Thermally Conductive Polymer Frame for LED Heat Dissipation
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Solution Overview
Problem
Current LED light source manufacturing is inefficient due to manual assembly and reliance on thermally conductive pastes or tapes, which can lead to air gaps and reduced thermal transmission, and aluminum frames require additional processing for oxidation prevention and thermal expansion management.
Innovation Solution
The method involves integrating an electric actuator arrangement with a thermally conductive and electrically non-conductive frame part using mold techniques, where the actuator's heat-sensitive surface is sunk into the frame, and using thermally conductive composite materials like rubber or plastic to enhance thermal management, while minimizing electrical conductivity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If aluminum frame is used for thermal conductivity, then heat dissipation is improved, but thermal expansion and oxidation require additional processing
Solution Approach 1:
The patent employs a composite structure consisting of an aluminum frame for thermal conduction combined with a thermally conductive polymer coating layer. This composite material approach allows the aluminum to provide excellent heat dissipation while the polymer coating prevents oxidation and reduces thermal expansion issues, eliminating the need for separate anodization or painting processes.
Solution Approach 2:
The thermally conductive polymer coating acts as an intermediary layer between the aluminum frame and the environment. This intermediate layer solves multiple problems simultaneously: it protects the aluminum from oxidation, reduces thermal expansion effects, maintains thermal conduction pathways, and eliminates the need for additional protective processing steps.
2Temperature
If manual assembly with thermally conductive paste is used, then thermal transmission is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent merges the thermally conductive paste function directly into the molded polymer frame structure. The thermally conductive polymer material is integrated into the frame during the molding process, combining the structural support function with the thermal conduction function that previously required separate paste application and manual assembly steps.
Solution Approach 2:
The patent replaces the manual mechanical assembly process with an automated injection molding process. The thermally conductive polymer is injected and molded in one automated operation, substituting the multi-step manual process of applying paste, positioning components, and fastening parts, thereby dramatically improving manufacturing efficiency.
3Temperature
If screw joints with thermally conductive paste are used, then thermal contact is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple separate components (screw joints, thermally conductive paste, mounting brackets) into a single integrated molded polymer frame structure. The thermally conductive polymer is formed directly in the mold to create integral mounting features and thermal pathways, eliminating the need for separate fasteners and paste applications.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components from the assembly process. By using the molded polymer frame to directly hold and thermally connect the LED module, the design removes the need for screw joints, separate paste layers, and additional mounting hardware, thereby reducing device complexity.
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
This approach simplifies and cost-reduces LED light source production, providing improved thermal efficiency, shape accuracy, and moisture protection, while eliminating the need for manual assembly and thermally conductive intermediates, resulting in more reliable and efficient LED lighting.
Implementation Method 1
an at least thermally conductive frame part (2)... exploiting a very usual processing as such, whereby the actuator arrangement is being sunk by its heat sensitive or thermally conductive surface at least partly inside the frame part
Implementation Method 2
a manufacturing material forming the frame part (2; 2') is being processed in connection with the actuator arrangement (1) by exploiting mold technique
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2a~2b
AI summary
The invention relates to a method for manufacturing of an electric actuator, which actuator consists of an electric actuator arrangement (1) that is sensible to heat and/or that generates heat, the actuator being put together to form a uniform organ, such as a light source, by coupling the electric actuator arrangement with an at least thermally conductive frame part (2). The actuator arrangement (1) and the frame part (2; 2') are being coupled with each other in an integral manner by processing a manufacturing material forming the frame part (2; 2') in connection with the actuator arrangement (1).