used as theheat sink 501 for LED lighting of the headlight of an automobile, respectively, whereasFIG. 33 andFIG. 34 show a usage state in which theheat sink 501 of the embodiment shown inFIG. 30 is used as theheat sink 501 for LED lighting of the headlight of an automobile, respectively. - In this regard, the
heat sink 501 shown inFIG. 27 is the same in the usage state as theheat sink 501 shown inFIG. 29 , whereas theheat sink 501 shown inFIG. 28 is the same in the usage state as theheat sink 501 shown inFIG. 30 , so that their descriptions will be omitted. - The
heat sink 501 shown inFIG. 29 , as shown inFIG. 31 andFIG. 32 , is fixed to a concave corner of the LED lighting in a state where thebase plate 502 shaped like a letter L constructs a portion of thehousing 510 of the case of the LED lighting. In this way, when theheat sink 501 having thebase plate part 502 shaped like a letter L shown inFIG. 29 is used (ditto for the case where theheat sink 501 shown inFIG. 27 is used), theheat sink 501 can be set even in a narrow limited space in which a conventional plate-shapedbase plate part 2 shown inFIG. 47 cannot be set. - Here, a
reference numeral 520 designates an outer lens fixed to the front of the LED lighting and having transparency, whereas areference numeral 530 designates a reflector for making light emitted from the LEDlight source 500 reflect to theouter lens 520. - The
heat sink 501 shown inFIG. 30 , as shown inFIG. 33 andFIG. 34 , is fixed in a state where one part of thebase plate part 502 shaped like a letter L constructs a part of thehousing 510 of the case of the LED lighting. In this way, when theheat sink 501 having thebase plate part 502 shaped like a letter L shown inFIG. 30 is used (ditto for the case where theheat sink 501 shown inFIG. 28 is used), theheat sink 501 can be set even in a narrow limited space in which the conventional plate-shapedbase plate part 2 shown inFIG. 47 cannot be set. - When the
heat sink 501 is fixed in a state where one part of thebase plate part 502 constructs a part of thehousing 510 of the LED lighting, there is brought about a state in which the other part of thebase plate part 502 is protruded to the outside from the LED lighting (in the case of the automobile, inner space in a bonnet) as is the case with thefin parts 503. However, sufficient heat dissipating area can be ensured by the surface area of thebase plate part 502 shaped like a letter L and by the surface area of thefin parts 503, so that a sufficient amount of heat can be dissipated. - Here, although a usage state is not shown especially, the
heat sinks 501 shown inFIG. 28 andFIG. 30 can be fixed even in a convex indented corner which is limited in space. - In various exemplary embodiments, the heat sink for LED lighting according to the present invention includes: a bent planar base plate; a first heat-dissipating fin; and a second heat-dissipating fin. In some such embodiments: the base plate, the first fin, and the second fin are formed integrally from aluminum or an aluminum alloy; the base plate comprises an inner surface and an outer surface opposite from the inner surface; the first fin extends from the inner surface or the outer surface of the base plate; and the second fin extends from the same surface of the base plate as the first fin.
- In further exemplary embodiments, in the heat sink according to the present invention: the inner surface of the base plate is suitable for mounting an LED element; the first fin and the second fin extend from the outer surface; the base plate comprises a first planar region and a second planar region that are joined by a bent region; the first fin extends from the outer surface of the base plate in the first planar region, the second planar region, and the bent region; and the second fin extends from the outer surface of the base plate in the first planar region, the second planar region, and the bent region.
- In further exemplary embodiments, in the heat sink according to the present invention: the outer surface of the base plate is suitable for mounting an LED element; the first fin and the second fin extend from the inner surface; the base plate comprises a first planar region and a second planar region that are joined by a bent region; the first fin extends from the inner surface of the base plate in the first planar region, the second planar region, and the bent region; and the second fin extends from the inner surface of the base plate in the first planar region, the second planar region, and the bent region.
- In further exemplary embodiments, the heat sink according to the present invention includes: a third heat-dissipating fin; and a fourth heat-dissipating fin. In some such embodiments, the inner surface of the base plate is suitable for mounting an LED element; the first fin, the second fin, the third fin, and the fourth fin extend from the outer surface; the base plate comprises a first planar region and a second planar region that are joined by a bent region; the first fin and the second fin extend from the outer surface of the base plate in the first planar region; and the second fin and the fourth fin extend from the outer surface of the base plate in the second planar region.
- In further exemplary embodiments, the heat sink according to the present invention includes: a third heat-dissipating fin; and a fourth heat-dissipating fin. In some such embodiments: the outer surface of the base plate is suitable for mounting an LED element; the first fin, the second fin, the third fin, and the fourth fin extend from the inner surface; the base plate comprises a first planar region and a second planar region that are joined by a bent region; the first fin and the second fin extend from the inner surface of the base plate in the first planar region; and the second fin and the fourth fin extend from the inner surface of the base plate in the second planar region.
