COOLING MEMBER FOR LIGHTING AND/OR SIGNALING SYSTEM
20170219182 · 2017-08-03
Inventors
- Marc Duarte (Villemomble, FR)
- Eric Stefura (Saint-Maur-des-Fosses, FR)
- Paul Jacquemin (Paris, FR)
- Christophe Cleto (Paris, FR)
- Lotfi Redjem Saad (Paris, FR)
- Brahim El Hachir (Paris, FR)
Cpc classification
F21S41/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V29/83
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L2924/0002
ELECTRICITY
F21V29/74
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S41/151
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S45/47
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2115/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2105/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L2924/00
ELECTRICITY
H01L2924/0002
ELECTRICITY
F21S43/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S43/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L2924/00
ELECTRICITY
F21V29/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
H01L23/40
ELECTRICITY
Abstract
A cooling member for a lighting and/or signaling system for a motor vehicle comprising a base and at least one heat dissipating device with a thermal conduction link to the base, the dissipating device comprising a plurality of dissipating elements, wherein each dissipating element comprises at least one dissipating wall extending from a fixing face.
The embodiments relate also to a lighting and/or signaling system and to a method for producing the cooling member.
Claims
1. A cooling member for a lighting and/or signaling system for a motor vehicle, said cooling member comprising a base having two opposite faces, at least one of which is configured to support a light source of said lighting and/or signaling system and at least one heat dissipating device with a thermal conduction link to said base, said at least one heat dissipating device comprising a plurality of dissipating elements, wherein each dissipating element of said plurality of dissipating elements comprises at least one dissipating wall extending from a fixing face taken from one of said two opposite faces of said base and in a plane inclined relative to the plane of said fixing face, said at least one dissipating wall of said plurality of dissipating elements being prolonged by a fixing portion by which said plurality of dissipating elements are added and fixed to said fixing face, said fixing portion being formed of a single piece with the corresponding dissipating wall and extending mainly in the plane of said fixing face.
2. The cooling member as claimed in claim 1, wherein said fixing portion and the corresponding dissipating wall are formed by a folded plate, a fold of said folded plate separating said fixing portion and the corresponding dissipating wall.
3. The cooling member as claimed in claim 2, wherein said fixing portion and said dissipating wall are at an angle of 90° at said fold.
4. The cooling member as claimed in claim 1, wherein said fixing portion of a first dissipating wall is added in contact with one out of: a second dissipating wall adjacent to the said first dissipating wall or a fixing portion of said second dissipating wall.
5. The cooling member as claimed in claim 1, wherein said fixing portion of a first dissipating wall is added at a distance less than the distance D from one out of: a second dissipating wall adjacent to said first dissipating wall or said fixing portion of said second dissipating wall, said distance D being less than or equal to half the distance separating said first and second dissipating walls at said fixing portions.
6. The cooling member as claimed in claim 1, wherein said fixing portion extends at right angles to said dissipating wall that it prolongs so as to form a fin.
7. The cooling member as claimed in claim 1, wherein said dissipating element forms an air circulation channel delimited by two dissipating walls, said air circulation channel being open at two of its ends in a direction at right angles to said fixing face and said air circulation channel is open in a main extension direction in which said dissipating wall extends.
8. The cooling member as claimed in claim 1, wherein said dissipating element forms an air circulation channel delimited by two dissipating walls, said air circulation channel being open at two of its ends in a direction at right angles to said fixing face and said air circulation channel is closed in the main extension direction.
9. The cooling member as claimed in claim 8, wherein said at least one heat dissipating device forms a cellular structure, each air circulation channel forming a cell.
10. The cooling member as claimed in claim 1, wherein said dissipating elements are all formed of a single piece, two adjacent dissipating walls exhibiting a continuity of material.
11. The cooling member as claimed in claim 1, wherein each dissipating element consists of a distinct folded plate, said dissipating elements being distinct from said base and fixed thereto, notably by glue or by a weld.
