Insulating Element Air Gap for High-Voltage LED Luminaire
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Solution Overview
Problem
High-voltage LED lights face interference from asymmetric surge voltages, leading to electronics failure, and existing solutions are limited by protection class requirements, particularly in outdoor environments where lightning can cause voltages up to 30 kV.
Innovation Solution
A high-voltage-resistant LED lamp design featuring a mounting element connected to the lamp housing with an insulating element creating an air gap between the system assembly and the mounting element, providing improved immunity to asymmetric interference voltages and thermal insulation, allowing flexible adaptation to interference immunity requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clamping asymmetrical surge voltages is used to protect electronics, then electrical interference immunity is improved, but protection class requirements (particularly SK2) limit the effectiveness
Solution Approach 1:
An insulating element is introduced as an intermediary component between the mounting element and the system assembly (electronic control gear and LED module). This insulating element creates an air gap that electrically isolates the electronics from the mounting structure, providing protection against asymmetrical surge voltages while maintaining compliance with protection class requirements.
2Reliability
If thermal conductivity film is used to insulate LEDs from external high-voltage EMS, then electrical isolation is achieved, but device complexity increases
Solution Approach 1:
The patent extracts the insulation function from the thermal management system by using a separate insulating element to create an air gap. This separates the electrical isolation requirement from the thermal conduction path, allowing simple thermal management without complex integrated solutions while achieving high-voltage resistance.
3Reliability
If air gap isolation barrier is implemented, then immunity to asymmetric interference voltages is improved and design is simplified, but thermal insulation between lighting assembly and housing increases
Solution Approach 1:
The mounting structure is segmented into electrically isolated sections using the insulating element. This segmentation creates distinct electrical zones while allowing thermal management to be addressed separately through dedicated thermal paths that do not compromise the electrical isolation provided by the air gap.
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 design enhances the immunity to asymmetric interference voltages, extends the service life of LEDs and driver electronics, and reduces production costs by simplifying the construction and production process while maintaining a compact and mechanically stable structure.
Implementation Method 1
at least one insulating element arranged between the system assembly and the mounting element, wherein the system assembly is spaced from the mounting element by a predetermined air gap
Implementation Method 2
The air gap also provides thermal insulation of the lighting assembly from the lighting housing, which improves the lifespan of the LEDs and the driver electronics
Data Source
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AI summary
The invention relates to a luminaire module (120) for a high-voltage-proof LED luminaire (100). The luminaire module (120) comprises at least one electric operating device (310), an LED module (320), and at least one insulating element (400). The at least one insulating element (400) together with securing elements (500) provides an electric and thermal insulation barrier between the luminaire module (120) and an LED luminaire housing (110). An air gap (410) can be variably designed by selecting suitable insulation elements (400).