Tray Bracket for LED Driver Thermal Management
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Solution Overview
Problem
The life expectancy of external LED drivers is reduced due to high internal operating temperatures, and existing solutions, such as heat sinks, are insufficient to effectively manage excess heat generated by these components.
Innovation Solution
A tray-type mounting bracket platform that is adjustable to fit different sizes and wattages of LED drivers, featuring a main bracket with uncovered areas for heat dissipation and covered splice connections for wiring, constructed from zinc-plated steel with conduit knockouts and grounding studs to secure the bracket to fixture housings, facilitating efficient heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LED drivers are used to convert AC to DC for LED operation, then LED lighting functionality is achieved, but excess heat is generated that reduces component life
Solution Approach 1:
The patent transitions from traditional single-dimensional heat sinks to a three-dimensional tray bracket structure with vertical fins and multiple heat dissipation surfaces. This dimensional expansion creates significantly larger surface area for heat rejection, allowing the LED driver to dissipate excess heat more effectively while maintaining compact form factor.
Solution Approach 2:
The tray bracket acts as an intermediary thermal management component between the LED driver and the mounting surface. It provides a standardized interface that couples the driver to the fixture housing, enabling heat transfer from the driver through the bracket to the housing while providing structural support and electrical grounding.
2Temperature
If heat sinks are added to LED drivers, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated tray bracket component: thermal management (heat dissipation), structural support (mounting), and electrical safety (grounding). This consolidation eliminates the need for separate heat sinks, mounting brackets, and grounding elements, thereby reducing overall device complexity while achieving effective heat dissipation.
Solution Approach 2:
The tray bracket is designed as a universal mounting and thermal management solution that can accommodate different LED driver sizes and configurations. The standardized design with adjustable features allows it to serve multiple fixtures and applications, reducing the need for custom-designed heat sinks for each specific driver model.
3Reliability
If LED drivers are housed in enclosed fixtures, then protection is provided, but heat accumulation occurs that shortens component life
Solution Approach 1:
The tray bracket implements localized heat dissipation features at the driver mounting location, including finned surfaces and open areas directly adjacent to the driver housing. This creates targeted thermal pathways that allow heat to escape from the highest temperature zones while maintaining enclosed protection for other components and wiring within the fixture.
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 mounting bracket effectively reduces heat generation and prolongs the life and efficiency of LED drivers and lighting fixtures by providing a secure and adjustable platform for heat dissipation, accommodating various LED driver sizes and wattages.
Implementation Method 1
The mounting bracket effectively reduces heat generation and prolongs the life and efficiency of LED drivers and lighting fixtures by providing a secure and adjustable platform for heat dissipation
Implementation Method 2
featuring a main bracket with uncovered areas for heat dissipation
Data Source
AI summary
An assembly for securely mounting and housing electrical power components. The assembly includes a tray-type mounting bracket for mounting and holding electrical equipments, specifically for an LED driver to a luminaire. The mounting bracket consists of tray-type bracket, at least two integral wiring compartments, one on each end of the mounting bracket, and at least two mechanically secured lid covers for securely covering any wiring. The tray-type mounting bracket includes a center part which is open to the surrounding environment for cooling the LED driver.