12. The cooling member as claimed in claim 1, wherein said at least one heat dissipating device comprises at least one link element added to at least a plurality of, and preferably all, said dissipating walls and linking together said dissipating walls of said plurality of dissipating walls.
13. The cooling member as claimed in claim 1, wherein said at least one dissipating device comprises at least one hook integral to a fixing portion and configured to cooperate with an opening formed in an adjacent fixing portion.
14. The cooling member as claimed in claim 1, wherein a fixing portion bears a male part configured to cooperate by fitting with a female part borne by an adjacent fixing portion, the cooperation of said male and female parts preventing the separation of said adjacent fixing portions by certain relative movements of the said fixing portions.
15. A lighting and/or signaling system for a motor vehicle comprising: a cooling member as claimed in claim 1, a light source supported by one of said opposite faces of said base, and an optical device configured to modify the direction of the light radiation emitted by said light source.
16. A method for producing a cooling member as claimed in claim 1, said method comprising the following steps: producing said base; producing said at least one dissipating device by performing at least the following steps: cutting a plate to form at least one part intended to form a dissipating wall of a dissipating element and at least one part intended to form a fixing portion prolonging said dissipating wall; folding said plate so that the said fixing portion is arranged in a plane inclined relative to the plane of said dissipating wall; placing said dissipating element by fixing said fixing portion to a face of said base.
17. The method as claimed in claim 16, wherein at least a plurality of the dissipating elements exhibit between them a continuity of material and are formed from one and the same plate.
18. The method as claimed in claim 16 wherein at least a plurality of dissipating elements are formed individually before being added to the face of said base.
19. The cooling member as claimed in claim 2, wherein said fixing portion of a first dissipating wall is added in contact with one out of: a second dissipating wall adjacent to said first dissipating wall or a fixing portion of said second dissipating wall.
20. The cooling member as claimed in claim 3, wherein said fixing portion of a first dissipating wall is added in contact with one out of: a second dissipating wall adjacent to said first dissipating wall or a fixing portion of said second dissipating wall.
Description
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0078] The aims, objects, and the features and advantages of the invention will become more apparent from the detailed description of an embodiment thereof which is illustrated by the following accompanying drawings in which:
[0079]
[0080]
[0081]
[0082]
[0083]
[0084]
[0085]
[0086]
[0087] The drawings are given by way of example and the invention is not limited thereto. They constitute schematic theoretical representations intended to simplify the understanding of the invention and are not necessarily to the scale of the practical applications.
[0088] In particular, the relative dimensions of the various elements are not necessarily representative.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0089] A first embodiment of the invention will now be described with reference to
[0090] The lighting and/or signaling system comprises one or more light sources 2. Preferably, they are LEDs. In this nonlimiting exemplary embodiment, there are three of them.
[0091] The LEDs 2 are electrically connected to an electronic circuit, for example in the form of a printed circuit 3 forming a rigid or flexible PCB (printed circuit board). The LEDs 2 are supported by a base 10. In a preferable but nonlimiting manner, the LEDs 2 are directly in contact with the base 10.
[0092] The base 10 thus forms a support for the LEDs 2. The base 10 also forms part of a cooling member 1 for the lighting and/or signaling system.
[0093] To this end, the base 10 has a thermal conduction link with the LEDs 2. It absorbs the heat produced by the LED 2 in order to cool the latter.
[0094] The cooling member 1 also comprises a heat dissipating device 100.
[0095] The dissipating device 100 has a thermal conduction link with the base 10. It also has a plurality of dissipating walls 102 (
[0096] Thus, the heat generated by the LED 2 is extracted therefrom and transmitted by the base 10 by conduction. At least a part of the heat absorbed by the base 10 is then transmitted, mainly by conduction, to the dissipating device 100 which then dissipates it by convection into the surrounding environment, typically the air.