-
FIG. 35 shows aheat sink 601 for LED lighting of a sixth embodiment. Theheat sink 601 for LED lighting is firstly characterized in that an aluminum alloy thin plate is formed in the heat dissipating fin shape of continuouswavy shapes heat sink 601 is secondly characterized in that the aluminum alloy thin plate previously has a pre-coating applied to the surface thereof before it is corrugated, the pre-coating having an emissivity ε of 0.7 or more. Still further, theheat sink 601 is thirdly characterized in that thewavy shapes wavy shapes wavy shapes -
FIG. 35 is a perspective view showing theheat sink 601 of the sixth embodiment andFIG. 36 is a plan view ofFIG. 35 . Further,FIG. 37 is a perspective view showing aheat sink 601 of a first modified example of the sixth embodiment andFIG. 38 is a plan view ofFIG. 37 . - These
FIG. 35 toFIG. 38 show theheat sink 601 manufactured by forming a heat dissipating fin shape in whichwavy shapes thin plate 601 a of a raw material having apre-coating film 610 applied previously to the surface thereof by pre-coating a black paint. Here, corrugating, as anyone knows, means forming a flat plate or a smooth pipe into a wavy shape. Thepre-coating film 610 of the black paint is a very thin surface coating and hence is designated only by a number of 610. The aluminum alloythin plate 601 a has thepre-coating film 610 applied to the whole surface (both surfaces) or a necessary portion of surface (including one surface). - In the
heat sink 601 shown inFIG. 35 toFIG. 38 , thewavy shapes wavy shapes FIG. 37 andFIG. 41 , theheat sink 601 has a step formed in a center portion in the longitudinal direction (in the left and right direction in the drawing) of theheat sink 601, and the left and right wavy shapes are different from each other in the level of the wavy shape with a boundary at the center portion. By forming the step like this in accordance with the design of space or the condition of space of theheat sink 601 in the vehicle-mounted LED lamp, the whole shape of the continuouswavy shapes FIG. 35 andFIG. 36 but in an irregular shape shown inFIG. 37 andFIG. 41 . - Wavy Shape of Heat Dissipating Fin:
- In
FIG. 35 toFIG. 38 , the heat dissipating fins=wavy shapes wavy shapes wavy shapes - Here, a width a of the
wavy shape 602, a width b of thewavy shape 603, a pitch p of thewavy shapes wavy shapes wavy shapes 602, 603 (heat sink 601), and a length l of the continuouswavy shapes 602, 603 (heat sink 601) are designed so as to be tailored to the specifications of the vehicle-mounted LED lamp to which theheat sink 601 is set and to satisfy the required heat dissipation characteristics of theheat sink 601. - When usage ranges of them are described by an example from the specifications of the LED lamp mounted in an ordinary passenger car, the width a of the
wavy shape 602 and the width b of thewavy shape 603 are 1 to 20 mm, the pitch p of thewavy shapes wavy shapes wavy shapes 602, 603 (heat sink 601) are 50 to 250 mm and 10 to 60 mm, respectively, and the length l of the continuouswavy shapes 602, 603 (heat sink 601) is 30 to 250 mm. Further, limit values in the design of thesewavy shapes thin plate 601 a of the raw material is corrugated. That is, in the case where the design values of thesewavy shapes - Pre-Coating:
- In
FIG. 35 toFIG. 38 , the aluminum alloythin plate 601 a of the raw material has a pre-coating (pre-coating film) 610 applied to the whole surface thereof, the pre-coating being performed by a black paint having an emissivity ε of 0.7 or more and a large amount of heat dissipation. This pre-coating 610 can increase the amount of heat transfer or the amount of heat dissipation by radiation as the heat dissipating fins=wavy shapes 602, 603 (heat sink 601). - Further, the pre-coating serves as a lubricant agent at the time of corrugating the aluminum alloy
thin plate 601 a of the raw material and hence has an effect on improving the formability of the heat dissipating fins=wavy shapes thin plate 601 a, the pre-coating of the black paint is previously applied to the aluminum alloythin plate 601 a. - The emissivity ε of the pre-coating (pre-coated film) 610 applied to the surface of the aluminum alloy
thin plate 601 a of the raw material is made 0.7 or more so as to increase the thermal emissivity of the heat dissipating fins=wavy shapes thin plate 601 a of the raw material having the pre-coating applied thereto has the effect of lubrication but is reduced in the amount of heat transfer or the amount of heat dissipation by radiation and is not much different from a bare aluminum alloythin plate 601 a not having any coating applied thereto. - This emissivity ε is the rate of heat radiation of an actual body to a theoretical value (heat radiation of a black body of an ideal thermal radiator) and the emissivity ε may be actually measured by a method described in Japanese Patent Application Laid-open No. 2002-234460 or by the use of a portable emissivity measurement device developed by Japan Aerospace Exploration Agency. The method described in the Japanese Patent Publication will be described below. The emissivity ε is measured by the use of an emissivity measurement device shown in
