Expandable Ring Heat Sink for Removable LED Mounting
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Solution Overview
Problem
Conventional heat-dissipating structures in lighting fixtures are permanent, causing distortion and damage to the housing during assembly, making maintenance difficult and costly, especially in fixtures with multiple LED modules.
Innovation Solution
A removable heat-sink assembly with a first and second plate and an expandable ring, where the second plate is drawn toward the first plate upon tightening, allowing the expandable ring to expand and make heat-transfer contact with the housing interior, facilitating easy access for maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat-dissipating structure is welded to the housing, then heat dissipation is effective, but the housing is distorted
Solution Approach 1:
The patent introduces a separate heat-dissipating structure that acts as an intermediary between the LED module and the housing. This structure includes a mounting plate with a heat-dissipating element that can be attached to the housing without welding, thereby mediating the heat transfer while protecting the housing from distortion.
Solution Approach 2:
The heat-dissipating structure is segmented into distinct components: a mounting plate for attachment to the housing, a heat-dissipating element (such as a finned structure), and a LED mounting portion. This segmentation allows each component to be optimized independently and facilitates non-destructive assembly.
2Ease of manufacture
If a heat-dissipating structure is forced into the housing, then assembly is achieved, but the housing is significantly damaged
Solution Approach 1:
The mounting plate serves as an intermediary that distributes assembly forces evenly across the housing surface, preventing localized damage. The plate can be secured with fasteners that apply controlled pressure without requiring excessive force that would damage the housing.
Solution Approach 2:
The heat-dissipating structure incorporates cushioning elements or compliant features that absorb assembly forces and prevent transmission of damaging shocks to the housing during installation.
3Temperature
If a heat-dissipating structure is permanently mounted, then heat dissipation is maintained, but maintenance access is blocked
Solution Approach 1:
The heat-dissipating structure is designed with dynamic, reversible mounting features that allow it to be easily installed and removed. The mounting plate can be attached with removable fasteners, enabling maintenance personnel to access the housing interior when needed while maintaining heat dissipation during normal operation.
Solution Approach 2:
The segmented design separates the heat-dissipating element from the housing, allowing the heat-dissipating portion to be removed independently for maintenance access while leaving the housing intact. The mounting plate can be detached without damaging the housing.
4Temperature
If multiple heat-dissipating plates are welded to the housing, then heat management is improved, but maintenance difficulty increases
Solution Approach 1:
Each heat-dissipating structure is segmented into removable modules that can be independently installed and removed. This allows multiple LED modules to have their own dedicated heat-dissipating structures without creating a permanently sealed housing, simplifying maintenance of multiple components.
Solution Approach 2:
The mounting plate design serves multiple functions: providing a mounting surface for the LED module, facilitating heat dissipation, enabling easy installation and removal, and protecting the housing. This multi-functionality reduces overall system complexity despite having multiple heat-dissipating structures.
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
The solution provides effective heat dissipation, simplifies assembly and maintenance, and reduces manufacturing and maintenance costs by allowing easy removal and reinstallation of the heat-sink assembly.
Implementation Method 1
The expandable ring includes an inward peripheral edge engaging the camming surface and an outward heat-transfer surface and is expandable to beyond the peripheries of the first and second plates
Data Source
AI summary
A heat sink assembly for mounting an LED module to a surrounding main heat sink member is disclosed. The heat sink assembly has a first plate with inner and outer faces and a peripheral edge. The assembly further includes a second plate that is movable with respect to the first plate and has inner and outer faces and an inwardly-tapered peripheral camming surface. Also included in the assembly is an expandable ring sandwiched between the first and second plates. The ring has an inward peripheral edge that engages the camming surface and an outward heat-transfer surface. The ring is expandable beyond the peripheries of the first and second plates. The heat sink assembly also has a sandwiching-device that adjustably interconnects the first and second plates such that sandwiching of the ring facilitates heat-transfer engagement of the heat-transfer surface with the main heat sink member.