[0097] The base 10 comprises at least one portion which has two opposite and substantially planar faces. This base portion can thus be qualified as base plate in the example illustrated. According to other embodiments, the base 10 has portions additional to the base plate.
[0098] These two faces are contained in parallel planes illustrated in
[0099] Advantageously, at least one of these two faces is configured to cooperate with the dissipating device 100 in order to ensure the fixing thereof to the base 10. This face is hereinafter designated fixing face 11. In the example illustrated in
[0100] The dissipating device 100 has a plurality of dissipating elements 101 each bearing two dissipating walls 102a, 102b. These dissipating elements 101 are preferably arranged parallel to one another. The dissipating walls 102a, 102b extend from the base 10 and in a plane inclined relative to the plane xy of the faces of the base 10 and notably of the fixing face 11. As illustrated, they can extend in a plane at right angles to that of the faces of the base 10, that is to say along the plane zx.
[0101] Particularly advantageously, the dissipating elements 101 extend in the direction x, exhibiting an overhang relative to the base 10. These dissipating elements 101 are fixed to the base 10 over a portion of their dimension along the axis x which does not exceed 0.5 and preferably which does not exceed 20% of the total dimension of the dissipating element 101 in this direction x. That makes it possible to increase the exchange surface area between the dissipating element 101 and the surrounding air so as to optimize the dissipation of heat by convection.
[0102] Particularly advantageously, the dissipating elements 101 have fixing portions 107 (
[0103] the fixing of the dissipating element 101 to the base 10;
[0104] the transfer by conduction of the calories from the base 10 to the dissipating element 101.
[0105] These fixing portions 107 are adjacent to the dissipating walls 102. While the dissipating walls 102 are contained in a plane different from that of the fixing face 11 (plane xy), preferably at right angles (plane zx), the fixing portions 107 are contained in a plane parallel (xy) to that of the fixing face 11. That makes it possible to provide a significant contact surface area between the base 10 and the fixing portions 107 to increase the strength of the dissipating elements 101 and increase the transfer of the calories from the base 10 to the dissipating device 100.
[0106] Particularly advantageously, each fixing portion 107 prolongs one of the dissipating walls 102. They form one and the same part, preferably made of a single piece.
[0107] Advantageously, the dissipating wall 102 and the fixing portion 107 are obtained from one and the same plate or one and the same sheet and are folded to be arranged in two different planes.
[0108] A join 116, illustrated in
[0109] Thus, and particularly advantageously, the dissipating device 100 is added to the base 10 and can therefore be produced independently of the base 10. The invention thus offers a great degree of freedom of choice both in materials and in the manufacturing methods for each of the base 10 and the dissipating element 101.
[0110] For example, the base 10 will be produced by molding or by injection molding (or die casting) or even by stamping or die-stamping. That makes it possible to obtain a base 10 simply and inexpensively, having a great thermal density in order to offer a high capacity to extract the heat from the LED 2 and to store it within the base 10. If the base 10 is formed by casting, an aluminum-based alloy, for example an alloy of aluminum and silicon, with a content by weight of approximately 11%, will for example be chosen. That makes it possible to facilitate the correct filling of the mold. If the base 10 is formed by stamping, it will then be possible to use aluminum or an aluminum alloy having a higher proportion of aluminum (typically greater than 90%). That makes it possible to improve the thermal conductivity of the base 10.
[0111] Regarding the dissipating device 100, it will be produced preferably from a previously cut plate or sheet. This technique makes it possible, unlike the casting or stamping, to easily obtain thin thicknesses. Typically, the thickness of the folded plate corresponds to the thickness of the dissipating walls 102. The dissipating elements 101 thus have a large surface area and small thicknesses making it possible thereby to optimize the exchange surface area with the air and very quickly dissipate the calories arriving from the base 10 at the dissipating device 100.
[0112] By injection, because of the clearances needed and the arrangement of the injectors, it would be much more difficult to obtain a great density of thin walls. Preferably, the dissipating elements 101 are made of aluminum.
