LED Module Base with Insulative Layer and Connecting Flange
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Solution Overview
Problem
Existing LED modules face challenges in balancing red, green, and blue colors for desired light output, and the reduction in size makes them difficult to handle and secure, particularly in fixtures or bulbs, due to the need for precise color balance and efficient wavelength conversion.
Innovation Solution
A thermally and electrically conductive base with a light engine and connecting flange, featuring an insulative layer applied via powder coating, conductive traces extending from the LEDs to the flange, and a protective covering, allowing for focused light emission and secure electrical connection without secondary fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the LED array size is reduced to lower cost, then manufacturing cost decreases, but handling and securing difficulty increases
Solution Approach 1:
The patent combines the LED array mounting substrate with the heat sink into a single integrated base structure. This merging eliminates the need for separate mounting hardware and simplifies handling while maintaining thermal management efficiency. The base serves dual functions as both the electrical/thermal connection medium and the mechanical mounting structure.
Solution Approach 2:
The base structure is designed to perform multiple functions simultaneously: it provides thermal conduction for heat dissipation, electrical conduction for power delivery, mechanical support for the LED array, and mounting capability for securing the module to fixtures or bulbs. This multi-functionality reduces the number of separate components needed.
2Ease of manufacture
If the LED array size is reduced, then cost decreases, but the ability to secure to fixtures or bulbs deteriorates
Solution Approach 1:
The mounting substrate and heat sink are merged into a single base structure that provides both thermal management and mechanical mounting functions. This integration ensures that even as the overall module size decreases, the securing capability is maintained through the multi-functional base design.
Solution Approach 2:
The base is designed as a universal component that simultaneously handles thermal conduction, electrical conduction, mechanical support, and mounting operations. This multi-functionality allows the reduced-size module to maintain reliable securing capability across various fixture and bulb applications.
3Ease of operation
If a holder is used to secure the LED array, then handling ease improves, but device complexity increases
Solution Approach 1:
The holder function is merged into the base structure itself. The base incorporates mounting features and structural elements that provide both support and securing capabilities, eliminating the need for separate holder components and reducing overall device complexity.
Solution Approach 2:
The base is designed as a multi-functional component that performs thermal management, electrical conduction, mechanical support, and mounting functions all in one structure. This eliminates the need for separate holder components, thereby reducing device complexity while maintaining handling ease.
4Temperature
If the base is made thermally and electrically conductive, then heat dissipation and power delivery improve, but insulation requirements increase
Solution Approach 1:
The electrical traces and thermal conduction paths are merged within the base structure. The same conductive base that provides thermal management also serves as the electrical conduction medium, with traces patterned on or within the base to deliver power to the LED array without requiring separate insulation layers.
Solution Approach 2:
The base is designed as a universal conductive structure that simultaneously provides thermal conduction for heat dissipation and electrical conduction for power delivery. The multi-functionality reduces the need for additional insulation components, as the base handles both thermal and electrical management in an integrated manner.
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 enables efficient electrical and thermal management, facilitates secure mounting, and provides a compact, cost-effective LED module with improved light emission and handling capabilities, allowing for flexible fixture designs and reduced interference with light output.
Implementation Method 1
A light emitting diode (LED) module includes a base that is thermally and electrically conductive
Implementation Method 2
A light emitting diode (LED) module includes a base that is thermally and electrically conductive
Implementation Method 3
LEDs are placed on a reflective area
Implementation Method 4
The base is curved and the light emitting region is positioned in the base such that the base is configured to shape emitted light in a focused manner
Data Source
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AI summary
A light emitting diode (LED) module includes a base that is conductive and is selectively covered with an insulative layer. The base can include a connecting flange and a light emitting region. Traces are provided on the insulative coating and can be used to connect LEDs positioned on the light emitting region to pads on the connecting flange. The connecting flange can be offset in angle and/or position from the base and can be configured to provide a contact shape suitable to mate with a connector in a polarized manner. The base can be shaped so as to provide the desired functionality.