FIG. 46 . InFIG. 46 , anemissivity measurement device 620 is basically constructed of: anelectric heater 621 whose bottom surface is covered with ablack paint layer 620, acooling bed 624 arranged at a given distance below theelectric heater 621, and aheat insulating layer 623 for surrounding theelectric heater 621 and thecooling bed 624. Aheat sink 601 is placed on thecooling bed 624 with an outer surface of awavy shape 602 on the top, and the temperature and the amount of temperature increase (amount of heat transfer Q1) of theheat sink 601 to a given amount of heat Q radiated from theelectric heater 621 are measured from electric power applied to theelectric heater 621 or the amount of temperature increase (amount of cooling water and increase in temperature) of coolingwater 625 in thecooling bed 624. Then, anemissivity ε 2, specified by the present invention, of the outer surface of thewavy shape 602 of theheat sink 601 is calculated from the followingmathematical equation 1. -
[Mathematical equation 1] -
Q1=α(T 1 4 −T 2 4)/(1/ε1+1/ε2−1)Equation 1 - where Q1=amount of heat transfer of an Al
alloy heat sink 601, α=Stefan-Boltzmann constant 5.67×10−8 W/m2K4, T1=temperature ofblack paint layer 622, T2=temperature ofheat sink 601, ε1=emissivity ofblack paint layer 622=0.9, and ε2=emissivity of outer surface ofwavy shape 602 ofheat sink 601. - Forming of Stepped Part:
- In the present invention, as a preferable mode, by crushing the portions of the heat dissipating fins=the
wavy shapes wavy shapes heat sink 601 is mounted as a heat sink for a vehicle-mounted LED lamp. Further, these stepped parts provide depressed and projected shapes for increasing rigidity as the heat sink against an external force (bending moment) around an axis vertical to the surface of paper, for example, as shown by arrows on the left and right sides of theheat sink 601 shown inFIG. 36 . - A
heat sink 601 of a second modified example of the sixth embodiment shown inFIG. 39 is the same in the basic shape in which thewavy shapes heat sink 601 shown inFIG. 35 andFIG. 36 . However, in theheat sink 601 of the second modified example, of thewavy shapes wavy shape 602 a, awavy shape 603 a adjacent to thewavy shapes 602 a, and awavy shape 602 b separated by several pitches from thewavy shape 602 a are respectively formed in larger widths a1, b1, and a2 than the widths a, b of the other standardwavy shapes wavy shapes elements parts elements elements parts wavy shapes wavy shapes - These stepped parts, including stepped parts to be described later, can be formed by crushing portions, in which these stepped parts in the wavy shapes are to be formed, by the use of a die without using other off-line process after forming the
wavy shapes - The other modes of a reinforcing example like this will be shown in
FIG. 40 toFIG. 43 in which the heat sink is placed laterally. In this regard, theheat sink 601 shown in these drawings are the same in the basic shape, in which thewavy shapes FIG. 35 andFIG. 36 . - In a third modified example of the sixth embodiment shown in
FIG. 40 , of thewavy shapes wavy shape 603 has a protruded part like a steppedpart 605 b formed at a height (level) equal to a face of thewavy shape 602 at a middle position (center position in this case). That is, theheat sink 601 including thewavy shapes parts 605 b formed continuously in the lateral direction of the wavy shape, thereby being reinforced and enhanced in the rigidity. The position, the number, and the height of the steppedpart 605 b can be selected as required. The steppedpart 605 b is formed by partially pressing up a portion, in which the steppedpart 605 b in thewavy shape 603 is to be formed, in the direction of thewavy part 602 after forming thewavy shapes - In a fourth modified example of the sixth embodiment shown in
FIG. 41 , protruded parts like steppedparts 605 c are formed at middle positions (center positions in this case) of the respectivewavy shapes 603 and depressed parts like steppedparts 604 c are formed at middle positions (center positions in this case) of the respectivewavy shapes 602 are formed in such a way that the steppedparts heat sink 601 is reinforced. In this regard, the protruded parts of the steppedparts 605 c and the depressed parts of the steppedparts 604 c are formed at the same height (level) and continuously with each other in the lateral direction of the wavy shape to thereby reinforce theheat sink 601. The position, the number, and the height of the steppedparts 605 c and the steppedparts 604 c are selected as required. These steppedparts parts 605 c in thewavy shapes 603 are to be formed, in the direction of thewavy shape 602 and by partially crushing (pressing down) portions, in which the steppedparts 604 c in thewavy shapes 602 are to be formed, in the direction of thewavy shape 603 after forming thewavy shapes - In a fifth modified example of the sixth embodiment shown in
FIG. 42( a), flat flanges like the steppedparts wavy shapes 602, 603 (heat sink 601). These stepped parts are formed by crushing (pressing down) thewavy shapes 602 and crushing (pressing up) thewavy shapes 603 at the peripheral edge portions (four sides) as shown inFIG. 42( b), which is a section view taken on a line X-X′ inFIG. 42 , after forming thewavy shapes heat sink 601 is easily fixed in the housing that these ribs or flanges are formed. - In a sixth modified example of the sixth embodiment shown in
FIG. 43 , there is formed a depressed part like a steppedpart 607 in which thewavy shape 602 is cut out at a middle position (center position in this case). At this time, the top (upper side) of thewavy shape 602 is not cut away but is left as asquare cut piece 608 a and thecut piece 608 a is bent at a right angle as shown by 608 b. It is because the element 600 and the necessary components are fixed without using the stepped parts that these cutpieces -
