LED Module Heat Sink Ambient Light Reflection Management

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

LED modules in vehicle headlamps face issues with visibility of the heat sink due to ambient light reflection, making them appear unattractive and increasing manufacturing costs when trying to improve illumination performance and ease of installation.

Innovation Solution

An LED module design featuring a heat sink with a mounting surface and reflection surface, where the reflection surface is oriented to direct ambient light in a way that it complements the LED light emission, using pigments to create a uniform or contrasting color effect, and includes stopper means for alignment with the reflector, ensuring high illumination performance and attractiveness while maintaining low manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If the heat sink is made visible to improve illumination performance and attractiveness, then the visual appeal and illumination performance are improved, but the manufacturing cost increases

Engineering Contradiction:

Improveillumination performanceVSAvoidmanufacturing cost

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent applies a colored coating or pigment layer to the heat sink surface, transforming its appearance from a typical metallic gray to an attractive colored finish. This color change enhances the visual appeal and illumination performance of the headlamp assembly while the coating process itself is a standard manufacturing technique that does not significantly increase production costs

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The patent converts the typically unwanted visibility of the heat sink (which can create unsightly reflections of ambient light) into a beneficial feature. By applying colored coating to the heat sink, the reflections become aesthetically pleasing and contribute to the overall illumination performance, turning a potential design flaw into a selling point

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Shape

If the heat sink is made visible to improve attractiveness, then the visual appeal is improved, but the manufacturing complexity increases

Engineering Contradiction:

ImproveattractivenessVSAvoidmanufacturing complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The colored coating on the heat sink serves multiple functions simultaneously: it provides aesthetic appeal, manages thermal radiation, and creates desirable light reflection patterns. This multi-functionality means that a single manufacturing step (applying the colored coating) achieves multiple design goals without requiring additional complex manufacturing processes

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the aesthetic function with the thermal management function by applying the colored coating directly to the heat sink surface. This combination eliminates the need for separate aesthetic components and simplifies the manufacturing process, as the heat sink itself becomes both the functional and aesthetic element

Inventive Principle:

Principle #5Merging (Combining)

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 enhances the attractiveness of LED modules in vehicle headlamps by effectively managing ambient light reflection, improving illumination performance, and simplifying installation and manufacturing processes.

Implementation Method 1

The heat sink has a reflection surface oriented such that, with respect to the ambient light incident on thereon, a main direction of the beam of the reflection surface is perpendicular to the reflection surface and points in a direction included in the angle range determined by the main direction of the beam of the mounting surface and the secondary directions of the beam of the mounting surface

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

pigments on the reflection surface

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Data Source

PatentUS11732865B2LED module, LED module and reflector arrangement, and vehicle headlamp

Publication Date: 2023.08.22 LUMILEDS SINGAPORE PTE LTD

AI summary

An LED module includes a heat sink. The heat sink has a mounting surface that defines, with respect to ambient light incident thereon, one main direction of a beam perpendicular to the mounting surface and secondary directions of the beam inclined to the main direction of the beam at angles having absolute values smaller than or equal to 90 degrees. The heat sink also has a reflection surface oriented such that, with respect to the ambient light incident on thereon, a main direction of the beam of the reflection surface is perpendicular to the reflection surface and points in a direction included in the angle range determined by the main direction of the beam of the mounting surface and the secondary directions of the beam of the mounting surface. The LED module further includes an LED light source on the mounting face and pigments on the reflection surface.