Compact LED Module with Integrated AC-DC Conversion and Thermal Management
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Solution Overview
Problem
Existing LED modules are limited by their size, light output, and compatibility with AC line voltage, as they require careful thermal management and often use metal clad PCBs, making them incompatible with line voltage and lacking in compact, high light output systems.
Innovation Solution
A compact LED module design featuring a base with circuitry for AC to DC voltage conversion, a non-reflective angled cover to minimize light shaping, and a thermal pad for efficient heat management, allowing for high lumens output while being compatible with AC line voltage and touch-safe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If LEDs are packaged in a compact design, then the device size is reduced, but thermal management becomes more difficult and light output is limited
Solution Approach 1:
The device is segmented into distinct functional zones: a thermal management zone with heat sink and thermal pad at the base, a light generation zone with LED array, and a light output zone with engineered aperture. This segmentation allows each zone to optimize its function independently within a compact form factor.
Solution Approach 2:
The patent utilizes three-dimensional space efficiently by positioning the LED array vertically above the base, with light exiting through a engineered aperture at the top surface. This vertical arrangement allows compact footprint while maintaining adequate thermal separation and light output pathways.
2Illumination intensity
If more LEDs are added to increase light output, then lumens increase, but device complexity and size increase
Solution Approach 1:
Multiple LEDs are merged into a single integrated array mounted on a common base with shared thermal management infrastructure. The circuit board integrates multiple LED mounting positions, common electrical connections, and unified thermal pathways, reducing overall device complexity while achieving high light output.
Solution Approach 2:
The base structure serves multiple functions simultaneously: it provides mechanical support for the LED array, acts as a thermal management interface with the heat sink, provides electrical connections through the circuit board, and defines the light output aperture. This multi-functionality reduces the need for separate components.
3Strength
If metal clad PCB base is used for structural support, then mechanical strength is improved, but compatibility with AC line voltage is lost
Solution Approach 1:
An insulating barrier (such as a non-conductive coating or insulating layer on the base) acts as an intermediary between the metal clad PCB and the AC line voltage components. This allows the structurally strong metal base to be used while preventing electrical conductivity issues and enabling AC voltage compatibility.
4Adaptability or versatility
If AC to DC conversion circuitry is integrated, then voltage compatibility is improved, but device volume increases
Solution Approach 1:
The AC to DC conversion circuitry is merged with the existing base structure and circuit board. The rectifier and capacitor components are integrated into the same physical footprint as the LED driver circuitry, utilizing shared mounting space and electrical pathways to minimize additional volume.
Solution Approach 2:
Thin-film capacitor and rectifier components are used to minimize the volume of the power conversion circuitry. These thin-film components provide the necessary AC to DC conversion functionality while occupying minimal space within the compact device architecture.
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 provides a compact, high light output LED module that is compatible with AC line voltage, maintains minimal light reflection, and ensures effective thermal management, achieving over 500 lumens of output in a small volume without noticeable flicker, enhancing durability and cost-effectiveness.
Implementation Method 1
Circuitry is provided on the base and the LED array is electrically connected to the circuitry which, in an embodiment, may convert AC line voltage to DC voltage
Implementation Method 2
The cover can include a non-reflective angled surface that is designed to have minimal impact on the shape of light emitted from the LED array
Implementation Method 3
A thermal pad for efficient heat management
Data Source
AI summary
A light emitting diode (LED) module is provided that includes a base and a cover. Circuitry is provided on the base. An LED array is provided on the base and is coupled to the circuitry, which in an embodiment may convert AC line voltage to DC voltage. The LED module can be configured to take up minimal space while providing desirable light output.