LED Light Module Thermal Management via Compression Ring
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Solution Overview
Problem
Existing solid-state lighting systems with LEDs face challenges in efficient power management and thermal dissipation, and are often difficult to assemble and integrate due to the need for multiple components from different suppliers, leading to complex wiring and increased risk of mis-wiring, especially in space-constrained fixtures.
Innovation Solution
A light module design featuring a printed circuit board with LEDs, a base ring with securing features, an optical component, and a top cover with a compression ring, which allows for efficient thermal dissipation and easy assembly by compressing the PCB against a heat sink, and includes a separable power connector interface for simplified power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If multiple wires are used to connect the circuit board to the lighting fixture, then electrical power can be transmitted to the LED, but the wiring time and complexity increase significantly
Solution Approach 1:
The patent combines multiple separate wire connections into a single integrated connector assembly. The connector housing contains multiple contact points that simultaneously establish electrical connections with the circuit board, replacing what would traditionally require multiple individual wire soldering operations. This merging of connection functions directly reduces wiring time while maintaining proper power transmission.
Solution Approach 2:
The connector assembly serves multiple functions simultaneously: it provides mechanical attachment, establishes electrical power connections, and positions the LED module within the fixture. This multi-functionality eliminates the need for separate wiring operations, addressing both the power transmission requirement and the time loss associated with traditional multi-wire connections.
2Use of energy by moving object
If multiple wires are used to connect the circuit board to the lighting fixture, then electrical power can be transmitted to the LED, but the number of terminations increases
Solution Approach 1:
The patent consolidates multiple wire terminations into a single connector assembly with integrated contact points. Instead of requiring separate termination operations for each wire, the connector housing provides a unified structure that accommodates and connects multiple electrical contacts simultaneously, thereby reducing the number of discrete terminations required.
Solution Approach 2:
The connector assembly is segmented into multiple functional contact regions within a single integrated housing. This segmentation allows different contact points to serve different electrical functions (power, ground, signal) while being managed as one unified component, reducing overall system complexity compared to individual wire terminations.
3Reliability
If wires are soldered between the circuit board and the fixture, then electrical connections are established, but the wires and circuit boards become difficult to replace
Solution Approach 1:
The patent replaces the soldering process with a mechanical connector system. The connector assembly uses mechanical engagement features (such as snap-fits, clips, or threaded connections) to establish electrical connections between the circuit board and fixture, eliminating the need for permanent solder joints. This substitution maintains reliable electrical connectivity while enabling easy disassembly and replacement of components.
4Temperature
If a heat sink is added to dissipate heat from the light engine, then thermal management improves, but the device complexity increases
Solution Approach 1:
The patent integrates the heat sink directly into the connector assembly or fixture housing, merging the thermal management function with the existing structural components. This integration eliminates the need for separate, complex thermal interfaces and allows the heat sink to be positioned optimally for heat dissipation while maintaining simplicity in the overall device architecture.
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 enhances thermal management, simplifies assembly and integration, reduces the risk of mis-wiring, and allows for customizable lighting characteristics by enabling easy replacement of components, thereby improving the efficiency and cost-effectiveness of LED lighting systems.
Implementation Method 1
the base ring is able to compress the printed circuit board against a heatsink of the structure
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A light module (10) includes a light engine having a printed circuit board and an array of light emitting diodes (LEDs) coupled to the printed circuit board. The printed circuit board has a power connector interface defining a separable interface for coupling with a power connector of the light module. A base ring (22) holds the light engine and has side walls (40) defining a cavity. The side walls (40) have a securing feature (142). An optical component (24) is received in the cavity (40) and is positioned to receive light from the LEDs. The optical component (24) has a predetermined lighting characteristic and emits the light generated by the LEDs in accordance with the predetermined lighting characteristic. A top cover (26) is coupled to the base ring (22) and has a securing feature (144) engaging the securing feature (142) of the base ring (22) to couple the top cover (26) to the base ring (22). A compression ring (28) is positioned between the base ring (22) and the optical component (24). The compression ring (28) is compressed between the base ring (22) and the optical component (24) when the top cover (26) is coupled to the base ring (22).