Flexible Heat Sink for LED Light Modules

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Solution Overview

Problem

Rigid and static heat sinks in LED light fixtures limit design flexibility and efficiency, as they require lowering power levels to maintain thermal operating levels, reducing the benefits of LED light sources compared to conventional sources.

Innovation Solution

A flexible heat sink member, such as a braided tin-plated copper component, is thermally coupled with the LED light module to allow for adjustable and rotatable LED light sources while effectively dissipating heat, thereby enabling higher power levels and improved efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If rigid and static heat sinks are used in LED light fixtures, then thermal control is provided, but design flexibility is limited and power efficiency is reduced

Engineering Contradiction:

Improvethermal controlVSAvoiddesign flexibility

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The patent applies the dynamics principle by transitioning from rigid, static heat sinks to flexible, movable heat sink components. The flexible heat sink can be positioned and oriented to accommodate various LED module configurations and directions, enabling the heat sink to adapt dynamically to different design requirements while maintaining effective thermal control.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent directly applies this principle by using a flexible heat sink component that can bend and conform to different spatial arrangements. This flexible component allows the heat dissipation system to adapt to enclosed fixture designs and various LED orientations without compromising thermal performance or design flexibility.

Inventive Principle:

Principle #30Flexible shells and thin films

2Temperature

If rigid heat sinks are used to control thermal operating levels, then heat dissipation is achieved, but power efficiency of LED sources decreases

Engineering Contradiction:

Improveheat dissipationVSAvoidpower efficiency

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The flexible heat sink enables better thermal management that allows LED sources to operate at higher power levels efficiently. By adapting to optimal positioning, the flexible heat sink maximizes heat dissipation effectiveness, allowing the LED to operate at higher efficiencies without thermal constraints.

Inventive Principle:

Principle #15Dynamics

3Temperature

If static heat sinks are used in enclosed fixtures, then thermal management is provided, but LED rotation and aiming capabilities are limited

Engineering Contradiction:

Improvethermal managementVSAvoidLED rotation capability

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The flexible heat sink component can move and conform alongside the LED module as it rotates or changes direction. This dynamic flexibility allows the LED to be aimed in various directions while the heat sink maintains optimal thermal contact, enabling both thermal management and directional adjustability in enclosed fixtures.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible nature of the heat sink allows it to accommodate the movement and repositioning of LED modules within enclosed fixtures. The flexible component can bend and adapt to different positions, enabling LED rotation and aiming capabilities while maintaining effective heat dissipation throughout the range of motion.

Inventive Principle:

Principle #30Flexible shells and thin films

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 flexible heat sink system allows for enhanced thermal management, enabling higher power and longer life of LED light sources while maintaining design flexibility, particularly in recessed or enclosed fixtures, by ensuring efficient heat dissipation without interfering with the rotation or aiming of directional LED light sources.

Implementation Method 1

at least one flexible heat sink member is thermally coupled with at least a portion of the LED light module

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8746927B1Systems, methods, and devices for providing flexible heat sinks to light modules

Publication Date: 2014.06.10 SIGNIFY HOLDING BV

AI summary

An LED-based light fixture that includes a light fixture housing forming a light emission aperture, one or more LEDs attached to a circuit board that is surrounded by the light fixture housing and emits light through the light emission aperture when powered. The LED-based light fixture further includes at least one flexible heat sink member that is thermally coupled with at least a portion of the circuit board and the light fixture housing.