Compact LED Light Driver with Planar PCB and Metal Heat Sink
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Solution Overview
Problem
Conventional LED light drivers have a significant Z dimension that limits design flexibility in residential lighting, as they often cannot fit within standard junction boxes and canopies, obstructing light output and requiring larger fixtures.
Innovation Solution
A compact LED light driver with a reduced Z dimension, utilizing a printed circuit transformer, epoxy insulation, and a metal base as a heat sink and ground, along with modular circuit boards and alternative packaging to minimize height and enhance thermal dissipation, allowing for various design configurations and wireless components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional LED light drivers are used, then they provide necessary voltage conversion and protection, but they occupy excessive Z dimension space that limits design flexibility and prevents placement within standard junction boxes and canopies
Solution Approach 1:
The patent reconfigures the LED light driver layout by transitioning from a conventional three-dimensional arrangement to a predominantly two-dimensional planar configuration. The circuit board is positioned horizontally within the canopy, with components arranged in a flattened layout that minimizes vertical protrusion. This dimensional transformation allows the driver to fit within standard junction box and canopy height constraints while maintaining all necessary electrical conversion and protection functions.
Solution Approach 2:
The LED light driver is divided into distinct functional modules: a rectifier bridge section for AC-to-DC conversion, a switching regulator section for voltage regulation, and a driver circuit section for LED control. Each module is separately positioned on the circuit board, allowing optimized spatial arrangement that minimizes overall Z dimension while ensuring proper electrical isolation and thermal management for each functional segment.
2Length of stationary object
If the LED light driver is made compact to reduce Z dimension, then design flexibility improves, but thermal dissipation becomes more challenging
Solution Approach 1:
A thermally conductive epoxy compound is applied between the power semiconductor components (rectifier diodes, switching transistors) and the metal canopy structure. This epoxy acts as a thermal intermediary, efficiently conducting heat from the compactly arranged components to the large thermal mass of the canopy, which serves as a heat sink. This allows compact component placement while maintaining effective thermal dissipation pathways.
Solution Approach 2:
The metal canopy structure is designed to serve multiple functions simultaneously: it provides the mechanical housing for the fixture, acts as the electrical ground reference for the circuit, and functions as a thermal heat sink for dissipating heat from power components. This multi-functionality eliminates the need for separate heat sink structures, maintaining compact Z dimension while ensuring adequate thermal management.
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
Enables the creation of more compact and versatile lighting designs by reducing the driver's height, allowing placement within standard junction boxes and canopies, improving thermal management, and accommodating diverse components without obstructing light output.
Implementation Method 1
a metal base enclosed inside an epoxy body functioning as a heat sink for the led light driver
Implementation Method 2
utilize epoxy material as insulation and exterior case material
Implementation Method 3
the aforementioned metal base further functions as a ground to compensate for impedance in current setting resistor circuit
Data Source
AI summary
A LED light driver having a reduced overall thickness so as to facilitate placement within an octagon junction box and canopy. The LED light driver of the present invention includes a printed circuit board wherein the printed circuit board includes a first side and a second side and is planar in manner. The printed circuit board further includes a plurality of recesses formed on the first side and second side thereof so as to facilitate the reduction in the overall Z dimension of the LED light driver. The printed circuit board includes a metal base having an epoxy material utilized for insulation and an exterior case material. The metal base enclosed inside the epoxy further functions as a heat sink. The reduced height of the present invention further provides for less blockage of light and as such the LED light drive can be more proximate the light source.