Flexible Printed Circuit Board Routing for LED Heat Dissipation
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Solution Overview
Problem
Semiconductor radiation sources face challenges in combining high power with good cooling and compact, adaptable arrangements, particularly in dental technology applications, where flexible carrier layers with high elasticity are required but restrict large line cross sections.
Innovation Solution
A semiconductor radiation source design featuring a base body with an LED chip thermally connected to it, and a pliable flexible printed circuit board that surrounds the LED chip, with angled or bent sections extending along the base body's side wall and into cutouts, allowing for large conductor track cross sections and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible carrier layer with high elasticity is used to follow a round form, then adaptability to different shapes is improved, but large line cross sections cannot be accommodated
Solution Approach 1:
The flexible printed circuit board extends in three-dimensional space by bending around the cooling rod and extending into cutouts, utilizing spatial dimensions rather than relying solely on planar area. This allows conductor tracks to achieve large effective cross-sections through 3D routing while maintaining flexibility for curved geometries.
Solution Approach 2:
The flexible printed circuit board is divided into multiple sections with different functions: a first section on the cooling rod surface, a second section extending into a cutout, and a third section continuing the conductor track. This segmentation allows each section to be optimized for its specific role, with conductor tracks distributed across multiple segments to achieve large effective cross-sections.
2Power
If currents of considerable magnitude are fed to provide desired light power, then power output is improved, but cooling requirements and feed line cross-sectional dimensions increase
Solution Approach 1:
Conductor tracks extend into the third dimension by routing through cutouts in the base body, increasing their effective path length and cross-sectional area without increasing the planar footprint. This enables high current capacity feed lines to be integrated into a compact structure.
Solution Approach 2:
The flexible printed circuit board with large cross-section conductor tracks is nested within the base body structure by extending into internal cutouts. This nesting approach allows large current-carrying conductors to be housed within the compact base body without increasing external dimensions.
3Ease of operation
If a flexible printed circuit board extends areally on the heat sink surface, then ease of bending is improved, but conductor track cross section is restricted
Solution Approach 1:
The flexible printed circuit board transitions from a purely planar arrangement on the heat sink surface to a three-dimensional configuration that extends into vertical cutouts. This dimensional transition allows conductor tracks to achieve large cross-sections while maintaining the flexibility needed to conform to the heat sink geometry.
Solution Approach 2:
Different regions of the flexible printed circuit board have different functional properties: the first section provides flexible mounting on the curved surface, while the second section extending into the cutout provides large cross-section conductor tracks for high current capacity. This local differentiation resolves the contradiction between flexibility and conductor size.
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 design enables high-power current supply to LED chips with improved cooling and compactness, accommodating electronic components in a protected manner without impairing heat dissipation, and allows for easy assembly and maintenance.
Implementation Method 1
at least one LED chip (16) which is thermally connected to an end side (22) of the base body (12)
Implementation Method 2
at least one LED chip (16) which is thermally connected to an end side (22) of the base body (12)
Data Source
AI summary
The invention relates to a semiconductor radiation source comprising a base body which is connected to at least one LED chip thermally connected to an end side of the base body and a pliable flexible printed circuit board fitted on the same end side of the base body. The flexible printed circuit board at least partly surrounds the LED chip, has at least one printed-on conductor track (20) electrically connected to the LED chip and, in the peripheral region of the base body, has an angled-away section (27) extending at least partly along a side wall of the base body. At least one part of the section of the flexible printed circuit board (14) extends at least partly in an in particular lateral cutout (34) into the base body (12).