LED Illumination Device with Projecting Insulating Layer for Thermal Dissipation
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Solution Overview
Problem
Existing illumination devices are complex to produce and lack a straightforward method for coupling with optical elements, which complicates their manufacturing and functionality.
Innovation Solution
The illumination device features a connection carrier with a light-emitting diode on one main area and an electrically insulating layer on another, which projects beyond the carrier's edge for enhanced thermal dissipation and electrical insulation, and a fixing means that secures the device while allowing for optical element integration, ensuring reliable operation and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing illumination devices are used, then they provide basic illumination function, but they are complex to produce and lack straightforward coupling method for optical elements
Solution Approach 1:
The patent combines multiple functions into the connection carrier: it serves as both the electrical connection substrate and the mechanical mounting structure for optical elements. The carrier integrates contact locations for electrical connections and mounting locations for optical elements, eliminating the need for separate mounting components and simplifying the manufacturing process.
Solution Approach 2:
The connection carrier is designed as a multi-functional component that simultaneously provides electrical connection, mechanical support, thermal management, and optical element mounting. This universal design reduces the overall device complexity and streamlines production by using a single component for multiple purposes.
2Temperature
If the electrically insulating layer projects beyond the connection carrier, then thermal dissipation and electrical insulation are enhanced, but the device dimensions increase
Solution Approach 1:
The electrically insulating layer is applied selectively to specific areas of the connection carrier where thermal dissipation and electrical insulation are most needed. The layer projects beyond the carrier edges only in regions required for heat sinking and insulation, rather than uniformly across the entire device, thus providing local enhancement without excessive dimensional increase.
3Reliability
If the fixing means presses the connection carrier against the mounting area, then reliable fixing is achieved, but the assembly process becomes more complex
Solution Approach 1:
The fixing means is integrated with the connection carrier itself rather than being a separate component. The carrier includes built-in fixing features such as mounting locations and pressing mechanisms that combine the functions of structural support and secure attachment, simplifying the assembly process while maintaining reliable fixing.
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 design simplifies production, enhances thermal management, ensures reliable electrical insulation, and facilitates easy integration with optical elements, resulting in a more efficient and robust illumination device.
Implementation Method 1
at least one light-emitting diode fixed on the first main area of the connection carrier. The light-emitting diode is suitable for generating light during operation
Implementation Method 2
The electrically insulating layer is preferably distinguished by a low thermal resistance, such that heat generated during operation of the light-emitting diode can be dissipated to the surroundings via the electrically insulating layer
Data Source
AI summary
An illumination device comprising a connection carrier (1), at least one light-emitting diode (10), an electrically insulating layer (3) and a fixing device (4) is specified. The connection carrier (1) has a first main area (1a) and a second main area (1b) remote from the first main area. The light-emitting diode (10) is fixed on the first main area (1a) of the connection carrier (1). The electrically insulating layer (3) is fitted to the second main area (1b) of the connection carrier (1) and projects laterally beyond the second main area (1b) of the connection carrier (1). The fixing device (4) is suitable for fixing the illumination device to a mounting area (2a) of a carrier (2), wherein the electrically insulating layer (3) is arranged between the second main area (1b) of the connection carrier (1) and the mounting area (2a) of the carrier (2). Furthermore, the fixing device (4) presses the connection carrier (1) against the mounting area (2a). The pressure exerted in this way is used to effect a fixing of the insulating layer (3) between the second main area (1b) of the connection carrier (1) and the mounting area (2a). The fixing device (4) is connected to an optical element (8), which optically influences the light generated by the light-emitting diode (10) during operation.