Lamp Assembly Thermal Module Staggered Fins
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Solution Overview
Problem
Conventional LED lamp assemblies face challenges in manufacturing low-cost lamp assemblies with high cooling efficiency due to the difficulties in forming complex structures with fine pitches and durable strengths using die extrusion and die casting processes.
Innovation Solution
A lamp assembly is designed with a thermal module comprising first and second thermal members formed by die casting, arranged in a staggered manner to increase the number of fins and surface area, combined with a connecting member formed by metal extrusion to enhance cooling efficiency, utilizing materials like aluminum for high thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If die extrusion process is used to form metal fins, then durable strength and fine pitch structures can be achieved, but manufacturing cost increases and complex structures are difficult to form
Solution Approach 1:
The thermal management system is divided into two distinct components: a heat dissipation plate formed by die casting and a connecting member formed by die extrusion. This segmentation allows each component to be manufactured using the process best suited for its specific requirements, reducing overall manufacturing cost while maintaining structural integrity.
Solution Approach 2:
The patent combines two different manufacturing processes (die casting and die extrusion) to create a hybrid structure. The die-cast heat dissipation plate provides complex fin structures at low cost, while the die-extruded connecting member provides strong mechanical support, achieving both cost-effectiveness and structural durability.
2Ease of manufacture
If die casting process is used to form thermal members, then manufacturing cost decreases, but forming fine pitch structures with durable strength becomes difficult
Solution Approach 1:
The thermal management assembly is segmented into two parts with different functional requirements: the heat dissipation plate (requiring complex geometry) and the connecting member (requiring high strength). This allows die casting to be used for the plate where cost is critical, while die extrusion is used for the connecting member where precision and strength are critical.
Solution Approach 2:
Different manufacturing processes are applied to different parts of the assembly based on local requirements. The heat dissipation plate uses die casting for cost-effective complex geometry, while the connecting member uses die extrusion for high strength and precision, optimizing the overall system performance.
3Temperature
If more heat dissipating fins are added to increase surface area, then cooling efficiency improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the heat dissipation function with the structural support function into a single integrated assembly. The die-cast heat dissipation plate with its complex fin structures is combined with the die-extruded connecting member, achieving high cooling efficiency without proportionally increasing manufacturing complexity.
Solution Approach 2:
The connecting member extends in the axial direction, providing an additional dimension for heat dissipation. This vertical extension allows for increased surface area and improved cooling efficiency without requiring excessive complexity in the radial fin structures.
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 solution effectively improves cooling efficiency and prevents overheating of the light source, achieving a balance between cost-effectiveness and high thermal performance by leveraging the strengths of both die casting and metal extrusion processes.
Implementation Method 1
The thermal module includes a first thermal member and a second thermal member which are formed by a die casting process, wherein the light source is disposed on the second thermal member
Implementation Method 2
The first and second thermal members respectively have a plurality of first and second fins which are arranged in a staggered manner
Data Source
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AI summary
A lamp assembly is provided, including a light source (50), a thermal module (30), a connecting member (20), and an adapter (10) electrically connected to the light source. The thermal module includes a first thermal member (31) and a second thermal member (32) which are formed by a die casting process, wherein the light source is disposed on the second thermal member. The first and second thermal members respectively have a plurality of first (311) and second (321) fins which are arranged in a staggered manner. The connecting member is formed by a metal extrusion process and extends through the first thermal member to connect the second thermal member with the adapter.