Retrofittable LED Module Heat Spreader for Street Light Thermal Management
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Solution Overview
Problem
The existing street lights with high-intensity discharge lamps are difficult to retrofit with LED modules due to the need for thermal connection modifications, making it costly and inefficient.
Innovation Solution
A modular LED array mounted on a heat spreader with a mounting carriage that uses spring bolts or similar mechanisms for direct thermal contact with the existing head, along with thermal interface materials like thermal grease or epoxy, allowing for adjustable installation in various lighting fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LED modules are retrofitted into existing street light head portions, then energy efficiency and cost savings are improved, but thermal connection difficulties prevent successful implementation
Solution Approach 1:
The LED lighting system is divided into separate functional modules: the LED array module and the heat spreader module. This segmentation allows the heat spreader to be independently designed and attached to the existing street light head, while the LED array can be mounted separately, simplifying the retrofit process without requiring modification of the existing head structure
Solution Approach 2:
A heat spreader acts as an intermediary component between the LED array and the existing street light head. The heat spreader includes a mounting carriage with spring bolts that provide thermal connection to the head through direct contact, eliminating the need to modify the head structure while still achieving effective heat dissipation
2Temperature
If the head portion is modified to provide thermal connection, then heat dissipation is improved, but cost and complexity increase
Solution Approach 1:
The heat spreader serves as a thermal intermediary that interfaces with the existing head through the reflector mounting structure. Spring bolts apply force to maintain thermal contact between the heat spreader and the head, providing effective heat dissipation without requiring any modification to the head portion
Solution Approach 2:
The heat spreader's mounting carriage is designed to utilize existing screw holes and mounting structures in the street light head, making the solution universally applicable to various existing head designs without requiring custom modifications for each application
3Ease of operation
If spring bolts are used for thermal connection, then ease of installation is improved, but contact pressure stability may be affected
Solution Approach 1:
Spring bolts are used instead of rigid fasteners to provide dynamic thermal connection. The spring mechanism automatically adjusts to maintain optimal contact pressure between the heat spreader and the head, compensating for manufacturing tolerances and thermal expansion while remaining easy to install
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
Enables cost-effective retrofitting of street lights by providing efficient heat dissipation and thermal conductivity, allowing for the integration of LED modules into existing infrastructure without extensive modifications.
Implementation Method 1
A heat spreader may be aluminum or some other suitable material. The mounting carriage may be attached using spring bolts or some other suitable mechanism that forces the heat spreader into direct contact with the head for thermal conductivity.
Implementation Method 2
The mounting carriage may be attached using spring bolts or some other suitable mechanism that forces the heat spreader into direct contact with the head for thermal conductivity.
Implementation Method 3
A thermal interface material may be used between the heat spreader and head to provide a better thermal connection. The thermal interface material may be thermal grease, thermal epoxy, or some other suitable material.
Data Source
AI summary
A light source includes one or more solid state light emitting devices, a heat spreader thermally coupled to the one or more light emitting devices, and a mounting carriage configured to mount the one or more solid state light emitting devices in a lighting fixture light and thermally couple the heat spreader to the lighting fixture.