Flexible Lighting Device with Segmented Heatsinks
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Solution Overview
Problem
Conventional flexible LED rope lights face limitations in heat dissipation, leading to shortened operating life when driven at high currents, and lack efficient means for individual emitter control without increasing cost and bulk.
Innovation Solution
The use of multiple heatsink elements with flexible connections, where each heatsink is arranged to dissipate heat generated by solid state emitters, with at least a portion exposed to an ambient air environment, allowing for effective thermal management and reduced thermal stratification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional flexible LED rope lights are used with limited heat dissipation means, then the device maintains flexibility and can conform to contours, but the LEDs overheat leading to shortened operating life and limited ability to handle high currents
Solution Approach 1:
The patent divides the heatsink into multiple discrete heatsink elements (first heatsink element, second heatsink element, etc.) that are distributed along the flexible circuit board. Each heatsink element is associated with specific LEDs and can dissipate heat independently, preventing thermal accumulation and allowing the device to handle higher currents without overheating.
Solution Approach 2:
The patent transitions from conventional end-ventilated heat dissipation to a multi-dimensional approach by distributing heatsink elements along the length of the flexible circuit board. This allows heat to be dissipated from multiple locations simultaneously, effectively adding a longitudinal dimension to the heat dissipation pathway and reducing thermal stratification.
2Temperature
If multiple heatsink elements are distributed along the flexible circuit board, then heat dissipation efficiency improves and thermal stratification is reduced, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into the heatsink elements: they serve as thermal management components, structural supports for mounting LEDs, and electrical connection pathways. This integration reduces the need for separate components and simplifies the overall device architecture despite the distributed configuration.
Solution Approach 2:
The heatsink elements are designed to perform multiple functions simultaneously: dissipating heat from associated LEDs, providing mechanical support for LED mounting, conducting electrical signals, and maintaining the flexible structure's integrity. This multi-functionality reduces the need for additional specialized components.
3Power
If conventional rope lights with heat trapped within the tube are used, then the structure remains simple and compact, but the ability to drive the rope light at high operating currents is limited
Solution Approach 1:
The patent extracts the heat dissipation function from the enclosed tube structure and implements it through distributed heatsink elements that extend beyond the flexible circuit board. This allows heat to be efficiently transferred from the LEDs to the heatsink elements and then to the surrounding air, enabling high operating currents without thermal accumulation within the tube.
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 enables flexible solid state lighting devices to operate at higher currents without reducing emitter life, while allowing for individual or group emitter control, reducing cost and bulk, and enhancing heat dissipation efficiency.
Implementation Method 1
multiple heatsink elements with flexible connections therebetween, with each heatsink element being arranged to dissipate heat generated by one or more solid state emitters
Data Source
AI summary
Lighting devices include multiple heatsink elements arranged to dissipate heat generated by the multiple solid state emitters, with non-rigid coupling between heatsink elements. At least a portion of each heatsink element is preferably exposed to an ambient environment. Each heatsink element may include a switching element, may be addressable, and may receive wired or wireless control signals. A modular solid state lighting unit includes a heatsink and at least one solid state light emitter, with at least one flexible element secured to the heatsink element and to multiple electrical couplings. Flexible rope lights and two-dimensional arrays of emitters are provided.