Replaceable LED Module with Integrated Thermal Spreader
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Solution Overview
Problem
Existing LED lighting devices require replacement of the entire unit, including heat sinks and auxiliary components, even if only the LED semiconductor needs upgrading, leading to inefficiency and high costs.
Innovation Solution
A replaceable LED module with an integrated thermal spreader that can be used with various external heat sinks, allowing for easy replacement and reuse of existing heat sinks and auxiliary components, while maintaining proper thermal dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire lighting device is replaced to upgrade LED semiconductors, then the lighting performance can be improved, but the cost and waste increase significantly due to replacing non-failed components like heat sinks and auxiliary components
Solution Approach 1:
The lighting device is divided into a replaceable LED module containing the LED semiconductor and a non-replaceable heat sink with auxiliary components. This segmentation allows selective replacement of only the LED module when upgrading, leaving the heat sink and other components in place, thereby reducing waste and cost while maintaining improved lighting performance.
2Temperature
If a large heat sink is integrated with the LED semiconductor to ensure proper thermal dissipation, then thermal management is improved, but the device complexity and replacement cost increase when the LED needs upgrading
Solution Approach 1:
The thermal management system is segmented by providing a thermal spreader integrated with the LED module that interfaces with the heat sink. This allows the heat sink to be a separate, reusable component while the LED module with its thermal spreader can be easily replaced, reducing device complexity for upgrades while maintaining effective thermal dissipation through the thermal spreader-heat sink interface.
3Adaptability or versatility
If the LED module includes an integrated thermal spreader to conduct thermal energy to external heat sinks, then thermal management flexibility is improved, but the manufacturing complexity increases
Solution Approach 1:
The thermal spreader is merged with the LED module as an integrated component, combining the LED semiconductor and thermal management functionality in a single replaceable unit. This integration provides thermal management flexibility through various interface configurations with external heat sinks while simplifying manufacturing by producing the LED module as a complete, self-contained assembly that can be manufactured and tested independently before final assembly with the heat sink.
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 upgrades and repairs by allowing only the LED module to be replaced, reducing waste and maintaining efficient thermal management without replacing the entire lighting device.
Implementation Method 1
a thermal spreader thermally coupled to at least one of the LED light source and the driver, the thermal spreader configured to provide a thermal conduction path to conduct thermal energy away from the LED module
Data Source
AI summary
LED module with integrated thermal spreader. In an aspect, an LED module is provided that includes an LED light source, a driver connected to energize the LED light source, and a thermal spreader thermally coupled to at least one of the LED light source and the driver, the thermal spreader configured to provide a thermal conduction path to conduct heat energy away from the LED module. In another aspect, a lighting device includes a heat sink and an LED module mated with the heat sink. The LED module includes an LED light source, a driver connected to energize the LED light source, and a thermal spreader thermally coupled to at least one of the LED light source and the driver, the thermal spreader forming a thermal conduction path with the heat sink to conduct thermal energy away from the LED module.