# US 9,435,527 B1 · Thermal venting apparatus and method for LED modules

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- Number: US 9,435,527 B1
- Document ID: US9435527B1
- Status: Granted
- Kind: B1
- Application number: 14/504,705
- Filed: 2014-10-02
- Granted: 2016-09-06
- Earliest claimed: 2013-10-04
- Assignees: Universal Lighting Technologies, Inc.
- Applicants: Universal Lighting Technologies, Inc.
- Inventors: Theodore E. Kluska; Travis L. Berry
- Web page: https://patentgrep.com/patent/US9435527B1

## CPC

- F21V 3/00: Globes; Bowls; Cover glasses (with refracting properties F21V5/00; with reflecting properties F21V7/00; characterised by cooling arrangements F21V29/506)
- F21V 29/83: the elements having apertures, ducts or channels, e.g. heat radiation holes
- H05K 1/0272: {Adaptations for fluid transport, e.g. channels, holes}
- F21Y 2105/10: comprising a two-dimensional [2D] array of point-like light-generating elements
- F21Y 2115/10: Light-emitting diodes [LED]
- H05K 3/0061: {onto a metallic substrate, e.g. a heat sink (heat sinks for electric apparatus H05K7/20)}
- H05K 2201/0116: Porous, e.g. foam
- H05K 2201/09063: Holes or slots in insulating substrate not used for electrical connections
- H05K 2201/10106: Light emitting diode [LED]
- H05K 2203/1178: Means for venting or for letting gases escape
- F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- 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

## Abstract

A light emitting apparatus includes a substrate, a light emitter mounted on the substrate, and a lens at least partially covering the light emitter, the lens defining a space about the light emitter. A heat sink is attached to the substrate. The heat sink is configured to dissipate heat from the light emitter via the substrate. The substrate includes an opening communicated with the space. A vent passage is at least partially defined between the heat sink and the substrate, the vent passage communicating the opening in the substrate with an exterior of the heat sink.

## Claims

### Claim 1

A light emitting apparatus comprising:
a substrate;
a light emitter mounted on the substrate;
a lens at least partially covering the light emitter, the lens defining a space about the light emitter;
a heat sink attached to the substrate, the heat sink configured to dissipate heat from the light emitter via the substrate;
an opening in the substrate, the opening communicated with the space; and
a vent passage at least partially defined between the heat sink and the substrate, the vent passage communicating the opening in the substrate with an exterior of the heat sink.

### Claim 2 (depends on 1)

The apparatus of claim 1, wherein the heat sink further comprises:
a substrate mating surface attached to the substrate; and
a channel defined in the substrate mating surface, the channel communicated with the opening in the substrate, the channel forming at least a portion of the vent passage between the heat sink and the substrate.

### Claim 3 (depends on 2)

The apparatus of claim 2, wherein the vent passage further comprises a vent hole through the heat sink, the vent hole communicating the channel defined in the substrate mating surface with the exterior of the heat sink, thereby communicating the opening in the substrate with the exterior of the heat sink.

### Claim 4 (depends on 3)

The apparatus of claim 3, wherein the vent hole extends through an exterior surface of the heat sink positioned opposite the substrate mating surface on the heat sink.

### Claim 5 (depends on 2)

The apparatus of claim 2, wherein:
the heat sink further comprises a lateral perimeter surface; and
the channel defined in the substrate mating surface extends through the lateral perimeter surface to communicate the opening in the substrate with the exterior of the heat sink.

### Claim 6 (depends on 2)

The apparatus of claim 2, wherein the channel extends beyond the substrate on the substrate mating surface, such that an exit opening for the vent passage is formed in the substrate mating surface.

### Claim 7 (depends on 1)

The apparatus of claim 1, further comprising a porous thermal interface material disposed in the vent passage.

### Claim 8 (depends on 1)

The apparatus of claim 1, further comprising:
a second light emitter mounted on the substrate;
a second lens at least partially covering the second light emitter, the second lens defining a second space about the second light emitter;
a second opening in the substrate, the second opening communicated with the second space; and
the vent passage communicating the second opening with an exterior of the heat sink.

### Claim 9 (depends on 1)

The apparatus of claim 1, wherein:
the apparatus further comprises
a plurality of lighting assemblies mounted to the substrate, each lighting assembly including a corresponding light emitter and a corresponding lens at least partially covering the corresponding light emitter, the corresponding lens defining a corresponding space about the corresponding light emitter, and
a plurality of openings in the substrate, each opening in the substrate communicated with a corresponding space in a corresponding lighting assembly of the plurality of lighting assemblies; and
the vent passage communicates each opening in the plurality of openings with the exterior of the heat sink.

### Claim 10 (depends on 9)

The apparatus of claim 9, wherein:
the plurality of lighting assemblies further comprises a first row of lighting assemblies and a second row of lighting assemblies;
the vent passage further comprises a first portion and a second portion;
the first portion of the vent passage is communicated with the openings in the substrate corresponding to the first row of lighting assemblies; and
the second portion of the vent passage is communicated with the openings in the substrate corresponding to the second row of lighting assemblies.

### Claim 11 (depends on 1)

The apparatus of claim 1 wherein the lens is a diffuser.

### Claim 12 (depends on 1)

The apparatus of claim 1, further comprising a breathable barrier in communication with the vent passage, the breathable barrier configured to allow gases to pass through the vent passage while preventing liquid and dust from passing through the vent passage.

### Claim 13 (depends on 1)

The apparatus of claim 1, wherein an encapsulant at least partially covers the lens and the substrate, the encapsulant providing a seal between the lens and the substrate.

### Claim 14 (depends on 1)

The apparatus of claim 1, wherein the substrate is a printed circuit board.

### Claim 15

A light emitting apparatus comprising:
a substrate;
an LED mounted on the substrate;
a lens attached to the substrate, the lens defining a space about the LED between the lens and the substrate;
a heat sink attached to the substrate, the heat sink configured to dissipate heat away from the LED via the substrate;
an opening in the substrate, the opening communicated with the space about the LED; and
a vent passage at least partially defined between the substrate and the heat sink, the vent passage communicating the opening in the substrate with an exterior of the apparatus.

### Claim 16 (depends on 15)

The apparatus of claim 15, wherein:
the lens further comprises a peripheral flange positioned adjacent the substrate; and
the apparatus further comprises an encapsulate covering the substrate and the flange on the lens, the encapsulant providing a seal between the lens and the substrate.

### Claim 17 (depends on 16)

The apparatus of claim 16, wherein the heat sink has a raised peripheral rim configured to retain the encapsulant.

### Claim 18 (depends on 15)

The apparatus of claim 15, wherein the heat sink defines a housing for the apparatus.

### Claim 19

A method of venting an LED light source, the method comprising:
(a) mounting an LED on a substrate;
(b) covering the LED with a lens to form an LED cavity about the LED, the LED cavity formed between the substrate and the lens;
(c) attaching a heat sink to the substrate on a side of the substrate opposite the LED; and
(d) providing an opening in the substrate in communication with the LED cavity and providing a vent passage at least partially defined between the substrate and the heat sink, the vent passage communicating the opening in the substrate and the LED cavity with an exterior of the heat sink.

### Claim 20 (depends on 19)

The method of claim 19, wherein the vent passage further comprises an exit opening to an exterior of the heat sink, and the method further comprises providing a breathable barrier over the exit opening, the breathable barrier allowing the passage of gases through the vent passage while preventing the passage of liquid and dust through the vent passage.