FIGS. 44( a), 44(b), and 44(c) are seventh modified examples of the sixth embodiment and show examples in which a reinforcingbracket 630 is attached to the bottom faces of thewavy shapes 602, 603 (heat sink 601).FIG. 44( a) shows an example in which anintegral bracket 630 is attached to the whole bottom faces of thewavy shapes 602, 603 (heat sink 601) andFIG. 44( b) shows an example in which two dividedbrackets 630 are attached to the bottom faces of thewavy shapes 602, 603 (heat sink 601), respectively.FIG. 44( c) shows a case in whichbrackets 630 each having a section nearly shaped like a letter C are fixed to both ends of thewavy shapes 602, 603 (heat sink 601), thebracket 630 having aflange part 631 used for fixing the other component. Here, inFIGS. 44( a), 44(b), and 44(c), an aluminum alloy or a resin material can be used as the material of thebrackets - Fixing Heat Sink in Vehicle-Mounted LED Lamp:
-
FIGS. 45( a) and 45(b) show a mode of fixing a heat sink in a vehicle-mounted LED lamp.FIG. 45( a) shows a longitudinal section of an LED lamp, andFIG. 45( b) is a view when a section taken on a line Y-Y′ inFIG. 45( a) is viewed from the top. InFIGS. 45( a) and 45(b), a vehicle-mounted LED lamp (vehicular lamp) 650 includes: anLED substrate 651 mounted with anLED 651 a as a light source; areflector 652 for reflecting light from theLED 651 a forward in the direction in which the light is emitted; ahousing 653 for wrapping theLED substrate 651 and thereflector 652; anouter lens 654 that closes an open front end of thehousing 653 and that is made of a transparent material; and aheat sink 601 arranged in thermal contact with theLED substrate 651. - Here, the
heat sink 601 having the continuouswavy shapes parts part 607 a has the bottom face of theLED substrate 651 thermally connected to the top face thereof via a sheet-shapedheat conducting member 655 a. Still further, the steppedpart 607 b has the top face of thereflector 652 connected to the bottom face thereof. - On the other hand, the
LED substrate 651 is arranged in the center portion of the steppedpart 607 of theheat sink 601 and has the LED 651 a mounted on the top thereof. Thereflector 652 is formed of a resin material and has a parabolic reflecting surface having a focal point near theLED 651 a on theLED substrate 651. - The
housing 653 is opened on the front side (side in which theouter lens 654 is mounted). Further, thehousing 653 has anopening 653 a on the back side (on the right side in the drawing) and has theheat sink 601 fixed thereto in such a way that theheat sink 601 closes the opening 653 a on the back side. - According to the vehicle-mounted
LED lamp 650 of this construction, theLED 651 a on theLED substrate 651 is driven to emit light and the light emitted from theLED 651 a is reflected by thereflector 652 and is radiated forward in the direction in which the light is radiated via theouter lens 654. Here, heat generated from theLED 651 a is transferred to theheat sink 601 viaheat conducting material 655 a from theLED substrate 651 and is dissipated to the outside of thehousing 653 from theheat sink 601. In this way, an increase in the temperature of theLED 651 a can be suppressed. - Aluminum Alloy as Raw Material:
- An aluminum alloy plate as a raw material used for the heat sink of the present invention is a thin plate having a thickness from 2 mm to 0.4 mm, and it is most important that the aluminum alloy plate can be formed into the shape of the
heat sink 601 and is excellent in corrugating workability. In addition, in terms of the required characteristics of the heat sink such that heat sink needs to be excellent in heat transfer and corrosion resistance, pure aluminum of 1000 series is preferably selected which has as little amount of alloy element as possible and which is specified or included by the AA standard or the JIS standards. In this regard, in the present invention, an aluminum plate made of pure aluminum is also expressed by an aluminum alloy plate. However, in terms of strength to ensure the rigidity, an aluminum alloy material selected from the 3000 series specified or included by the AA standard or the JIS standards is selected as required. These aluminum alloy plates are manufactured in normal manufacturing processes including casting (DC casting and continuous casting), homogenized heat treatment, hot rolling, process annealing, cold rolling, and thermal refining such as solution heat treatment and quenching heat treatment. - According to the present invention, a heat sink manufactured at high productivity can be provided by using an aluminum alloy plate as a raw material and by corrugating the aluminum alloy plate into the whole shape of heat dissipating fins formed in a continuous wavy shape. For this reason, the heat sink manufactured by the present invention is most suitable for a heat sink for a vehicle-mounted LED lamp.
- In various exemplary embodiments, the heat sink for LED lighting according to the present invention includes a corrugated sheet of aluminum or an aluminum alloy. In some such embodiments, at least one ridge of the corrugated sheet comprises a depression comprising a surface suitable for mounting an LED element.