[0113] The base 10 and the dissipating elements 101 thus have two complementary functions which, by synergy, allow for a very effective cooling of the LEDs 2.
[0114] The base 10 extracts the calories produced by the LEDs 2, stores them and can transfer them quickly to the dissipating elements 101 via the fixing portions 107. For their part, the dissipating elements 101 dissipate the calories added by the base 10 into the air by convection.
[0115] As illustrated in
[0116] In this example illustrated in
[0117] Thus, certain channels 103′ (
[0118] It will be noted that, particularly advantageously, the presence of the fixing portions 107 makes it possible to ensure a good thermal transfer between the base 10 and the dissipating device 100 while promoting the circulation of the air within the channels 103. In effect, these channels 103 are mostly open.
[0119] Compared to a configuration in which the channels 103 would be formed by fins joined two-by-two so as to form a “U”, the ends of the branches of the “U” resting partly on the base 10 and extending along the dimension x, the invention offers the same advantage as previously. Moreover, it offers the advantage of not closing the channel 103 over its entire dimension along the axis x, but only over the portion of channel 103 in contact with the base 10, thereby enhancing the circulation of the air along the axis z, and the dissipation of the calories.
[0120] Compared to a configuration in which the channels 103 would be formed by fins joined two-by-two so as to form a “U”, the bottom of the “U” extending at right angles to the base 10 and therefrom, the invention offers the advantage of increasing the exchange surface area between the dissipating elements 101 and the base 10 without hampering the circulation of the air.
[0121] Advantageously, and as illustrated in
[0122] This configuration makes it possible to dissipate the calories even more effectively. Preferably, the dissipating walls 102a of the dissipating device 100a are situated in line with the dissipating walls 102b of the dissipating device 100b. Two dissipating walls 102a, 102b therefore together form one and the same dissipating wall 102a, of one and the same channel. The air can therefore more easily circulate along the axis z.
[0123]
[0124] In each of these variants, the dissipating device 100 is preferably formed by a continuous plate folded so as to define the dissipating walls 102 parallel to one another and the fixing portions 107 at right angles to the dissipating walls 102. There is thus continuity of material between the dissipating elements 101.
[0125]
[0126] The dissipating device 100 comprises seven dissipating elements 101 together bearing 14 dissipating walls 102 and 13 channels 103. The distance between two dissipating walls 102 is consecutive and for example 6 mm. Two consecutive dissipating walls 102 are linked together by a rounded portion. The dissipating walls 102 situated at the end of the dissipating device 100 along the axis x are shorter than those situated at the center. That makes it possible to increase the exchange surface area with the central part of the base 10, so as to promote the dissipation of the calories while reducing the footprint and the weight at the point where a less strong dissipation is required.
[0127]
[0128] The weight of the dissipating device 100 is therefore reduced compared to that of
[0129]
[0130] The variants of
[0131]
[0132]
[0133] This plate forms a flat element, of substantially longitudinal form, delimited by two longitudinal edges 119 each extending along the axis y. This plate defines the two fixing ends 108, the fixing portions 107 and fold lines 110, 111, 112.
[0134] The fold lines 110, 111 extend transversely from one longitudinal edge 119 to the other. The fold lines 110, 111 are intended to form the join two consecutive dissipating walls 102 (that is to say the bottom of a “U”).
[0135] Depending on the folding and the arrangement of the fold lines 110, 111, the bottom of the “U” will be rounded or flat.
[0136] The lines 110 define the folds at the proximal ends 105 whereas the folds 111 define the folds at the distal ends 104.
[0137] The fixing portions 107 are defined by cuts 113, 114, 115 and each have a join 116 with the dissipating wall 102 with which it is associated. This join 116 is intended to be folded to allow the dissipating wall 102 to be contained in the plane zx and the fixing portion 107 to be contained in the plane xy.
