LEDs making the cut for light surgical headsets

Using active cooling technology, Cool-View has developed a surgical headlight system that uses a single LED to match the light output of a 350W xenon fiber-optic system. Headlight systems designed to illuminate delicate and complicated surgical procedures typically use a xenon lamp as the light source. However, LEDs are proving to be ideal for this application, and enable portable headsets with much improved performance.
Xenon-based systems typically include a 400W light source, mounted on a stand, which is connected to the surgeon's headset via a fiber-optic cable. This causes movement restrictions, and carries the risk of overheating and electrical problems.
The use of an LED source eliminates the fiber-optic cable, and enables a battery-powered headset to be truly portable. However, one major issue is to ensure that sufficient light can be generated without the LED source becoming too hot.

Cool-View of Lakeland, Florida has developed a surgical headlight system (the Novalite Micro XL 1400) that uses a single LED source to produce 100,000 lux at a distance of 14 inches with a 50 mm-diameter light field. The beam diameter can be Focused between 50 and 120 mm.
The light-source module contains a single LED from Cree. “We overdrive it at 125-150% of the recommended current,” says Cool-View's Dave Medinis. “The light output is equivalent to a 350 W xenon system.”
The key to generate plenty of light is active cooling to prevent the LED getting too hot, explains Medinis. "Our first-generation system used liquid cooling, but we now have an air-cooled system covered by granted and pending patents," he says "Although we dissipate around 25W of heat, the LED is practical at ambient temperature."
Of course, this cool operation is necessary to prevent discomfort for the surgeon, who may have to wear the headset for several hours.

The LED-based light source is mounted onto a lightweight headset, and powered by a battery pack providing a 4-hour life from a 30-minute charge. The headset weighs 3.5 oz and the battery pack weighs 7 oz.
The 24 V battery produces up to 2.5 A, and the LED is driven in constant-current mode using an in-house driver built around a driver IC from Linear Technology.
The LED has a color temperature of 6500K, which is higher in value than halogen or xenon sources, and means the light is closer in appearance to daylight, further assisting the surgeon.

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