LED Lighting Device Insulating Cap for Compact Power Supply
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Solution Overview
Problem
Miniaturizing LED luminaires is hindered by the need for significant distance between the primary and secondary sides of the power supply due to electrical conductivity and safety requirements, leading to a large design that compromises compactness and safety.
Innovation Solution
A lighting device design where the light source and power supply are separated by a heat sink, with an electrically insulating cap that extends the clearance and creepage distance, allowing for a more compact and safer arrangement by routing connections around the cap, and potentially incorporating a one-piece cap with a receptacle for the power supply unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the power supply unit is placed close to the heat sink for compact design, then the device size is reduced, but the electrical insulation between primary and secondary sides is insufficient
Solution Approach 1:
An electrically insulating cover cap is introduced as an intermediary component between the power supply unit and the heat sink. This cap extends the clearance and creepage distances required for electrical insulation, allowing the power supply to be positioned closer to the heat sink while maintaining safety standards. The cap acts as a mediator that enables both compact design and adequate insulation simultaneously.
2Reliability
If the clearance distance between power supply and heat sink is increased for safety, then electrical insulation is improved, but the device volume increases
Solution Approach 1:
The insulating cover cap utilizes the vertical dimension by extending downward from the power supply unit. This vertical extension provides the required clearance and creepage distances without increasing the horizontal footprint of the device. The cap transforms the insulation problem from a horizontal spacing issue into a vertical dimension solution, enabling compact overall device design.
3Reliability
If a traditional spacing arrangement is used to maintain clearance distances, then electrical insulation is achieved, but the design becomes comparatively large
Solution Approach 1:
The insulating cover cap merges multiple functions into a single component: it provides electrical insulation, maintains required clearance and creepage distances, and serves as a structural element of the power supply unit housing. This consolidation eliminates the need for separate insulation barriers or increased spacing, achieving both safety requirements and compact design in a unified structure.
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 electrical insulation and safety while enabling a more compact form factor, meeting higher safety standards and allowing for closer placement of the power supply to the heat sink, thus improving the miniaturization of LED luminaires.
Implementation Method 1
a heat sink for cooling the at least one light source
Implementation Method 2
a heat sink for cooling the at least one light source
Implementation Method 3
The power supply has an electrically insulating cap that separates the power supply from the heat sink
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The lighting device (1,18,22,24,27) of the present invention comprises at least one lighting means (2), a power supply unit (10) for the at least one lighting means (2), and a cooling body (6) for cooling the at least one lighting means (2), wherein the at least one lighting means (2) is fastened to the cooling body (6) and is separated from the power supply unit (10) by the cooling body (6), and wherein the power supply unit (10) comprises an electrically insulating cap (17,19,23,25,29), which is attached at least partially over the power supply unit (10) and separates the power supply unit from the cooling body (6).