Integrated Reflector and Thermal Spreader and Thermal Spray Fabrication Method

摘要

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.

主权项

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.