[0138]
[0139] The fixing portion 107 arranged on the left has been folded. It thus extends in the plane xy. The fixing portion 107 arranged to the right has not yet been folded and will be folded at the fold line 112 of the join 116 as illustrated in
[0140] This figure clearly shows the clearance of an edge 117 formed by the cutting line 113 and which appears after the folding. This edge 117 is intended to abut against the thickness of the base 10 to facilitate the positioning and the holding in position of the dissipating device 100 on the base 10.
[0141]
[0142] According to
[0143] It will be noted that this structure also allows for a contact between the fixing portion 107 and the bottom of the “U”, which enhances the propagation of the calories from the fixing portion 107 to the bottom of the “U” and dissipating walls 102 adjacent to the “U”.
[0144]
[0145] In these last two figures, it can clearly be seen that the fixing portions 107 form a mount 106 with no empty space to increase the contact surface area 109 with the base 10.
[0146] Thus, particularly advantageously, two adjacent fixing portions 107 have a discontinuity of material but are attached or are away from one another by a small distance D. D is typically less than 1/10 of the distance separating the two adjacent dissipating walls 102 at their proximal ends 105. This distance D is measured in a direction at right angles to the direction in which the dissipating walls 102 extend, in the examples illustrated, the direction y.
[0147] In all the embodiments described above, the air can circulate in channels 103 freely, along the axis z, and also along the axis x, apart from either at the proximal end 105 or at the distal end 104 of the channel 103.
[0148]
[0149] Preferably, each dissipating element 101 has a proximal portion forming a rectilinear wall extending along the axis x and which is prolonged by several cell-form channels 103.
[0150] Preferably, each dissipating element 101 is obtained individually. It is not formed of a single piece with the dissipating element 101 which is adjacent to it.
[0151] The assembly of the dissipating elements 101 forms the dissipating device 100. Preferably, the juxtaposition of two dissipating elements 101 forms, between these dissipating elements 101, cells. The assembly obtained forms a continuously cellular structure.
[0152] Preferably, a dissipating element 101 is obtained by folding on itself a sheet of metal or a plate. The two ends of the plate being fixed to one another after folding, this fixing being ensured preferentially by clinching, crimping or by electrical welding.
[0153] Advantageously, each rectilinear portion is formed by two dissipating walls 102 folded over one another. Each dissipating wall 102 is prolonged by a fixing portion 107 folded in the plane at right angles to that of the dissipating walls 102. The dissipating elements 101 are thus formed individually, but possibly simultaneously. They are then assembled and fixed to one another, preferably by clinching, crimping or by electrical welding. The assembly thus constructed forms the dissipating device 100 illustrated in
[0154] A so-called submount method can be used in which an element, for example the diode 2, is fixed directly onto a support, here the base 10, via glue or welding to optimize the thermal dissipation. This method involves the disappearance of the metal substrate on which the diode 2 is mounted. A wire bonding is therefore generally produced to a PCB 3 away from the diode 2, here a flexible PCB 3 which thus links the diode 2 to a driving circuit.
[0155] Preferably, the fixing portions 107 extend over all of the dimension along the axis x of the proximal rectilinear portion. The continuous juxtaposition of these fixing portions 107 forms the fixing mount 106, as illustrated in
[0156] Thus, and as described for the preceding embodiment, two adjacent fixing portions exhibit a discontinuity of material but are attached or are away from one another by a small distance D, typically less than 1/10 of the distance separating the two adjacent dissipating walls 102 at their proximal ends 105.
[0157] Preferably, as illustrated in
[0158] To facilitate production and reduce the costs, the dissipating devices 100a, 100b are identical.
[0159] In this embodiment, a reflector 12 is provided, arranged on the face of the base 10 which supports the LED 2.
[0160] This embodiment thus offers a structure having an optimized exchange surface area and allowing a free circulation of the air in the channels 103 along the axis z.
[0161] Depending on the constraints of weight and of thermal power to be dissipated, the density of the cells will be varied for one and the same footprint.
