Angled LED Frame Heat Sink Design
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Solution Overview
Problem
Conventional LED lighting fixtures face challenges in integrating effective heat management, mechanical support, and optical control, leading to efficiency degradation and premature failure due to heat accumulation, and lack compactness and cost-effective manufacturing.
Innovation Solution
The LED lighting fixture incorporates a reflective enhancing material, aluminum frames and housing acting as a heat sink, with LED modules mounted at an angle and a lens for light distribution, along with a vented junction box for natural convection, to manage heat and provide efficient lumens output while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional heat management systems are separated from optical systems, then manufacturing is simplified, but compactness and integration are reduced
Solution Approach 1:
The patent combines the heat management system (heat sink) and optical system (reflector, lens, LED modules) into a single integrated housing structure. The housing simultaneously serves as the structural framework, thermal dissipation pathway, and optical element mounting platform, eliminating the need for separate heat management components and reducing overall system complexity while improving compactness
2Illumination intensity
If LED modules are mounted at an angle on the frame, then light distribution is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements different mounting configurations for different LED modules within the same system. Some LED modules are mounted at angles on frames while others may be positioned differently, allowing each module to be optimized for its specific lighting function and directionality requirements, thereby improving overall light distribution without requiring all modules to meet the same stringent precision standards
3Temperature
If the housing acts as a heat sink, then thermal management is improved, but manufacturing complexity increases
Solution Approach 1:
The housing is designed to perform multiple functions simultaneously: it provides the structural framework for mounting optical components, serves as the heat sink for thermal management, and acts as the enclosure for the entire lighting system. This multi-functionality eliminates the need for separate heat sink components, reducing the total number of parts and simplifying the manufacturing process while maintaining effective heat dissipation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively dissipates heat, maintains low operating temperatures, and achieves high lumen output with extended lifespan and improved reliability, enhancing thermal management and manufacturing efficiency.
Implementation Method 1
The LED based lighting fixture can be substantially made of an aluminum material, and acts as a heat sink to dissipate heat generated by the one or more LED module
Implementation Method 2
the junction box can be vented via natural convection by one or more vents
Implementation Method 3
at least one reflector having a reflective enhancing material to reflect light
Data Source
AI summary
A light-emitting diode (“LED”) based lighting fixture is provided. The LED based lighting fixture includes at least one reflector having a reflective enhancing material to reflect light and at least one frame are attached on a top surface of at least one housing. Further, one or more LED module mounted on a top surface of the at least one frame to emit light, the at least one frame oriented at an angle in a range of 10° to 45° degrees or approximately 30° degrees extending from a plane perpendicular to a plane of the top surface of the at least one housing. Finally, at least one lens such as a frost lens or a translucent lens can be positioned approximate to a bottom surface of the at least one housing for reflective light to emit there through.