LED Lighting Device With Composite Insulated Housing
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Solution Overview
Problem
LED lighting devices face inefficiencies due to heat generation, which affects light output and lifespan, and safety concerns with metal components leading to electrical short circuits, while insulated driver systems require higher energy input and complicate heat dissipation.
Innovation Solution
An LED lighting device with a thermally conductive and electrically conductive plastic housing, coated with an electrically insulating material on the outside, providing effective heat dissipation and safety without the need for internal shields, allowing for use with non-insulated driver systems and enabling high-power operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal housing is used for thermal management, then heat dissipation is improved, but electrical safety deteriorates due to risk of short circuits
Solution Approach 1:
The housing is made from a composite material comprising a thermally conductive electrically conductive plastic material (TC/EC-material-A) covered with an electrically insulating material (El-material-B). This composite structure combines the thermal conductivity of metal with the electrical insulation properties of non-conductive materials, resolving the contradiction between heat dissipation and electrical safety.
2Reliability
If insulated driver systems are used for safety, then electrical safety is improved, but energy efficiency deteriorates due to higher energy input requirements
Solution Approach 1:
The electrically insulating material (El-material-B) serves as an intermediary layer between the conductive housing and the external environment, providing electrical safety without requiring insulated driver systems. This allows the use of non-insulated driver systems while maintaining safety, thereby improving energy efficiency.
3Reliability
If internal insulating shields are used for safety, then electrical safety is improved, but heat dissipation deteriorates due to complicated thermal pathways
Solution Approach 1:
The invention extracts the insulation function from internal components and relocates it to the outer surface of the housing. By applying the electrically insulating material (El-material-B) as a coating on the external surface, the insulation function is separated from the thermal management function, allowing heat to dissipate efficiently through the thermally conductive base material while maintaining electrical safety.
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 enhances heat management and safety, maintaining light efficiency while allowing for mass production and compliance with safety regulations, even with non-insulated driver systems, and is more effective than alternative solutions like internal isolating layers.
Implementation Method 1
a housing, optionally encapsulating the electronic components and the electrical leads or wiring system, being in thermally conductive contact with the heat spreader
Implementation Method 2
covered with a protection layer consisting of an electrically insulating material (El-material-B) on the outside of the housing
Data Source
AI summary
The invention relates to a LED lighting device LLD) comprising a heat spreader, having a front side and a back side; LEDs mounted on a PCB positioned on the front side of the heat spreader; a reflector or lens covering the LEDs; a socket for being received by an electrical supply system; optionally a base part; electronic driver components mounted on the back side of the heat spreader or inside the socket or base part; electrical leads or wiring system connecting the socket, the electronic driver components and the heat spreader; and a housing, optionally encapsulating the electronic components and the electrical leads or wiring system, being in thermally conductive contact with the heat spreader, wherein the housing is made of an thermally conductive, electrically conductive plastic material (TC/EC-material-A), covered with a protection layer consisting of an electrically insulating material (EI-material-B), on the outside of the housing.