[0162]
[0163] These embodiments will be highly advantageous if they are applied to dissipating elements 101 obtained individually and fixed to one another to form a dissipating device 100. Nevertheless, they apply equally to the cases where the assembly of the dissipating elements 101 is formed of a single piece, typically by folding a single sheet of metal.
[0164] In this embodiment of
[0165] Advantageously, an edge of the dissipating walls 102 has a notch complementing the form of the bar 130 and configured to house at least a part of the bar 130.
[0166] The bar 130, once inserted into the notch, can be fixed to the dissipating walls 102 by welding or brazing. Thus, the cohesion of the dissipating walls 102 is reinforced.
[0167]
[0168] Preferably, the dissipating walls 102 also have slits 133 configured to receive the comb 131 at the slits 132. The fitting of the slits 132 into the slits 133 allows for a good fixing of the comb 131 to the dissipating walls 102, a fixing that is reinforced as required by welding or brazing.
[0169] Preferably, the comb 131 is obtained by cutting a metal sheet, notably to form the slits 132 and by folding one edge to form a rib 134 reinforcing the robustness of the assembly.
[0170]
[0171] A hook 135 borne by the fixing portions 107 of the first dissipating wall 102 is provided to penetrate into an opening 136 formed in the second dissipating wall 102 and in proximity thereto. The hook 135 is configured to engage with the second dissipating wall 102.
[0172] Advantageously, the hooks 135 form part of the metal sheet forming the dissipating walls 102.
[0173] To ensure the activation of the hook 135 fixing after the juxtaposition of the dissipating walls 102 and of the fixing portions 107, the hooks 135 are folded by bending them back so as to make them penetrate into the opening 136 of the adjacent fixing portion 107.
[0174]
[0175] As illustrated in these figures, the fixing portions 107 bearing these two male and female parts 137, 138 form two pieces of a puzzle. That makes it possible to facilitate the mutual positioning and holding in position of the dissipating elements 101. Thus, a fixing portion 107 bears a male part 137 configured to cooperate by fitting with a female part 138 borne by a fixing portion 107 which is adjacent to it. The dissipating device 100 is configured so that the cooperation of the male and female parts 137, 138 prevents the separation of the adjacent fixing portions 107 when the adjacent fixing portions 107 are displaced relatively in a direction (direction X or Y) parallel to the plane of the faces of the base 10. On the other hand, a relative displacement of the fixing portions 107 in a direction (direction Z) at right angles to the plane of the faces of the base 10 allows for a separation of the fixing portions 107.
[0176] Also, the dissipating walls 102 of the dissipating device 100 have a particular form based on the embodiment illustrated in
[0177] The corrugation thus generates an alternation of dips and peaks on the faces of the dissipating walls 102. As in the example illustrated, the peaks of the faces of two adjacent dissipating walls 102 forming an air channel, these faces facing one another, are opposite to one another. Similarly, the dips of these faces are opposite to one another.
[0178] This corrugation can for example be formed by a plurality of successive folds, for example the dissipating walls being in zig-zag form. From the above description, it clearly emerges that the invention offers a particularly effective solution for dissipating the calories stored by the base 10. The arrangement of the dissipating walls 102, in particular their overhang relative to the base 10, their forming possibly by folding, the free circulation of air that they allow and the good thermal transfer between the base 10 and the dissipating walls 102, reinforce the effectiveness of the thermal dissipation.
[0179] The invention is not limited to the embodiments previously described and extends to all the embodiments covered by the claims.
[0180] In particular, the invention extends to dissipating devices 100 formed by dissipating elements 101 produced individually then assembled together or, on the other hand, from dissipating elements 101 linked together and formed from one and the same family of metal.
[0181] Moreover, the invention is not limited to walls and channels having the forms illustrated in the figures. It encompasses any form of walls and channels and extends in particular to walls forming fins.
[0182] While the system, apparatus, process and method herein described constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to this precise system, apparatus, process and method, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.