LED Lighting Device with Dual-Layer Thermal Support Structure
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Solution Overview
Problem
Current LED retrofits for halogen lamps in automotive applications fail to optimally mimic the light emission properties of halogen lamps, particularly in terms of light intensity distribution and heat management, which are crucial for both near and far field applications.
Innovation Solution
A lighting device with a support structure comprising two metal layers separated by an insulating layer, featuring a central mounting face and lateral mounting faces, where LEDs are arranged to mimic the filament of a halogen lamp, enabling improved light intensity distribution and effective heat management through enhanced thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a PCB-based support structure is used for LED retrofits, then the device complexity is reduced and ease of manufacture is improved, but the capability to mimic halogen lamp light emission properties and manage heat densities deteriorates
Solution Approach 1:
The support structure uses a composite design combining a thermally conductive substrate (metal or ceramic) with a thermally insulating but electrically conductive coating layer. This composite material approach enables simultaneous thermal management for heat density coping and electrical functionality for LED mounting, resolving the contradiction between ease of manufacture and light emission mimicry capability
Solution Approach 2:
The support structure features spatially varying thermal conductivity - high thermal conductivity in the substrate for heat dissipation from LEDs, and controlled thermal insulation in specific regions to maintain temperature gradients necessary for mimicking halogen lamp emission characteristics. This local quality differentiation enables both manufacturing feasibility and optical performance
2Illumination intensity
If LEDs are arranged to mimic halogen lamp filament geometry, then the light intensity distribution in near and far fields is improved, but the heat density management becomes more challenging
Solution Approach 1:
The invention transitions from planar LED arrangements to a three-dimensional support structure with vertical and lateral extensions. This dimensional expansion allows LEDs to be positioned at multiple heights and angles, creating a spatial distribution that mimics the volumetric light emission of a halogen filament while distributing heat generation across a larger three-dimensional volume, thereby improving both light intensity distribution and heat management
Solution Approach 2:
The thermally conductive substrate acts as an intermediary between the LEDs and the heat sink system. It provides a thermal pathway that efficiently conducts heat away from the LED junctions while maintaining the LEDs at appropriate operating temperatures, thus enabling high heat density LEDs to be arranged in configurations that mimic halogen emission patterns
3Temperature
If a single-layer metal support structure is used, then the thermal conductivity is improved for heat management, but the optical properties for mimicking halogen emission deteriorate
Solution Approach 1:
The support structure employs a composite material system with a thermally conductive substrate (for heat management) and a thermally insulating but electrically conductive coating layer (for optical performance). This composite structure enables the substrate to efficiently conduct heat away from LEDs while the coating layer provides thermal insulation to maintain temperature gradients necessary for mimicking halogen lamp emission characteristics
Solution Approach 2:
The support structure features spatially varying thermal conductivity - high thermal conductivity in the substrate for heat dissipation and controlled thermal insulation in specific regions to maintain temperature gradients necessary for mimicking halogen emission characteristics
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 solution effectively mimics the light emission properties of halogen lamps, meeting automotive headlight requirements by providing a compact and efficient LED lighting system that manages heat effectively, suitable for both near and far field applications.
Implementation Method 1
support structure comprising a first layer comprising metal and a second layer comprising metal
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A lighting device (1) is provided comprising a support structure (13, 13'), the support structure (13, 13') comprising a first layer (13a, 13a') comprising metal and a second layer (13b, 13b') comprising metal; a central mounting face (18c) formed by a portion of the first layer (13a, 13a') and by a portion of the second layer (13b, 13b'); and at least one lateral mounting face (18a, 18b) formed by a portion of one of the first layer (13a, 13a') and the second layer (13b, 13b'); the lighting device (1) further comprising: at least one first light emitting element (11.1, 11.2, 11.3, 11.4, 11.5) arranged on the central mounting face (18c) in contact with the first layer (13a, 13a') and in contact with the second layer (13b, 13b'); at least one second light emitting element (12a.1, 12a.2, 12a.3, 12a.4, 12a.5, 12b.1) arranged on the lateral mounting face (18a, 18b) in contact with the one of the first layer (13a, 13a') and the second layer (13b, 13b') forming the lateral mounting face (18a, 18b), and separated from the other one of the first layer (13a, 13a') and the second layer (13b, 13b'). Furthermore, a method for manufacturing such lighting device (1) and an automotive headlight comprising such lighting device (1) are provided.