Vehicle LED lamp having recirculating air channels

An automotive solid-state lamp module (32) adapted to be selectively secured to a reflector (12) having a lamp-receiving socket (121), said lamp module in combination with the reflector (12) disposed in a headlamp housing (601) forming a headlamp assembly (6), said lamp module comprising:

• a base (2) defining a central post (4) having an outer peripheral surface (44), the post defining an internal first air flow passage (401) in an interior of the post,
• a circuit board (14) bearing at least one solid-state light source (17);
• the post (4) defining a mounting surface for the circuit board (14) bearing the at least one solid-state light source (17);
• a mounting flange (42) disposed on the base (2), the mounting flange configured to be coupleable to the reflector socket (121);
• the base (2) further defining at least one exterior second air flow passage (405) exteriorly adjacent the post (4), the second air flow passage (405) being oriented to direct air exiting the second air flow passage past the mounting flange (42) and adjacent the post outer peripheral surface (44);
• the base (2) further defining a third air flow passage (410) having an air outlet disposed axially rearward of the mounting flange (42) and radially outward from the second air flow passage (405);
• and
• an air-moving fan (8) disposed in the base (2) arranged to, when energized, move air to the first, second and third air flow passages (401, 405, 410);
• wherein
• the first air flow passage (401) and the second air flow passage (405) direct air received from the fan (8) into an interior (122) within the reflector (12);
• and
• the third air flow passage (410) directs air received from the fan (8) towards an exterior region (123) rearward of the reflector (12).

A method of cooling a solid-state vehicle lamp module (32) retained in a vehicle headlamp reflector (12), comprising

• inserting a lamp module (32) having a solid-state light source (17) into a reflector interior (122) of a vehicle headlamp reflector (12) having a lamp-receiving socket (121) configured to receive the lamp module (32), the reflector (12) defining adjacent the socket (121) a plurality of circumferentially disposed slots (15);
• latching the lamp module (32) to the headlamp reflector (12);
• directing a first flow of air (F1) from an exterior region (123) exterior the reflector (12) through the lamp module (32) and adjacent the solid-state light source (17);
• directing a second flow of air (F2) from the exterior region (123) exterior the reflector (12) through the lamp module (32) and through the plurality of slots (15) and thereby into the reflector interior (122);
• and
• directing a third flow of air (F3) from the lamp module (32) away from the reflector interior (122) to the exterior region (123) exterior the reflector (12).

A method of cooling a solid-state vehicle lamp module (32) retained in a vehicle headlamp reflector (12), comprising

• inserting a lamp module (32) having a solid-state light source (17) into a reflector interior (122) of a vehicle headlamp reflector (12) having a lamp-receiving socket (121) configured to receive the lamp module (32), the reflector (12) defining adjacent the socket (121) a plurality of circumferentially disposed slots (15);
• latching the lamp module (32) to the headlamp reflector (12);
• directing a first flow of air (F1) from an exterior region (123) exterior the reflector (12) through the lamp module (32) and adjacent the solid-state light source (17);
• directing a second flow of air (F2) from the exterior region (123) exterior the reflector (12) through the lamp module (32) and through the plurality of slots (15) and thereby into the reflector interior (122);
• and
• directing a third flow of air (F3) from the lamp module (32) rearward of the reflector (12) thereby bypassing the reflector interior (122).