Rotating LED Lighting Module with Offset Heat Sink
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Solution Overview
Problem
Existing lighting modules struggle to utilize a large heat sink within limited spaces of luminaires, especially in street lighting applications, due to size constraints, which hampers the installation and efficiency of LED lighting systems.
Innovation Solution
A lighting module design featuring a heat sink extending along the longitudinal axis at a non-zero angle, allowing for rotational connection to a carrier, enabling the use of a larger heat sink without modifying the luminaire, and incorporating a driver circuit for safe and efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a large heat sink is used to cool LED light sources, then cooling efficiency and lumen output are improved, but the lighting module cannot be installed in existing luminaires with limited space
Solution Approach 1:
The light unit is nested within the carrier structure, with the heat sink positioned inside the reflector cavity. The carrier acts as an intermediate container that holds the light unit, allowing the entire assembly to fit within the luminaire's socket while maintaining adequate cooling capacity through the heat sink's integration with the reflector's internal space.
Solution Approach 2:
The heat sink extends in a direction that utilizes the depth dimension of the reflector cavity rather than only radial space. By positioning the heat sink at a non-zero distance to the longitudinal axis and extending it along the longitudinal direction, the design maximizes the use of available three-dimensional space within the luminaire, particularly the depth available along the optical axis.
2Illumination intensity
If a large heat sink is used to increase LED capacity, then lumen output is improved, but the lighting module cannot be rotatably installed in the socket
Solution Approach 1:
The lighting module is divided into two main segments: the carrier that rotates within the socket, and the light unit that remains stationary relative to the reflector. The connecting construction allows the light unit to be decoupled from the rotational movement, enabling the carrier to rotate for installation while the light unit with its large heat sink remains fixed in the optimal optical position.
Solution Approach 2:
The connecting construction provides a dynamic, flexible connection between the carrier and light unit. This connection allows relative movement and rotation of the carrier while maintaining electrical and mechanical connectivity, enabling the light unit to stay stationary during rotational installation of the carrier into the socket.
3Ease of manufacture
If the heat sink is positioned on the longitudinal axis, then installation is simplified, but space utilization is suboptimal
Solution Approach 1:
The heat sink is positioned asymmetrically at a non-zero distance to the longitudinal axis rather than centered on it. This asymmetric positioning allows the heat sink to extend into the available space within the reflector cavity more effectively, utilizing the three-dimensional volume available while maintaining proper thermal management and optical alignment.
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 allows for optimal space utilization within luminaires, enabling higher lumen output and improved cooling, while ensuring safe and easy installation and operation of the lighting module.
Implementation Method 1
a heat sink for dissipating thermal energy from the light source
Data Source
AI summary
The invention provides a lighting module (100) for use in a luminaire (200). The lighting module (100) comprises: a base (101) having a longitudinal axis (LA) and being constructed for rotatably connecting the base (101) to a socket (119) of a luminaire (200). The lighting module (100) further comprises a carrier (102) connected to the base (101) and extending from the base (101) in the direction of the longitudinal axis (LA). The lighting 5 module (100) further comprises a light unit (103) comprising a light source (104) and a heat sink (105) for dissipating thermal energy of the light source (104). The heat sink (105) extends in the direction of the longitudinal axis (LA) and is positioned at a non-zero distance D1 to the longitudinal axis (LA). The lighting module (100) further comprising a connecting construction (106) connecting the light unit (103) rotatably to the carrier (102) for rotating 10 the light unit (103) both around the carrier (102) and longitudinal axis (LA).