- In further exemplary embodiments, in the heat sink according to the present invention: the corrugated sheet comprises a lower step portion and a higher step portion; and the lower step portion and the higher step portion are not coplanar.
- In further exemplary embodiments, in the heat sink according to the present invention: the corrugated sheet comprises a narrow pitch portion and a wide pitch portion; and a pitch of ridges of the corrugated sheet in the narrow pitch portion is less than a pitch of ridges of the corrugated sheet in the wide pitch portion.
- In further exemplary embodiments, in the heat sink according to the present invention, the corrugated sheet comprises a raised portion extending transverse to ridges of corrugated sheet.
- In further exemplary embodiments, in the heat sink according to the present invention, the corrugated sheet comprises a depressed portion extending transverse to ridges of corrugated sheet.
- In further exemplary embodiments, in the heat sink according to the present invention, at least one portion of the corrugated sheet is not corrugated.
- In various exemplary embodiments, heat sinks according to the present invention include one or more base plates and one or more heat-dissipating fins. Although the base plates and fins are not limited to strictly planar shapes, the base plates and fins may be generally planar and/or may include multiple generally planar portions (e.g., a bent planar structure including two generally planar portions joined at a bent portions). Further, even if the base plates and fins are not strictly planar, they may be said to define planes. Thus, the arrangement of base plates and fins with respect to each other may be defined with reference to the planes defined by such base plates and fins (e.g., the first fin is parallel to the second fin, the first fin is perpendicular to the base plate, the first fin defines a plane that intersects a plane defined by the second fin, etc.). Further, the arrangement of base plates and fins with respect to each other may be defined with reference to angles at which the base plates and fins (or planes defined by the base plates and fins) intersect (e.g., an angle between the first fin and the base plate is 45 degrees, the first fin defines a plane that intersects a plane defined by the second fin at an angle of 45 degrees, etc.). Base plates and fins may be arranged at angles of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, and/or 85 degrees, with respect to each other, as well as any subranges of angles therein.
- A base plate or fin may be said to extend from a surface of another base plate or fin. For example, in the case that a generally planar fin extends from a surface of a generally planar base plate, an edge of the fin may be joined with the surface of the base plate. Such joint may be located at any location on the surface of the base plate. If the fin extends perpendicularly from a central location on the surface of the base plate, the joint between the fin and the base plate may be T-shaped when viewed from an end. If the fin extends perpendicularly from an edge of the surface of the base plate, the joint between the fin and the base plate may be L-shaped when viewed from an end.
- In various exemplary embodiments, a fin may be a single unitary body. In alternative embodiments, a fin may be comprised of multiple coplanar or substantially coplanar fins.
- In the above detailed description, reference was made by way of non-limiting example to preferred embodiments of the invention. Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
Claims (38)
1-16. (canceled)
17. A heat sink for LED lighting, comprising:
a base plate;
a first heat-dissipating fin; and
a second heat-dissipating fin;
wherein:
the base plate, the first fin, and the second fin are formed integrally from aluminum or an aluminum alloy;
the base plate comprises a first surface suitable for mounting an LED element and a second surface opposite from the first surface;
the first fin extends from the first surface or the second surface of the base plate;
the second fin extends from the first surface or the second surface of the base plate;
no more than one additional heat-dissipating fin extends from the surface of the base plate from which the first fin extends and is parallel or substantially parallel to the first fin; and
no more than one additional heat-dissipating fin extends from the surface of the base plate from which the second fin extends and is parallel or substantially parallel to the second fin.
18. The heat sink of claim 17 , comprising:
a third heat-dissipating fin; and
a fourth heat-dissipating fin;
wherein:
the first fin is not parallel or substantially parallel to the second fin;
the third fin is parallel or substantially parallel to the first fin; and
the fourth fin is parallel or substantially parallel to the second fin.
19. The heat sink of claim 18 , wherein each of the first fin, the second fin, the third fin, and the fourth fin extends from the first surface of the base plate.
20. The heat sink of claim 19 , wherein:
the heat sink is formed by bending a blank of the aluminum or aluminum alloy; and
each of the first fin, the second fin, the third fin, and the fourth fin is formed by bending the blank such that the base plate joins each of the first fin, the second fin, the third fin, and the fourth fin at a location of a respective bend.
21. The heat sink of claim 19 , comprising:
a fifth heat-dissipating fin;
a sixth heat-dissipating fin;
a seventh heat-dissipating fin; and
an eighth heat-dissipating fin;
wherein:
each of the fifth fin, the sixth fin, the seventh fin, and the eighth fin extends from the second surface of the base plate;
the fifth fin is not parallel or substantially parallel to the sixth fin;
the seventh fin is parallel or substantially parallel to the fifth fin; and
the eighth fin is parallel or substantially parallel to the sixth fin.
22. The heat sink of claim 18 , wherein each of the first fin, the second fin, the third fin, and the fourth fin extends from the second surface of the base plate.
