# US 2014/0193929 A1 · Integrated Reflector and Thermal Spreader and Thermal Spray Fabrication Method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0193929 A1 - Document ID: US20140193929A1 - Status: Published application - Kind: A1 - Application number: 14/101,240 - Filed: 2013-12-09 - Published: 2014-07-10 - Earliest claimed: 2010-12-21 - Assignees: Palo Alto Research Center Incorporated - Applicants: Palo Alto Research Center Incorporated - Inventors: John S. Paschkewitz; Eric Shrader - Web page: https://patentgrep.com/patent/US20140193929A1 ## CPC - F21V 29/51: using condensation or evaporation of a fluid, e.g. heat pipes - F21V 7/10: Construction - F21V 29/505: of reflectors - F21V 29/773: {the planes containing the fins or blades having the direction of the light emitting axis} - F28D 15/0233: {the conduits having a particular shape, e.g. non-circular cross-section, annular (F28D15/0241, F28D15/0266 take precedence)} - F28D 15/0266: {with separate evaporating and condensing chambers connected by at least one conduit; Loop-type heat pipes; with multiple or common evaporating or condensing chambers (F28D15/043 takes precedence)} - H10H 20/8582: {characterised by their shape} - F21Y 2115/10: Light-emitting diodes [LED] - F28F 2255/00: Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes - H10W 40/73: for cooling by change of state - F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR - F28D: HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT (fluid heaters having heat generating means and heat transferring means F24H; furnaces F27; details of heat-exchange apparatus of general) - H10H: INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS - 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 - F28F: DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION (water and air traps, air venting F16) - H10W: GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10 ## Abstract A low-cost integrated reflector and heat spreader for high-density high power solid-state (e.g., LED) lighting arrays includes a base structure onto which is applied a sacrificial material. A relatively thick thermal spray coating is applied over the base structure and sacrificial material. The sacrificial material is removed. A channel(s) is thereby provided within the thermal spray coating layer and in physical contact with the base structure. The channel may be filled with a cooling fluid. A pulsating heat pipe heat spreader may thereby be provided. A reflective material may be provided either over another surface of the base structure or alternatively over the thermal spray coating layer to provide a surface for reflecting and directing light emitted from a solid state light source that may be secured to the integrated reflector and heat spreader. ## Claims ### Claim 1 A method for fabricating an optical element comprising: forming over a first surface of a base structure having a light emitter receiving region formed therein a pattern of sacrificial material; applying a thermal spray coating over said first surface of said base structure and said sacrificial material to thereby form a thermal spray coating layer except over said light emitter receiving region; and removing said sacrificial material to thereby leave a substantially enclosed channel within said thermal spray coating layer, said channel configured to receive and retain a cooling medium therein, said channel further configured in a serpentine pattern extending between a hot region of said base structure proximate said light emitter region and a cold region of said base structure spaced away from said hot region. ### Claim 2 (depends on 1) The method of claim 1, further comprising forming a sealable port in said channel and filling said channel through said port with a cooling fluid. ### Claim 3 (depends on 2) The method of claim 2, wherein said cooling fluid is selected from the group consisting of: water, saturated steam, alcohol, propylene glycol, and ethylene glycol. ### Claim 4 (depends on 2) The method of claim 2, wherein said channel thereby forms a pulsating heat pipe thermal spreader. ### Claim 5 (depends on 1) The method of claim 1, wherein said thermal spraying comprises spraying a molten metal powder onto the base structure. ### Claim 6 (depends on 1) The method of claim 1, wherein said thermal spraying comprises powder coating a polymer onto the base structure. ### Claim 7 (depends on 3) The method of claim 3, further comprising applying a reflective coating to a second surface of said base structure opposite said first surface. ### Claim 8 (depends on 7) The method of claim 7, wherein said reflective coating is deposited by way of physical vapor deposition. ### Claim 9 (depends on 7) The method of claim 7, further comprising securing a solid-state light emitting device to said base structure at said light emitter receiving region. ### Claim 10 (depends on 1) The method of claim 1, further comprising forming a plurality of discrete patterns of sacrificial material over said first surface of said base structure, whereby following said applying a thermal spray coating and removing said sacrificial material a plurality of non-interconnected channels are formed in said thermal spray coating layer. ### Claim 11 (depends on 10) The method of claim 10, further comprising forming a sealable port in each said channel, and filling each said channel through its port with a cooling fluid. ### Claim 12 (depends on 1) The method of claim 1, wherein said sacrificial material is formed to have serpentine shape and said channel forms a micro heat pipe. ### Claim 13 (depends on 1) The method of claim 1, wherein said sacrificial material is formed to have a first cross-section shape over a first portion of said base structure closest to said light emitter receiving region and a second different cross-section shape over a second portion of said base structure farthest from said light emitter receiving region.