Thermally Protected LED Module with Heat Sink and Thermal Protector
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Solution Overview
Problem
Traditional recessed light fixtures are unable to effectively manage the thermal protection of LED modules, as they do not radiate enough heat to trip housing-mounted thermal protectors, potentially leading to overheating of components like the driver, especially when the LED module is oriented in a way that the driver is far from the thermal protector.
Innovation Solution
A thermally protected LED module is designed with a heat sink that includes a core member and fins to efficiently dissipate heat, and a thermal protector is mounted either to the driver or a mounting bracket to monitor temperature and trip the circuit when the temperature exceeds a certain threshold, ensuring the LED module operates within safe temperature limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal protectors are mounted on the housing of the light fixture, then the housing and its surroundings are protected from overheating, but the thermal protector may not trip before the driver reaches its thermal limit because the LED module does not radiate enough heat to the housing
Solution Approach 1:
A thermal transfer member is introduced as an intermediary between the driver and the thermal protector. This member conducts heat from the driver to the thermal protector, ensuring that the thermal protector receives sufficient thermal signal to trip before the driver reaches its thermal limit, even when the LED module is oriented away from the thermal protector
Solution Approach 2:
The patent replaces reliance on radiant heat transfer (which is insufficient) with conductive heat transfer through the thermal transfer member. This substitution of heat transfer mechanism ensures reliable thermal coupling between the driver and thermal protector regardless of the LED module's orientation or distance from the thermal protector
2Illumination intensity
If the LED module is oriented with the driver far from the thermal protector, then light distribution may be improved, but thermal protection becomes ineffective as the thermal protector cannot detect driver temperature in time
Solution Approach 1:
The thermal transfer member acts as a dedicated heat conduction pathway that bridges the physical distance between the driver and thermal protector. This allows the LED module to be oriented for optimal light distribution while the thermal transfer member ensures continuous thermal coupling for effective protection
3Temperature
If heat sink fins are added to increase heat dissipation, then thermal management of the LED package is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The heat sink is merged with the mounting bracket, combining two structural components into one. This integration provides effective heat dissipation for the LED package while avoiding the complexity and cost of separate heat sink and mounting bracket assemblies
Solution Approach 2:
The mounting bracket is given dual functionality: it serves both as a structural support for the LED package and as a heat sink with fins for thermal management. This multi-functionality eliminates the need for additional dedicated heat dissipation components
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 effectively manages heat dissipation and thermal protection, preventing overheating of the LED module components by ensuring the thermal protector activates before the driver reaches its thermal limit, thus ensuring safe and efficient operation.
Implementation Method 1
The LED package can be thermally coupled to a heat sink configured to transfer heat from the LEDs
Implementation Method 2
The heat sink can include a core member extending away from the LED package and fins extending from the core member
Implementation Method 3
a thermal protector is mounted either to the driver or a mounting bracket to monitor temperature
Data Source
AI summary
A recessed light fixture includes a thermally protected light emitting diode (“LED”) module. The thermally protected LED module includes a thermal protector positioned in series between a source of electrical power and an LED driver and is configured to open a circuit to prevent power from being supplied by the power source to the LED driver for an LED package when a thermal rating or activation temperature of the thermal protector is exceeded. For example, the maximum operating temperature of the LED driver may be 90 degrees Celsius, and the thermal rating of the thermal protector may be 80 degrees Celsius, and when the temperature of the driver or a mounting bracket upon which the driver is mounted reaches 80 degrees Celsius, the thermal protector opens a circuit and removes current flow from the power source to the driver, thereby removing power to the LED package.