23. The heat sink of claim 17 , comprising:
a third heat-dissipating fin;
a fourth heat-dissipating fin; and
a fifth heat-dissipating fin;
wherein:
each of the first fin, the third fin, and the fourth fin extends from the first surface of the base plate;
each of the second fin and the fifth fin extends from the second surface of the base plate; the first fin is not parallel or substantially parallel to the second fin;
the third fin is parallel or substantially parallel to the first fin;
the fourth fin is not parallel or substantially parallel to the first fin; and
the fifth fin is parallel or substantially parallel to the second fin.
24. The heat sink of claim 17 , comprising:
a third heat-dissipating fin; and
a fourth heat-dissipating fin;
wherein:
each of the first fin and the third fin extends from the first surface of the base plate;
each of the second fin and the fourth fin extends from the second surface of the base plate;
the first fin is parallel or substantially parallel to the second fin
the third fin is parallel or substantially parallel to the first fin; and
the fourth fin is parallel or substantially parallel to the second fin.
25. The heat sink of claim 18 , wherein:
each of the first fin and the third fin extends from the first surface of the base plate; and
each of the second fin and the fourth fin extends from the second surface of the base plate.
26. The heat sink of claim 25 , wherein:
the heat sink is formed by bending a blank of the aluminum or aluminum alloy; and
each of the first fin, the second fin, the third fin, and the fourth fin is formed by bending the blank such that the base plate joins each of the first fin, the second fin, the third fin, and the fourth fin at a location of a respective bend.
27. A heat sink for LED lighting, comprising:
a base plate;
a first heat-dissipating fin; and
a second heat-dissipating fin;
wherein:
the base plate, the first fin, and the second fin are formed integrally from aluminum or an aluminum alloy;
the base plate comprises a first surface suitable for mounting an LED element and a second surface opposite from the first surface;
the first fin comprises a first surface and a second surface opposite from the first surface;
the first fin extends from the first surface or the second surface of the base plate; and
the second fin extends from the first surface or the second surface of the first fin.
28. The heat sink of claim 27 , comprising:
a third heat-dissipating fin;
a fourth heat-dissipating fin;
a fifth heat-dissipating fin;
a sixth heat-dissipating fin;
a seventh heat-dissipating fin; and
an eighth heat-dissipating fin;
wherein:
the first fin extends from the first surface of the base plate;
the second fin extends from the second surface of the first fin;
the third fin extends from the second surface of the first fin;
the fourth fin extends from the second surface of the base plate;
the fifth fin extends from the second surface of the base plate;
the sixth fin comprises a first surface and a second surface opposite from the first surface;
the sixth fin extends from the second surface of the base plate;
the seventh fin extends from the first surface of the sixth fin; and
the eighth fin extends from the first surface of the sixth fin.
29. The heat sink of claim 28 , wherein:
the heat sink is formed by bending a blank of the aluminum or aluminum alloy;
each of the first fin, the fourth fin, the fifth fin, and the sixth fin is formed by bending the blank such that the base plate joins each of the first fin, the fourth fin, the fifth fin, and the sixth fin at a location of a respective bend;
each of the second fin and the third fin is formed by bending the blank such that the first fin joins each of the second fin and the third at a location of a respective bend; and
each of the seventh fin and the eighth fin is formed by bending the blank such that the sixth fin joins each of the seventh fin and the eighth fin at a location of a respective bend.
30. The heat sink of claim 29 , wherein the blank comprises a thick portion corresponding to the base plate, the first fin, and the sixth fin and a thin portion corresponding to corresponding to the second fin, the third fin, the fourth fin, the fifth fin, the seventh fin, and the eighth fin.
31. The heat sink of claim 30 , wherein the blank is prepared by welding sheets of the aluminum or aluminum alloy.
32. The heat sink of claim 30 , wherein the blank is prepared by coining.
33. The heat sink of claim 27 , comprising:
a third heat-dissipating fin;
a fourth heat-dissipating fin;
a fifth heat-dissipating fin;
a sixth heat-dissipating fin;
a seventh heat-dissipating fin;
an eighth heat-dissipating fin;
a ninth heat-dissipating fin;
a tenth heat-dissipating fin; and
an eleventh heat-dissipating fin;
wherein:
the first fin extends from the first surface of the base plate;
the second fin comprises a first surface and a second surface opposite from the first surface;
the second fin extends from the second surface of the first fin;
the third fin extends from the first surface of the first fin;
the fourth fin extends from the first surface of the first fin;
the fifth fin extends from the second surface of the surface of the second fin;
the sixth fin extends from the second surface of the surface of the second fin;
the seventh fin extends from the second surface of the base plate;
the eighth fin extends from the second surface of the base plate;
the ninth fin comprises a first surface and a second surface opposite from the first surface;
the ninth fin extends from the second surface of the first fin;
the tenth fin extends from the first surface of the ninth fin; and
the eleventh fin extends from the first surface of the ninth fin.
34. The heat sink of claim 33 , wherein:
a portion of the fifth fin overlaps and contacts a portion of the fourth fin;
a portion of the fifth fin overlaps and contacts a portion of the seventh fin;
a portion of the sixth fin overlaps and contacts a portion of the third fin;
a portion of the sixth fin overlaps and contacts a portion of the eighth fin;
a portion of the seventh fin overlaps and contacts a portion of the eleventh fin; and
a portion of the eighth fin overlaps and contacts a portion of the tenth fin.
