LED Heatsink With Integrated Copper Electrical Contacts
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Solution Overview
Problem
The challenge in LED lighting is to provide an effective thermal management system that also simplifies the assembly process, particularly in compact designs where conventional heatsinks can lead to electrical short-circuits and complex wire handling, making automation difficult and increasing the risk of connection failures.
Innovation Solution
An integrated heatsink assembly with metallic components and a non-electrically conducting housing that includes separate electrical contacts for the hot and neutral lines, allowing direct electrical connection to the LED driver board without the need for wires, and a thermally conductive silicone potting material for heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional heatsink is used in LED lighting devices, then thermal dissipation is achieved, but electrical short-circuits and complex wire handling occur
Solution Approach 1:
The patent combines the heatsink with electrical contact functions by integrating copper inserts directly into the aluminum heatsink structure. The copper portions serve dual purposes: thermal conduction pathways and electrical contacts for hot and neutral lines, eliminating the need for separate wires and reducing assembly complexity
Solution Approach 2:
The heatsink structure is designed to perform multiple functions simultaneously: thermal management through convection and radiation, electrical conduction through integrated copper contacts, and mechanical support for the LED assembly. This multi-functionality reduces the number of separate components needed
2Temperature
If conventional heatsink designs are used, then thermal management is provided, but assembly automation becomes difficult
Solution Approach 1:
The heatsink is divided into distinct functional zones with integrated copper inserts positioned at specific locations for electrical contacts. The copper inserts are strategically placed to provide both thermal pathways and electrical connection points, allowing for standardized assembly processes that can be automated
Solution Approach 2:
The copper electrical contacts are pre-integrated into the heatsink structure during manufacturing, so that when the heatsink is installed, electrical connections are already established. This preliminary integration of electrical pathways eliminates the need for complex wire routing during final assembly, enabling automation
3Temperature
If conventional heatsink designs are used, then thermal dissipation is achieved, but connection failures increase
Solution Approach 1:
By merging the electrical contact function directly into the heatsink structure through integrated copper inserts, the patent eliminates multiple connection points and potential failure modes associated with separate wire connections. The integrated design reduces the number of assembly steps where connection errors could occur
Solution Approach 2:
The heatsink structure itself provides the electrical connection service through its integrated copper portions, eliminating the need for separate wiring systems. The copper inserts are positioned to automatically establish electrical contacts with the driver board when the heatsink is installed, reducing reliance on complex external wiring
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 solution simplifies the assembly process, enhances reliability, and enables automation, while maintaining adequate thermal dissipation characteristics, making it easier and less expensive to manufacture LED lamps of various sizes and types.
Implementation Method 1
two over molded stampings create an electrical and thermally conductive heatsink
Implementation Method 2
The heatsink provides a means for removing the energy from the LEDs of the lighting device through convection and radiation of the energy away from the LEDs
Implementation Method 3
The heatsink provides a means for removing the energy from the LEDs of the lighting device through convection and radiation of the energy away from the LEDs
Implementation Method 4
a thermally conductive silicone potting material for heat dissipation
Data Source
AI summary
A heatsink having integrated electrical and base contacts for use with a light emitting diode (LED) light source. In some embodiments, a heatsink assembly for an LED lamp includes a first metallic heatsink component having a first wall portion and a first electrical contact, and a second metallic heatsink component having a second wall portion and a second, separate contact portion. A non-electrically conducting heatsink housing is configured to house the first wall portion and the second wall portion of the first and second heatsink components such that the first electrical contact extends from the non-electrically conducting heatsink housing and the second contact portion extends from the plastic housing in a manner to facilitate connection to hot and neutral lines of a power source.