LED Lighting Module Thermal Management and Waterproofing
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Solution Overview
Problem
Existing LED lighting devices face challenges in effectively managing heat and protecting the light emitter from water and impurities, which can lead to reduced reliability and lifespan.
Innovation Solution
The proposed lighting module incorporates a heat radiating layer with electrical insulation and thermal conductivity, a waterproof packing structure, and an optical structure with dome-shaped lenses to manage heat and prevent water ingress, while using a thermally conductive case with heat radiating fins and a clad metal substrate for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional LED lighting device is used, then the device structure is simple, but heat management is ineffective and the LED is vulnerable to water and impurities
Solution Approach 1:
The lighting device is divided into distinct functional modules: a LED module containing the light emitter, a heat radiating assembly with heat dissipation fins, a waterproof housing with sealing structures, and an optical assembly with lenses. This segmentation allows each component to specialize in its function while protecting the LED from environmental factors.
Solution Approach 2:
The patent employs composite material structures including a waterproof housing combining protective and sealing properties, heat radiating fins with specific thermal conductivity characteristics, and optical lenses with light-guiding properties. These composite structures simultaneously achieve protection, heat management, and optical functionality.
2Duration of action of stationary object
If heat dissipation structures are added to manage thermal energy, then the lifespan of the LED is extended, but the device complexity increases
Solution Approach 1:
The heat radiating fins are designed to passively dissipate heat from the LED through natural convection and radiation, without requiring active cooling systems. The structure serves itself by utilizing the temperature difference between the hot LED and ambient air to drive heat away, extending LED lifespan without complex control mechanisms.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical protection for the LED, acts as a mounting structure for heat radiating fins, provides waterproof sealing, and facilitates thermal management. This multi-functionality reduces the need for separate dedicated components.
3Reliability
If waterproof packing structures are implemented, then the LED is protected from water ingress, but the manufacturing complexity increases
Solution Approach 1:
The patent employs waterproof membranes and sealing films that conform to the housing structure, providing effective water protection through flexible barrier layers. These thin film structures are integrated into the housing assembly, creating waterproof seals without requiring complex gasket systems or multiple fastening operations.
4Illumination intensity
If optical structures with dome-shaped lenses are added, then light distribution and color rendering are improved, but the device complexity increases
Solution Approach 1:
The patent employs dome-shaped spherical lenses in the optical assembly. The curved spherical geometry of these lenses naturally focuses and distributes light in specific patterns, improving illumination quality and color rendering through geometric optics principles without requiring complex multi-element optical systems.
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 configuration enhances the reliability and lifespan of the LED lighting device by effectively managing heat and protecting the light emitter from water and impurities, improving light distribution and color rendering index.
Implementation Method 1
a heat radiating layer (600) having electrical insulation characteristics and thermal conductivity
Implementation Method 2
a case (100) made of a thermal conductive material... an outer surface of the case may include a plurality of heat radiating fins (110) for radiating the heat from the light emitter (400)
Implementation Method 3
a case (100) made of a thermal conductive material... an outer surface of the case may include a plurality of heat radiating fins (110) for radiating the heat from the light emitter (400)
Implementation Method 4
an optical structure (300) including a plurality of dome-shaped lenses (310)... improving light distribution and color rendering index
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present invention relates to a lighting module comprising: a heat radiating layer having, thermally, a heat radiating characteristic; a light emitter (400) comprising a substrate (410) disposed on the heat radiating layer and a light emitting device (430) disposed on the substrate (410); an optical structure (300) covering the light emitter (400) and comprising a lens (310) disposed on the light emitting device (430) of the light emitter (400) and an outer frame (330) surrounding the substrate (410); an insulating structure (500) surrounding the outer frame (330) of the optical structure (300); and a case (100) disposed on the heat radiating layer and covering the outer frame (330) of the optical structure (300) and the insulating structure (500), wherein the case has an opening (G) for allowing light which has passed through the lens (310) of the optical structure (300), wherein the case (100) has a hole (HI), wherein the heat radiating layer has a locking recess (H2), and wherein a coupler passes through the through-hole (HI) and is coupled with the locking recess (H2).