35. The heat sink of claim 33 , wherein:
the heat sink is formed by bending a blank of the aluminum or aluminum alloy;
each of the first fin, the seventh fin, the eighth fin, and the ninth fin is formed by bending the blank such that the base plate joins each of the first fin, the seventh fin, the eighth fin, and the ninth fin at a location of a respective bend;
each of the second fin, the third fin, and the fourth fin is formed by bending the blank such that the first fin joins each of the second fin, the third fin, and the fourth fin at a location of a respective bend;
each of the fifth fin and the sixth fin is formed by bending the blank such that the second fin joins each of the fifth fin and the sixth fin at a location of a respective bend; and
each of the tenth fin and the eleventh fin is formed by bending the blank such that the ninth fin joins each of the tenth fin and the eleventh fin at a location of a respective bend.
36. The heat sink of claim 27 , comprising:
a third heat-dissipating fin;
a fourth heat-dissipating fin; and
a fifth heat-dissipating fin;
wherein:
the first fin extends from the first surface of the base plate;
the second fin extends from the second surface of the first fin;
the third fin extends from the first surface of the base plate;
the fourth fin extends from the first surface of the base plate; and
the fifth fin extends from the second surface of the base plate.
37. The heat sink of claim 28 , wherein:
the heat sink is formed by bending a blank of the aluminum or aluminum alloy;
each of the first fin, the fourth fin, the fifth fin, and the sixth fin is formed by bending the blank such that the base plate joins each of the first fin, the fourth fin, the fifth fin, and the sixth fin at a location of a respective bend;
each of the second fin and the third fin is formed by bending the blank such that the first fin joins each of the second fin and the third at a location of a respective bend; and
each of the seventh fin and the eighth fin is formed by bending the blank such that the sixth fin joins each of the seventh fin and the eighth fin at a location of a respective bend.
38. A heat sink for LED lighting, comprising:
a base plate;
a first heat-dissipating fin;
a second heat-dissipating fin; and
a third heat-dissipating fin;
wherein:
the base plate, the first fin, the second fin, and the third fin are formed integrally from aluminum or an aluminum alloy;
the base plate comprises a first surface suitable for mounting an LED element and a second surface opposite from the first surface;
the first fin extends from the second surface of the base plate;
the second fin comprises a first surface and a second surface opposite from the first surface;
the second fin extends from the second surface of the base plate; and
the third fin extends from the first surface or the second surface of the second fin.
39. The heat sink of claim 38 , comprising:
a fourth heat-dissipating fin;
a fifth heat-dissipating fin;
a sixth heat-dissipating fin;
a seventh heat-dissipating fin; and
an eighth heat-dissipating fin;
wherein:
the third fin extends from the first surface of the second fin;
the fourth fin extends from the first surface of the second fin;
the fifth fin extends from the second surface of the base plate;
the sixth fin comprises a first surface and a second surface opposite from the first surface;
the sixth fin extends from the second surface of the base plate;
the seventh fin extends from the first surface of the sixth fin; and
the eighth fin extends from the first surface of the sixth fin.
40. The heat sink of claim 38 , comprising:
a fourth heat-dissipating fin;
a fifth heat-dissipating fin; and
a sixth heat-dissipating fin;
wherein:
the fourth fin extends from the second surface of the base plate;
the fifth fin comprises a first surface and a second surface opposite from the first surface; and
the sixth fin extends from the first surface or the second surface of the fifth fin.
41. The heat sink of claim 38 , comprising:
a fourth heat-dissipating fin;
a fifth heat-dissipating fin;
a sixth heat-dissipating fin;
a seventh heat-dissipating fin; and
an eighth heat-dissipating fin;
wherein:
the third fin extends from the first surface of the second fin;
the fourth fin extends from the second surface of the second fin;
the fifth fin extends from the second surface of the base plate;
the sixth fin comprises a first surface and a second surface opposite from the first surface;
the sixth fin extends from the second surface of the base plate;
the seventh fin extends from the first surface of the sixth fin; and
the eighth fin extends from the second surface of the sixth fin.
42. The heat sink of claim 38 , comprising:
a fourth heat-dissipating fin; and
a fifth heat-dissipating fin;
wherein:
the third fin extends from the first surface of the second fin;
the fourth fin extends from the second surface of the second fin; and
the fifth fin extends from the second surface of the base plate.
43. A heat sink for LED lighting, comprising:
a bent planar base plate;
a first heat-dissipating fin; and
a second heat-dissipating fin;
wherein:
the base plate, the first fin, and the second fin are formed integrally from aluminum or an aluminum alloy;
the base plate comprises an inner surface and an outer surface opposite from the inner surface;
the first fin extends from the inner surface or the outer surface of the base plate; and
the second fin extends from the same surface of the base plate as the first fin.
