Folded Thermal Plate Press-Fit Assembly for Luminaire Housings
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Solution Overview
Problem
Conventional methods for fabricating heat sinks, such as impact extrusion and pressure fit plates, are difficult and expensive, and require precise machining, making them challenging to implement in luminaire manufacturing.
Innovation Solution
A method involving pre-folded thermal elements with petals that are inserted and unfolded to create a solid joint with the housing, using a pressing process to secure and thermally couple the thermal element to the housing, eliminating the need for impact extrusion and precise machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional impact extrusion process is used to fabricate heat sinks, then the heat sink can be formed with desired shape, but the manufacturing process becomes difficult and expensive
Solution Approach 1:
The thermal element is divided into a central body and multiple petals that can be separately formed and then assembled together. The petals are created as separate components that attach to the central body, allowing each part to be manufactured using simpler, less expensive processes rather than requiring complex impact extrusion for the entire structure.
Solution Approach 2:
The petals are nested within the central body during assembly, with each petal attaching to the central body in sequence. This nested arrangement allows the components to be manufactured separately and then assembled together, simplifying the overall manufacturing process while maintaining the desired heat sink shape.
2Temperature
If conventional pressure fit plates are used to conduct heat, then heat can be dissipated to external faces, but the plates require precise machining and tight interference tolerances making them difficult to fabricate
Solution Approach 1:
The petals are designed to be deformable and adaptable, allowing them to conform to the housing surface through elastic deformation rather than requiring precise pre-machining. The petals can elastically deform during installation to create intimate thermal contact with the housing, eliminating the need for tight interference tolerances and complex machining operations.
Solution Approach 2:
The petal geometry includes specific design parameters such as thickness, width, and curvature that allow them to elastically deform under installation forces. By optimizing these geometric parameters, the petals can achieve adequate thermal contact pressure without requiring precision machining, thereby simplifying fabrication while maintaining effective heat dissipation.
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 approach simplifies the manufacturing process, reduces costs, and enhances thermal coupling with low resistance, providing a robust and efficient heat dissipation solution for luminaire components.
Implementation Method 1
a pressing element to press the folded panels against the housing
Implementation Method 2
a thermal element with pre-folded petals that can be inserted into the body of a device and then unfolded to create a solid joint of friction and a low resistance heat path to the external faces of the device
Data Source
AI summary
A method for coupling a thermal plate (10) and a housing (20) is disclosed. The method includes the steps of inserting the thermal plate (10) having a main area (14) and one or more folded panels (11) configured at an angle (15) from the main area (14) to allow the thermal plate (10) to be inserted within the housing (20) and stopping the thermal plate (10) within the housing (20) at a predetermined location using a stop support (101). The one or more folded panels (11) are flattened using a pressing element (100) so that the angle from the main area (14) is substantially zero degrees so that the thermal plate (10) is physically and thermally coupled to an inside wall of the housing (20). The thermal plate (10) within the housing (20) may be aligned using one or more groves (12) and grove guides (21). The coupled thermal plate (11) and the housing may form part of a luminaire (200).