Press-Formed Dome Heat Sink for LED Lighting
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Solution Overview
Problem
Conventional bulb-type LED lamps face challenges with high production costs, limited material choices, and reduced heat dissipation efficiency due to the use of aluminum die cast heat sinks, which are heavy, expensive, and difficult to scale for large-size lighting devices.
Innovation Solution
A lighting device with a heat dissipation portion formed by press-working a metal plate into a dome-like shape with vertically extending peak and valley portions, allowing for efficient heat dissipation and reduced production costs, using materials like brass or copper for improved thermal conductivity, and incorporating a metal cap and cooling fin structure for enhanced cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If aluminum die cast heat sink is used for heat dissipation, then heat dissipation function is provided, but material cost increases and weight reduces are limited
Solution Approach 1:
The invention changes the material parameter from aluminum die cast to pressed metal plate, and changes the structural parameter from solid cast structure to thin-walled pressed structure with fin extensions. This transforms the heat dissipation component into a lightweight yet effective heat dissipation structure that reduces weight while maintaining heat dissipation functionality.
Solution Approach 2:
The invention extends the heat dissipation surface into the vertical dimension by forming fin structures (protrusions) on the metal plate. This dimensional extension increases the heat dissipation area without increasing the footprint, allowing effective heat dissipation with reduced material usage and lower weight.
2Temperature
If aluminum die cast heat sink is used, then heat dissipation is achieved, but production time is prolonged and manufacturing complexity increases
Solution Approach 1:
The invention replaces the complex die casting mechanical process with a simpler metal plate pressing/forming process. This substitution eliminates the need for complex mold designs and post-processing operations, significantly reducing production time and manufacturing complexity while achieving the same heat dissipation function.
Solution Approach 2:
The heat dissipation structure is segmented into a base metal plate and attached fin structures. This segmentation allows for simpler manufacturing of individual components that can be assembled together, reducing the complexity of the overall manufacturing process and improving productivity.
3Temperature
If conventional heat dissipation structure is used, then heat dissipation function is provided, but material choice is limited and thermal conductivity optimization is restricted
Solution Approach 1:
The invention changes the material parameter from restricted aluminum die cast materials to any pressed metal plate material, enabling the use of materials with superior thermal conductivity such as copper or brass. This parameter change expands material versatility and allows optimization of thermal properties without being constrained by die casting limitations.
4Temperature
If die cast heat sink with grooves is used, then heat dissipation surface is increased, but manufacturing complexity and post-processing requirements increase
Solution Approach 1:
The fin structures are formed as integral parts of the metal plate during the pressing operation, eliminating the need for separate post-processing steps to create grooves or fins. This preliminary formation of the heat dissipation surface structure reduces manufacturing complexity while achieving increased heat dissipation area.
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 significantly reduces production costs, allows for lightweight and large-size lighting devices, improves heat dissipation efficiency, and extends the lifespan of LED modules by effectively managing heat, while maintaining reliability and luminous efficiency.
Implementation Method 1
heat conducted from the LED device or the power supply circuit is dissipated to the outside
Implementation Method 2
a structure in which a metal heat dissipation portion is provided in a part of a case and heat conducted from the LED device or the power supply circuit is dissipated to the outside
Data Source
AI summary
There is provided a lighting device excellent in mass productivity and capable of significantly reducing a production cost and allowing easy provision of a light-weight and large-size lighting device as well as improving a degree of freedom in choosing materials and exhibiting an adequate heat dissipation effect. A heat dissipation portion is obtained by press-working a metal plate. For example, the heat dissipation portion is configured by press-deforming the metal plate into a substantially dome-like shape having a vertically extending peak portion and a vertically extending valley portion that are peripherally and consecutively formed, by repeatedly bending the metal plate along a circumferential direction into a wave shape and concurrently warping the metal plate in an axial direction such that the outer peripheral side of the metal plate is positioned closer to the tip in the axial direction than the central side thereof.