Segmented LED Lamp Holder Housing for Heat Dissipation
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Solution Overview
Problem
The high defective rate and manufacturing cost associated with die casting processes for hybrid metal and plastic lamp holders in LED illuminating devices, which hinder efficient heat dissipation and insulation.
Innovation Solution
A two-part metal housing structure where the body part and assembling part are made through different processes, such as stamping and extrusion, and assembled via interference fit without additional fasteners, ensuring thermal conductivity and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If die casting process is used to manufacture the first housing integrally, then good heat dissipation and insulation are achieved, but the defective rate increases and manufacturing cost rises
Solution Approach 1:
The first housing is divided into two separate parts: a metal housing body for heat dissipation and a plastic housing for insulation. These parts are manufactured independently through suitable processes (stamping/extrusion for metal, injection molding for plastic) and then assembled together, avoiding the high defective rate and cost of integral die casting while maintaining both heat dissipation and insulation functions
Solution Approach 2:
The lamp holder uses a composite structure combining metal and plastic materials in the first housing. The metal portion provides thermal conductivity for heat dissipation, while the plastic portion provides electrical insulation. This composite approach achieves the required performance without the manufacturing problems of integral die casting
2Reliability
If the second housing is made as a single integral piece through die casting, then thermal conductivity is ensured, but manufacturing complexity and cost increase
Solution Approach 1:
The second housing is segmented into a body part and an assembling part that can be manufactured separately through stamping and extrusion processes respectively, then assembled via interference fit. This reduces manufacturing complexity while maintaining thermal conductivity through the thermal contact between parts
Solution Approach 2:
The patent employs interference fit assembly where dimensional parameters of the body part and assembling part are precisely controlled to create a tight thermal contact. This parameter control ensures good thermal conductivity between the segmented parts without requiring complex joining processes
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 reduces the defective rate and manufacturing costs while maintaining effective heat dissipation and insulation, improving the yield and efficiency of the lamp holder production.
Implementation Method 1
the body part and the assembling part are installed together in a manner of thermal expansion and contraction. For instance, the body part can be heated to slightly increase the major-diameter end thereof, thereby the assembling part can be successfully embedded therein, and then it is quickly cooled to ensure formation of interference fit between the body part and the assembling part
Implementation Method 2
the second housing comprises a body part and an assembling part in thermal contact with each other, wherein the second housing is embedded integrally in the first housing and in thermal contact with the first housing
Data Source
AI summary
The present invention relates to a lamp holder (100) of a lighting module, comprising a first housing (1) and a second housing (2) made from different materials, characterized in that the second housing (2) comprises a body part (21) and an assembling part (22) in thermal contact with each other, wherein the second housing (2) is embedded integrally in the first housing (1) and in thermal contact with the first housing (1), and the assembling part (22) and the body part (21) are installed together. In addition, the present invention further relates to a method for manufacturing the lamp holder and an illuminating device comprising the lamp holder.