LED Lighting Module Heat Sink with Integrated Positioning
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Solution Overview
Problem
Current LED lighting modules for automotive applications are complex and expensive to manufacture, requiring manual handling and precise positioning, which leads to variations in quality and increased costs, and struggle with heat dissipation and light intensity at elevated temperatures.
Innovation Solution
An LED lighting module with a specially shaped heat sink that includes a receptacle for automatic mounting of the LED element and second reference elements for precise positioning with secondary optics, integrated with an electronic driving arrangement and a compact design for efficient heat dissipation and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual handling is used for connecting and positioning the LED to the electronic driver, then positioning precision is improved, but assembly complexity and cost increase
Solution Approach 1:
The heat sink is designed with integrated positioning features including a receptacle with first reference elements that automatically guide and position the LED element during assembly. The LED element itself incorporates positioning structures that engage with the heat sink's reference elements, enabling self-alignment and self-positioning without manual intervention. This self-service mechanism maintains precise positioning while eliminating complex manual assembly procedures.
Solution Approach 2:
The heat sink serves multiple functions simultaneously: it provides thermal management for the LED, acts as a mounting structure with integrated positioning features, and incorporates reference elements for optical alignment. By combining these functions into a single component, the design eliminates the need for separate positioning mechanisms and reduces assembly complexity while maintaining precision.
2Illumination intensity
If complex shaped reflectors and TIR optics are used to achieve required optical performance, then light intensity is improved, but assembly complexity increases
Solution Approach 1:
The patent integrates the positioning reference elements directly into the heat sink structure, merging the thermal management function with the optical alignment function. The second reference elements on the heat sink work in conjunction with the complex shaped reflectors and TIR optics to provide automatic positioning of the LED relative to these optical components, simplifying the assembly of complex optical systems.
3Power
If LED operates at elevated ambient temperatures to meet power requirements, then light intensity is improved, but junction temperature increases causing light output to decrease
Solution Approach 1:
The patent extracts the electronic driving arrangement from the LED element itself and places it in a separate location within the heat sink's cavity. This separation allows the LED element to be optimized purely for light emission while the electronic driver operates in a thermally managed environment within the heat sink, potentially improving the LED's operational temperature and light output efficiency.
4Manufacturing precision
If precise positioning and referencing is implemented to achieve required optical performance, then optical performance is improved, but manufacturing cost increases
Solution Approach 1:
The positioning reference elements are integrated into the heat sink and LED element structures themselves, which are manufactured using standard manufacturing processes. The reference elements automatically guide alignment during assembly without requiring specialized precision manufacturing equipment or complex measurement systems, thereby achieving precise optical positioning at lower manufacturing costs.
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 cost-effective, automated assembly of high-quality LED lighting modules with improved thermal management and precise optical performance, suitable for automotive applications and other lighting uses, while maintaining mechanical stability and reducing manufacturing complexity.
Implementation Method 1
a heat sink, which heat sink forms a casing for the electronic driving arrangement
Implementation Method 2
the generated heat can therefore very easily be dissipated
Data Source
Figure 1~2
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Figure 5
AI summary
The invention describes an LED lighting module (1) comprising an LED element (10), an electronic driving arrangement (30) for driving the LED(11), and a heat sink (20). The heat sink (20) forms a casing for the electronic driving arrangement (30) and comprises a receptacle interface (26) on a front side (F) of the heat sink (20) with a number of first reference elements (27) for coupling the LED element (10) to the heat sink (20) in a defined orientation. The heat sink further comprises a cavity (28) for enclosing at least parts of the electronic driving arrangement (30) and a number of second reference elements (22) for coupling the LED light module (10) to a secondary optic (70,70'). Moreover the invention describes a lighting assembly (80, 80') comprising such an LED lighting module (1).