Folded Heat Sink Shielding Electrical Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fragile electrical connections, wires, or ribbons in lighting modules are prone to breakage during manufacturing and installation, leading to potential failure of the entire module if the connection between light sources and the printed circuit board is compromised.
Innovation Solution
A heat sink is designed with folded walls to protect the electrical connections and wires by positioning them between the first and second wall portions, providing a shield and support while mounting the light sources and printed circuit board, and incorporating a light guide and cover to secure the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical connections, wires or ribbons are made more robust to prevent breakage, then the reliability improves, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the heat dissipation function and the electrical connection protection function into a single integrated heat sink structure. The heat sink body includes folded walls that form protective enclosures around the electrical connections, eliminating the need for separate protection components and reducing overall device complexity while maintaining reliability
Solution Approach 2:
The heat sink is designed to perform multiple functions simultaneously: it dissipates heat from the light sources and at the same time protects the fragile electrical connections through its folded wall structure. This multi-functionality reduces the number of separate components needed in the lighting module
2Reliability
If additional protection components are added to shield the electrical connections, then the reliability improves, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The protective enclosure for electrical connections is integrated into the heat sink body itself through folded walls, eliminating the need for separate protection components. This reduces part count, material costs, and assembly operations while providing effective protection during manufacturing and installation
Solution Approach 2:
The heat sink structure automatically provides protection for electrical connections through its own geometric configuration (folded walls), without requiring additional protective components or complex assembly steps. The structure protects itself and the connections it supports
3Reliability
If the heat sink structure is modified to include protection walls, then the electrical connection protection improves, but the device complexity increases
Solution Approach 1:
The protection walls are formed as an integral part of the heat sink body through folding operations, combining the heat dissipation structure and protection structure into one unified component. This avoids the need for separate protection brackets or enclosures that would increase complexity
Data Source
Figure 1~2
Figure 3~4B
Figure 5A~5B
AI summary
A lighting module having a heat sink and at least one light source supported by the heat sink. A printed circuit board is also supported on the heat sink and electrically coupled to the at least one light source with at least one conductor. The heat sink is folded or formed to define a conductor protector for protecting the at least one conductor and has at least one wall that is situated in operative relationship with the at least one conductor in order to shield or protect the at least one conductor.