LED Board Mounting Frame With Alternating Bosses for Thermal Venting

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Solution Overview

Problem

Existing LED light fixtures face issues with inadequate thermal ventilation and configuration, leading to reduced LED performance and lifespan due to high operating temperatures, especially when retrofitting fluorescent fixtures.

Innovation Solution

An LED board mounting system with a fixture frame featuring alternating bosses formed by punching through the planar surface, securing LED boards between these bosses, and electrical contacts extending through the surface for easy installation and improved heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If LED boards are mounted in retrofit fixtures without adequate thermal ventilation, then installation is simple, but heat dissipation is insufficient leading to reduced LED lifespan

Engineering Contradiction:

Improveinstallation simplicityVSAvoidoperating temperature

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The fixture frame is segmented into multiple mounting regions with alternating bosses distributed across the frame surface. This segmentation allows LED boards to be mounted in specific locations that optimize thermal ventilation while maintaining installation simplicity. The bosses create discrete mounting zones that facilitate proper air flow channels around the LED boards.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fixture frame incorporates alternating bosses with different characteristics (e.g., varying heights, spacing patterns, or thermal conductive properties) at different locations. This local quality variation enables optimized heat dissipation in critical areas while maintaining simple overall installation. The alternating pattern ensures that LED boards mounted between bosses experience improved thermal management.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If traditional fluorescent fixtures are retrofitted with LEDs, then existing fixture infrastructure is utilized, but thermal ventilation is inadequate reducing LED performance

Engineering Contradiction:

Improvefixture compatibilityVSAvoidLED lifespan

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The fixture frame design with alternating bosses serves multiple functions simultaneously: it provides mechanical mounting support for LED boards, creates thermal ventilation channels, and maintains compatibility with existing fluorescent fixture infrastructures. This multi-functionality allows retrofitting while improving thermal management and extending LED lifespan.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The alternating bosses create three-dimensional thermal ventilation channels and air flow paths around the LED boards. By utilizing the vertical and lateral dimensions created by the boss structures, the design improves heat dissipation without requiring complete fixture replacement, thus maintaining adaptability while enhancing reliability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If LED boards are secured between alternating bosses, then mounting is secure and ventilation is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvemounting securityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The alternating bosses are pre-formed as integral features of the fixture frame during the frame manufacturing process, rather than being added as separate components. This preliminary action ensures secure mounting and improved ventilation while minimizing additional manufacturing steps. The bosses are created using standard forming techniques compatible with existing fixture production methods.

Inventive Principle:

Principle #10Preliminary action

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 system provides efficient heat dissipation and secure mounting, enhancing LED performance and extending the lifespan of LED lights by maintaining optimal operating temperatures.

Implementation Method 1

The second side of the at least one LED board being adjacent to the planar surface of the fixture frame

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

adequate thermal ventilation

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12467606B2LED board mounting system for a light fixture

Publication Date: 2025.11.11 IND LIGHTING PRODUCTS LLC

AI summary

A light board mounting system includes a fixture frame having a planar surface and a plurality of alternating bosses disposed along a length of the fixture frame. The system also includes a light board having a first side and a second side, a plurality of lights disposed along a length of the light board on the first side, and a pair of electrical contacts coupled to the plurality of lights and mounted to the second side of the light board and extending away from the second side. In addition, the light board mounting system includes a first edge and opposing second edge of the light board secured to the planar surface of the fixture frame between the plurality of alternating bosses, the second side of the light board being adjacent to the planar surface of the fixture frame and the pair of electrical contacts extending through the planar surface.