LED Light Modules with Integrated PCB Thermal Conductor
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Solution Overview
Problem
Conventional outdoor lighting systems face challenges in integrating LED lighting components with their driver circuitry due to space constraints and thermal management issues, making it difficult to retrofit existing fixtures with LED technology.
Innovation Solution
A light module design that integrates LED components and their driver circuitry onto a single printed circuit board (PCB), combined with optical elements like filters and reflectors, which includes a thermal conductor for heat management and a modular structure for easy attachment and detachment, allowing for efficient thermal dissipation and retrofitting into existing fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If LED components are mounted on a PCB with driver circuitry in separate locations, then thermal management is improved, but device complexity and connection difficulty increase
Solution Approach 1:
The patent combines the LED components and driver circuitry onto a single PCB assembly, integrating functions that were previously separated. This merging reduces the number of discrete components and connections needed, simplifying the overall device while maintaining effective thermal management through the integrated design.
2Temperature
If LED driver is housed within the fixture post at a distance from LED, then thermal management is improved, but ease of repair and connection difficulty worsen
Solution Approach 1:
The patent creates a modular LED assembly that can be easily removed and replaced as a single unit. This segmentation allows the entire LED module with its driver circuitry to be treated as a replaceable component, significantly easing repair and maintenance operations while maintaining thermal management benefits.
3Use of energy by moving object
If conventional LED lighting components are used in outdoor fixtures, then energy efficiency is improved, but adaptability to existing fixtures and ease of manufacture worsen
Solution Approach 1:
The patent designs a universal LED module that can be adapted to fit various existing outdoor fixture types. The standardized PCB assembly with integrated components can serve multiple fixture configurations, enabling retrofits of conventional fixtures with energy-efficient LED technology while maintaining ease of manufacture and installation.
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 solution enables the use of LED lighting in pathway fixtures, maximizes light output, and extends the lifespan of LED components by effective thermal management, while allowing for easy retrofitting and customization of existing lighting systems.
Implementation Method 1
A thermal conductor is disposed on the lower surface of the printed circuit board
Implementation Method 2
A reflector array comprises an integrated array of individual parabolic reflectors, where each individual reflector disposed at a position corresponding to a position of an LED element within the array of LED elements
Implementation Method 3
An array of LED elements is mounted on the upper surface of the printed circuit board
Data Source
AI summary
A light module for use in a lighting fixture includes a printed circuit board with one or more LED elements and one or more LED drivers. An electrical connector extends from the lower surface of the printed circuit board for attachment to an electrical socket within the fixture. A thermal conductor is attached on the lower surface of the printed circuit board. A reflector array comprises one or more individual parabolic reflectors, where each individual reflector is disposed at a position corresponding to a position of an LED element. Fastening means releasably attach each of the printed circuit board, the thermal conductor and the reflector array to a support surface within the interior cavity of the base. At least one optical element is releasably mounted on top of the reflector array.