LED Lamp Thermal Management via Segmented PCB and Adhesive Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional LED lamps have short lifespans, generate excessive heat, consume high power, and are expensive due to the use of metal PCBs, requiring separate controllers and inadequate thermal control, which limits their efficiency and practicality for vehicle lighting applications.
Innovation Solution
An LED lamp design featuring a casing part with through holes for enhanced heat radiation, a two-stage PCB configuration with nonpolar circuits for efficient heat dissipation, and a cover part with a coupling protrusion for secure assembly, allowing for the collection and dispersion of light while reducing material costs and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a metal PCB is used for LED mounting, then heat dissipation is improved, but manufacturing cost increases significantly
Solution Approach 1:
The PCB is divided into two functional layers: a lower metal PCB for heat dissipation and an upper general PCB for circuit functions. This segmentation allows each layer to use the most appropriate material for its purpose, reducing overall cost while maintaining heat dissipation performance.
Solution Approach 2:
The patent uses a composite structure combining metal PCB and general PCB in a stacked configuration. The metal PCB provides thermal management while the general PCB provides cost-effective circuit implementation, creating a composite solution that balances performance and cost.
2Adaptability or versatility
If separate controllers are used for LED control, then lighting functionality is improved, but device complexity and cost increase
Solution Approach 1:
The controller is integrated directly into the PCB circuit board, merging the control function with the mounting structure. This eliminates the need for separate external controllers and reduces assembly complexity while maintaining full lighting functionality.
3Productivity
If LEDs are mounted in a compact arrangement, then productivity and space utilization are improved, but heat dissipation becomes more difficult
Solution Approach 1:
The patent transitions from planar LED arrangement to a three-dimensional stacked PCB configuration. LEDs are mounted on both the upper and lower surfaces of the PCB structure, utilizing the vertical dimension to increase LED density while maintaining heat dissipation pathways through the metal PCB layer.
4Reliability
If the entire LED lamp assembly is replaced during after-service, then reliability is maintained, but loss of time and material increases
Solution Approach 1:
The LED lamp is designed as a modular assembly where the PCB can be independently replaced from the housing and other components. This segmentation enables partial replacement during after-service, reducing service time and material waste while maintaining product reliability.
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 design extends LED lamp lifespan, improves heat management, reduces material expenses, and allows for more components to be mounted in a compact space, enhancing usability and efficiency in vehicle lighting applications.
Implementation Method 1
an adhesive applied to the bottom surface of the coupling protrusion such that the cover part is more firmly coupled to the casing part when the coupling protrusion is inserted into the cover fixing part
Implementation Method 2
a predetermined space defined by the cover part, the casing part, and the PCB part, and a plurality of vent holes formed on the base part
Data Source
AI summary
A light emitting diode (LED) lamp comprises a casing part inserted into the region on which the lamp is installed. A PCB part is seated on the casing part in two stage. A connector part connects and fixes the PCB part to the casing part to supply power to the PCB part. A cover part is disposed above the PCB part to protect the LED mounted on the PCB part. The casing part comprises a cover fixing part and a coupling protrusion is disposed on the cover part. The coupling protrusion is inserted and fixed into the cover fixing part. An adhesive is applied to the bottom surface of the coupling protrusion to insert the coupling protrusion into the cover fixing part, thereby firmly coupling the coupling protrusion to the cover fixing part.