Quick-Release LED Module Mounting With Keyhole Slots
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Solution Overview
Problem
Conventional methods for attaching LED modules to heat sinks are limited, making it difficult to replace defective or worn-out modules, and often require specialized tools, posing safety risks and inefficiencies in heat management.
Innovation Solution
A modular LED light engine system with elongated slots and keyholes on the LED module and heat sink, allowing for easy removal and replacement of the LED module using screws that pass through these slots and keyholes, enabling quick release without specialized tools and maintaining thermal communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If solder or adhesives are used to attach LED modules to heat sinks, then thermal communication is improved, but replaceability of the LED module deteriorates
Solution Approach 1:
The attachment mechanism is divided into separate components: a mounting structure with mounting holes and an LED module with corresponding mounting features. This segmentation allows the LED module to be attached and detached without permanent bonding, enabling replacement while maintaining thermal communication through the mounting interface.
Solution Approach 2:
The patent replaces chemical bonding methods (soldering, adhesives) with a mechanical attachment system using mounting holes, fasteners, or interference-fit features. This mechanical substitution enables the LED module to be securely attached for thermal management while allowing for easy removal and replacement.
2Ease of repair
If conventional fasteners are used to attach LED modules, then replaceability is improved, but control over tools and modules deteriorates
Solution Approach 1:
The mounting holes are positioned at specific locations on the LED module housing that allow for stable one-handed operation. The spatial arrangement of multiple mounting holes provides geometric stability, enabling the user to securely hold the module with one hand while manipulating fasteners with the other, thus improving control during replacement operations.
Solution Approach 2:
The mounting holes serve as intermediaries between the LED module and the fastening system. These pre-positioned holes provide stable reference points and grip locations, facilitating easier control during the attachment and detachment process compared to conventional fastener systems that require direct manipulation of the module body.
3Temperature
If LED modules are permanently attached to heat sinks, then thermal management is improved, but accessibility for replacement deteriorates
Solution Approach 1:
The mounting holes are pre-positioned on the LED module housing during manufacturing, and the attachment mechanism is designed to maintain consistent thermal contact. This preliminary configuration ensures that when the module is attached, thermal communication is immediately established without requiring complex installation procedures, while still allowing for future removal and replacement.
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
Facilitates safe and efficient replacement of LED modules, improves heat management by allowing for easy access and replacement, and ensures proper thermal communication between the module and heat sink, enhancing the longevity and efficiency of LED lighting systems.
Implementation Method 1
The LED module can include an outer housing having a multiple elongated slots that extend along a front surface of the outer housing. The elongated slots can extend through the outer housing and provide a passageway through the LED modules. Each of the elongated slots can also be configured to receive a portion of a screw through the slot. The illumination apparatus can also include a thermally conduct back side.
Data Source
AI summary
A light emitting diode module is removably coupled to a heat sink with screws and includes slots configured to receive at least a portion of the screw therethrough, the width of the slot being greater than the thread-width of the screw but less than the width of the screw head. Some slots also include a keyhole having a diameter greater than the width of the screw head. For embodiments without keyholes, the module is coupled to a heat sink by loosening the screws, sliding them into the slots, and tightening the screws to hold the LED module in place. For embodiments with one or more keyholes, the keyhole is vertically aligned with the screw, the module is moved down over the screw, and the screw is moved into the narrower portion of the slot. Then, the screws are tightened to hold the module in place against the heat sink.