44. The heat sink of claim 43 , wherein:
the inner surface of the base plate is suitable for mounting an LED element;
the first fin and the second fin extend from the outer surface;
the base plate comprises a first planar region and a second planar region that are joined by a bent region;
the first fin extends from the outer surface of the base plate in the first planar region, the second planar region, and the bent region; and
the second fin extends from the outer surface of the base plate in the first planar region, the second planar region, and the bent region.
45. The heat sink of claim 43 , wherein:
the outer surface of the base plate is suitable for mounting an LED element;
the first fin and the second fin extend from the inner surface;
the base plate comprises a first planar region and a second planar region that are joined by a bent region;
the first fin extends from the inner surface of the base plate in the first planar region, the second planar region, and the bent region; and
the second fin extends from the inner surface of the base plate in the first planar region, the second planar region, and the bent region.
46. The heat sink of claim 43 , comprising:
a third heat-dissipating fin; and
a fourth heat-dissipating fin;
wherein:
the inner surface of the base plate is suitable for mounting an LED element;
the first fin, the second fin, the third fin, and the fourth fin extend from the outer surface;
the base plate comprises a first planar region and a second planar region that are joined by a bent region;
the first fin and the second fin extend from the outer surface of the base plate in the first planar region; and
the second fin and the fourth fin extend from the outer surface of the base plate in the second planar region.
47. The heat sink of claim 43 , comprising:
a third heat-dissipating fin; and
a fourth heat-dissipating fin;
wherein:
the outer surface of the base plate is suitable for mounting an LED element;
the first fin, the second fin, the third fin, and the fourth fin extend from the inner surface;
the base plate comprises a first planar region and a second planar region that are joined by a bent region;
the first fin and the second fin extend from the inner surface of the base plate in the first planar region; and
the second fin and the fourth fin extend from the inner surface of the base plate in the second planar region.
48. A heat sink for LED lighting, comprising a corrugated sheet of aluminum or an aluminum alloy, wherein at least one ridge of the corrugated sheet comprises a depression comprising a surface suitable for mounting an LED element.
49. The heat sink of claim 48 , wherein:
the corrugated sheet comprises a lower step portion and a higher step portion; and
the lower step portion and the higher step portion are not coplanar.
50. The heat sink of claim 48 , wherein:
the corrugated sheet comprises a narrow pitch portion and a wide pitch portion; and
a pitch of ridges of the corrugated sheet in the narrow pitch portion is less than a pitch of ridges of the corrugated sheet in the wide pitch portion.
51. The heat sink of claim 48 , wherein the corrugated sheet comprises a raised portion extending transverse to ridges of corrugated sheet.
52. The heat sink of claim 48 , wherein the corrugated sheet comprises a depressed portion extending transverse to ridges of corrugated sheet.
53. The heat sink of claim 48 , wherein at least one portion of the corrugated sheet is not corrugated.
Applications Claiming Priority (11)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2011-066326 | 2011-03-24 | ||
JP2011-066327 | 2011-03-24 | ||
JP2011066327A JP2012204509A (en) | 2011-03-24 | 2011-03-24 | Heat sink for led lighting |
JP2011066326A JP2012204508A (en) | 2011-03-24 | 2011-03-24 | Heat sink for led lighting |
JP2011080432 | 2011-03-31 | ||
JP2011-080432 | 2011-03-31 | ||
JP2011-280062 | 2011-12-21 | ||
JP2011280062A JP5662926B2 (en) | 2011-12-21 | 2011-12-21 | LED lighting heat sink |
JP2012065237A JP5902973B2 (en) | 2012-03-22 | 2012-03-22 | Heat sink for in-vehicle LED lamp |
JP2012-065237 | 2012-03-22 | ||
PCT/JP2012/057691 WO2012128383A1 (en) | 2011-03-24 | 2012-03-26 | Heat sink for led lighting |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/JP2012/057691 Continuation WO2012128383A1 (en) | 2011-03-24 | 2012-03-26 | Heat sink for led lighting |
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Publication Number | Publication Date |
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US20140020882A1 true US20140020882A1 (en) | 2014-01-23 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US14/034,696 Abandoned US20140020882A1 (en) | 2011-03-24 | 2013-09-24 | Heat sink for led lighting |
Country Status (4)
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US (1) | US20140020882A1 (en) |
KR (1) | KR101586888B1 (en) |
CN (1) | CN103443944B (en) |
WO (1) | WO2012128383A1 (en) |
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US10544915B2 (en) | 2017-04-27 | 2020-01-28 | Valeo North America, Inc. | Vehicle lamp assembly having an improved heat sink with light shield |
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Also Published As
Publication number | Publication date |
---|---|
KR101586888B1 (en) | 2016-01-19 |
CN103443944B (en) | 2017-03-08 |
CN103443944A (en) | 2013-12-11 |
WO2012128383A1 (en) | 2012-09-27 |
KR20130124393A (en) | 2013-11-13 |
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Owner name: KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL, LTD.) Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KONISHI, HARUYUKI;MATSUDA, HARUYUKI;MUKAI, YOSHIKAZU;AND OTHERS;REEL/FRAME:031585/0337 Effective date: 20131009 |
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